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Weld formation during material extrusion additive manufacturing.

Jonathan E Seppala1, Seung Hoon Han, Kaitlyn E Hillgartner

  • 1Materials Science and Engineering Division, National Institute of Standards and Technology, Gaithersburg, MD 20899, USA. jonathan.seppala@nist.gov.

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Summary
This summary is machine-generated.

Material extrusion (ME) parts have weak layer adhesion. This study links polymer interdiffusion during printing to inter-layer strength, using thermal imaging, rheology, and fracture testing to improve 3D printed part performance.

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Area of Science:

  • Additive Manufacturing
  • Polymer Science
  • Materials Engineering

Background:

  • Material extrusion (ME) is a widely used additive manufacturing process for prototyping and customization.
  • ME parts often suffer from inferior mechanical properties compared to traditionally manufactured components.
  • Limited understanding exists regarding the development of inter-layer strength in the non-isothermal ME process.

Purpose of the Study:

  • To investigate the development of inter-layer weld strength in material extrusion by examining polymer interdiffusion.
  • To establish a framework correlating thermal history, molecular mobility, and mechanical performance.
  • To identify key factors influencing the fracture energy of ME-printed parts.

Main Methods:

  • In situ thermal measurements using infrared imaging.
  • Rheological analysis to determine temperature-dependent polymer mobility.
  • Mode III fracture testing to quantify inter-layer mechanical strength.
  • Development and application of an equivalent isothermal weld time concept.

Main Results:

  • Quantified inter-layer weld strength development through polymer interdiffusion dynamics.
  • Established a relationship between equivalent isothermal weld time and fracture energy.
  • Determined equivalent isothermal weld times ranging from 0.1 ms to 100 ms at a reference temperature of 230 °C.
  • Identified critical process parameters influencing inter-layer adhesion.

Conclusions:

  • The study provides a fundamental understanding of inter-layer strength development in material extrusion.
  • Findings offer a basis for optimizing ME process parameters to enhance part mechanical performance.
  • The developed framework guides the design of novel materials with improved interlayer adhesion for additive manufacturing.