Incremental Forming of Polymeric Sheet Printed by Fused Deposition Modeling

Single point incremental forming (SPIF) and fused deposition modeling 3D printing (FDM) are two methods of rapid prototyping. Each method has its own pros and cons. using SPIF method can provide an accurate forming process to shape sheets fabricated by 3D printing with their special characteristics. In this study, single-point incremental forming of Poly Lactic Acid (PLA) sheets fabricated by FDM 3D printer was investigated by experiments. The formability process was evaluated by two different experiments. In the first experiment, a lubricant was used at ambient temperature and SPIF was investigated and for the second experiment hot air and lubrication were employed to achieve better formability. In addition, the effects of sheet thickness and strategy of layering of printed sheets by FDM were also studied on SPIF formability. The results showed that the incremental forming of printed PLA sheets in hot air is a more successful state to produce dome shapes parts and ruptures are less and this forming method can be used for some applications such as making partial curve of skull as a medicine solution in surgeries. Also, it was shown that the best layering strategy to print the PLA sheets used for better forming of SPIF is triangular pattern strategy against with rectangular strategy. It was found that thickness of 2mm printed sheet has better formability and less rupture versus 3mm of thickness.