Improving the forming quality of fused filament fabrication parts by applied vibration

Purpose The purpose of this study is to investigate the efficiency of applied vibration in improving the forming quality (mechanical property and dynamics characteristics) of fused filament fabrication (FFF) parts. Design/methodology/approach A vibrating FFF three-dimensional printer was set up, with which the samples fabricated in different directions were manufactured separately without and with vibration applied. A series of experimental tests, including tensile tests, dynamics tests and scanning electron microscopy (SEM) tests, were performed on these samples to experimentally quantify the effect of applied vibration on their forming quality. Findings It has been found that the applied vibration can significantly increase the tensile strength and plasticity of the samples built in Z-direction, and obviously decrease the orthogonal anisotropy. It can also significantly change the sample’s natural frequency, decrease the resonant response and increase the modal damping ratio, thus improve the anti-vibration capability of FFF samples. In addition, the SEM analysis confirmed that applying vibration into FFF process could improve the forming quality of the fabricated part. Research limitations/implications Future research may be focused on investigating the efficiency of applied vibration in improving the forming quality of parts fabricated by the other additive manufacturing techniques. Practical implications This study helps to improve the reliability of FFF parts and extend the application range of FFF technology. Originality/value A novel method to improve the forming quality of FFF parts is provided and the available information about the performance of dynamics characteristics.