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<p>Large-scale extrusion additive manufacturing (LSEAM) enables production of sizeable polymer components; however, correctly assessing the capabilities of the materials used careful selection of the printing parameters is needed (Tagscherer et al. in Appl Sci, 2022), (Duty et al. in Rapid Prototyp J 23:181–189, 2017), (Quelho de Macedo et al. in Addit Manuf, 2024). This work presents a quality-driven optimization approach to rapidly determine suitable print settings for initial mechanical assessment of a material’s capabilities. A recycled polyamide 12 composite reinforced with 35% glass fibers was used as test feedstock material. Salient aspects of printed part quality were identified and quantified through a weighted scoring system prioritizing characteristics relevant for automotive prototyping applications like dimensional accuracy and proper layer positioning and adhesion. Preliminary definitive screening experiments revealed layer width and height as the two most critical process parameters influencing quality scores. Then, these factors were optimized for a 4&#xa0;mm nozzle diameter using a central composite design (Duty et al. in Rapid Prototyp J 23:181–189, 2017) guided by the quality evaluations on test geometry. The optimal parameters and those from the highest-scoring experimental run were used to produce tensile specimens in 0°, 45°, and 90° orientations relative to the printed layers. Tensile testing captured the expected anisotropic performance, with the 0° aligned orientation exhibiting highest strength but lower ductility due to fiber alignment along the print direction. Conversely, off-axis orientations showed greater elongation from interlayer deformation but reduced strength. While model predictions identified promising regions, the best experimental parameters provided superior overall mechanical properties, avoiding quality degradation possibly from phenomena such as material accumulation on the surface of the nozzle unaccounted for in modeling. For the 4&#xa0;mm nozzle, large-scale printed tensile strengths approached injection molded values, while higher elongations at break were observed. This quality-driven methodology effectively optimized LSEAM parameters to characterize key performance capabilities of a new feedstock material, enabling efficient initial screening before more exhaustive qualification efforts.</p>

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Quality-driven parameter optimization for the large-scale extrusion additive manufacturing of polymers

  • 期刊论文

  • 发表日期：

    2025年5月13日

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  • Felipe Arango Callejas,
  • Paul Victor Osswald,
  • Jaan-Willem Simon

摘要

Large-scale extrusion additive manufacturing (LSEAM) enables production of sizeable polymer components; however, correctly assessing the capabilities of the materials used careful selection of the printing parameters is needed (Tagscherer et al. in Appl Sci, 2022), (Duty et al. in Rapid Prototyp J 23:181–189, 2017), (Quelho de Macedo et al. in Addit Manuf, 2024). This work presents a quality-driven optimization approach to rapidly determine suitable print settings for initial mechanical assessment of a material’s capabilities. A recycled polyamide 12 composite reinforced with 35% glass fibers was used as test feedstock material. Salient aspects of printed part quality were identified and quantified through a weighted scoring system prioritizing characteristics relevant for automotive prototyping applications like dimensional accuracy and proper layer positioning and adhesion. Preliminary definitive screening experiments revealed layer width and height as the two most critical process parameters influencing quality scores. Then, these factors were optimized for a 4 mm nozzle diameter using a central composite design (Duty et al. in Rapid Prototyp J 23:181–189, 2017) guided by the quality evaluations on test geometry. The optimal parameters and those from the highest-scoring experimental run were used to produce tensile specimens in 0°, 45°, and 90° orientations relative to the printed layers. Tensile testing captured the expected anisotropic performance, with the 0° aligned orientation exhibiting highest strength but lower ductility due to fiber alignment along the print direction. Conversely, off-axis orientations showed greater elongation from interlayer deformation but reduced strength. While model predictions identified promising regions, the best experimental parameters provided superior overall mechanical properties, avoiding quality degradation possibly from phenomena such as material accumulation on the surface of the nozzle unaccounted for in modeling. For the 4 mm nozzle, large-scale printed tensile strengths approached injection molded values, while higher elongations at break were observed. This quality-driven methodology effectively optimized LSEAM parameters to characterize key performance capabilities of a new feedstock material, enabling efficient initial screening before more exhaustive qualification efforts.