Optimization of Laser Direct Structuring Process Parameters for Material Extrusion of Polycarbonate

Abstract

Laser direct structuring is critical in the integration of circuits onto 3D‐shaped plastic parts, such as antennas and RF components. Laser direct structuring process encompasses three stages: deposition of 3D parts, laser structuring, and metallization. While laser direct structurable parts have been manufactured through plastic injection molding, material extrusion is a favored additive manufacturing process for economic low‐volume production and fast prototyping advantages. Although injection‐molded laser direct structuring literature is available, 3D printed laser direct structured components merit further investigation. This study focuses on material extrusion of catalyst‐loaded polycarbonate parts and its laser direct structuring process. Parameters from the nanosecond fiber laser, including scan speed, power, and frequency, were thoroughly analyzed to understand the surface property changes and metallization performance of the printed polycarbonate parts. The single scan track width corresponds to the accuracy of conductive path width and metallization thickness, was employed to elucidate the findings. A process map was built to keep the track width constant aimed at enhancing the uniform metallization of intricate components. Thresholds were established, identifying a minimum track width of 22.1 µm and metallization thickness of 2.5 µm. These delineate clusters of process parameters that yield conductivity levels suitable for various applications.This article is protected by copyright. All rights reserved.