Development of a laser‐assisted fused deposition modeling process for improvement in bond tensile strength of ABS

Abstract

AbstractFused deposition modeling (FDM), an advanced 3D printing method, is a rapidly growing technology for realizing geometrically complex parts. FDM utilizes a thermoplastic feedstock that is heated and extruded through a nozzle to build up layers of material following toolpaths prescribed by three‐dimensional (3D) data. However, the rapid thermal cycles that the material undergoes during this process limit the formation, growth, and entanglement of the molecular chains in the material. Herein, we have proposed a novel laser‐assisted fused deposition modeling (LAFDM) process for the improvement in printed part properties such as bond width and tensile strength. The LAFDM system was developed consisting of an infrared laser, coupled with an industrial FDM printer. Using an adapted tensile testing method, the bond strength between deposited layers of acrylonitrile butadiene styrene (ABS) in 3D‐printed structures was assessed. Thermogravimetric analysis was used to monitor the thermal stability of the polymer to detect alterations to the chemical composition of the material as a result of the processing conditions. A 9.5% increase in the average bond tensile strength for the LAFDM‐printed specimen was observed compared to that of the non‐laser‐assisted FDM‐printed specimen. The improvement to the bond strengths was achieved without compromising the thermal stability of the polymer.