Modeling and Characterization of Interlayer Weld Formation During Fused Filament Fabrication

Fused Filament Fabrication (FFF) is the most widely used additive manufacturing technique,involving a movable heated nozzle through which a molten thermoplastic polymer fiber is extruded onto a platform. Deposited filaments weld together and solidify to form a layer, and successive layers form the final part. In most scientific literature, incomplete weld formation between the filaments is cited as the main reason for inferior mechanical properties of FFF printed parts. The weld formation mechanisms during the print are not well understood yet. This work focuses on modeling and characterizing the weld formation process. A 2D thermal model in COMSUL will be validated by the experimental temperature measurements carried out in a controlled and highly instrumented test bench. A weld strength model combining the healing with the evolution of crystallinity at the interface will be developed and weld strength predictions will be validated through mechanical characterizations using a novel sample configuration.

Faculty Supervisor:

Ilyass Tabiai

Student:

Partner:

Université de Nantes

Discipline:

Engineering

Sector:

Education

University:

École de technologie supérieure

Program: