Increase Inter-Layer Bonding in 3D Printed Parts

A method for 3D printing multi-layer structures with improved interlayer adhesion to prevent delamination. The method involves creating cavities that cross multiple layers during printing and then filling the cavities with a second material to form rivets perpendicular to the layers. The rivets compress the surrounding layers as they cool and contract, increasing adhesion.

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Improving the tensile strength of 3D printed green bodies to prevent damage during transportation and handling prior to fusing. The method involves selectively applying an adhesion promoter containing multihydrazide compounds like adipic dihydrazide to the binder fluid used in 3D printing. The multihydrazide adhesion promoter enhances the bonding between layers of particulate build material when forming the green body.

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Method for manufacturing a three-dimensional shaped object with high adhesion between layers without using solvents. The method involves shaping a first layer, cutting it, heating it to a temperature below the resin's glass transition temperature, and then shaping subsequent layers on top. The heating step increases adhesion between the layers.

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Printing head for 3D printers that improves adhesion between layers of printed objects. The nozzle of the head includes a texturing member that protrudes from the main surface of the printed layer. These protrusions increase the contact surface area between layers, improving adhesion strength. The textured layer interfaces lock together better when subsequent layers are printed on top. The protrusions can be clamping features that grip the next layer.

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A method to improve interlayer adhesion in 3D printed objects made by fused material extrusion, e.g., FDM. The method involves extruding adjacent layers at different temperatures. The temperature difference between layers should be at least 5°C. This sequence of alternating temperatures enhances bonding between layers to improve the overall strength of the printed object. The layers are fused together after extrusion to form the final article.

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A feedstock for additive manufacturing that enables strong interlayer bonding in 3D printed objects. The feedstock contains removable capsules that, when extracted after printing, leave voids on the surface of the solidified layer. The voids are then filled by the next layer's material, forming mechanical interlocks between layers. This provides enhanced adhesion compared to regular printing.

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Additive Manufacturing (AM) is considered a vital ingredient in Industry 4.0. Its manner of production depositing material on layer-on-layer basis. However, this normally generates undesirable layer lines. A common solution used to address technique known as Vapor Smoothing (VS). VS modern process where chemical vapor produced contact the surface Fused Deposition Modelling (FDM) fabricated parts. This would result disruption parts outer layers resulting smoothening its surface. type study has abundant Acrylonitrile Butadiene Styrene (ABS)-based research but currently lacks Polylactic Acid (PLA). Roughness only one criteria for good FDM PLA part. Mechanical strength should also be an acceptance criterion. Having said this, characterization such Optical Microscopy with ImageJ processing; and tensile testing via Universal Testing Machine (UTM) were utilized. introduced calculated response roughness can attained without sacrificing too much form S/R ratio. It was identified that optimum smoothing parameters are 55 degrees C exposure time 4-min, we able attain from 10.600 3.999 um whil... Read More

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ABSTRACT Fused deposition modeling (FDM) of carbon fiber reinforced thermoplastics is a key technology for advanced industrial applications due to its simplicity and costeffectiveness. The properties FDMprinted parts are significantly influenced by printing parameters, necessitating thorough understanding their effects. This study investigates the impact print speed on thermal, structural, chemical, mechanical polylactic acid (CFRPLA), lightweight composite widely used in engineering. Thermal behavior was analyzed using differential scanning calorimetry thermogravimetric analysis. Structural chemical were characterized via xray diffraction Fourier transform infrared spectroscopy. Tensile testing employed evaluate performance. Results reveal that higher promotes CFRPLA crystallinity but reduces thermal stability degradation resistance. Increased also led decrease stiffness strength (by 29.7% 5.1%, respectively), coupled with enhanced ductility toughness 18.77% 15.4%, attributed presence large air voids fibermatrix debonding, as observed through electron microscopy (SEM). A... Read More

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ABSTRACT Material extrusion additive manufacturing demonstrates considerable potential in fabricating core structures with complex and advanced geometries, which greatly promotes the mechanical performances of sandwich composites. However, interfacial bonding limitations between skin sheets restrict promised superior properties overall This study addresses weak interface issue by innovatively combining mesogrooves submicro GNP addition to form a multiscale enhancement strategy. Measured data from threepoint bending tests revealed that these modifications resulted 28% increase strength 59.2% modulus compared untreated composite structures. Scanning electron microscopy (SEM) schematic illustrations further explained underlying mechanisms contributing improved strength. During fused deposition modeling process, were created onto top surfaces shortcarbon fiberfilled ABS (CFABS) core, establishing interlocking textures for continuouscarbon fiber fabric skin. Controlled alignment chopped fibers extending beyond deposited bead boundaries microscale connections epoxy ... Read More

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Deposition Modeling, or FDM, is a popular method for 3D printing technology capable of constructing intricate models purely based on design. Recently, there has been shift towards using FDM mass production purposes due to the evolution materials making it easier create unique products personal and commercial purposes. Particularly, conductive thermoplastic composites are used make sensors electronic parts incorporation into printed structures. Nevertheless, can have some issues such as weak interlayer adhesion among constituent layers, from which mechanical strength objects reduced. In this case, heat treatment procedures aimed at increasing interlaminar shear (ILSS) fiber-reinforced PEEK proposed. Evidence suggests that controlling rates yields robust improvement performance.

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Adhesive bonding is a widely used technique in large-scale composite manufacturing for joining fibre-reinforced laminates. This study introduces an innovative modification to single-lap joint (SLJ) fabrication through co-curing, employing novel interleaved and conventional lamination methods, incorporating untreated 3-Glycidyloxypropyl-trimethoxysilane (GPTMS) treated stainless steel 304 wire mesh (SS 304) reinforcement. The investigates the impact of these reinforcements on vibrational shear properties various SLJ configurations, such as Plain (PSLJ), Mesh-reinforced (MSLJ), Interleaved Mesh (IMSLJ), GPTMS-treated (GMSLJ), (GIMSLJ) with 1 wt% glass powder adhesive. Results showed that strength increased by 76.97%, 64.55%, 56.79%, 44.59% GIMSLJ, GMSLJ, IMSLJ, MSLJ, respectively, compared PSLJ (35.72%) pure epoxy SLJ. Furthermore, GIMSLJ GMSLJ adhesive exhibited higher natural frequency other reinforced Fractography revealed incorporation (over layer) mesh, along 1wt% adhesive, enhances interfacial between adherend. Additionally, one-way (ANOVA analysis variance) was performed using J... Read More

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Automatically identifying and correcting defects during 3D printing jobs to improve the bonding strength between layers and overall quality of 3D printed objects. The system monitors the printing process to detect bonding failures, analyzes the defects to determine corrective actions, and performs them during the print job to fix weak points and prevent layer separation. Corrective actions include inserting pins through layers that haven't bonded properly, filling cavities with additional material, and encouraging bonding at predicted weak points prior to printing.

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ABSTRACT The production of nanocomposite parts through the additive manufacturing process has become popular due to its precision in creating complex geometries. This study focuses on predicting tensile strength 3Dprinted nanocomposites with varying print orientations. Filament properties, interlayer adhesion, and porosity serve as model inputs. Finite element modeling shows that adhesion raster path have very little effect part longitudinal, transverse, shear directions. A semiempirical formulation is developed calculate strengths based properties utilized filament feedstock printer. results show a good agreement numerical experimental results. Finally, simple quadratic failure criterion combination classical lamination theory predict for specimens different analytical an excellent observations.

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Multimaterial 3D printing allows for the production of intricate parts with customized mechanical properties, enhancing versatility material extrusion additive manufacturing. Typically, machines are fed commercially available filament feedstock, which limits multiple materials. Hence, this study introduces in-house prepared filaments creating polymer blend structures improved properties. In study, polylactic acid and thermoplastic poly ester urethane (PEU) blends different composition ratios were processed by varying infill densities to evaluate their impacts on thermal, morphological The effects percentage mechanical, thermal behaviour investigated. results indicate that increasing tends significantly increase elastic modulus tensile strength. maximum strain increased as increased. Overall, indicated that, without sacrificing any strength, composite 25% PEU exhibited better toughness than did neat PLA could be printed similarly PLA. Furthermore, scanning electron images revealed had a homogeneous structure fibrillar morphology. These is an effective technique next generation 4D

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This paper is focused on the modification of commercial resin by using biobased fillers during stereolithography (SLA) 3D printing. research aims to create a composite material with matrix made commercially available photosensitive modified filler based secondary raw materials and formed as by-products in processing biological materials. The determines effect different tensile properties hardness samples printed SLA printing, it also investigates their integrity SEM analysis. study evaluate feasibility these for producing 3D-printed parts technology. results this open up new possibilities designing additive 3D-printing technology fillers. Within framework activities, positive an improved interfacial interface between was demonstrated several tested Significant increases strength 22% occurred systems filled cotton flakes (CF), miscanthus (MS), walnut (WN), spruce tree (SB), wheat (WT) eggshells (ES). potential further activities added value shown most bio-fillers. A significant contribution current demonstration mechanical performance natural

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Additive manufacturing of articles using reformable resin feed materials that combine the processing characteristics of thermoplastics with the performance characteristics of thermosets. The feed materials are polymeric, reformable epoxy resins that can be melt processed like thermoplastics but also exhibit epoxy-like properties like rigidity and adhesion. They are made by reacting epoxide-containing reactants with functional groups like amines. The reformable epoxy resin can be extruded, pelletized, or dispersed for additive manufacturing. The materials soften and adhere when heated but remain tack-free at room temperature. This allows layer-by-layer buildup without crosslinking or fusing between layers. The articles can be made by depositing the reformable resin layers on a substrate and selectively bonding dissimilar materials with intermediate layers.

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Polyaryletherketone (PAEK) polymers with specific properties for use in additive manufacturing to improve layer adhesion and mechanical properties of 3D printed parts. The PAEK polymers have a shear viscosity of 145-350 Pa·s at 400°C and 1000 s−1, measured by capillary rheometry. This viscosity range allows the polymer to flow well during printing and not crystallize too quickly, improving mixing between adjacent layers. The polymers also have long isothermal crystallization half-lives of greater than 12 minutes at 280°C, measured by DSC. This slow crystallization rate prevents premature solidification between layers during printing.

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ABSTRACT In this work, polypropylene (PP)based filaments for Fused Filament Fabrication (FFF) containing boron nitride (BN) and talc (T) were developed, aiming at formulating multimaterial 3D printed parts showing thermal conductivity balanced mechanical properties. Particularly, skincore structures obtained by localizing BN in the surface layers while confining T core characterized, their properties compared to those of correspondent monomaterial samples. The characterization PP/BN samples revealed a crucial role FFF process inducing higher radial direction specimens as axial one, owing preferential alignment fillers along printing allowing creation continuous conductive paths inplane direction. For structures, it was demonstrated that thermally allows achieving samples; instance, nearly doubled values decreasing number BNcontaining from 15 3. Most importantly, exhibit tensile modulus stress practically identical PP/T samples, despite lower content reinforcing filler presence interfaces between two different composites.

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This study investigates the impact of open time and binder composition on interlayer adhesion in 3D printed cementitious materials. As additive manufacturing (AM) emerges as a transformative tool construction, optimizing layer-to-layer bonding becomes critical for structural safety scalability. We assess how hydration heat rheological behavior various bindersincluding ordinary Portland cement (OPC), fly ash, ground granulated blast furnace slag (GGBFS)interact with intervals between layer depositions. Findings confirm that delayed deposition weakens adhesion, particularly under high heat. Blended binders offer improved resilience due to moderated kinetics extended workability. work contributes standardizing performance criteria digital construction.

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3D printing method using a pasty polyurethane composition that enables layer-by-layer printing of 3D parts with improved interlayer adhesion and dimensional stability. The pasty composition has a thixotropic viscosity that allows dimensional stability of printed layers without deformation. The composition is radiation and heat curable, with radiation curing providing initial dimensional stability and heat curing providing final thermoset properties. The thixotropy prevents layer collapse during printing, while the dual cure enables good interlayer adhesion.

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