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The Influence of Processing Parameters on the Transition Zone for Blended Material 3D Printing...

by James C Brackett, Dakota Cauthen, Tyler C Smith, Vlastimil Kunc, Chad Duty
Publication Type
Conference Paper
Book Title
Sampe north america Virtual Presentation series 2020
Publication Date
Page Numbers
1 to 15
Publisher Location
California, United States of America
Conference Name
SAMPE Conference and Exhibition
Conference Location
Seattle, Washington, United States of America
Conference Sponsor
Airtech, Boeing, Instron
Conference Date

The use of Multiple Materials (MM) in Additive Manufacturing (AM) is increasingly important for expanding the range of applications in the manufacturing industry, particularly for large-format processes. Typically, polymer-based AM incorporates MM transitions through discrete interfaces between layers. This arrangement significantly increases the occurrence of layer delamination failures due to decreased bonding between dissimilar polymers. Elimination of discrete material interfaces by continuously transitioning from Material A to B provides a possible solution. Such continuous gradients could be used to create functionally graded structures that take full advantage of AM’s capability to deliberately impart site-specific properties. Cincinnati’s Big Area Additive Manufacturing (BAAM) system at Oak Ridge National Lab has been equipped with a dual-hopper system that enables in-situ material switching specifically intended for functionally graded and MM printing. The resulting material transition exhibits varied behavior based on printing conditions, which can have an impact on part design and resulting mechanical properties. In this work, the transition zone is characterized as a function of the printing screw speed (related to volumetric flow) and the screw geometry.