Material extrusion (ME) is a layer-by-layer additive manufacturing process that is now used in personal and commercial production where prototyping and customization are required. However, parts produced from ME frequently exhibit poor mechanical performance relative to those from traditional means; moreover, fundamental knowledge of the factors leading to development of inter-layer strength in this highly non-isothermal process is limited. In this work, we seek to understand the development of inter-layer weld strength from the perspective of polymer interdiffusion under conditions of rapidly changing mobility. Our framework centers around three interrelated components: in situ thermal measurements (via infrared imaging), temperature dependent molecular processes (via rheology), and mechanical testing (via mode III fracture). We develop the concept of an equivalent isothermal weld time and test its relationship to fracture energy. For the printing conditions studied the equivalent isothermal weld time for T_ref = 230 °C ranged from 0.1 ms to 100 ms. The results of these analysis provide a basis for optimizing inter-layer strength, the limitations of the ME process, and guide development of new materials.

In embedded 3D printing, wherein a submerged nozzle extrudes fluid inks into a support bath, the viscosity ratio and interfacial energy between the ink and support control the shape of extruded filaments and droplets.

It is widely known that the printing quality of fused filament fabrication (FFF) is heavily affected by environmental temperature and humidity, taking the form of warping and porosity. However, there is little understanding about the quantitative relations between environmental conditions, geometry, and the mechanical properties of printed parts. In this study, we systematically investigated those relations using bisphenol A polycarbonate as a model material system. For the environmental temperature, an in-situ infrared imaging analysis revealed the presence of an up to 5.4 °C/mm thermal gradient when printing using an open-chamber printer and a heated build plate. For the environmental humidity, an analysis of X-ray micro-computed tomography (micro-CT) scans showed an up to 11.7% porosity that was brought by polymer water content absorbed from environmental moisture. Meanwhile, tensile tests showed a mechanical performance loss associated with those defects, but, surprisingly, the transverse direction ductility had the potential to increase at a higher porosity. Furthermore, the experimental results were combined with analytical and parametrical studies to elucidate quantitative relations between environmental conditions and printing quality. Based on the results, quantitative guidelines for the estimation of printing quality based on environmental conditions are provided that would also help users to obtain desired printing results with a better understanding of the effects of environmental conditions.

Biofabrication has been adapted in engineering patient-specific biosynthetic grafts for bone regeneration. Herein, we developed a three-dimensional (3D) high-resolution, room-temperature printing approach to fabricate osteoconductive scaffolds using calcium phosphate cement (CPC). The non-aqueous CPC bioinks were composed of tetracalcium phosphate, dicalcium phosphate anhydrous, and Polyvinyl butyral (PVB) dissolved in either ethanol (EtOH) or tetrahydrofuran (THF). They were printed in an aqueous sodium phosphate bath, which performs as a hardening accelerator for hydroxyapatite formation and as a retainer for 3D microstructure. The PVB solvents, EtOH or THF, affected differently the slurry rheological properties, scaffold microstructure, mechanical properties, and osteoconductivity. Our proposed approach overcomes limitations of conventional fabrication methods, which require high-temperature (>50 °C), low-resolution (>400 μm) printing with an inadequate amount of large ceramic particles (>35 μm). This proof-of-concept study opens venues in engineering high-resolution, implantable, and osteoconductive scaffolds with predetermined properties for bone regeneration.