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PurposeA main cause of defects within material extrusion (MatEx) additive manufacturing is the nonisothermal condition in the hot end, which causes inconsistent extrusion and polymer welding. This paper aims to validate a custom hot end design intended to heat the thermoplastic to form a melt prior to the nozzle and to reduce variability in melt temperature. A full 3D temperature verification methodology for hot ends is also presented. Design/methodology/approachInfrared (IR) thermography of steady-state extrusion for varying volumetric flow rates, hot end temperature setpoints and nozzle orifice diameters provides data for model validation. A finite-element model is used to predict the temperature of the extrudate. Model tuning demonstrates the effects of different model assumptions on the simulated melt temperature. FindingsThe experimental results show that the measured temperature and variance are functions of volumetric flow rate, temperature setpoint and the nozzle orifice diameter. Convection to the surrounding air is a primary heat transfer mechanism. The custom hot end brings the melt to its setpoint temperature prior to entering the nozzle. Originality/valueThis work provides a full set of steady-state IR thermography data for various parameter settings. It also provides insight into the performance of a custom hot end designed to improve the robustness of melting in MatEx. Finally, it proposes a strategy for modeling such systems that incorporates the metal components and the air around the system. 

Die-swell is a flow effect that occurs in polymer extrusion whereby the material experiences rapid stress and dimensional changes upon exiting the nozzle orifice. Material extrusion additive manufacturing is no exception, and this effect influences the final dimensions of the printed road and imparts residual stresses. Die-swell is measured via a custom test cell that uses optical and infrared cameras and an instrumented hot end with an infeed pressure load cell. The instrumented hot end is mounted onto a stationary extruder above a conveyor to simulate printhead translation at steady state conditions for a wide range of volumetric flow rates. Investigated factors for an acrylonitrile butadiene styrene (ABS) filament include volumetric flow rate (0.9 mm3/s to 10.0 mm3/s), hot end temperature setpoint (200–250 ◦C), and nozzle orifice diameter (0.25–0.60 mm). The die-swell increases as a function of the volumetric flow rate and shear stress but decreases as a function of the hot end temperature setpoint and nozzle orifice diameter. For modelling, an implementation of the Tanner model for die swell displays good agreement with experimental results. The model also demonstrates that the same proportionality constant, k_N1 , which relates first normal stress difference to shear stress, can be used for different nozzle orifice diameters with the same length to diameter ratios, and that kN1 increases as a function of hot end temperature setpoint as expected with the rheological concept of time temperature superposition. 

It is widely known that the printing quality of fused filament fabrication (FFF) is heavily affected by environmental temperature and humidity, taking the form of warping and porosity. However, there is little understanding about the quantitative relations between environmental conditions, geometry, and the mechanical properties of printed parts. In this study, we systematically investigated those relations using bisphenol A polycarbonate as a model material system. For the environmental temperature, an in-situ infrared imaging analysis revealed the presence of an up to 5.4 °C/mm thermal gradient when printing using an open-chamber printer and a heated build plate. For the environmental humidity, an analysis of X-ray micro-computed tomography (micro-CT) scans showed an up to 11.7% porosity that was brought by polymer water content absorbed from environmental moisture. Meanwhile, tensile tests showed a mechanical performance loss associated with those defects, but, surprisingly, the transverse direction ductility had the potential to increase at a higher porosity. Furthermore, the experimental results were combined with analytical and parametrical studies to elucidate quantitative relations between environmental conditions and printing quality. Based on the results, quantitative guidelines for the estimation of printing quality based on environmental conditions are provided that would also help users to obtain desired printing results with a better understanding of the effects of environmental conditions. 

Abstract 3D printing is a popular fabrication technique because of its ability to produce complex architectures. Melt‐based 3D printing is widely used for thermoplastic polymers like poly(caprolactone) (PCL), poly(lactic acid) (PLA), and poly(lactic‐co‐glycolic acid) (PLGA) because of their low processing temperatures. However, traditional melt‐based techniques require processing temperatures and pressures high enough to achieve continuous flow, limiting the type of polymer that can be printed. Solvent‐cast printing (SCP) offers an alternative approach to print a wider range of polymers. Polymers are dissolved in a volatile solvent that evaporates during deposition to produce a solid polymer filament. SCP, therefore, requires optimizing polymer concentration in the ink, print pressure, and print speed to achieve desired print fidelity. Here, capillary flow analysis shows how print pressure affects the process‐apparent viscosity of PCL, PLA, and PLGA inks. Ink viscosity is also measured using rheology, which is used to link a specific ink viscosity to a predicted set of print pressure and print speed for all three polymers. These results demonstrate how this approach can be used to accelerate optimization by significantly reducing the number of parameter combinations. This strategy can be applied to other polymers to expand the library of polymers printable with SCP.