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<p>3D-printed components fabricated by processing high-performance polymers through Material Extrusion continue to face challenges with poor interlayer adhesion, resulting in reduced mechanical performance. In this study, the authors propose an innovative thermal-free method to enhance interlayer adhesion by integrating atmospheric plasma treatment directly into commercial 3D printers. Various features of plasma-treated surfaces were investigated, and optimal conditions for working distance and treatment time were experimentally determined. The mechanisms underlying the plasma-polymer interaction were characterized on multiple levels: i) surface energy, ii) surface morphology, and iii) surface chemical composition. The primary benefits observed for treated polycarbonate (PC) and polyetheretherketone (PEEK) included a significant increase in wettability (exceeding 60%), surface crystallization, and the introduction of new functional groups such as hydroxyl, carboxyl, and carbonyl groups. These key factors collectively resulted in a 30.7% improvement in Interlaminar Shear Strength (ILSS), demonstrating the potential of this approach to significantly enhance the mechanical properties of high-performance 3D-printed components. This study lays the foundation for broader adoption of plasma treatment in the fabrication of structurally demanding and high-performance polymer components.</p>

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Atmospheric plasma enhances interlayer adhesion in high-performance 3D-printed polymers by modifying surface energy, morphology and chemical composition

  • 期刊论文

  • 发表日期：

    2025年6月12日

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  • Valentina Trimini,
  • Gianni Stano,
  • Sara Varetti,
  • Stefano Corvaglia,
  • Abhishek Kumar,
  • Gianluca Percoco

摘要

3D-printed components fabricated by processing high-performance polymers through Material Extrusion continue to face challenges with poor interlayer adhesion, resulting in reduced mechanical performance. In this study, the authors propose an innovative thermal-free method to enhance interlayer adhesion by integrating atmospheric plasma treatment directly into commercial 3D printers. Various features of plasma-treated surfaces were investigated, and optimal conditions for working distance and treatment time were experimentally determined. The mechanisms underlying the plasma-polymer interaction were characterized on multiple levels: i) surface energy, ii) surface morphology, and iii) surface chemical composition. The primary benefits observed for treated polycarbonate (PC) and polyetheretherketone (PEEK) included a significant increase in wettability (exceeding 60%), surface crystallization, and the introduction of new functional groups such as hydroxyl, carboxyl, and carbonyl groups. These key factors collectively resulted in a 30.7% improvement in Interlaminar Shear Strength (ILSS), demonstrating the potential of this approach to significantly enhance the mechanical properties of high-performance 3D-printed components. This study lays the foundation for broader adoption of plasma treatment in the fabrication of structurally demanding and high-performance polymer components.