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Title: Z-Pinning approach for 3D printing mechanically isotropic materials

Abstract

Conventional 3D printing approaches are restricted to building up material in a layer-by-layer format, which is more appropriately considered “2.5-D” printing. The layered structure inherently results in significant mechanical anisotropy in printed parts, causing the tensile strength in the build direction (z-axis) to be only a fraction of the in-plane strength – a decrease of 50–75% is common. In this study, a novel “z-pinning” approach is described that allows continuous material to be deposited across multiple layers within the volume of the part. Here, the z-pinning process is demonstrated using a Fused Filament Fabrication (FFF) printer for polylactic acid (PLA) and carbon fiber reinforced PLA. For both materials, z-pinning increased the tensile strength and toughness in the z-direction by more than a factor of 3.5. Direct comparisons to tensile strength in the x-axis showed a significant decrease in mechanical anisotropy as the volume of the pin was increased relative to the void in the rectilinear grid structure. In fact, the PLA sample with the largest pin volume demonstrated mechanically isotropic properties within the statistical uncertainty of the tests. Tensile test results were also analyzed relative to the functional area resisting deformation for each sample.

Authors:
ORCiD logo [1]; ORCiD logo [2]; ORCiD logo [1];  [1]; ORCiD logo [2]; ORCiD logo [3]
+ Show Author Affiliations
  1. Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  3. Univ. of Tennessee, Knoxville, TN (United States); Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Purdue Univ., West Lafayette, IN (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1808415
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Accepted Manuscript
Journal Name:
Additive Manufacturing
Additional Journal Information:
Journal Volume: 27; Journal ID: ISSN 2214-8604
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 3D printing; extrusion; fused filament fabrication; anisotropy; interlayer strength

Citation Formats

Duty, Chad, Failla, Jordan, Kim, Pum, Smith, Tyler, Lindahl, John, and Kunc, Vlastimil. Z-Pinning approach for 3D printing mechanically isotropic materials. United States: N. p., 2019. Web. doi:10.1016/j.addma.2019.03.007.
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Duty, Chad, Failla, Jordan, Kim, Pum, Smith, Tyler, Lindahl, John, & Kunc, Vlastimil. Z-Pinning approach for 3D printing mechanically isotropic materials. United States. https://doi.org/10.1016/j.addma.2019.03.007
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Duty, Chad, Failla, Jordan, Kim, Pum, Smith, Tyler, Lindahl, John, and Kunc, Vlastimil. Thu . "Z-Pinning approach for 3D printing mechanically isotropic materials". United States. https://doi.org/10.1016/j.addma.2019.03.007. https://www.osti.gov/servlets/purl/1808415.
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@article{osti_1808415,
title = {Z-Pinning approach for 3D printing mechanically isotropic materials},
author = {Duty, Chad and Failla, Jordan and Kim, Pum and Smith, Tyler and Lindahl, John and Kunc, Vlastimil},
abstractNote = {Conventional 3D printing approaches are restricted to building up material in a layer-by-layer format, which is more appropriately considered “2.5-D” printing. The layered structure inherently results in significant mechanical anisotropy in printed parts, causing the tensile strength in the build direction (z-axis) to be only a fraction of the in-plane strength – a decrease of 50–75% is common. In this study, a novel “z-pinning” approach is described that allows continuous material to be deposited across multiple layers within the volume of the part. Here, the z-pinning process is demonstrated using a Fused Filament Fabrication (FFF) printer for polylactic acid (PLA) and carbon fiber reinforced PLA. For both materials, z-pinning increased the tensile strength and toughness in the z-direction by more than a factor of 3.5. Direct comparisons to tensile strength in the x-axis showed a significant decrease in mechanical anisotropy as the volume of the pin was increased relative to the void in the rectilinear grid structure. In fact, the PLA sample with the largest pin volume demonstrated mechanically isotropic properties within the statistical uncertainty of the tests. Tensile test results were also analyzed relative to the functional area resisting deformation for each sample.},
doi = {10.1016/j.addma.2019.03.007},
journal = {Additive Manufacturing},
number = ,
volume = 27,
place = {United States},
year = {Thu Mar 07 00:00:00 EST 2019},
month = {Thu Mar 07 00:00:00 EST 2019}
}
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https://doi.org/10.1016/j.addma.2019.03.007
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    • Ajinjeru, Christine; Kishore, Vidya; Chen, Xun
    • Journal of Thermoplastic Composite Materials
    • DOI: 10.1177/0892705719873941

    Strength Increasing Additive Manufacturing Fused Filament Fabrication Technology, Based on Spiral Toolpath Material Deposition
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