skip to main content


Title: The influence of porosity, crystallinity and interlayer adhesion on the tensile strength of 3D printed polylactic acid (PLA)
Purpose The purpose of this study is to understand how printing parameters and subsequent annealing impacts porosity and crystallinity of 3D printed polylactic acid (PLA) and how these structural characteristics impact the printed material’s tensile strength in various build directions. Design/methodology/approach Two experimental studies were used, and samples with a flat vs upright print orientation were compared. The first experiment investigates a scan of printing parameters and annealing times and temperatures above the cold crystallization temperature ( T cc ) for PLA. The second experiment investigates annealing above and below T cc at multiple points over 12 h. Findings Annealing above T cc does not significantly impact the porosity but it does increase crystallinity. The increase in crystallinity does not contribute to an increase in strength, suggesting that co-crystallization across the weld does not occur. Atomic force microscopy (AFM) images show that weld interfaces between printed fibers are still visible after annealing above T cc , confirming the lack of co-crystallization. Annealing below T cc does not significantly impact porosity or crystallinity. However, there is an increase in tensile strength. AFM images show that annealing below T cc reduces thermal stresses that form at the interfaces during printing and slightly “heals” the as-printed interface resulting in an increase in tensile strength. Originality/value While annealing has been explored in the literature, it is unclear how it affects porosity, crystallinity and thermal stresses in fused filament fabrication PLA and how those factors contribute to mechanical properties. This study explains how co-crystallization across weld interfaces is necessary for crystallinity to increase strength and uses AFM as a technique to observe morphology at the weld.  more » « less
Award ID(s):
1734981
NSF-PAR ID:
10293259
Author(s) / Creator(s):
; ; ; ;
Date Published:
Journal Name:
Rapid Prototyping Journal
Volume:
27
Issue:
7
ISSN:
1355-2546
Page Range / eLocation ID:
1327 to 1336
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. This research investigates on how extruder nozzle temperature, model infill rate (i.e. density) and number of shells affect the tensile strength of three-dimensional polylactic acid (PLA) products manufactured with the fused deposition model technology. Our goal is to enhance the quality of 3D printed products using the Makerbot Replicator. In the last thirty years, additive manufacturing has been increasingly commercialized, therefore, it is critical to understand properties of PLA products to broaden the use of 3D printing. We utilize a Universal Tensile Machine and Quality Engineering to comprehend tensile strength characteristics of PLA. Tensile strength tests are performed on PLA specimens to analyze their resistance to breakage. Statistical analysis of the experimental data collected shows that extruder temperature and model infill rate (i.e. density) affect tensile strength. 
    more » « less
  2. Abstract

    The processing–structure–property relationship using poly(lactic acid) (PLA) and poly(ethylene terephthalate) (PET) is explored. Specifically, both pre‐extension and preshear of amorphous PLA and PET above their glass transition temperaturesTg, carried out in the affine deformation limit, can induce a specific type of cold crystallization during annealing, i.e., nanoconfined crystallization (NCC) where crystal sizes are limited to a nanoscopic scale in all dimensions so as to render the processed PLA and PET optically transparent. The new polymer structure after premelt deformation can show considerably enhanced mechanical properties. For example, premelt stretching produces geometric condensation of the chain network. This structural alternation can profoundly change the mechanical characteristics, e.g., turning brittle PLA ductile. In contrast, after preshear of amorphous PLA aboveTg, the NCC containing PLA remains brittle, showing the importance to have geometric condensation from processing. Both AFM imaging and SAXS measurements are performed to verify that premelt deformation of PLA and PET indeed results in NCC from annealing that permits the strain‐induced cold crystallization to take place on the length scale of the mesh size of the deformed chain network.

     
    more » « less
  3. Post-drawn PCL nanofibers can be molecularly tuned to have a variety of mechanical properties and drug release profiles depending on the temperature and time of annealing, which has implications for regenerative medicine and drug delivery applications. Post-drawing polycaprolactone (PCL) nanofibers has previously been demonstrated to drastically increase their mechanical properties. Here the effects of annealing on post-drawn PCL nanofibers are characterized. It is shown that room temperature storage and in vivo temperatures increase crystallinity significantly on the order of weeks, and that high temperature annealing near melt significantly increases crystallinity and molecular orientation on the order of minutes. The kinetics of crystallization were assessed using an anneal and quench approach. High temperature annealing also increased the ultimate tensile strength and toughness of the fibers and changed the release profile of a model drug absorbed in PCL nanofibers from first-order to zero-order kinetics. 
    more » « less
  4. Additive manufacturing promises to revolutionize manufacturing industries. However, 3D printing of novel build materials is currently limited by constraints inherent to printer designs. In this work, a bench-top powder melt extrusion (PME) 3D printer head was designed and fabricated to print parts directly from powder-based materials rather than filament. The final design of the PME printer head evolved from the Rich Rap Universal Pellet Extruder (RRUPE) design and was realized through an iterative approach. The PME printer was made possible by modifications to the funnel shape, pressure applied to the extrudate by the auger, and hot end structure. Through comparison of parts printed with the PME printer with those from a commercially available fused filament fabrication (FFF) 3D printer using common thermoplastics poly(lactide) (PLA), high impact poly(styrene) (HIPS), and acrylonitrile butadiene styrene (ABS) powders (< 1 mm in diameter), evaluation of the printer performance was performed. For each build material, the PME printed objects show comparable viscoelastic properties by dynamic mechanical analysis (DMA) to those of the FFF objects. However, due to a significant difference in printer resolution between PME (X–Y resolution of 0.8 mm and a Z-layer height calibrated to 0.1 mm) and FFF (X–Y resolution of 0.4 mm and a Z-layer height of 0.18 mm), as well as, an inherently more inconsistent feed of build material for PME than FFF, the resulting print quality, determined by a dimensional analysis and surface roughness comparisons, of the PME printed objects was lower than that of the FFF printed parts based on the print layer uniformity and structure. Further, due to the poorer print resolution and inherent inconsistent build material feed of the PME, the bulk tensile strength and Young’s moduli of the objects printed by PME were lower and more inconsistent (49.2 ± 10.7 MPa and 1620 ± 375 MPa, respectively) than those of FFF printed objects (57.7 ± 2.31 MPa and 2160 ± 179 MPa, respectively). Nevertheless, PME print methods promise an opportunity to provide a platform on which it is possible to rapidly prototype a myriad of thermoplastic materials for 3D printing. 
    more » « less
  5. Hydrolytic degradation of commercially available 3D printing filament, i.e. poly (lactic acid) with broad molecular weight distribution was induced by incubating 3D-printed parts in deionized water at 3 temperatures. Small changes in orthogonal dimensions occurred due to relaxation of printing stresses, but no mass or volume loss were detected over the time-frame of the experiments. Molecular weight decreased while polydispersity remained constant. The most sensitive measure of degradation was found to be nondestructive, small-amplitude oscillatory tensile measurements. A rapid decay of tensile storage modulus was found with an exponential decay time constant of about an hour. This work demonstrates that practical monitoring of commercially available PLA degradation can be achieve with linear viscoelastic measurements of modulus. 
    more » « less