Hybrid material additive manufacturing: interlocking interfaces for fused filament fabrication on laser powder bed fusion substrates

Abstract

ABSTRACT The fabrication of polymer–metal hybrids in an additive process makes it possible to further improve the geometrical and material adaption in a multi-material design. In this work, PLA is fabricated through a fused filament fabrication process on AlSi10Mg structures manufactured by laser powder bed fusion. The mechanical connection is realised by form fit, for which different geometries are examined through tensile tests. Deep penetration of the PLA into the metallic structures is achieved by optimisation of the process parameters. The penetration depth is assessed through the use of micro-computed tomography. Finally, the interplay of mechanisms leading to a firm connection is discussed.