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AMB2018-03: Benchmark Physical Property Measurements for Material Extrusion Additive Manufacturing of Polycarbonate.

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  • 1Vehicle Technology Directorate, CCDC US Army Research Laboratory, Aberdeen Proving Ground, MD, USA.

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Material extrusion 3D printing of polycarbonate shows anisotropic strength due to pores and poor bonding. This study provides experimental data to guide models predicting final part properties.

Keywords:
3-D printingAM-benchAdditive manufacturingFDMFused deposition modelingPolycarbonateRheologyThermoplastic material extrusionX-ray computed tomography

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Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Polymer Science

Background:

  • Material extrusion (MatEx) is widely used for thermoplastic additive manufacturing.
  • Predicting anisotropic part strength in MatEx is challenging.
  • Existing models require comprehensive experimental data for validation.

Purpose of the Study:

  • To provide experimental data for developing theoretical and computational models of MatEx part properties.
  • To establish benchmarks for processing-structure-property relationship studies.
  • To investigate the mechanical properties of 3D printed polycarbonate.

Main Methods:

  • Characterization of precursor polycarbonate filament (rheology, GPC, DMA).
  • Analysis of printed parts using X-ray CT, SEM, indentation, and AFM.
  • Tensile testing to evaluate strength and anisotropy.

Main Results:

  • Identified pore networks, poor interfacial bonding, and variable interfacial behavior as key factors degrading tensile properties.
  • Observed negative deviation in part strength compared to injection molding.
  • Quantified local modulus variations and failure mechanisms.

Conclusions:

  • Experimental data offers insights into processing-structure-property relationships in MatEx.
  • Findings serve as benchmarks for mechanical model development.
  • Understanding degradation factors is crucial for optimizing 3D printed part performance.