Fused Granular Fabrication (FGF) is one of the lesser-known additive manufacturing (AM) technologies in which material pellets, typically thermoplastics, are melted and deposited on a bed layer by layer to create 3D-objects from CAD data. This thesis aims to explain the working principles of FGF, describe its strengths and weaknesses, address common printing issues, propose effective solutions, and provide practical validation of troubleshooting strategies and the feasibility of producing durable goods through the use of a non-industrial FGF machine. The paper begins by introducing the fundamentals concepts of the additive manufacturing processes and the corresponding design guidelines (DfAM). It then provides an explanation of material extrusion processes, with a focus on two different technologies: Fused Modelling Deposition (FDM) and FGF. Through a comparative analysis, the distinctions, advantages, and disadvantages of FDM and FGF are examined, offering an understanding of their unique characteristics. Subsequently, the thesis identifies and discusses potential printing defects and issues encountered when using an FGF machine. Each issue is analyzed to determine its potential causes and suitable solutions, aiming to equip practitioners with effective troubleshooting strategies. To practically validate the covered topics, the thesis documents the encountered printing faults and their corrective action during a two-month internship utilizing a low-cost, large-scale FGF printer (ginger.one printer by Ginger Additive). Additionally, a short project developed using the Generative Design tool was carried out as part of the internship. This was documented and used to demonstrate the applicability of the technology when producing durable goods and to draw useful conclusions about the printer and its technology. Overall, this thesis offers a comprehensive exploration of Fused Granular Fabrication, providing valuable insights into its operation, strengths, weaknesses, and troubleshooting strategies.
La Fused Granular Fabrication (FGF) è una delle tecnologie di produzione additiva (AM) meno conosciute, in cui granuli di materiale, tipicamente termoplastici, vengono fusi e depositati strati dopo strato su un piatto di stampa per creare oggetti tridimensionali a partire da dati CAD. Questa tesi mira a spiegare i principi di funzionamento della FGF, descrivere i suoi punti di forza e di debolezza, affrontare i problemi comuni di stampa, proporre soluzioni efficaci e fornire una validazione pratica delle strategie di risoluzione dei problemi e della fattibilità della produzione di beni durevoli tramite l'uso di una macchina FGF non industriale. Il documento inizia introducendo i concetti fondamentali dei processi di produzione additiva e le relative linee guida di progettazione (DfAM). Successivamente, fornisce una spiegazione dei processi di estrusione del materiale, focalizzandosi su due diverse tecnologie: Fused Modelling Deposition (FDM) e FGF. Attraverso un'analisi comparativa, vengono esaminati le distinzioni, i vantaggi e gli svantaggi di FDM e FGF, offrendo una comprensione delle loro caratteristiche uniche. Posteriormente, la tesi identifica e discute i potenziali difetti di stampa e le problematiche riscontrate nell'uso di una macchina FGF. Ogni problema viene analizzato per determinarne le possibili cause e le soluzioni appropriate, al fine di fornire agli operatori strategie efficaci di risoluzione dei problemi. Per convalidare in modo pratico gli argomenti trattati, la tesi documenta i difetti di stampa riscontrati e le relative azioni correttive durante uno stage di due mesi utilizzando una stampante FGF di grandi dimensioni a basso costo (ginger.one printer di Ginger Additive). Inoltre, come parte dello stage, è stato realizzato un breve progetto utilizzando lo strumento di Progettazione Generativa. Questo progetto serve a dimostrare l'applicabilità della tecnologia nella produzione di beni durevoli e a trarre conclusioni utili sulla stampante e la sua tecnologia. In generale, questa tesi offre una completa esplorazione della Fused Granular Fabrication, fornendo importanti conoscenze sul suo funzionamento, punti di forza, debolezze e strategie per la risoluzione dei problemi.
Exploring Fused Granular Fabrication (FGF) technology : principles, troubleshooting and design considerations
Villano, Fabio
2022/2023
Abstract
Fused Granular Fabrication (FGF) is one of the lesser-known additive manufacturing (AM) technologies in which material pellets, typically thermoplastics, are melted and deposited on a bed layer by layer to create 3D-objects from CAD data. This thesis aims to explain the working principles of FGF, describe its strengths and weaknesses, address common printing issues, propose effective solutions, and provide practical validation of troubleshooting strategies and the feasibility of producing durable goods through the use of a non-industrial FGF machine. The paper begins by introducing the fundamentals concepts of the additive manufacturing processes and the corresponding design guidelines (DfAM). It then provides an explanation of material extrusion processes, with a focus on two different technologies: Fused Modelling Deposition (FDM) and FGF. Through a comparative analysis, the distinctions, advantages, and disadvantages of FDM and FGF are examined, offering an understanding of their unique characteristics. Subsequently, the thesis identifies and discusses potential printing defects and issues encountered when using an FGF machine. Each issue is analyzed to determine its potential causes and suitable solutions, aiming to equip practitioners with effective troubleshooting strategies. To practically validate the covered topics, the thesis documents the encountered printing faults and their corrective action during a two-month internship utilizing a low-cost, large-scale FGF printer (ginger.one printer by Ginger Additive). Additionally, a short project developed using the Generative Design tool was carried out as part of the internship. This was documented and used to demonstrate the applicability of the technology when producing durable goods and to draw useful conclusions about the printer and its technology. Overall, this thesis offers a comprehensive exploration of Fused Granular Fabrication, providing valuable insights into its operation, strengths, weaknesses, and troubleshooting strategies.| File | Dimensione | Formato | |
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2023_07_Villano Battagliese.pdf
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Descrizione: Thesis file - Fabio Villano Battagliese
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https://hdl.handle.net/10589/211420