Browsing by Author "Nemes, Vivien"

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Deformation Characterization of Glass Fiber and Carbon Fiber-Reinforced 3D Printing Filaments Using Digital Image Correlation
(MDPI, Basel, Switzerland, 2025) Nemes, Vivien; Szalai, Szabolcs; Szívós, Brigitta Fruzsina; Sysyn, Mykola; Kurhan, Dmytro; Fischer, Szabolcs
ENG: The paper offers an in-depth deformation study of glass fiber-reinforced and carbon composite filaments of 3D printers. During the certification, the authors used DIC (Digital Image Correlation) as a full-field strain measurement technique to explore key material traits as a non-contact optical measurement method. The insights captured through the DIC technology enabled to better understand the localized strain distributions during the loading of these reinforced filaments. The paper analyzes the glass fiber and carbon fiber filaments used in 3D printing that are reinforced with these materials and are subjected to bending and compressive loading. The segment presents how loading affects the performance of reinforced filaments when varying such factors as the deposition patterns, layer orientation, and other process parameters. Different types and combinations of reinforcements and printing variables were tested, and the resulting dependencies of mechanical parameters and failure modes were established for each case. Key conclusions demonstrate that the mechanical behavior of both carbon- and glass fiber-reinforced filaments is strongly affected by the 3D printing parameters, particularly infill density, pattern, and build orientation. The application of Digital Image Correlation (DIC) allowed for a precise, full-field analysis of strain distribution and deformation behavior, offering new insights into the structural performance of fiber-reinforced 3D printed composites. The findings from the study provide guidance for the proper choice of filling material and the optimal parameters for the 3D printing process of models with high-performance indexes and seamless applications in the automotive and industrial manufacturing sectors.
Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming
(MDPI, Basel, Switzerland, 2025) Szalai, Szabolcs; Szívós, Brigitta Fruzsina; Nemes, Vivien; Szabó, György; Kurhan, Dmytro; Sysyn, Mykola; Fischer, Szabolcs
ENG: This study addresses the emerging need for efficient and cost-effective solutions in low-volume production by exploring the mechanical performance and industrial feasibility of cutting tools that are fabricated using stereolithography apparatus (SLA) technology. SLA’s high-resolution capabilities make it suitable for creating precise cutting dies, which were tested on aluminum sheets (Al99.5, 0.3 mm, and AlMg3, 1.0 mm) under a 60-ton hydraulic press. Measurements using digital image correlation (DIC) revealed minimal wear and deformation, with tolerances consistently within IT 0.1 mm. The results demonstrated that SLA-printed tools perform comparably to conventional metal tools in cutting and bending operations, achieving similar surface quality and edge precision while significantly reducing the production time and cost. Despite some limitations in wear resistance, the findings highlight SLA technology’s potential for rapid prototyping and short-run manufacturing in the automotive and electronics sectors. This research fills a critical gap in understanding SLA-based tooling applications, offering insights into process optimization to enhance tool durability and broaden material compatibility. These advancements position SLA technology as a transformative tool-making technology for flexible manufacturing.
Investigation of FDM-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Cutting
(MDPI, Basel, Switzerland, 2025) Szalai, Szabolcs; Szívós, Brigitta Fruzsina; Nemes, Vivien; Szabó, György; Kurhan, Dmytro; Sysyn, Mykola; Fischer, Szabolcs
ENG: Within the scope of the work, the possible use of fused deposition modeling (FDM) technology in executing rapid prototypes of cutting tools for aluminum sheets was systematically studied. Relevant investigations have thus far mainly concentrated on tools for the 3D printing of bent and deep-drawn pieces, yet the implementation of FDM tools in cutting has been insufficiently covered. This study aims to determine the characteristics of FDM cutting tools, such as wear and tear, dimensional stability, and cutting efficiency. Various tool designs were tested under different wall thicknesses and orientations with respect to the feed of Al99.5 sheets with thicknesses of 0.22 mm and 0.3 mm. According to the results, in the best case, three-dimensional printed PLA tools performed six cuts with no burrs and an acceptable wear level due to the IT tolerances (IT9 and IT10). Tools with thicker walls and more appropriate orientations were found to be more robust. However, some designs failed when subjected to greater loads, revealing a deficiency in some of the strength properties of the material. These observations suggest that it is possible to create 3D printed tools for modeling and small-scale production at considerably cheaper and faster rates than conventional methods. Future work will integrate advanced materials and designs to enhance tool performance, further solidifying FDM as a transformative approach in industrial tool manufacturing. With this research, the authors wanted to demonstrate that FDM technology can also be used to produce a classic sheet cut, which, of course, is still of great importance for prototyping or setting up production processes. This research demonstrated that FDM printing can play a role in this area.