Additive manufacturing (AM) is a process for fabricating parts directly from 3-D digital models which has tremendous potential for producing high-value, complex, individually customized parts. Companies across the globe are using AM to reduce time-to-market, improve product quality, and reduce the cost to manufacture products. Polymers are attractive materials in this regard because they are economical, they provide for a large range of properties and they are amenable to many low energy fabrication technologies. In the industrial sector, polymers are being used in a wide range of part applications including aerospace, defense, automotive, sports, telecommunications, and medical devices.
While the use of polymeric materials for AM has been growing, challenges impede its more widespread adoption and commercialization. In many cases, new measurement methods, standards, data, and models are needed to overcome these challenges. We have a particular focus on the rheological and processing aspects of additive manufacturing because their critical importance in the processes. The problems encountered necessitate a thorough understanding of non-isothermal and non-equililibrium kinetics in polymers.
We are measuring the fundamental processes and material parameters that are critical to understanding and furthering polymers-based AM. These efforts will aid the AM ecosystem through better online monitoring capabilities and developing strategies for materials optimization.
Fundamentals of the materials extrusion 3D printing process
In the common thermoplastic additive manufacturing (AM) process known as materials extrusion (FFF), a solid polymer filament is melted, extruded though a rastering nozzle, welded onto neighboring layers and solidified. We developed a framework to measure and understand the physical processes that underly this 3D printing process. Our framework centers around three interrelated components: in situ thermal measurements (via infrared imaging), temperature dependent molecular processes (via rheology), and mechanical testing (via mode III fracture). We developed the concept of an equivalent isothermal weld time and test its relationship to fracture energy. The results of these analysis provide a basis for optimizing inter-layer strength, the limitations of the ME process, and guide development of new materials.
Temperature measurements, the temperature of the polymer at each stage is the key parameter governing these non- equilibrium processes, but due to its strong spatial and temporal variations, it is difficult to measure accurately. We utilized IR imaging - in conjunction with necessary reflection corrections and calibration procedures - to measure these temperature profiles of a model polymer during 3D printing. The resulting temperature profiles and resultant mechanical properties yield great insight into the fundamental kinetics of the welding process and provides direct data to directly input into theoretical models.
Mechanical properties, we developed a mode III fracture test whereby by we print a wall which is one "road" wide. With this geometry, the fracture plane occurs at a point where we have taken our IR temperature measurements, thus allowing a direct comparison between weld strength and the temperature profile. We work with theorists and modelers from Georgetown University, Johns Hopkins, U Mass (Lowell) and University of Texas (Arlington) to predict mechanical strength based on the rheology, molecular considerations and temperature profile.
Current work focuses on molecular weight dependence on bringing additional novel measurement capabilities online.
Development of rheo-Raman-microscope We developed a novel combination of off-the-shelf instruments —called the rheo-Raman microscope- that integrates a Raman spectrometer, a rotational rheometer and an optical microscope. This instrument will be utilized to measure the behavior of polymers under conditions of rapid flow and temperature changes, such as those that occur in additive manufacturing. Knowledge from these measurements will be utilized in modeling and characterizing the 3D printing process. This device has now been commercialized by several major vendors of torsional rheometers. See Press Release and publications link (below). The rheo-Raman-microscope will have uses in understanding kinetic processes by linking rheolgy to chemistyr and conformational changes. Applications include curing, reactive blends, gelation, crystallization and emulsions.
We have utilized the rheo-Raman-microscope to address longstanding questions in polymer crystallization. In particular, the functional relationship between modulus and crystallinity during the crystallization process had been unclear because simultaneous measurements of these measureands has hitherto been impossible. With our device, we were able to make such measurements and to propose a model based on a suspension mechanics that incorporates a percolation transition. Current work includes understanding the full frequency dependence of the modulus-crystallinity relationship, and also in understanding the role of spherulites in the percolation process.
AM-Bench is developing a continuing series of controlled benchmark tests, in conjunction with a conference series, with two initial goals, 1) to allow modelers to test their simulations against rigorous, highly controlled additive manufacturing benchmark test data, and 2) to encourage additive manufacturing practitioners to develop novel mitigation strategies for challenging build scenarios. We organized the polymers component of AM Bench.
Measurement Science Roadmap for Polymer-Based Additive Manufacturing
In June of 2016 we co-sponsored a workshop with NSF on polymer-based AM to develop a roadmap that identifies the primary challenges in polymers additive manufacturing from the perspective of measurement science.
The final workshop report can be found here: https://doi.org/10.6028/NIST.AMS.100-5