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Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing
Published on: February 11, 2016
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Shear Performance and Numerical Simulation of Adhesively Bonded Joints in Multi-Jet Fusion 3D-Printed Polyamide
Frantisek Sedlacek1, Martin Stejskal1, Nikola Bednarova1
1Faculty of Mechanical Engineering-Regional Technological Institute, University of West Bohemia, Univerzitni 8, 31200 Pilsen, Czech Republic.
Polymers
|November 27, 2025
Summary
This study tested four adhesives for bonding 3D printed polyamides (PA12 and PA12GB). A polyurethane adhesive achieved the highest shear strength, outperforming epoxy alternatives for additive manufacturing applications.
Area of Science:
- Materials Science and Engineering
- Additive Manufacturing
- Adhesion Science
Background:
- Additive manufacturing (AM) technologies like HP Multi-Jet Fusion (MJF) are increasingly used for functional end-use parts.
- Polyamides (PA12) are common MJF materials but are challenging to bond effectively.
- Optimizing adhesive bonding is crucial for expanding the application range of AM components.
Purpose of the Study:
- To investigate the shear strength of bonded joints using two common MJF polyamides: PA12 and glass-bead-filled PA12 (PA12GB).
- To evaluate the performance of four different industrial adhesives on these 3D printed substrates.
- To analyze the influence of surface roughness and substrate composition on adhesive joint strength.
Main Methods:
- Single-lap-shear test specimens were fabricated using an HP MJF 4200 printer.
- Adhesive bonding was performed using a custom jig, followed by mechanical testing on a Zwick-Roell Z250 machine.
- Surface roughness was measured using a 3D optical microscope; finite element analysis (FEA) simulated stress distribution.
Main Results:
- A polyurethane-based adhesive (3M Scotch-Weld DP620NS) yielded the highest shear strengths: 5.0 MPa for PA12 and 4.4 MPa for PA12GB.
- The hybrid cyanoacrylate-epoxy adhesive (Loctite HY4090) showed increased performance on the PA12GB substrate.
- Adhesive type significantly impacted performance, accounting for 65.7% of the variance in bond strength.
Conclusions:
- Polyurethane adhesives offer superior performance for bonding MJF polyamides compared to epoxy alternatives.
- Substrate composition (PA12 vs. PA12GB) affects adhesive performance, with specific adhesives showing varied responses.
- FEA simulations provide valuable insights into stress distribution, complementing experimental shear strength data for AM applications.
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