The impact of infill percentage and layer height in small-scale material extrusion on porosity and tensile properties

Brackett, James; Cauthen, Dakota; Condon, Justin; Smith, Tyler; Gallego, Nidia; Kunc, Vlastimil; Duty, Chad

doi:10.1016/j.addma.2022.103063

The impact of infill percentage and layer height in small-scale material extrusion on porosity and tensile properties

Journal Article · Wed Jul 27 00:00:00 EDT 2022 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2022.103063· OSTI ID:1881083

Brackett, James ^[1]; Cauthen, Dakota ^[1]; Condon, Justin ^[2]; Smith, Tyler ^[3]; ^[3]; ^[3]; Duty, Chad ^[2]

University of Tennessee, Knoxville, TN (United States)
University of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

We report material extrusion additive manufacturing is prone to introducing porosity within the structure due to the layer-by-layer construction using elliptical beads of material. This open porosity ultimately plays a role in determining the mechanical properties of printed parts. The shape, size, and amount of porosity within a printed part is influenced by a variety of factors, including nozzle diameter, infill percentage, layer height, raster orientation, and print speed. While several studies have investigated these and other parameters’ effects on mechanical performance and porosity, better understanding the interconnected relationships is crucial in balancing the various input parameters to achieve maximum strength. This work initially examined the influence of key print parameters (infill percentage and layer height) on the internal porosity of a printed Acrylonitrile Butadiene Styrene (ABS) part. Then, the print parameters and internal porosity were statistically correlated to final mechanical properties. Porosity was further classified as either open or closed to differentiate between connected voids in the mesostructure from isolated voids within the material itself. Mechanical performance increased with an increasing density and infill percentage, displaying a 224 % increase in elastic modulus and a 150 % increase in ultimate tensile strength. The contribution of layer height was found to be conditional upon the infill percentage.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: National Science Foundation (NSF); USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1881083

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: 58 Vol. 58; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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