Factors affecting interface bonding in multi-material additive manufacturing

Abstract

Additive manufacturing or 3D printing is the process of depositing material layer-by-layer to create 3-dimensional products. When creating 3D-printed products from two or more materials, multi-material additive manufacturing processes are used which eliminate the need for assembly operations. Fused filament fabrication multi-material additive manufacturing permits the production of a single printed item employing multiple materials in fused filament fabrication. This work studied the factors affecting fused filament fabrication multi-material additive manufacturing, by reviewing existing works, designing part(s), conducting design of experiments, and carrying out parts’ performance test. An E3D multi-material filament 3D printer was utilised throughout this study. The chosen polymer combination was polycarbonate (PC) and poly(methyl methacrylate) (PMMA), whilst the design and testing of the multi-material parts was limited to lap-shear testing. Results showed that the interface bonding of the PMMA/PC (PMMA printed first and followed by PC) specimens was stronger than the one of the PC/PMMA specimens. Furthermore, to investigate the effect of the contact or overlapping area on the interface bonding strength, PMMA/PC specimens with varying dimensions were designed, printed, and tested. When the contact area was reduced, a strong interface bonding between the PMMA and PC layers was still maintained.