Crystallization modeling of two semi-crystalline polyamides during material extrusion additive manufacturing

In this work, a heat transfer model is developed for thermally-driven material extrusion additive manufacturing of semicrystalline polymers that considers the heat generated during crystallization by coupling crystallization kinetics with heat transfer. The materials used in this work are Technomelt PA 6910, a semicrystalline hot melt adhesive with sub-ambient glass transition temperature (T_g) and slow crystallization, and PA 6/66, a traditional semicrystalline polyamide with a higher T_g and fast crystallization. The coupled model shows that the released heat during crystallization depends on material selection, with Technomelt PA 6910 and PA 6/66's temperatures increased by less than 1 °C and up to 6.3 °C, respectively, due to enthalpy of crystallization. Increasing the layer time decreases the layer temperature as well as the initial crystallinity. However, its effect on final crystallinity in Technomelt PA 6910 is negligible due to continued crystallization of the material after printing. Experimental validation shows good agreement for Technomelt PA 6910, but consistently underpredicts PA 6/66 crystallinity. Increasing modeled environmental temperature leads to better agreement with experimental results for PA 6/66, suggesting that higher temperatures may have been experienced. Shear-induced crystallization may also be contributing to crystallinity in this material. The results from this model highlight the importance of and interrelationships between material and processing parameter selection and can aid in achieving quality prints from semicrystalline thermoplastics.