Abstract

Recent focus on light-weight design and fuel efficiency in several sectors (such as aerospace and automotive), as well as advances in polymer technologies, have made plastic parts more viable for high-value systems. These are often low-production, high-precise parts which require expensive tooling for traditional manufacture, making them difficult to reproduce later; this is especially true when the original tooling is no longer available, and full additive manufacturing (AM) is infeasible. This study explores the application of fused deposition modeling (FDM - extrusion-based AM) in the repair of cracks, chips, and broken features in such plastic parts. A framework for repairing various kinds of plastic parts using FDM is presented, including establishment of repair candidacy, selection of repair material and parameters, post-processing, and repair evaluation. Three case studies, one repairing an optimized truss, one exploring the use of sewing-stitch patch patterns, and one replacing a broken part feature, were developed to demonstrate the presented concepts.

Original languageEnglish (US)
Pages1732-1755
Number of pages24
StatePublished - 2019
Event30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019 - Austin, United States
Duration: Aug 12 2019Aug 14 2019

Conference

Conference30th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2019
CountryUnited States
CityAustin
Period8/12/198/14/19

Keywords

  • Additive manufacturing
  • Damage repair
  • Fused deposition modeling
  • Plastic materials

ASJC Scopus subject areas

  • Surfaces, Coatings and Films
  • Surfaces and Interfaces

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