A Review of Fused Filament Fabrication of Metal Parts (Metal FFF): Current Developments and Future Challenges
Fused filament fabrication (FFF) is the most widespread and versatile material extrusion (MEX) technique. Although powder-based systems have dominated the metal 3D printing landscape in the past, FFF’s popularity for producing metal parts (“metal FFF”) is growing. Metal FFF starts from a polymer–met...
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MDPI AG
2024-12-01
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| author | Johnson Jacob Dejana Pejak Simunec Ahmad E. Z. Kandjani Adrian Trinchi Antonella Sola |
| author_facet | Johnson Jacob Dejana Pejak Simunec Ahmad E. Z. Kandjani Adrian Trinchi Antonella Sola |
| author_sort | Johnson Jacob |
| collection | DOAJ |
| description | Fused filament fabrication (FFF) is the most widespread and versatile material extrusion (MEX) technique. Although powder-based systems have dominated the metal 3D printing landscape in the past, FFF’s popularity for producing metal parts (“metal FFF”) is growing. Metal FFF starts from a polymer–metal composite feedstock and proceeds through three primary stages, namely shaping (i.e., printing), debinding, and sintering. As critically discussed in the present review, the final quality of metal FFF parts is influenced by the characteristics of the composite feedstock, such as the metal loading, polymer backbone, and presence of additives, as well as by the processing conditions. The literature shows that a diverse array of metals, including steel, copper, titanium, aluminium, nickel, and their alloys, can be successfully used in metal FFF. However, the formulation of appropriate polymer binders represents a hurdle to the adoption of new material systems. Meanwhile, intricate geometries are difficult to fabricate due to FFF-related surface roughness and sintering-induced shrinkage. Nonetheless, the comparison of metal FFF with other common metal AM techniques conducted herein suggests that metal FFF represents a convenient option, especially for prototyping and small-scale production. Whilst providing insights into the functioning mechanisms of metal FFF, the present review offers valuable recommendations, facilitating the broader uptake of metal FFF across various industries. |
| format | Article |
| id | doaj-art-6e475893d3d64bde878ae3482f63d544 |
| institution | DOAJ |
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| language | English |
| publishDate | 2024-12-01 |
| publisher | MDPI AG |
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| series | Technologies |
| spelling | doaj-art-6e475893d3d64bde878ae3482f63d5442025-08-20T02:43:49ZengMDPI AGTechnologies2227-70802024-12-01121226710.3390/technologies12120267A Review of Fused Filament Fabrication of Metal Parts (Metal FFF): Current Developments and Future ChallengesJohnson Jacob0Dejana Pejak Simunec1Ahmad E. Z. Kandjani2Adrian Trinchi3Antonella Sola4Commonwealth Scientific and Industrial Research Organisation (CSIRO), Manufacturing Research Unit—Research Way, Melbourne, VIC 3168, AustraliaCommonwealth Scientific and Industrial Research Organisation (CSIRO), Manufacturing Research Unit—Research Way, Melbourne, VIC 3168, AustraliaCommonwealth Scientific and Industrial Research Organisation (CSIRO), Manufacturing Research Unit—Research Way, Melbourne, VIC 3168, AustraliaCommonwealth Scientific and Industrial Research Organisation (CSIRO), Manufacturing Research Unit—Research Way, Melbourne, VIC 3168, AustraliaCommonwealth Scientific and Industrial Research Organisation (CSIRO), Manufacturing Research Unit—Research Way, Melbourne, VIC 3168, AustraliaFused filament fabrication (FFF) is the most widespread and versatile material extrusion (MEX) technique. Although powder-based systems have dominated the metal 3D printing landscape in the past, FFF’s popularity for producing metal parts (“metal FFF”) is growing. Metal FFF starts from a polymer–metal composite feedstock and proceeds through three primary stages, namely shaping (i.e., printing), debinding, and sintering. As critically discussed in the present review, the final quality of metal FFF parts is influenced by the characteristics of the composite feedstock, such as the metal loading, polymer backbone, and presence of additives, as well as by the processing conditions. The literature shows that a diverse array of metals, including steel, copper, titanium, aluminium, nickel, and their alloys, can be successfully used in metal FFF. However, the formulation of appropriate polymer binders represents a hurdle to the adoption of new material systems. Meanwhile, intricate geometries are difficult to fabricate due to FFF-related surface roughness and sintering-induced shrinkage. Nonetheless, the comparison of metal FFF with other common metal AM techniques conducted herein suggests that metal FFF represents a convenient option, especially for prototyping and small-scale production. Whilst providing insights into the functioning mechanisms of metal FFF, the present review offers valuable recommendations, facilitating the broader uptake of metal FFF across various industries.https://www.mdpi.com/2227-7080/12/12/267material extrusionfused filament fabricationmetaladditive manufacturingsintering |
| spellingShingle | Johnson Jacob Dejana Pejak Simunec Ahmad E. Z. Kandjani Adrian Trinchi Antonella Sola A Review of Fused Filament Fabrication of Metal Parts (Metal FFF): Current Developments and Future Challenges Technologies material extrusion fused filament fabrication metal additive manufacturing sintering |
| title | A Review of Fused Filament Fabrication of Metal Parts (Metal FFF): Current Developments and Future Challenges |
| title_full | A Review of Fused Filament Fabrication of Metal Parts (Metal FFF): Current Developments and Future Challenges |
| title_fullStr | A Review of Fused Filament Fabrication of Metal Parts (Metal FFF): Current Developments and Future Challenges |
| title_full_unstemmed | A Review of Fused Filament Fabrication of Metal Parts (Metal FFF): Current Developments and Future Challenges |
| title_short | A Review of Fused Filament Fabrication of Metal Parts (Metal FFF): Current Developments and Future Challenges |
| title_sort | review of fused filament fabrication of metal parts metal fff current developments and future challenges |
| topic | material extrusion fused filament fabrication metal additive manufacturing sintering |
| url | https://www.mdpi.com/2227-7080/12/12/267 |
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