Design Guidelines for Material Extrusion of Metals (MEX/M)
This study introduced a systematic framework to develop practical design guidelines specifically for filament-based material extrusion of metals (MEX/M), an additive manufacturing (AM) process defined by ISO/ASTM 52900. MEX/M provides a cost-efficient alternative to conventional manufacturing method...
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| Language: | English |
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MDPI AG
2025-05-01
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| Series: | Journal of Experimental and Theoretical Analyses |
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| Online Access: | https://www.mdpi.com/2813-4648/3/2/15 |
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| author | Karim Asami Mehar Prakash Reddy Medapati Titus Rakow Tim Röver Claus Emmelmann |
| author_facet | Karim Asami Mehar Prakash Reddy Medapati Titus Rakow Tim Röver Claus Emmelmann |
| author_sort | Karim Asami |
| collection | DOAJ |
| description | This study introduced a systematic framework to develop practical design guidelines specifically for filament-based material extrusion of metals (MEX/M), an additive manufacturing (AM) process defined by ISO/ASTM 52900. MEX/M provides a cost-efficient alternative to conventional manufacturing methods, which is particularly valuable for rapid prototyping. Although AM offers significant design flexibility, the MEX/M process imposes distinct geometric and process constraints requiring targeted optimization. The research formulates and validates design guidelines tailored for the MEX/M using an austenitic steel 316L (1.4404) alloy filament. The feedstock consists of a uniform blend of 316L stainless steel powder and polymeric binder embedded within a thermoplastic matrix, extruded and deposited layer by layer. Benchmark parts were fabricated to examine geometric feasibility, such as minimum printable wall thickness, feature inclination angles, borehole precision, overhang stability, and achievable resolution of horizontal and vertical gaps. After fabrication, the as-built (green-state) components undergo a two-step thermal post-processing treatment involving binder removal (debinding), followed by sintering at elevated temperatures to reach densification. Geometric accuracy was quantitatively assessed through a 3D scan by comparing the manufactured parts to their original CAD models, allowing the identification of deformation patterns and shrinkage rates. Finally, the practical utility of the developed guidelines was demonstrated by successfully manufacturing an impeller designed according to the established geometric constraints. These design guidelines apply specifically to the machine and filament type utilized in this study. |
| format | Article |
| id | doaj-art-baf1bf5466d44cb59ce0ebeedfc1633a |
| institution | Kabale University |
| issn | 2813-4648 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Experimental and Theoretical Analyses |
| spelling | doaj-art-baf1bf5466d44cb59ce0ebeedfc1633a2025-08-20T03:27:14ZengMDPI AGJournal of Experimental and Theoretical Analyses2813-46482025-05-01321510.3390/jeta3020015Design Guidelines for Material Extrusion of Metals (MEX/M)Karim Asami0Mehar Prakash Reddy Medapati1Titus Rakow2Tim Röver3Claus Emmelmann4Institute of Laser and Systems Technology, Hamburg University of Technology, Am Schwarzenberg-Campus 1, 21073 Hamburg, GermanyInstitute of Laser and Systems Technology, Hamburg University of Technology, Am Schwarzenberg-Campus 1, 21073 Hamburg, GermanyInstitute of Laser and Systems Technology, Hamburg University of Technology, Am Schwarzenberg-Campus 1, 21073 Hamburg, GermanyInstitute of Laser and Systems Technology, Hamburg University of Technology, Am Schwarzenberg-Campus 1, 21073 Hamburg, GermanyInstitute of Laser and Systems Technology, Hamburg University of Technology, Am Schwarzenberg-Campus 1, 21073 Hamburg, GermanyThis study introduced a systematic framework to develop practical design guidelines specifically for filament-based material extrusion of metals (MEX/M), an additive manufacturing (AM) process defined by ISO/ASTM 52900. MEX/M provides a cost-efficient alternative to conventional manufacturing methods, which is particularly valuable for rapid prototyping. Although AM offers significant design flexibility, the MEX/M process imposes distinct geometric and process constraints requiring targeted optimization. The research formulates and validates design guidelines tailored for the MEX/M using an austenitic steel 316L (1.4404) alloy filament. The feedstock consists of a uniform blend of 316L stainless steel powder and polymeric binder embedded within a thermoplastic matrix, extruded and deposited layer by layer. Benchmark parts were fabricated to examine geometric feasibility, such as minimum printable wall thickness, feature inclination angles, borehole precision, overhang stability, and achievable resolution of horizontal and vertical gaps. After fabrication, the as-built (green-state) components undergo a two-step thermal post-processing treatment involving binder removal (debinding), followed by sintering at elevated temperatures to reach densification. Geometric accuracy was quantitatively assessed through a 3D scan by comparing the manufactured parts to their original CAD models, allowing the identification of deformation patterns and shrinkage rates. Finally, the practical utility of the developed guidelines was demonstrated by successfully manufacturing an impeller designed according to the established geometric constraints. These design guidelines apply specifically to the machine and filament type utilized in this study.https://www.mdpi.com/2813-4648/3/2/15material extrusion of metals (MEX/M)design guidelinesstainless steel 316L (1.4404) |
| spellingShingle | Karim Asami Mehar Prakash Reddy Medapati Titus Rakow Tim Röver Claus Emmelmann Design Guidelines for Material Extrusion of Metals (MEX/M) Journal of Experimental and Theoretical Analyses material extrusion of metals (MEX/M) design guidelines stainless steel 316L (1.4404) |
| title | Design Guidelines for Material Extrusion of Metals (MEX/M) |
| title_full | Design Guidelines for Material Extrusion of Metals (MEX/M) |
| title_fullStr | Design Guidelines for Material Extrusion of Metals (MEX/M) |
| title_full_unstemmed | Design Guidelines for Material Extrusion of Metals (MEX/M) |
| title_short | Design Guidelines for Material Extrusion of Metals (MEX/M) |
| title_sort | design guidelines for material extrusion of metals mex m |
| topic | material extrusion of metals (MEX/M) design guidelines stainless steel 316L (1.4404) |
| url | https://www.mdpi.com/2813-4648/3/2/15 |
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