Transition Behavior in Blended Material Large Format Additive Manufacturing

Large-Format Additive Manufacturing (LFAM) offers the ability to 3D print composites at multi-meter scale and high throughput by utilizing a screw-based extrusion system that is compatible with pelletized feedstock. As such, LFAM systems like the Big Area Additive Manufacturing (BAAM) system provide a pathway for incorporating AM techniques into industry-scale production. Despite significant growth in LFAM techniques and usage in recent years, typical Multi-Material (MM) techniques induce weak points at discrete material boundaries and encounter a higher frequency of delamination failures. A novel dual-hopper configuration was developed for the BAAM platform to enable in situ switching between material feedstocks that creates a graded transition region in the printed part. This research studied the influence of extrusion screw speed, component design, transition direction, and material viscosity on the transition behavior. Material transitions were monitored using compositional analysis as a function of extruded volume and modeled using a standard Weibull cumulative distribution function (CDF). Screw speed had a negligible influence on transition behavior, but averaging the Weibull CDF parameters of transitions printed using the same configurations demonstrated that designs intended to improve mixing increased the size of the blended material region. Further investigation showed that the relative difference and change in complex viscosity influenced the size of the blended region. These results indicate that tunable properties and material transitions can be achieved through selection and modification of composite feedstocks and their complex viscosities.