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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ABSTRACT In this paper, polyether ether ketone (PEEK) composites reinforced with CFs (20%; 30%, 40% by weight) have been manufactured and fully investigated means of structural, morphological, functional analytical techniques. The structural analyses Xray Diffraction (XRD), Wide Angle Scattering (WAXS) Small (SAXS) revealed nonlinear crystalline disorder in the PEEK matrix induced incorporation different amounts CF. Raman spectroscopy corroborated these findings, showing shifts key vibrational bands associated fillerpolymer interactions disorder. Thermal analysis indicated that obtained maintain high thermal stability (degradation temperature > 540C) slight changes melting behavior crystallinity degree (36 30%) due to CF inclusion. Furthermore, presence filler increases mechanical properties (E 19 GPa, max 170 MPa). According specific rheological properties, CFmodified are suitable for extrusionbased applications, such as 3D printing.

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Innovative multimaterial for additive manufacturing with mechanically robust regions and recyclability. The multimaterial is made by a reaction scheme of thiol-ene, thiol-epoxy, and epoxy-epoxy monomers that can be printed using volumetric additive manufacturing techniques. The resulting material has regions with different mechanical properties due to the chemical composition. The multimaterial also contains urethane bonds that allow recycling by depolymerization using excess thiols.

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Silicone elastomers are widely used in biomedical devices and soft machines because of their compliance, inertness, biocompatibility. Their sol-gel transition during curing enables mold casting layer-by-layer manufacturing, allowing the fabrication fully elastomeric hybrid soft-rigid devices. However, controlling adhesion at material interfaces remains elusive, especially under diverse temperature conditions. This study introduces a framework that relates strength to dimensionless reaction coordinate coupling time temperature. can be predict from bulk fracture adhesive failure, which is crucial create robust with strong interfaces. Using this framework, we fabricated robotic actuators demonstrated 3D printing direct ink writing. The achieved 50% higher curvature same design, 3D-printed parts exhibited over 200% improvement interlayer adhesion. work serves as tool for optimizing interfacial materials across different approaches.

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Three-dimensional printing device that improves layer adhesion by actively cooling the previous layer before dispensing the next one. The device has a movable stage and a print head with a nozzle. After dispensing a layer, the stage moves away from the heater to cool the previous layer. Then, the stage moves closer to the heater again for the next dispensing. This active cooling prevents the previous layer from collapsing when the next layer is dispensed on top.

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Faster 3D printing of stronger parts using a modified extrusion nozzle that allows filling cavities within printed shells. The method involves dispensing material to create walls that define cavities, then contacting the nozzle distal surface to the walls to seal. Material is injected through the nozzle into the sealed cavities. The injected material interlocks with the walls due to variations in cavity width. This provides stronger parts compared to decomposing wide cavities into smaller parallel ones. The modified nozzle allows wider cavity filling. The technique involves planning the shell and cavity geometry for optimal injection.

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In this paper, titanium oxide nanoparticles (TiO2-NPs) with complex surface topologies were obtained for the first time using simple procedures applied in laser sintering. Based on and polymethyl methacrylate-like photopolymer resin, a composite material (MPR/TiO2-NPs) 3D printing was created MSLA technology. Products made of containing from 0.001 to 0.1% wt. TiO2-NPs didnt contain internal defects less brittle than resin without nanoparticles. MPR/TiO2-NPs well polished; after polishing, areas variation profile height 10 nm found surfaces. Nanoparticles volume products are apparently unevenly distributed; there alternating micrometer sizes slightly higher lower concentrations Spectroscopy showed that adding developed promoted better polymerization MPR resin. The addition increased its ability generate active forms oxygen damage biomacromolecules. At same time, resulting exhibits significant antibacterial properties doent affect growth reproduction animal cells. can be very effective basis additive manufacturing improved physical chemical balanced biological activity.

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Improving the appearance and structural stability of 3D printed objects with multiple color layers. The method involves stacking thin outer color layers around the thick base layers on each print level, gradually building up the outer shell. This allows higher precision for the outermost parts compared to base layers. The thin outer layers also adhere to the base layers, enhancing bonding. The method avoids protruding edges that can peel.

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ABSTRACT Nanofillers are widely used to enhance the properties of polymeric materials due their small particle size and high specific surface area. In this study, functionalized silicabased Janus nanosheets (JNS) grafted with styreneacrylonitrile copolymer (SAN) chains on one side epoxy groups opposite have been synthesized, termed SANSilicaepoxy JNS, incorporated as modifiers into acrylonitrilebutadienestyrene copolymer/polyethylene terephthalate (ABS/PET) blends for fused deposition modeling (FDM) applications via meltextrusion processing. Compared unmodified blends, ABS/PET addition only 0.5 phr SANsilicaepoxy JNS exhibited significant property enhancements, where melt flow rate was increased by 47.9%, layer adhesion enhanced 115.7%, warpage degree reduced 48.8%. Furthermore, mechanical performance endowed simultaneous optimization, such a 74% increase in impact strength 13% tensile strength. This work introduces strategy developing 3D printing that combine excellent processability superior through interfacial compatibility optimization nanofiller reinfo... Read More

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Additively manufacturing a component with improved uniformity and reduced energy waste by optimizing energy application at each layer. The method involves calculating an energy parameter at the current layer location based on the shape overlap between the new layer and existing part. This parameter is used to determine the optimal amount of energy to apply at that location. By tailoring the energy input based on the geometry of the previous layers, it prevents over- or under-melting and promotes more consistent consolidation.

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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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