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<p>Material extrusion additive manufacturing technique faces challenges in products’ forming quality due to inherent limitations in polymer melt rheological property and interlayer bonding. This study introduces ultrasonic vibration-assisted machining (UVAM) to address these issues by actively modulating melt flow behavior and interfacial bonding mechanisms. A coupled theoretical framework integrating dynamic rheological properties (DRP) and bonding neck evolution (DBN) under ultrasonic excitation is established and validated by experimental analysis. Systematic parametric investigations reveal that UVAM significantly reduces key rheological parameters (i.e. pressure drop, apparent viscosity and shear stress), while enhancing bonding neck formation. With the increasing frequency or amplitude of UVAM, the effect is further strengthened.. The proposed theoretical model demonstrates UVAM’s potential to synergistically improve the melt flow behavior and interfacial bonding quality in material extrusion process.</p>

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The material extrusion additive manufacturing process with ultrasonic-vibration aided machining

  • 期刊论文

  • 发表日期：

    2026年3月3日

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  • Shijie Jiang,
  • Chaoqun Yun,
  • Jiaqi Chen,
  • Hongwei Ying,
  • Chunyu Zhao,
  • Huisheng yao

摘要

Material extrusion additive manufacturing technique faces challenges in products’ forming quality due to inherent limitations in polymer melt rheological property and interlayer bonding. This study introduces ultrasonic vibration-assisted machining (UVAM) to address these issues by actively modulating melt flow behavior and interfacial bonding mechanisms. A coupled theoretical framework integrating dynamic rheological properties (DRP) and bonding neck evolution (DBN) under ultrasonic excitation is established and validated by experimental analysis. Systematic parametric investigations reveal that UVAM significantly reduces key rheological parameters (i.e. pressure drop, apparent viscosity and shear stress), while enhancing bonding neck formation. With the increasing frequency or amplitude of UVAM, the effect is further strengthened.. The proposed theoretical model demonstrates UVAM’s potential to synergistically improve the melt flow behavior and interfacial bonding quality in material extrusion process.