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Large-Area Additive Manufacturing (LAAM) has seen increased application in manufacturing meter-scale, polymeric composite structural parts, especially for tooling and fixturing. Unfortunately, LAAM introduces manufacturing-induced defects in printed composites, e.g., intrabead microvoids and poor interbead adhesion that are not otherwise seen when traditional manufacturing methods are used, causing degradation of mechanical and fracture properties. In this paper, the fracture behavior of neat acrylonitrile butadiene styrene (ABS) and short carbon fiber-reinforced ABS (CF/ABS) fabricated by LAAM is compared and analyzed by evaluating their energy release rate 𝐺𝐼𝑐 and fracture mechanisms. A double cantilever beam with doublers (DCB-D) test for single-bead, double-bead, and multiple-bead configurations is developed by incorporating rigid doublers to reduce the compressive failure at the crack tip, allowing for the measurement of crack propagation. A new data reduction method for these configurations is derived to remove the doubler effect from the 𝐺𝐼𝑐 calculation, producing ‘pure’ intrabead and interbead 𝐺𝐼𝑐 values. We show that CF/ABS is more damage tolerant than ABS at the intrabead level, but less damage tolerant than ABS at the interbead level. The development of plastic ligaments in ABS helps dissipate additional strain energy, improving the overall energy release rate. The experimental fracture test approach developed here is expected to provide mechanistic insight into their damage tolerance capability, accelerating the qualification process of LAAM-produced polymer and polymer composites. 

The presence of voids within the microstructure of short carbon fiber polymer composites produced by additive manufacturing (AM) technology are known to alter the expected material behavior that impair part performance. Previous research efforts aimed at understanding the formation mechanisms of these micro-voids during the polymer extrusion/deposition process have not kept up with the advancement of this AM technology. The present study investigates the phenomenon of micro-void nucleation at the fiber/matrix interface, especially those that form at fiber tips, by characterizing the microstructural configuration of a 13 % carbon fiber filled ABS polymer composite print bead specimen using 3D X-ray micro computed tomography image acquisition and analysis. The results reveal a high level of micro-voids segregation at the ends of fibers that are relatively larger in size and less spherical as compared to micro-voids isolated within the ABS matrix. Additionally, by simulating the hydrostatic flow-field pressure distribution surrounding a single rigid ellipsoidal fibre in colloidal suspension using Jeffery’s model equations, we show that the pressure drops to a critical value at the fibre tips where the micro-voids nucleation is experimentally observed to occur. The study helps to improve our understanding of the potential mechanisms that may be responsible for micro-void development within beads printed with extrusion/ deposition AM. 

Micro-voids within the bead microstructure of additively manufactured short carbon fiber- reinforced polymer composites are known to compromise the material performance. Unfortunately, a comprehensive understanding of the formation mechanisms of micro-voids during polymer processing is currently lacking. The present study considers micro-void nucleation at fiber inter-faces, particularly those occurring at the end of suspended fibers. Micro-computed tomography (μCT) image acquisition techniques are used to characterize microstructural features of a 13wt% carbon fiber reinforced ABS compo-site bead manufactured via Large Area Additive Manufacturing (LAAM). The results reveal a significant collection of micro-voids at the tips of fibers approaching 80% of the total micro-void volume fraction. In addition, fiber tip micro-voids are relatively larger and less spherical than micro-voids isolated within the ABS matrix. Theoretical formulations of several known mechanisms for micro-void nucleation during LAAM material processing indicate that local-ized fluid pressure likely plays a pivotal role in micro-void formation. To better expose this mechanism, we simulate the hydrostatic flow-field pressure distri-bution surrounding a single rigid fiber suspended in simple shear flow using fi-nite element analysis (FEA). Computed results demonstrate that the polymer matrix pressure decreases significantly at the fiber ends where micro-void nucleation is experimentally observed to occur. Our approach provides the fiber surface pressure distribution in simple shear flow that typifies nozzle regions with extreme flow conditions, enhancing our understanding of micro-void development mechanisms as the polymer melt flows through the nozzle. 

This paper proposes an efficient experimental method to measure the mode I fracture toughness of large-area additive manufactured polymeric composites. By utilizing either single-bead or double-bead systems bonded to the double cantilever beam (DCB) configuration, we measure intrabead and interbead fracture toughness of acrylonitrile butadiene styrene (ABS) and short carbon fiber-reinforced ABS. The effect of rigid doublers (which are used to eliminate a premature compressive failure) is excluded in the calculation of total energy dissipation, producing a purely interlayer fracture toughness. We found that the critical fracture toughness of carbon fiber/ABS is lower than that of ABS due to the voids within and between the beads. The experimental and data reduction methods developed here can be utilized to optimize the interlayer adhesion of large-scale 3D printed materials. 

Short carbon fiber-reinforced polymer composites are widely used in polymer extrusion additive manufacturing (AM), including large-area additive manufacturing (LAAM), due to their enhanced mechanical properties as compared to neat polymers. However, the mechanical properties of these composites depend on microstructural characteristics, including fibers and micro-voids, which are determined during processing. In this work, the correlation between fibers and micro-voids within the microstructure of LAAM polymer composites throughout various processing stages of short carbon fiber-reinforced acrylonitrile butadiene styrene (SCF/ABS) is investigated. The processing stages considered here include the incoming pellets, a single freely extruded strand, a single regularly deposited bead, and a single regularly deposited bead pressed by a mechanical roller. A high-resolution X-ray micro-computed tomography (µCT) system is employed to characterize the microstructural features in terms of the fibers (volume fraction, fiber orientation tensor) and micro-voids (volume fraction, sphericity) in the SCF/ABS samples. The results indicate that micro-voids exist within the microstructure of the SCF/ABS composite in all four stages considered here and that the micro-void volume fraction and micro-void sphericity vary among the test samples. Moreover, the results show a considerable variation in fiber orientation and fiber volume fraction within the microstructure throughout all the stages considered; however, all the samples show the highest alignment in the extrusion/print direction. Furthermore, a correlation is identified between the fiber orientation and the micro-void volume fraction within samples from all four stages considered here. This finding suggests that fibers tend to align more in the extrusion/print direction in regions with less micro-void content. 

Material extrusion (MEX) additive manufacturing has successfully fabricated assembly-free structures composed of different materials processed in the same manufacturing cycle. Materials with different mechanical properties can be employed for the fabrication of bio-inspired structures (i.e., stiff materials connected to soft materials), which are appealing for many fields, such as bio-medical and soft robotics. In the present paper, process parameters and 3D printing strategies are presented to improve the interfacial adhesion between carbon fiber-reinforced nylon (CFPA) and thermoplastic polyurethane (TPU), which are extruded in the same manufacturing cycle using a multi-material MEX setup. To achieve our goal, a double cantilever beam (DCB) test was used to evaluate the mode I fracture toughness. The results show that the application of a heating gun (assembled near the nozzle) provides a statistically significant increase in mean fracture toughness energy from 12.3 kJ/m2 to 33.4 kJ/m2. The underlying mechanism driving this finding was further investigated by quantifying porosity at the multi-material interface using an X-ray computed tomography (CT) system, in addition to quantifying thermal history. The results show that using both bead ironing and the hot air gun during the printing process leads to a reduction of 24% in the average void volume fraction. The findings from the DCB test and X-ray CT analysis agree well with the polymer healing theory, in which an increased thermal history led to an increased fracture toughness at the multi-material interface. Moreover, this study considers the thermal history of each printed layer to correlate the measured debonding energy with results obtained using the reptation theory. 

Fusion-based Material Extrusion (MEX) Additive Manufacturing (AM) processes have been extensively used for the fabrication of smart structures with embedded sensors, proving to have several benefits such as reduction in cost, manufacturing time, and assembly. A major issue negatively affecting 3D printed sensors is related to their poor electrical conductivity, as well as inconsistent electrical performance, which leads to electrical power losses amongst other issues. In the present paper, a set of process parameters (ironing, printing temperature, and infill overlap) has been analyzed by performing a Design of Experiment (DoE) factorial plan to minimize the electrical resistance. The best process parameters configuration involves a remarkable reduction of electrical resistance of 47.9%, as well as an improvement of mechanical properties of 31.9% (ultimate tensile strength), 25.8% (elongation at break) and 28.14% (flexural stress). The microstructure of the obtained results has also been analyzed by employing a high-resolution, X-ray Computed Tomography (X-Ray CT) system showing a reduction of intralayer voids of 19.5%. This work demonstrates a clear correlation between process parameters and the corresponding electrical properties, mechanical properties, and internal microstructure. In the present research, it has been shown that i) it is possible to significantly improve the overall 3D printed sensors performance by process parameter selection, and ii) small changes in the microstructure lead to remarkable improvements in electrical and mechanical performance. 

The process-structure-property relationship in Large Area Additive Manufacturing (LAAM) technology is an ongoing area of research as the inherent microstructural properties (chiefly fibers and voids) affect the performance of printed parts. Unfortunately, we currently lack adequate understanding of micro void nucleation and evolution during the LAAM and fused deposition modelling (FDM) processes. Modeling of the polymer melt flow during the extrusion process is important in understanding the underlying microstructural formation and associated properties of the print, that determines the part performance in service conditions. In this paper we compute fiber-induced local pressure fluctuations which may promote void formation in the bead’s microstructure. On a macro-scale, we determine flow fields of a purely viscous, Newtonian planar polymer deposition flow through a LAAM nozzle which are utilized on a micro-scale model where we simulate the evolution of a single ellipsoidal fiber along streamlines obtained from the macro-model. On the micro-scale, we determine instantaneous values of the translational and rotational velocities of the rigid ellipsoidal fiber that satisfies a balance of hydrodynamic forces and couples on the fiber’s surface based on a Newton Raphson algorithm and we track the fiber’s motion along the flow path via an explicit numerical iterative algorithm. Model verification is achieved by benchmarking results with solutions from well-known Jeffery’s equation of motion of a particle in homogeneous simple shear flow. We account for rotary diffusivity due to short-range fiber-fiber interaction in the FEA simulation by determining an effective fluid domain size representative of the interaction coefficient of the melt flow through a correlation analysis that yields an equivalent steady state orientation based on the Advani- Tucker equation. We also consider different possible motions of the fiber along individual LAAM flow paths from a given set of random initial fiber conditions to determine pressure bounds on the fiber surface along each streamline. For improved computational efficiency, calculations are carried out with respect to the fiber’s local coordinate axes to overcome the rigor of adaptive remeshing during the quasi-transient analysis. Results show low pressure extremes near the fiber’s surface which varies across the printed bead as well as through its thickness. Discussion is provided to gain insight into the effect of low-pressure extremes on micro void formation, particularly at the nozzle exit and during die swell/expansion. 

The flow-induced fibre orientation formed during polymer extrusions causes the composite to exhibit non-homogeneous thermal-mechanical behaviours during Large Area extrusion deposition Additive Manufacturing (LAAM) processes. This study numerically evaluates the fibre orientation state of a 20 wt.% short carbon fibre reinforced polyethylenimine fabricated by LAAM. The fibre orientation state of the solidified deposited bead is determined by a fully coupled flow/orientation simulation approach. The material properties of deposited composites are computed by assuming that the deposited bead has heterogeneous regions with varying local fibre orientation states. A finite element simulation is performed to model the LAAM process of a thin-wall structure, where the predicted inhomogeneous material properties are employed. Computed results show notable differences between simulations performed by employing homogenous properties and those obtained using heterogeneous properties. The bead-direction tensile stress contours computed under the heterogeneous assumption are comparable to experimental data in the literature, supporting our numerical approach. 

Abstract Many viruses eject their DNA via a nanochannel in the viral shell, driven by internal forces arising from the high-density genome packing. The speed of DNA exit is controlled by friction forces that limit the molecular mobility, but the nature of this friction is unknown. We introduce a method to probe the mobility of the tightly confined DNA by measuring DNA exit from phage phi29 capsids with optical tweezers. We measure extremely low initial exit velocity, a regime of exponentially increasing velocity, stochastic pausing that dominates the kinetics and large dynamic heterogeneity. Measurements with variable applied force provide evidence that the initial velocity is controlled by DNA–DNA sliding friction, consistent with a Frenkel–Kontorova model for nanoscale friction. We confirm several aspects of the ejection dynamics predicted by theoretical models. Features of the pausing suggest that it is connected to the phenomenon of ‘clogging’ in soft matter systems. Our results provide evidence that DNA–DNA friction and clogging control the DNA exit dynamics, but that this friction does not significantly affect DNA packaging.