Changing the Paradigm-Controlling Polymer Morphology during 3D Printing Defines Properties

Area of Science:

• Materials Science
• Manufacturing Engineering
• Polymer Science

Background:

• Direct digital manufacturing (DDM) allows fabrication from digital models, streamlining prototyping and mass customization.
• Current DDM often focuses solely on product form, neglecting potential for property control.
• Medical device applications offer significant opportunities for advanced DDM.

Purpose of the Study:

• To expand DDM beyond form specification to include control over material properties.
• To develop a methodology for printing spatially varying material properties.
• To demonstrate the creation of products with tailored mechanical characteristics.

Main Methods:

• Utilized in situ time-resolving small-angle X-ray scattering (SAXS) at the ALBA Synchrotron Light Source.
• Investigated control over semi-crystalline polymer morphology during extruder-based 3D printing.
• Correlated printed morphology patterns with resultant material properties, specifically modulus.

Main Results:

• Successfully demonstrated control over polymer morphology during 3D printing.
• Established a link between controlled morphology and spatially varied material properties.
• Produced example products exhibiting designed variations in polymer modulus.

Conclusions:

• DDM can be advanced to control both the form and properties of fabricated products.
• In situ SAXS is an effective method for evaluating and controlling morphology during 3D printing.
• This approach enables the creation of advanced polymeric materials with tailored spatial property distributions.