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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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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Abstract A 3D Benchy was successfully printed using kraft lignin as the primary component of a fused deposition modeling (FDM) filament. The filament produced by compounding (TcC) with thermoplastic polyurethane (TPU) and adding up to 10% micro crystalline cellulose (MCC). compound then extruded into 1.75 mm influence addition MCC on morphological, thermal, rheological, mechanical properties composite studied. Rheological data reveal that increases processable temperature range 10C 190210C. show reduces tensile strength 27.5% while increasing Young's Modulus 40.7%. When printed, ligninbased shows high surface adhesion between layers, resolution dimensional accuracy, along excellent shape retention parts. Highlights Lignin filaments are majority component. is microcrystalline (MCC) assessed High print resolution, post printing

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Abstract Fused filament fabrication (FFF) technology, recognized as a leading 3D printing method for the production of continuous carbon fiber reinforced thermoplastic polymer (CCFRTP) components, has garnered significant attention due to its design flexibility, independence from molds, and capability rapid prototyping complex structures. This paper presents comprehensive analysis review challenges associated with enhancing mechanical properties stemming interfacial bonding issues pore defects in 3Dprinted CCFRTP parts. Specifically, this study thoroughly examines modification techniques pertinent two critical constituents materials: resin matrix reinforcement. It also explores advancements FFF equipment specifically designed alongside current developments related impregnation processes. Furthermore, work introduces an evolution continuum path planning grounded principles structural lightweight while applying topology optimization create anisotropic The influence various process parameters on is analyzed systematically; additionally, processing strategies that incorporate auxiliar... Read More

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Abstract 3D printing, such as fused deposition modeling (FDM), is an advanced shaping technology, employing a layerbylayer process to construct objects. However, the weak interlayer bonding restricts performance and functionality of FDMfabricated parts. Herein, boronate bond exchange utilized enhance mechanical strength enable modular 4D printing polylactic acid (PLA). Blending dynamic system endows PLA with improved adhesion welding capabilities. The blended filaments demonstrate excellent printability, 150% enhancement in Zaxis strength, while nearly unchanged along Xaxis. Moreover, this enhanced facilitates assembly intricate structures, eliminating need for traditional 3Dprinted supports. Combined shape memory effects, diverse possibilities are demonstrated. This strategy highlights potential covalent bonds enhancing not only material but also intelligent designs.

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Abstract The fused deposition modeling or threedimensional (3D) extrusion fabrication of material parts from thermoplastics, including poly(lactic acid) (PLA) usually results in inferior mechanical performance due to weak interlayer bonding compared injection molded parts. In this work, a solventfree, effective, and inexpensive method is developed by incorporating photoinitiators during 3D followed postprocess UV treatment improve the 3Dprinted PLA part's performance. This addresses key challenges printed parts, such as poor toughness sensitivity, while enabling its use highperformance additive manufacturing (AM) processes. UVcuring process enhances PLA's suitability for printing, supporting complex geometries custom designs enhancing crosslinking between adjacent chains, under exposure. solventfree nature aligns with sustainable manufacturing, strengthening role an ecofriendly alternative petroleumbased polymers. A standout result approach 64% improvement tensile properties photoinitiator samples untreated PLA, achieved through UVcuring. advanc... Read More

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3D printer with integrated welding capability to join 3D printed parts during printing. The printer has a movable hot air welding head in addition to the print head. The controller coordinates the movement of both heads to weld parts together as they are being printed. This allows creating complex 3D structures with joined sections made from different materials that can't be 3D printed alone. The hot air welding fuses the melted plastics together.

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Method for 3D printing without using a start plate by directly printing on the build platform. The method involves gradually increasing the energy level of the laser or electron beam used for powder melting as the layers are built. This allows sintering the powder without melting it, forming a strong build platform. The part is then printed on top of the sintered platform. The platform is removed after printing. This eliminates the need for a separate start plate and reduces build times.

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Three-dimensional printing compositions with improved properties for additive manufacturing of objects. The compositions contain two coreactive components with functional groups that react with each other. At least one functional group in each component is saturated, without double bonds. This reduces viscosity and reaction rate compared to unsaturated functional groups. The saturated functional groups prevent excessive crosslinking during deposition, allowing better shape retention. The compositions can be used in 3D printing techniques like extrusion or inkjetting to build objects layer by layer. The saturated functional groups enable controlled curing and shape maintenance.

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Device for heat control and accurate welding of dissimilar additively-manufactured parts. The device has a temperature control mechanism with a platform to hold the parts, cooling beneath the LMD part, heating beneath the SLM part, and protective gas spray. It also has a pressing mechanism to prevent deformation during welding. The platform moves, the pressing mechanism folds, and the heating head rotates to optimize welding quality. A supporting mechanism cleans and maintains gap between the parts during welding. This provides precise control of temperature, pressure, and gap during welding to mitigate distortion and improve joint quality in dissimilar additively-manufactured parts.

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Enhancing the structural integrity of synthetic scaffolds used for tissue engineering to prevent delamination and failure during cellularization and implantation. The techniques involve tethering layers of the scaffold together mechanically and chemically during synthesis. This can be done by using gradient percentages of polymers in the fibers, incorporating support rings, and slowing electrospinning speed to place components mid-process. The tethering promotes bonding between layers and components to maintain scaffold integrity.

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Inorganic fiber sizing agent containing cellulose nanofibers and a resin to improve adhesion, falling prevention, and handling properties of fiber-reinforced composites. The sizing agent contains cellulose nanofibers in an amount of 10 ppm to 50,000 ppm by weight when applied to the fiber surface. This improves fiber-matrix adhesion by forming anchor points when the composite is cured, prevents fiber shedding, and enables smoother fiber handling compared to traditional sizing agents.

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Laminated body with high adhesion between a fluorine-based resin layer and a metal layer without using an intermediate layer. The adhesion is improved by performing a plasma treatment on the resin surface, stacking the metal directly on the treated resin, and heating/compressing without allowing the resin to expand excessively. The plasma treatment modifies the resin surface chemistry to increase adhesion. Controlling expansion prevents delamination due to resin tearing.

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Abstract With increased design and manufacturing complexity of required components in various industries, additive composites shows great potential the production nextgeneration lightweight structures. Fused filament fabrication (FFF) is one such method composite where are 3D printed by heating a material above its gel temperature depositing it on previously layers. The fabricated FFF known to be susceptible delamination owing weak interlayer adhesion. This experimental study an attempt understand underlying interlaminar phenomenon FFFprinted endnotched flexure (ENF) specimens subjected modeII loading conditions. industrial printer utilizing micro carbon fiber infused Nylon aka Onyx as base specimen material. Either Onyx, continuous fibers, or Kevlar fibers used interfacial materials for current study. In addition, ENF arms optimally reinforced with preselected layers specimen. first category comprising three different interface configurations aims behavior other (Onyx//Onyx, Onyx//Kevlar, Onyx//carbon). On hand, second (Kevlar//Kevlar, carbon//carbon, Kevlar//carbon).... Read More

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