One of the fundamental issues in the Fused Filament Fabrication (FFF) additive manufacturing process lies in the mechanical property anisotropy where the strength of the FFF-3D printed part in the build-direction can be significantly lower than that in other directions. The physical phenomenon that governs this issue is the coupled effect of macroscopic thermal mechanical issues associated with the thermal history of the interface, and the microscopic effect of the polymer microstructure and mass transfer across interfaces. In this study it was found that the use of 34.4 kHz ultrasonic vibrations during FFF-3D printing results in an increase of up to 10% in the interlayer adhesion in Acrylonitrile Butadiene Styrene (ABS), comparing the printing in identical thermal conditions to that in conventional FFF printing. This increase in the interlayer adhesion strength is attributed to the increase in polymer reptation due to ultrasonic vibration-induced relaxation of the polymer chains from secondary interactions in the interface regions.
Fused lament fabrication is one of the most widely used additive manufacturing processes for producing thermal plastic polymer materials due to the affordable cost and capability to build objects with complex structures. However, parts fabricated with this process exhibit lower mechanical strength when compared to parts manufactured using traditional methods. In this work, an in-process orbiting laser healing technique is developed and implemented on a 3D printer to enhance mechanical strength by improving interlayer adhesion. The orbiting laser assembly can position and align the laser-heated spot before the change of nozzle direction occurs, ensuring that the previous layer is heated prior to material deposition. This laser-heating technique increases the bending strength along build direction by 40% and reaches 88.9% of strength along track direction. With this technique, the displacement at facture also increased by 54.3% compared to control sample. The thermal pro le of the melting pool and fracture surface was further characterized using a thermal camera and SEM to support the effect of laser heating on polymer microstructure, respectively. Due to its enhanced print quality and lower cost, this technique has the potential to expand the application eld of fused lament fabrication to small batch and series production that are currently dominated by injection molding, as well as the high-quality prototyping eld.
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