Understanding softening of amorphous materials for FFF applications

Abstract

Abstract The work explores the fundamentals of the softening process for amorphous materials expanding on the work presented by Stammers and Beek (Stammers, E. and Beek, W.J. (1969). The melting of a polymer on a hot surface. Polym. Eng. Sci. 9). The pressure induced melt removal process was studied in detail. The process, although fundamental, allows for an understanding of the phase transition of materials during the fused filament fabrication (FFF) process. Experimental results were analyzed using state-of-the-art equipment. A total of four materials were tested. PVC and PC are amorphous materials, and PA6 and PP are semi-crystalline materials. A setup was built to allow the application of a constant force. The resulting melt film was analyzed using computed tomography technology. The experimental results were compared with numerical simulation results originating from COMSOL Multiphysics and the analytical solution derived by Stammers and Beek. Rheological and thermo-mechanical tests were used to find the softening temperature of amorphous materials. Results showed a straightforward transition for the melting temperature of semi-crystalline materials and softening temperature of amorphous materials. It is suggested that for amorphous materials, the glass transition temperature can be used as the softening temperature (T s  = T g ). When comparing all three results (experimental, analytical, and numerical), values are within the same range and magnitude. A good approximation was achieved for PA6 and PVC, which have semi-crystalline and amorphous structures, respectively. Results provide insights into the phase transition process and phase change mechanisms during the extrusion of materials in the fused filament fabrication process.