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Large Scale Additive Manufacturing (LSAM) defines a system that can be used for printing
components on the order of several meters at high extrusion rates (up to 50 kg/hr). The feed stock
material is in the form of thermoplastic or fiber reinforced thermoplastic pellets which are almost 20
times cheaper than the filament based feedstock. The system has the potential to significantly affect
automobile, aerospace and energy industries. However, the design constraints of small-scale 3D
printing may not be applied to the large-scale printing due to the nature of the process. New design
rules and limitations should be taken into consideration. In this study, the maximum bridging distance
in large scale direct extrusion 3D printing system is investigated experimentally. A specially designed
V-shaped model is used for testing. The experiments were carried out for 2 mm, 4 mm and 6 mm
nozzle diameters under free- and forced-air cooling conditions. The failure of bead is determined in
terms of break off and sags down. The maximum bridge distance is dependent on the printer settings
(nozzle diameter, extrusion rate, travel speed, etc.), material, surface area-to-volume ratio of the
extruded bead and cooling rate (thermal effects).
International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019
Ömer Eyercioğlu
Mehmet Aladağ
Adem Aksoy
Kursad Gov