Purpose: The purpose of this paper is to investigate the factors governing bond strength in fused deposition modeling (FDM) compared to strength in the fiber direction. Design/methodology/approach: Acrylonitrile butadiene styrene (ABS) boxes with the thickness of a single fiber were made at different platform and nozzle temperatures, print speeds, fiber widths and layer heights to produce multiple specimens for measuring the strength. Findings: Specimens produced with the fibers oriented in the tensile direction had 95 per cent of the strength of the constitutive filament. Bond strengths ranged from 40 to 85 per cent of the filament strength dependent on the FDM processing conditions. Diffusion, wetting and intimate contact all separately affect bond strength. Practical implications: This study provides processing recommendations for producing the strongest FDM parts. The needs for higher nozzle temperatures and more robust feed motors are described; these recommendations can be useful for companies producing FDM products as well as companies designing FDM printers. Originality/value: This is the first study that discusses wetting and intimate contact separately in FDM, and the results suggest that a fundamental, non-empirical model for predicting FDM bond strength can be developed based on healing models. Additionally, the role of equilibration time at the start of extrusion as well as a motor torque limitation while trying to print at high speeds are described.

An in-line rheometer has been incorporated into a fused deposition modeling printer for the first time by designing a modified nozzle with a custom pressure transducer and a thermocouple for measuring the processed melt temperature. Additionally, volumetric flow rates and shear rates were monitored by counting the stepper motor pulses as well as the pulses from a custom filament encoder to account for filament slippage and skipped motor steps. The incorporation of the sensors and the design and development of the in-line rheometer are described; and pressures, temperatures, and viscosities within the 3D printing nozzle are presented. The in-line rheometer was validated against traditional, off-line rotational rheology and capillary rheology measurements by analyzing two polymeric materials: polycarbonate and high-impact polystyrene. A variety of rheological corrections were considered for the in-line rheometer, including entrance effects, non-Newtonian corrections, shear heating, pressure effects, and temperature fluctuations/inaccuracies. Excellent agreement was obtained between the in-line and off-line rheometers after applying the most critical corrections, which were found to be entrance effects, non-Newtonian corrections, and temperature inaccuracies. After applying the appropriate corrections, the in-line rheometer provides an accurate viscosity measurement that can be used for real-time monitoring and process control.

Purpose: The purpose of this paper is to present a diffusion-controlled healing model for predicting fused deposition modeling (FDM) bond strength between layers (z-axis strength). Design/methodology/approach: Diffusion across layers of an FDM part was predicted based on a one-dimensional transient heat analysis of the interlayer interface using a temperature-dependent diffusion model determined from rheological data. Integrating the diffusion coefficient across the temperature history with respect to time provided the total diffusion used to predict the bond strength, which was compared to the measured bond strength of hollow acrylonitrile butadiene styr (ABS) boxes printed at various processing conditions. Findings: The simulated bond strengths predicted the measured bond strengths with a coefficient of determination of 0.795. The total diffusion between FDM layers was shown to be a strong determinant of bond strength and can be similarly applied for other materials. Research limitations/implications: Results and analysis from this paper should be used to accurately model and predict bond strength. Such models are useful for FDM part design and process control. Originality/value: This paper is the first work that has predicted the amount of polymer diffusion that occurs across FDM layers during the printing process, using only rheological material properties and processing parameters.

Polyamides (PAs) are repeatedly exposed to environments of varying humidity throughout their service life. Due to their hygroscopic nature, moisture diffusion can alter the polymer properties, sometimes irreversibly. It has been previously found that the effect of transport of water on the structure, morphology, and physical properties of polymers is not negligibly small. In certain semi-crystalline polyamides, the diffusion coefficient has been shown to be governed by the local chain dynamics (β relaxation). The final molecular weight of PAs achieved after melt processing is a result of the equilibrium between the forward and reverse polycondensation depending on the water concentration. With the growing demand for unreinforced and reinforced polyamides as well as polyamide fibers in high-performance applications, it is critical to understand the physics of the interaction between water molecules and polymer or composite systems. This article reviews the existing literature about polyamide-water interactions with a focus on the governing physical laws of moisture transport within the polyamide matrix, drying kinetics, and dynamics of water in the polymer system. The implications of moisture on the processing and properties of the polyamides class of materials are also discussed, suggesting the need for best practices in instrumentation and control.

An in-line rheometer and data acquisition system are used to monitor the melt pressure, melt temperature, and environmental temperatures while producing parts via fused filament fabrication (FFF). Melt pressures are observed to increase when printing parts with small layer heights, which is attributed to the confined space created between the nozzle and the previous layer (i.e., an exit pressure). These exit pressures (referred to as contact pressure) and the resulting interlayer contact areas are analyzed for 2863 layers created at 21 different processing conditions. The measured contact pressure was found to directly influence the shape of the layers and the resulting interlayer contact. An intimate contact model based on contact pressure is combined with a wetting model to accurately predict the interlayer contact of FFF parts. This pressure-driven intimate contact model for FFF shows strong agreement with the observed interlayer contact. No theoretical model has previously existed for predicting interlayer contact, so this research provides a critical component for developing a comprehensive part strength model. Both the measurements and proposed model are sufficiently simple and accurate for real-time analysis of FFF quality, so the described in-line sensors provide valuable quality insights and are recommended for future researchers, printer manufacturers, and end-users.