Effect of process parameters on thermal and mechanical properties of polymer‐based composites using fused filament fabrication

Abstract

The fused filament fabrication (FFF) process of polymer-based composites has been developed due to its capability to make complex geometries and shapes with reasonable mechanical properties. However, the improvement of mechanical properties of the obtained parts and products are still under study and are interesting for designers. There are several strategies to enhance these desired properties of produced pieces, for example optimizing the process parameters and/or using different architecting designs. This paper presents the effect of some overriding process parameters (liquefier temperature, print speed, layer height, and platform temperature) on the temperature evolution and mechanical behavior of PA6 reinforced with chopped carbon fibers produced by FFF. Due to deposition of multilayers, there is a cyclic profile of temperature in the FFF process, which is a considerable note related to fabrication and consequently the strength of the manufactured parts. In parallel with the study of process parameters effect, this cyclic temperature profile has been measured. The preliminary results related to physicochemical and mechanical properties revealed that differences in crystallinity percentage exist and failure stress/strain can be considered as an indicator to evaluate the mechanical properties of FFF manufactured products. Moreover, measuring the temperature profile of the deposited filaments revealed that process parameters have a considerable influence on the cooling process of deposited filaments which itself affects the bonding of adjacent filaments. The higher temperatures led to slower cooling rate. Finally, the results confirm the impact of mentioned parameters roles on the bonding formation in the FFF process and also the subsequent obtained mechanical properties of the printed parts. Therefore, selection of the optimized and suitable process parameters is an important design consideration.