Nonisothermal welding in fused filament fabrication

Fused filament fabrication (FFF), sometimes called material extrusion (ME) offers an alternative option to traditional polymer manufacturing techniques to allow the fabrication of objects without the need of a mold or template. However, these parts are limited in the degree to which the welding interface is eliminated post deposition, resulting in a decrease in the interlaminar fracture toughness relative to the bulk material. Here reptation theory under nonisothermal conditions is utilized to predict the development of healing over time, from the rheological and thermal properties of Acrylonitrile-Butadiene-Styrene (ABS). ABS is rheologically complex and acts as a gel and as such considerations had to be made for the relaxation time of the matrix which is important in predicting the degree of interfacial healing. The nonsiothermal healing model developed is then successfully compared to experimental interlaminar fracture experiments at variable printing temperatures, allowing future optimization of the process to make stronger parts.