Fused filament fabrication - Wikipedia

Fused filament fabrication (FFF), also known as fused deposition modeling (with the trademarked acronym FDM), or called filament freeform fabrication, ... Fusedfilamentfabrication FromWikipedia,thefreeencyclopedia Jumptonavigation Jumptosearch 3Dprintingprocess Mainarticle:3Dprintingprocesses PrusaI3,asimplefusedfilamentprinter Fusedfilamentfabrication(FFF),alsoknownasfuseddepositionmodeling(withthetrademarkedacronymFDM),orcalledfilamentfreeformfabrication,isa3Dprintingprocessthatusesacontinuousfilamentofathermoplasticmaterial.[1]Filamentisfedfromalargespoolthroughamoving,heatedprinterextruderhead,andisdepositedonthegrowingwork.Theprintheadismovedundercomputercontroltodefinetheprintedshape.Usuallytheheadmovesintwodimensionstodepositonehorizontalplane,orlayer,atatime;theworkortheprintheadisthenmovedverticallybyasmallamounttobeginanewlayer.Thespeedoftheextruderheadmayalsobecontrolledtostopandstartdepositionandformaninterruptedplanewithoutstringingordribblingbetweensections."Fusedfilamentfabrication"wascoinedbythemembersoftheRepRapprojecttogiveanacronym(FFF)thatwouldbelegallyunconstrainedinitsuse.[2] Fusedfilamentprintingisnowthemostpopularprocess(bynumberofmachines)forhobbyist-grade3Dprinting.[3]Othertechniquessuchasphotopolymerisationandpowdersinteringmayofferbetterresults,buttheyaremuchmorecostly. Illustrationofadirectdriveextruderwhichshowsthenameofparts. The3Dprinterheador3Dprinterextruderisapartinmaterialextrusionadditivemanufacturingresponsibleforrawmaterialmeltingorsofteningandformingitintoacontinuousprofile.Awidevarietyoffilamentmaterialsareextruded,includingthermoplasticssuchasacrylonitrilebutadienestyrene(ABS),[4]polylacticacid(PLA),polyethyleneterephthalateglycol(PETG),polyethyleneterephtathalate(PET),high-impactpolystyrene(HIPS),thermoplasticpolyurethane(TPU)andaliphaticpolyamides(nylon).[5] Contents 1History 2Process 2.1Materialextrusion 2.1.1Variantsoftheprocess 2.2Printing 2.2.1Physicsoftheprocess 3Applications 3.1Commercialapplications 3.2Freeapplications 3.2.1Development 3.2.2Costof3Dprinter 3.3Materials 4Printheadkinematics 4.1Extrudermounttorestofmachine 4.1.1Deltarobotprinters 5Seealso 6References 7Furtherreading History[edit] AdesktopFFFprintermadebyStratasys. FuseddepositionmodelingwasdevelopedbyS.ScottCum,co-founderofStratasys,in1988.[6][7]Withthe2009expirationofthepatentonthistechnology,[8]peoplecouldusethistypeofprintingwithoutpayingStratasysfortherighttodoso,openingupcommercial,DIY,andopen-source(RepRap)3Dprinterapplications.Thishasledtoatwo-orders-of-magnitudepricedropsincethistechnology'screation.[9]Stratasysstillownsthetrademarkontheterm"FDM".[10][11] Process[edit] Thissectionismissinginformationaboutpost-processing(solventsmoothing,annealing/remelting,etc.).Pleaseexpandthesectiontoincludethisinformation.Furtherdetailsmayexistonthetalkpage.(December2020) 3Dprinting,alsoreferredtoasadditivemanufacturing(AM),involvesmanufacturingapartbydepositingmateriallayerbylayer.[12]ThereisawidearrayofdifferentAMtechnologiesthatcandothis,includingmaterialextrusion,binderjetting,materialjettinganddirectedenergydeposition.[13]Theseprocesseshavevariedtypesofextrudersandextrudedifferentmaterialstoachievethefinalproduct. Materialextrusion[edit] Filamentproductionwithextruder Diagramofadirectdriveextruder. Fusedfilamentfabricationusesmaterialextrusiontoprintitems,whereafeedstockmaterialispushedthroughanextruder.Inmostfusedfilamentfabrication3Dprintingmachines,thefeedstockmaterialcomesintheformofafilamentwoundontoaspool. The3Dprinterliquefieristhecomponentpredominantlyusedinthistypeofprinting.Extrudersfortheseprintershaveacoldendandahotend.Thecoldendpullsmaterialfromthespool,usinggear-orroller-basedtorquetothematerialandcontrollingthefeedratebymeansofasteppermotor.Thecoldendpushesfeedstockintothehotend.Thehotendconsistsofaheatingchamberandanozzle.Theheatingchamberhoststheliquefier,whichmeltsthefeedstocktotransformitintoaliquid.Itallowsthemoltenmaterialtoexitfromthesmallnozzletoformathin,tackybeadofplasticthatwilladheretothematerialitislaidon.Thenozzlewillusuallyhaveadiameterofbetween0.3 mmand1.0 mm.Differenttypesofnozzlesandheatingmethodsareuseddependinguponthematerialtobeprinted.[14] Differenttypesofnozzleshavedifferentwaysofreplacingthem.ThemostcommonusednozzlesaretheV6nozzlesmadepopularbyE3DandMK8nozzles.Changingthenozzle[15]mustbedonewhilehot,toavoidplasticleaks. Variantsoftheprocess[edit] Hotextrusionofrods-Inthesetypesof3dprintingmachines,thefeedstockisinformofarodinsteadofafilament.Sincetherodisthickerthanthefilament,itcanbepushedtowardsthehotendbymeansofapistonorrollers,applyingagreaterforceand/orvelocitycomparedtoconventionalFFF.[16] Coldextrusionofslurries-[17]Inthesetypesof3Dprintingmachines,thefeedstockcomesinformofaslurry,apasteoraclay—allofwhichareviscoussuspensionofsolidpowderparticlesinaliquidmedium,whichisdriedafterdeposition.Inthiscase,thematerialisgenerallypushedtowardsthenozzlebytheactionofapiston,andthenozzleisnotheated.Paste-likematerialssuchasceramicsandchocolatecanbeextrudedusingthefusedfilamentprocessandaspecializedpasteextruder.[18] Hotextrusionofpellets-Inthesetypesof3dprintingmachinesthefeedstockcomesinformofpellets,i.e.smallgranulesofthermoplasticmaterial[19]ormixturesofthermoplasticbinderwithpowderfillers.[20]Thematerialispushedtowardsthenozzlebytheactionofapistonorarotatingscrew,whicharecontainedbyanextrusionbarrel.Inthiscasethewholeextrusionbarrelisheated,alongwiththenozzle. Printing[edit] Infusedfilamentfabrication,afilamenta)ofplasticmaterialisfedthroughaheatedmovingheadb)thatmeltsandextrudesitdepositingit,layerafterlayer,inthedesiredshapec).Amovingplatforme)lowersaftereachlayerisdeposited.Forthiskindof3Dprintingtechnologyadditionalverticalsupportstructuresd)areneededtosustainoverhangingparts Exampleofa3Dprinter. Timelapsevideoofahyperboloidobject(designedbyGeorgeW.Hart)madeofPLAusingaRepRap"PrusaMendel"3Dprinterformoltenpolymerdeposition. Atimelapsevideoofarobotmodel(logoofMakemagazine)beingprintedusingFFFonaRepRapProFisherprinter. FFFbeginswithasoftwareprocesswhichprocessesanSTLfile(STereoLithographyfileformat),orientingthemodelforthebuildprocessandmathematicallyslicingthemodelaccordingtotheprocessingparametersselected.Ifrequired,supportstructuresmaybegenerated.[21] Thenozzlecanbemovedinbothhorizontalandverticaldirections,andismountedtoamechanicalstage,whichcanbemovedinthexyplane. Process:1–3DPrinterExtruder,2–depositedmaterial(modeledpart),3–controlledmovabletable Asthenozzleismovedoverthetableinaprescribedgeometry,itdepositsathinbeadofextrudedplastic,calleda‘‘road’’whichsolidifiesquicklyuponcontactwiththesubstrateand/orroadsdepositedearlier.[22]Solidlayersaregeneratedbyfollowingarasterizingmotionwheretheroadsaredepositedsidebysidewithinanenvelopingdomainboundary. Steppermotorsorservomotorsaretypicallyemployedtomovetheextrusionhead.ThemechanismusedisoftenanX-Y-Zrectilineardesign,althoughothermechanicaldesignssuchasdeltabothavebeenemployed. Oncealayeriscompleted,theplatformisloweredinthezdirectioninordertostartthenextlayer.Thisprocesscontinuesuntilthefabricationoftheobjectiscompleted. Forsuccessfulbondingoftheroadsintheprocess,thermalcontrolofthedepositedmaterialisnecessary.Thesystemcanbekeptinsideachamber,maintainedatatemperaturebelowthemeltingpointofthematerialbeingdeposited. AlthoughasaprintingtechnologyFFFisveryflexible,anditiscapableofdealingwithsmalloverhangsbythesupportfromlowerlayers,FFFgenerallyhassomerestrictionsontheslopeoftheoverhang,andcannotproduceunsupportedstalactites. Myriadmaterialsareavailable,suchasAcrylonitrileButadieneStyrene(ABS),Polylacticacid(PLA),Polycarbonate(PC),Polyamide(PA),Polystyrene(PS),lignin,rubber,amongmanyothers,withdifferenttrade-offsbetweenstrengthandtemperatureproperties.Inaddition,eventhecolorofagiventhermoplasticmaterialmayaffectthestrengthoftheprintedobject.[23]RecentlyaGermancompanydemonstratedforthefirsttimethetechnicalpossibilityofprocessinggranularPEEKintofilamentformand3DprintingpartsfromthefilamentmaterialusingFFFtechnology.[24] DuringFFF,thehotmoltenpolymerisexposedtoair.OperatingtheFFFprocesswithinaninertgasatmospheresuchasnitrogenorargoncansignificantlyincreasethelayeradhesionandleadstoimprovedmechanicalpropertiesofthe3Dprintedobjects.[25]Aninertgasisroutinelyusedtopreventoxidationduringselectivelasersintering. Physicsoftheprocess[edit] 3DPrinterExtruderDrivingForce.WhereD_fisDiameterofFilamentandL_fisLengthoffilament Duringextrusionthethermoplasticfilamentisintroducedbymechanicalpressurefromrollers,intotheliquefier,whereitmeltsandisthenextruded.Flowgeometryoftheextruder,heatingmethodandthemeltflowbehaviorofanon-Newtonianfluidareofmainconsiderationinthepart.Therollersaretheonlydrivemechanisminthematerialdeliverysystem,thereforefilamentisundertensilestressupstreamtotherollerandundercompressionatthedownstreamsideactingasaplunger.Therefore,compressivestressisthedrivingforcebehindtheextrusionprocess. Theforcerequiredtoextrudethemeltmustbesufficienttoovercomethepressuredropacrossthesystem,whichstrictlydependsontheviscouspropertiesofthemeltedmaterialandtheflowgeometryoftheliquefierandnozzle.Themeltedmaterialissubjectedtosheardeformationduringtheflow.Shearthinningbehaviorisobservedinmostofthematerialsusedinthistypeof3-Dprinting.ThisismodeledusingpowerlawforgeneralizedNewtonianfluids. Thetemperatureisregulatedbyheatinputfromelectricalcoilheaters.Thesystemcontinuouslyadjuststhepowersuppliedtothecoilsaccordingtothetemperaturedifferencebetweenthedesiredvalueandthevaluedetectedbythethermocouple,forminganegativefeedbackloop.Thisissimilartoambientheatingofaroom. Applications[edit] Commercialapplications[edit] FFFandtheothertechnologiesofadditivemanufacturingbymaterialextrusion(EAM)techniquesarecommonlyusedforprototypingandrapidmanufacturing.Rapidprototypingfacilitatesiterativetesting,andforveryshortruns,rapidmanufacturingcanbearelativelyinexpensivealternative.[26]EAMisalsousedinprototypingscaffoldsformedicaltissueengineeringapplications.[27]Moreover,EAMwithmultiextrusionhavebecomeverypopulartofabricatebiomimeticcomposites.[28]FFFisalsoappliedinmanufacturingwithinothersectors,includingaerospace,automotive,construction,electronics,energy,pharmaceuticals,sports, textiles,andtoys.[29] Freeapplications[edit] RepRapversion2.0(Mendel) Fab@HomeModel2(2009) PrintinginprogressinanUltimaker3DprinterduringMozillaMakerparty,Bangalore Airwolf3DAW3Dv.4(Prusa) Therearemultipleprojectsintheopen-sourcedcommunityaimedatprocessingpost-consumerplasticwasteintofilament.Theseinvolvemachinesusedtoshredandextrudetheplasticmaterialintofilamentsuchasrecyclebots. Severalprojectsandcompaniesaremakingeffortstodevelopaffordable3Dprintersforhomedesktopuse.MuchofthisworkhasbeendrivenbyandtargetedatDIY/enthusiast/earlyadoptercommunities,withadditionaltiestotheacademicandhackercommunities.[30] RepRapisoneofthelongestrunningprojectsinthedesktopcategory.TheRepRapprojectaimstoproduceafreeandopensourcehardware(FOSH)3Dprinter,whosefullspecificationsarereleasedundertheGNUGeneralPublicLicense,andwhichiscapableofreplicatingitselfbyprintingmanyofitsown(plastic)partstocreatemoremachines.[2][31]RepRapshavealreadybeenshowntobeabletoprintcircuitboards[32]andmetalparts.[33][34]Fab@HomeistheotheropensourcehardwareprojectforDIY3Dprinters. BecauseoftheFOSHaimsofRepRap,manyrelatedprojectshaveusedtheirdesignforinspiration,creatinganecosystemofrelatedorderivative3Dprinters,mostofwhicharealsoopensourcedesigns.Theavailabilityoftheseopensourcedesignsmeansthatvariantsof3Dprintersareeasytoinvent.Thequalityandcomplexityofprinterdesigns,however,aswellasthequalityofkitorfinishedproducts,variesgreatlyfromprojecttoproject.Thisrapiddevelopmentofopensource3Dprintersisgaininginterestinmanyspheresasitenableshyper-customizationandtheuseofpublicdomaindesignstofabricateopensourceappropriatetechnology.Thistechnologycanalsoassistinitiativesinsustainabledevelopmentsincetechnologiesareeasilyandeconomicallymadefromresourcesavailabletolocalcommunities.[35][36] Development[edit] Customer-drivenproductcustomizationanddemandforcostandtimesavingshaveincreasedinterestinagilityofmanufacturingprocess.Thishasledtoimprovementsinrapidprototypingtechnologies.[37]Thedevelopmentofextrudersisgoingrapidlybecauseoftheopensource3-DprintermovementcausedbyproductslikeRepRap.E3DandBondTecharethemostknownextrudermanufacturerscurrentlyonthemarket.Consistentimprovementsareseenintheformofincreasedheatingtemperatureofliquefiers,bettercontrolandprecisionofprints,andimprovedsupportforawidevarietyofmaterials.Besidestheimprovedhardware,theabilitytocalibratetheextruder[38]accordingtothehardwaresetuphascomealongway. Costof3Dprinter[edit] Thecostof3Dprintershasdecreaseddramaticallysinceabout2010,withmachinesthatusedtocostUS$20,000nowcostinglessthanUS$1,000.[39]Forinstance,asof2017,severalcompaniesandindividualsaresellingpartstobuildvariousRepRapdesigns,withpricesstartingataboutGB£99/US$100.[40] TheopensourceFab@Homeproject[41]hasdevelopedprintersforgeneralusewithanythingthatcanbeextrudedthroughanozzle,fromchocolatetosiliconesealantandchemicalreactants.Printersfollowingtheproject'sdesignshavebeenavailablefromsuppliersinkitsorinpre-assembledformsince2012atpricesintheUS$2,000range. TheLulzBot3DprintersmanufacturedbyAlephObjectsareanotherexampleofanopen-sourceapplicationoffuseddepositionmodelingtechnology.TheflagshipmodelintheLulzBotline,theTAZprintertakesinspirationforitsdesignfromtheRepRapMendel90andPrusai3models.TheLulzBot3Dprinteriscurrentlytheonlyprinteronthemarkettohavereceivedthe"RespectsYourFreedom"certificationfromtheFreeSoftwareFoundation.[42] AsofSeptember2018RepRapstyleprintersarereadilyavailableinkitformthroughonlineretailers.Thesekitscomecompletewithallpartsneededtomakeafunctioningprinter,oftenincludingelectronicfilesfortestprintingaswellasasmallquantityofPLAfilament. FIlamentsusedforprintingwithFDMprintersarealsosubstantiallymorecost-effectivethantheirSLAresincounterparts.Ifweuse3DBenchyasabenchmarkforcomparingbothtechnologies,itwouldcostroughly$0.20toprintsuchamodelwithanFDMmachine,whereasthesameobjectwouldcostalmost$1.00ifcreatedwithresin[43]. Materials[edit] Plasticisthemostcommonmaterialfor3dprintingviaFFFandotherEAMvariants.Variouspolymersmaybeused,includingacrylonitrilebutadienestyrene(ABS),polycarbonate(PC),polylacticacid(PLA),high-densitypolyethylene(HDPE),PC/ABS,polyethyleneterephthalate(PETG),polyphenylsulfone(PPSU)andhighimpactpolystyrene(HIPS).Ingeneral,thepolymerisintheformofafilamentfabricatedfromvirginresins.Additionally,fluoropolymerssuchasPTFEtubingareusedintheprocessduetothematerial'sabilitytowithstandhightemperatures.Thisabilityisespeciallyusefulintransferringfilaments. ThemanydifferentvariantsofEAM,i.e.ofmaterialExtrusionbasedAdditiveManufacturingallowdealingwithmanyadditionalmaterialtypes,summarisedinthetablebelow.Severalmaterialclassescanbeextrudedand3dprinted: Thermoplasticpolymers,itisthemosttypicalapplicationofFDM; Compositematerialswithpolymericmatrixandshortorlonghardfibers; Ceramicslurriesandclays,oftenusedincombinationwiththerobocastingtechnique; Greenmixturesofceramicormetalpowdersandpolymericbinders,usedinEAMofmetalsandceramics; Foodpastes; Biologicalpastes,usedinbioprinting. Materialsthatcanbe3dprintedwithEAM(AdditiveManufacturingtechnologiesbymaterialExtrusion) Materialclass examples Post-processingrequirements Typicalapplications Thermoplasticpolymers PLA,ABS,ABSi,HDPE,PPSF,PC,PETG,Ultem9085,PTFE,PEEK,recycledplastics supportremoval Thesematerialsareusedfortheirheatresistanceproperties.Ultem9085alsoexhibitsfireretardancymakingitsuitableforaerospaceandaviationapplications. Polymermatrixcomposites GFRP,CFRP[44] supportremoval,curing Structuralapplications Ceramicslurriesandclays Alumina,Zirconia,Kaolin[45] supportremoval,furnacedryingandsintering Insulation,consumersobjects,dentalapplications Greenceramic/bindermixture Zirconia,Calciumphosphate[46] supportremoval,debinding,sintering structuralceramics,piezoelectriccomponents Greenmetal/bindermixture Stainlesssteel,Titanium,Inconel[20] supportremoval,debinding,sintering Tooling,fixtures,mechanicalparts Greenmetal/ceramic/bindermixture Stainlesssteel,Iron,tricalciumphosphate,yttria-stabilizedzirconia[47] supportremoval,debinding,sintering Mechanicalparts,implants Foodpastes chocolate,sugar[48] cooking Biologicalmaterials bioink[49] bioprintedorgansandscaffolds Conductivepolymercomposites CompositeswithCarbonBlack,Graphene,CarbonNanotubesorCopperNanoparticles[50] Annealingforlowerconductivity Sensors FFFprintedandsinteredcomponentsmadeofstainlesssteel(316L) Metallographicsectionofprintedandsinteredfilamentlayer(iron-tricalciumphosphate-composite) Printheadkinematics[edit] RepRap-typeprinter Themajorityoffusedfilamentprintersfollowthesamebasicdesign.Aflatbedisusedasthestartingpointfortheprintworkpiece.Agantryabovethiscarriesthemovingprinthead.ThegantrydesignisoptimizedformovementmostlyinthehorizontalX&Ydirections,withaslowclimbintheZdirectionasthepieceisprinted.Steppermotorsdrivethemovementthrougheitherleadscrewsortoothedbeltdrives.Itiscommon,owingtothedifferencesinmovementspeed,tousetoothedbeltsfortheX,YdrivesandaleadscrewforZ.SomemachinesalsohaveXaxismovementonthegantry,butmovethebed(andprintjob)forY.As,unlikelasercutters,headmovementspeedsarelow,steppermotorsareuniversallyusedandthereisnoneedtouseservomotorsinstead. Manyprinters,originallythoseinfluencedbytheRepRapproject,makeextensiveuseof3Dprintedcomponentsintheirownconstruction.Thesearetypicallyprintedconnectorblockswithavarietyofangledholes,joinedbycheapsteelthreadedrod.Thismakesaconstructionthatischeapandeasytoassemble,easilyallowsnon-perpendicularframingjoints,butdoesrequireaccesstoa3Dprinter.Thenotionof'bootstrapping'3DprinterslikethishasbeensomethingofadogmaticthemewithintheRepRapdesigns.Thelackofstiffnessintherodalsorequireseithertriangulation,orgivestheriskofagantrystructurethatflexesandvibratesinservice,reducingprintquality. Manymachinesnowusebox-likesemi-enclosedframesofeitherlaser-cutplywood,plastic,pressedsteelsheetandmorerecentlyaluminumextrusions.Thesearecheap,rigidandcanalsobeusedasthebasisforanenclosedprintvolume,allowingtemperaturecontrolwithinittocontrolwarpingoftheprintjob. Ahandfulofmachinesusepolarcoordinatesinstead,usuallymachinesoptimizedtoprintobjectswithcircularsymmetry.Thesehavearadialgantrymovementandarotatingbed.Althoughtherearesomepotentialmechanicaladvantagestothisdesignforprintinghollowcylinders,theirdifferentgeometryandtheresultingnon-mainstreamapproachtoprintplanningstillkeepsthemfrombeingpopularasyet.Althoughitisaneasytaskforarobot'smotionplanningtoconvertfromCartesiantopolarcoordinates,gaininganyadvantagefromthisdesignalsorequirestheprintslicingalgorithmstobeawareoftherotationalsymmetryfromtheoutset. Extrudermounttorestofmachine[edit] Thewaysextrudersaremountedontherestofthemachinehaveevolvedovertimeintoinformalmountingstandards.Suchfactorstandardsallowsnewextruderdesignstobetestedonexistingprinterframes,andnewprinterframedesignstouseexistingextruders.Theseinformalstandardsinclude:[14] VerticalXAxisStandard Quick-fitextrudermount OpenXmount Deltarobotprinters[edit] Printingbyalargedeltarobotprinter Adifferentapproachistakenwith'Rostock'or'Kossel'patternprinters,basedonadeltarobotmechanism.[51][52]Thesehavealargeopenprintvolumewithathree-armeddeltarobotmountedatthetop.Thisdesignofrobotisnotedforitslowinertiaandabilityforfastmovementoveralargevolume.Stabilityandfreedomfromvibrationwhenmovingaheavyprintheadontheendofspindlyarmsisatechnicalchallengethough.Thisdesignhasmostlybeenfavoredasameansofgainingalargeprintvolumewithoutalargeandheavygantry. Astheprintheadmovesthedistanceofitsfilamentfromstoragecoiltoheadalsochanges,thetensioncreatedonthefilamentisanothertechnicalchallengetoovercometoavoidaffectingtheprintquality. 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Furtherreading[edit] "ResultsofMakeMagazine's20153DPrinterShootout".Retrieved1June2015. "EvaluationProtocolforMakeMagazine's20153DPrinterShootout".makezine.com.2014-11-07.Retrieved1June2015. Stephens,Brent;Azimia,Parham;ElOrcha,Zeineb;Ramos,Tiffanie(November2013)."UltrafineParticleEmissionsfromDesktop3DPrinters".AtmosphericEnvironment.79:334–339.Bibcode:2013AtmEn..79..334S.doi:10.1016/j.atmosenv.2013.06.050. "HowFusedDepositionModelingWorks".THRE3D.com.ArchivedfromtheoriginalonFebruary21,2014.Retrieved7February2014. "3DPrintingprocessandHowFDMtechnologyworks".homeshop3dprinting.com(Video).Retrieved4June2014. "RepRapproject'scompletelistofG-codeusedby3Dprinter'sfirmware".RepRap.org.Retrieved26August2015. "FDMTechnologyMadeSimple".chizel.io.2018-07-16.Retrieved10July2019. 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