“Metal Fused Filament Fabrication (MFFF or MF3) is a promising additive manufacturing technique that democratizes metal production, allowing small-scale manufacturers and researchers to access advanced metal fabrication capabilities. This master thesis investigates the feasibility and optimization of Aluminum Metal Fused Filament Fabrication. The research encompasses a comprehensive analysis of the filament material, the printing process, as well as studies on chemical and thermal debinding, and subsequent sintering trials. The first phase of the study focuses on the study and analysis of an aluminum-based filament produced by The Virtual Foundry, the PLA-based Aluminum 6061 Filamet™. In-depth material analysis, including X-ray tomography and thermal analysis, is conducted to understand the base material, its properties and effects on the rest of the manufacturing process. Then, printing parameters are proposed and an analysis of the printed parts in made. The parts were then analyzed, from the dimensional accuracy to the voids distribution and crystallinity, as well as the effects of those properties on the remaining manufacturing steps. Subsequently, chemical and thermal debinding trials were done and, since the chemical debinding trials were inconclusive, in the end only thermal debinding was performed. A throughout analysis of the thermal debinding process was conducted and the influences of various parameters as the atmosphere and the isotherm length was studied. Finally, the sintering process was studied from encapsulated mediums to full sized ovens. It was found that it is not possible to sinter parts neither when encapsulated nor in TGA-sized ovens, but sintering was accomplished when sintering in a full-sized oven at 675◦C. Although not perfect, the results are encouraging and this works serves as a proof of concept for Aluminum Metal Fused Filament Fabrication.”
Full paper published to DIAL.mem in 2023 https://dial.uclouvain.be/memoire/ucl/fr/object/thesis%3A43260