Additive Manufacturing of Thermoset Elastomer-Thermoplastic Composites Using Dual-Extrusion Printing

Area of Science:

• Materials Science
• Polymer Engineering
• Additive Manufacturing

Background:

• 3D printing of multi-material systems is challenging.
• Integrating thermoset elastomers with thermoplastics requires understanding interfacial adhesion.

Purpose of the Study:

• Investigate 3D printing of compounded thermoset elastomers.
• Evaluate adhesion between thermoset elastomers and thermoplastics.
• Determine the influence of process parameters on adhesion.

Main Methods:

• Utilized a custom 3D printer for processing elastomers and thermoplastics.
• Studied adhesion strength by varying material combinations and process parameters.
• Performed elemental analysis to investigate interfacial interactions.

Main Results:

• Interfacial bonding improved with proximity of solubility parameters and amorphous thermoplastic morphology.
• Increased chain mobility at processing temperature enhanced adhesion.
• Lower temperature, longer duration curing yielded superior adhesion compared to shorter, higher-temperature cures.
• Elemental analysis confirmed interfacial migration of rubber components.

Conclusions:

• Successful 3D printing of thermoset elastomers with thermoplastics is feasible.
• Material properties and processing parameters critically influence adhesion.
• Findings enable multi-material 3D printing for demanding applications.