Mechanical strength of welding zones produced by polymer extrusion additive manufacturing

As more manufacturing processes and research institutions adopt customized manufacturing as a key element in their design strategies and finished products, the resulting mechanical properties of parts produced through additive manufacturing (AM) must be characterized and understood. In polymer extrusion (PE), the most recently extruded polymer filament must bond to the previously extruded filament via polymer diffusion to form a "weld". The strength of the weld limits the performance of the manufactured part and is controlled through processing conditions. Understanding the role of processing conditions, specifically extruder velocity and extruder temperature, on the overall strength of the weld will allow optimization of PE-AM parts. Here, the fracture toughness of a single weld is determined through a facile "trouser tear" Mode III fracture experiment. The actual weld thickness is observed directly by optical microscopy (OM) characterization of cross sections of PE-AM samples. Representative data of weld strength as a function of printing parameters on a commercial 3D printer demonstrates the robustness of the method. Published by Elsevier B.V.