Deposition Speed Research Articles

Tailoring the interfacial properties of glass fiber-epoxy microcomposites through the development of a self-healing poly(ϵ-caprolactone) coating

The aim of this study was the development and characterization of a continuous poly(ε-caprolactone) (PCL) coating, which was applied on glass fibers by a fluid coating method, in order to tailor the interfacial properties in glass fiber-epoxy microcomposites. Scanning electron microscopy revealed that a uniform coating was formed without noticeable discontinuities or irregularities, and its thickness increased with the deposition speed. To achieve consistent results with this approach, it is essential to consider the homogeneity of the coating thickness, which is influenced by the viscosity of the solution. The PCL-coated fibers were used for the preparation of microcomposites combined with epoxy resin (EP). The samples were tested in the microdebonding configuration to determine the interfacial shear strength (IFSS) and to assess their interfacial self-healing capability. For all deposition speeds, no significant degradation of interfacial adhesion was observed indicating the applicability of PCL coating on glass fibers. However, a decrease in self-healing efficiency was observed after multiple self-healing stages. The possible cause was identified in the progressive alteration of the EP droplet's shape after repeated microdebonding tests. This phenomenon altered the stress distribution along the fiber-matrix contact area and, therefore, underestimated the values of interfacial adhesion and self-healing efficiency. Hence, the experimental results from microdebonding tests were presented along with a finite element analysis of the interfacial region, in order to provide a comprehensive understanding of the debonding and self-healing mechanisms after multiple repairing steps.

Particles depositions onto non-smooth surfaces of ventilation ducts

Abstract In a previous paper, a model was established to account for particles’ deposition onto the inner surfaces of small spaces. In that paper, only smooth surfaces were considered. A modification of that model is proposed here in this article to provide a description for non-smooth (rough) surfaces. This is attained by altering the limits of the boundary-layer that are used to do the integrations required to calculate the deposition speeds. To apply the model, deposition of particles onto the inner rough surfaces of a ventilation-duct is considered, as an example. Deposition speeds onto the walls, floor and ceiling of the duct are estimated with comparing them to the experimental-data. By considering different values of the friction velocities, the alterations of the lower-limit in the boundary-layer are mathematically related to the corresponding friction velocities. The proposed model has the advantage of predicting the alteration in the limits of the boundary-layer, once the friction-velocity is provided. This is very important as the friction-velocity is a key parameter used in the descriptions of particles’ deposition and penetration.

Data-driven optimization of additive composite manufacturing using automated fibre placement: A study on process parameters effects and interactions

The influence of process parameters and their interactions on the interlaminar shear strength (ILSS) of additively manufactured CF-PEEK composites was investigated. The composites were made using a hot gas torch (HGT)-based automated fibre placement (AFP) process. Experimental short beam shear (SBS) tests and FEA numerical simulations with bonding models were conducted to generate data. Various process parameter combinations were analyzed using full-factorial statistical assessment. Results show that ILSS increases with decreasing deposition speeds and increasing HGT temperatures, with consolidation forces having a milder effect. A strong interaction effect between parameters was observed, and the effect of HGT temperature on ILSS depends on material deposition speed. The optimum ILSS were at low deposition speeds (76 mm/s) with high HGT temperatures (900 °C or 950 °C), also evident in the fracture surfaces. This database can aid smart production planning in additive manufacturing of composites by optimizing process parameters for maximum interlaminar strength.

Analysis of Microstructural and Wear Mechanisms for 3D-Printed PET CF15 Using Box–Behnken Design

We examined the impact of 3D-printing parameters, such as the deposition pattern, deposition speed, and layer height, on the tribological performance measured through the coefficient of friction and cumulative linear wear. Optimizing these factors can significantly influence material wear and friction, which is critical for ensuring durability and functionality in practical applications like a cylindrical gear assembly for a vertical-articulated robot. The purpose of the study was to investigate these relationships by employing the Box–Behnken design (BBD) method to systematically analyze the effects of these parameters, while also using scanning electron microscopy (SEM) for detailed microstructural characterization. The findings aim to provide insights that can guide the development of more efficient and wear-resistant 3D-printed materials. The strong impact of layer height on CLW was noted, showing that lower layer heights can either improve or worsen wear depending on the combination of speed and pattern, with layer height playing a dominant role in determining wear performance. Lower speeds and specific patterns, particularly lines and concentric patterns, tend to result in higher COF values. The validation test results, with a COF of 0.2215 and CLW of 29.2075, closely align with the predicted values of 0.2064 and 27.3, showing small percentage errors of 7.3% for COF and 6.5% for CLW.

Movement Characteristics of Droplet Deposition in Flat Spray Nozzle for Agricultural UAVs

At present, research on aerial spraying operations with UAVs mainly focuses on the deposition outcomes of droplets, with insufficient depth in the exploration of the movement process of droplet deposition. The movement characteristics of droplet deposition as the most fundamental factors affecting the effectiveness of pesticide application by UAVs are of great significance for improving droplet deposition. This study takes flat spray nozzles as the research object, uses the Particle Image Velocimetry (PIV) technique to obtain movement data of water droplet deposition under the influence of rotor flow fields, and investigates the variation characteristics of droplet deposition speed under different influencing factors. The results show that the deposition speed and the distribution area of high-speed (>12 m/s) particles increase with the increase of rotor speed, spraying pressure, and nozzle size. When the rotor speed increases from 0 r/min to 1800 r/min, the average increase in maximum droplet deposition speed for nozzle models LU120-02, LU120-03 and LU120-04 is 33.26%, 19.02%, and 7.62%, respectively. The rotor flow field significantly increases the number of high-speed droplets, making the dispersed droplet velocity distribution more concentrated. When the rotor speed is 0, 1000, 1500, and 1800 r/min, the average decay rates of droplet deposition speed are 36.72%, 20.00%, 15.47%, and 13.21%, respectively, indicating that the rotor flow field helps to reduce the decrease in droplet deposition speed, enabling droplets to deposit on the target area at a higher speed, reducing drift risk and evaporation loss. This study’s results are beneficial for revealing the mechanism of droplet deposition movement in aerial spraying by plant protection UAVs, improving the understanding of droplet movement, and providing data support and guidance for precise spraying operations.

Prediction of catchment efficiency in direct energy deposition using dimensional analysis and machine learning

Direct Energy Deposition (DED) is an additive manufacturing process used to fabricate thin/thick-walled structures and high-value component restorations. As blown powder-based DED gains prominence, catchment efficiency becomes imperative for enhancing material utilization and process effectiveness. This study focuses on predicting catchment efficiency within a DED process by investigating four significant process parameters: laser power, powder feed rate, carrier gas flow rate, and deposition speed. The primary objective is to devise a dimensionless number capable of predicting catchment efficiency based on a combination of these parameters, categorizing efficiency into low, medium, and high regions. This approach reduces the need for resource-intensive experimentation. The experimental validation of the proposed dimensionless number was conducted, showing an error rate of around 8%. Additionally, six machine learning classifier algorithms – Support Vector Machines, K-Nearest Neighbours, Decision Tree, Random Forest, Linear Regression, and Gaussian Naive Bayes – were employed to categorize catchment efficiency zones. Support Vector Machine demonstrated the best performance with a predictive accuracy of 0.98. This study provides a methodology for catchment efficiency prediction, enhancing decision-making and resource optimization, and can be used to optimize process parameters for thin-wall or relatively thin-wall fabrication.

Evaluating Benchtop Additive Manufacturing Processes Considering Latest Enhancements in Operational Factors

With the evolution of additive manufacturing technologies, concerning their material processing techniques, range of material choices and deposition speed, 3D printers are extensively employed in academia and industry for a number of purposes. It is no longer uncommon to have a portable, desktop 3D printer and build specific designs in a matter of minutes or hours. The functionality, costs, materials and applications of desktop 3D printers differ. Among the several desktop 3D printers with a variety of characteristics, it might be challenging to choose which one is optimal for the intended applications and uses. In this study, a variety of commercially available thermoplastic and photopolymer resin desktop 3D printers are presented and compared for user selection. This article intends to provide end-users of desktop 3D printers with fundamental information and guidelines via a comparison of desktop 3D-printing technologies and their technical characteristics, enabling them to assess and select appropriate desktop 3D printers for a variety of applications.

Process development and heat flow analysis for thin walls made of aluminum using extreme high-speed laser material deposition (EHLA3D)

Extreme high-speed laser material deposition (EHLA) is an adapted variant of directed energy deposition (DED-LB-P/M), also known as laser material deposition, and has been developed for the efficient manufacturing of thin layers with high deposition speeds. With precise control of the energy input into the powder gas jet and the substrate, EHLA allows deposition speeds of up to 200 m/min and weld beads as thin as 25 μm. Advantages include a smaller melt pool and a heat-affected zone, allowing the processing of difficult-to-weld material combinations. The development of EHLA for additive manufacturing (EHLA3D) aims to produce highly customized components with improved structural accuracy compared to standard LMD at increased build rates compared to laser powder bed fusion (PBF-LB/M). A promising application is complex lightweight structures for the aerospace industry. However, there is a lack of systematic investigation on lightweight materials processed with EHLA3D at feed rates >20 m/min. In this work, a specially designed tripod machine (maximum feed rate 200 m/min) was used to investigate the buildup of aluminum in process regimes at 30 m/min. After confirming the existing single-track parameters, the tracks were metallographically examined and checked for pores, cracks, and bonding defects. The process was applied to thin-wall geometries and line energies as well as return-times that were varied. To gain an understanding of process-induced heat development, the process was monitored using thermography. Since the process shows geometry-specific heat flow patterns, guidelines have been developed that enable the buildup using different process adaptions.

A Net Shape Profile Extraction Approach for Exploring the Forming Appearance of Inclined Thick-Walled Structures by Wire Arc Additive Manufacturing

Wire arc additive manufacturing (WAAM) offers a viable solution for fabricating large-scale metallic parts, which contain various forms of inclined thick-walled structure. Due to the variety of heat dissipation conditions at different positions, the inclined thick-walled structure is a major challenge in fabrication that may produce collapses and defects. However, there is a lack of effective sensing method for acquiring the forming appearance of individual beads in the structure. This paper proposes a novel approach for extracting individual bead profiles during the WAAM process. The approach utilizes a structured-laser sensor to capture the morphology of the surface before and after deposition, thereby enabling an accurate acquisition of the bead profile by integrating the laser stripes. Utilizing the proposed approach, the research investigated the forming mechanism of beads in inclined thick-walled components that were fabricated by various deposition parameters. The width of the overlapping area at the overhanging feature decreased as the layer number increased, while the height of the same area increased. The height of the overlapping area in each layer increased with an increase in deposition current and decreased when the deposition speed was increased. These phenomena suggest that the heat input is a major factor that influences the formation of the overhanging feature. Both the deposition current and deposition velocity influence heat input, and thereby have an effect in enhancing the geometrical accuracy of an overhanging feature. The experimental results indicate that the proposed approach facilitates morphology change investigation, providing a sufficient reference for optimizing deposition parameters.

Continuous and Stable Printing Method of Planar Microstructure Based on Meniscus-Confined Electrodeposition.

The meniscus-confined electrodeposition (MCED) technique offers advantages such as low cost and wide applicability, making it a promising method in the field of micro/nanofabrication. However, unstable meniscal morphology and poor deposition quality during planar deposition in MCED necessitate the development of improved methods. Therefore, a planar adaptive micro-tuning deposition method (PAMTDM), which utilizes the positioning technology of scanning electrochemical cell microscopy (SECCM) and employs a singular value decomposition (SVD) planar fitting method to determine the flatness of the deposition plane, is proposed. An adaptive micro-tuning motion mode was proposed by analyzing the variation patterns of the meniscus. Moreover, a combination of multi-physics finite element simulations and orthogonal experimental methods was introduced to determine the optimal motion parameters. The experimental results demonstrate that the PAMTDM effectively addresses the issues encountered during planar growth. Compared to the point-by-point deposition method, the PAMTDM achieves a threefold increase in deposition speed for continuous deposition of 105-μm-long line segments in two-dimensional planes, with a deposition current error of less than 0.2 nA. In conclusion, the proposed method provides significant insights into the broad future applications of MCED.

Role of the magnetic layer interface, roughness, and thickness in the temperature-dependent magnetic properties of Al2O3/Co/CoO thin films deposited by magnetron sputtering

Using the methods of atomic force and electron microscopy and the magneto-optical Kerr effect, the role of the interface, roughness, and thickness of the magnetic layer in the temperature-dependent magnetic properties of thin Al2O3–Co films with a naturally oxidized cobalt surface was studied. The layers were deposited by magnetron sputtering. The thickness of the cobalt layer varied from 2 to 100 nm. For the first time, the dependences of coercive forces and exchange displacements on the thickness of the cobalt film in the temperature range from 80 to 300 K were obtained and analyzed. The contribution to the coercive force and exchange displacement from the oxidized cobalt surface increases as the temperature decreases below 160 K. The magnitude of the contribution depends on the base material on which the cobalt film is deposited and is maximum for a cobalt film with a thickness of ∼20 nm in the Al2O3/Co structure. A weakly magnetic layer was found at the Al2O3/Co interface. The behavior of the exchange bias in this layer is similar to the behavior of a ferromagnetic Co core with a naturally oxidized CoO shell. The thickness of this layer depends on the speed and order of deposition of the layers. When the order of deposition of layers (Co/Al2O3) changes, the behavior of the exchange displacement of the interface becomes similar to that observed in the ferromagnet/antiferromagnet system. That is, when the deposition order changes, the value of the exchange shift changes sign when the cobalt layer thickness is below 10 nm.

Effect of Ni Addtion on Electroless Cu for High Density Interconnect PCB Substrate

Introduction Nowadays, high-density interconnect (HDI) printed circuit board (PCB) substrates have been widely applied to high-end electronics to meet the increasing input and output (I/O) density and small footprint area. Micro-via, a tiny structure buried among build-up layers that provide electrical interconnection is a key component in the HDI substrate. However, the preparation of micro-via is facing new challenges. It is not only required that the size of the micro-via scales down to meet the increased interconnect density, but also that the micro-via should withstand severe operating conditions in different scenarios. Therefore, it is of great importance to improve the quality of micro-vias during processing and manufacturing. The micro-via structure is a sandwich structure that is processed by electroless Cu plating and Cu electrolyte plating sequentially, and thus the quality of the electroless Cu layer can significantly affect the reliability of micro-via. In this work, we mainly focused on the electroless Cu plating process and investigated the effect of the electroless Cu deposition speed on the quality of the micro-via structure. SIM and HR-TEM characterizations were employed to investigate the micro-structure inside the electroless Cu layer. Materials and Method In this study, we used the common alkaline ion catalyst method to prepare the electroless Cu layer. The electroless Cu plating and electrolyte Cu plating was conducted on a PCB Resin Coated Copper (RCC) substrate that was cleaned by soft etching in an acid condition. The surface is then pre-dipped in an anionic solution, and palladium ions were adsorbed using an alkaline ion catalyst. The electroless Cu processes adopted in a reaction bath that consists of Cu resource (CuSO4·5H2O), complexing agent (KNaC4H4O6·4H2O) and reductant (HCHO). The whole reaction was conducted in the alkaline condition with a PH of 12.5, and the thickness of the electroless Cu deposition was controlled at around 0.20 µm. NiSO4 is selected as the Ni precursor to alter the Ni concentration in the reation bath. The contents of Ni addition were selected as 50 %, 100 %, 200 % and 300% of a conventional process at a bath temperature of 27 ºC. The thickness of the plated Cu layer was measured by a gravimetric method. Results and discussion TEM observation was used to identify the structure at the interface. Fig. 1 shows the TEM observation of the sample with 50 % and 200 % Ni concentrate. There are some nanovoids found at the interface between the Cu substrate and electroless Cu, which is arguably due to hydrogen generated during electroless Cu plating. The sample with a higher reaction speed has more nanovoids. It can be due to that the higher reaction speed can generate more hydrogen bubbles in the bath that can attach to the electroless Cu layer, leading to nanovoids as shown in Fig. 1. The samples prepared at different bath temperatures are under investigation to illustrate that the reaction speed can significantly affect the Cu electroless layer quality. Conclusions In this work, we investigated the Ni effect in electroless Cu on the RCC substrate. It is found that the higher Ni incorporation can lead to massive nanovoids generation and fine Cu grains in the electroless layer, which is a potential risk for the reliability of the HDI substrate. By reducing the Ni incorporation content, the number of nanovoids can be effectively reduced. Figure 1

Non-close-packed plasmonic Bravais lattices through a fluid interface-assisted colloidal assembly and transfer process

AbstractThe assembly of colloids at fluid interfaces followed by their transfer to solid substrates represents a robust bottom-up strategy for creating colloidal monolayers over large, macroscopic areas. In this study, we showcase how subtle adjustments in the transfer process, such as varying the contact angle of the substrate and controlling deposition speed and direction, enable the realization of all five two-dimensional Bravais lattices. Leveraging plasmonic core–shell microgels as the building blocks, we successfully engineered non-close-packed plasmonic lattices exhibiting hexagonal, square, rectangular, centered rectangular, and oblique symmetries. Beyond characterizing the monolayer structures and their long-range order, we employed extinction spectroscopy alongside finite difference time domain simulations to comprehensively investigate and interpret the plasmonic response of these monolayers. Additionally, we probed the influence of the refractive index environment on the plasmonic properties by two methods: first, by plasma treatment to remove the microgel shells, and second, by overcoating the resulting gold nanoparticle lattices with a homogeneous refractive index polymer film. Graphical Abstract

Improving the formability and quality of CMT additively manufactured aluminum thin-wall parts via laser stabilization effect

In the recent past, the deposition efficiency has been one of the most concerned problems in aluminum additive manufacturing. In this research, a comparative study on the formation quality, microstructures and mechanical properties of aluminum alloy thin-wall structures between the oscillating laser-arc hybrid additive manufacturing (O-LHAM) and wire-arc additive manufacturing (WAAM) at high deposition speed was performed. The formation quality of the additively manufactured thin-wall parts under O-LHAM was significantly improved compared with WAAM. The molten pool overflow was significantly eliminated due to the higher support force on the molten pool, thus the surface roughness Sa and the maximum surface height difference Sz of O-LHAM thin walls were reduced by 13% and 22%, respectively. Compared with thin wall manufactured via WAAM, the microstructure of O-LHAM mainly consisted of coarse columnar grains and showed anisotropic characteristics due to the increased heat accumulation. Moreover, owing to the higher porosity in the interlayer combination regions of WAAM sample, the elongation of thin walls manufactured via O-LHAM was higher than WAAM in both horizontal and vertical directions, reaching 36.8% and 32.5%, respectively. This work will provide more guidance on thin-wall additive manufacturing with high deposition efficiency.

The effect of the interlayer time and deposition speed on the tensile properties of material extrusion components

This study investigates the influence of the substrate temperature in material extrusion (MEX) on tensile behavior of PLA samples. A full factorial experimental plan was conducted by varying the deposition speed and the interlayer time. Infrared thermography was conducted to determine the influence of the deposition conditions on the temperature of the substrate just before the deposition of the next layer. Tensile tests were conducted along the “upright direction” to determine the influence of the thermal history on the interlayer adhesion. The results indicate the strong influence of the interlayer time on the thermal history and the mechanical behavior. The temperature of the substrate before subsequent overlying deposition was mainly influenced by the interlayer time, while it was less affected by the deposition speed. The Young modulus of the samples was poorly affected by the adopted process conditions; on the other hand, the maximum strength and the elongation at rupture were strongly affected by the interlayer time. The identified variances in mechanical behavior underscore the pivotal significance of sample dimensions in dictating the ultimate mechanical characteristics of vertically oriented samples. These outcomes illuminate the intricate interaction between deposition speed and interlayer duration, highlighting their substantial influence on mechanical performance.

Numerical and experimental study of attenuation inspection during FDM with ultrasonic leaky waveguide

ABSTRACT This work proposes an ultrasonic leaky waveguide (ULWG) for in-situ structural integrity inspection during fused deposition modeling (FDM). Since the ultrasonic wave propagation speed (m·s−1) is much higher than the deposition speed (mm·s−1), a quasi-static finite element model is first established to simulate the wave propagation during this dynamic process. The amplitude and energy attenuation coefficients (α and ζ) are chosen as the inspection features. Processing parameters including deposition layer thickness and number, inspection frequency, plate thickness and interface impedance are explored. For the first layer printing, a thinner thickness, higher frequency and proper interface impedance will enable a better inspection with high sensitivity. For multilayer printing, the multimodal dispersion curves change continuously and α oscillation is observed due to waveform aliasing that ζ is more reliable. Printing failures such as detachment can be predicted as well from the model established. The ULWG is then integrated into a commercial FDM machine to capture the attenuation coefficients of an “S” shape sample. The poor adhesion, local and global detachments, path planning impact can all be revealed by ζ experimentally. Moreover, being consistent to the simulation, the fluctuation of α in multilayer printing increases, which prevents a further printing evaluation.

A Methodology for Shielding-Gas Selection in Wire Arc Additive Manufacturing with Stainless Steel.

The main objective of this work was to propose and evaluate a methodology for shielding-gas selection in additive manufacturing assisted by wire arc additive manufacturing (WAAM) with an austenitic stainless steel as feedstock. To validate the proposed methodology, the impact of multi-component gases was valued using three different Ar-based blends recommended as shielding gas for GMA (gas metal arc) of the target material, using CMT (cold metal transfer) as the process version. This assessment considered features that potentially affect the building of the case study of thin walls, such as metal transfer regularity, deposition time, and geometrical and metallurgical characteristics. Different settings of wire-feed speeds were conceived to maintain a similar mean current (first constraint for comparison's sake) among the three gas blends. This approach implied different mean wire-feed speeds and simultaneously forced a change in the deposition speed to maintain the same amount of material deposited per unit of length (second comparison constraint). The composition of the gases affects the operational performance of the shielding gases. It was concluded that by following this methodology, shielding-gas selection decision-making is possible based on the perceived characteristics of the different commercial blends.

Powder bed fusion factory productivity increases using discrete event simulation and genetic algorithm

AbstractPowder bed fusion is importance is growing with uses across industries in both polymer and metallic components, particularly in mass individualization. However, due to the relatively slow mass deposition speed compared to conventional methods, scheduling and production planning play a crucial role in scaling up additive manufacturing productivity to higher volumes. This paper introduces a framework combining discrete event simulation and a genetic algorithm showing makespan improvement opportunities for multiple powder bed fusion factories varying workers, jobs and available equipment. The results show that bottlenecks move among workstations based on worker and capital equipment availability, which depend on the size of the facility indicating a resource-driven constraint for makespan. A makespan reduction of 78% is achieved in the simulation. This shows the trade-off of worker and capital equipment to achieve makespan improvements. The addition of personnel or equipment increases production with further gains achieved by scheduling optimization. Two levels of job demands are analyzed showing productivity gains of 45% makespan improvement when adding the first worker and additional savings with scheduling optimization using a genetic algorithm up to 11%. Most research on additive manufacturing production has focused on the quality of produced parts and printing technology rather than factory level management. This is the first application of this methodology to varying sizes of these potential factories. The method developed here will help decision-makers to determine the appropriate number of resources to meet their customer demand on time, additionally, finding the optimal route for jobs before starting the production process.

From 2D to 3D electrochemical microfabrication of nickel architectures at room temperature: Synthesis and characterization of microstructure and mechanical properties

Recent development in direct electrochemical 3D microprinting allows the fabrication of 3D metallic micro-components of predominantly noble metals with the positive standard reduction potentials (e.g., Cu, Au, or Pt). These pure metals (e.g., Cu, Au, or Pt) have a small shear modulus up to 60 GPa, which limits one of the important strengthening mechanisms, Taylor hardening. Hence, their mechanical strength is relatively low and limits the application in a structural component. 3D printing of mechanically high-strength metals (e.g., Ni), specifically, printing of microscale parts by direct electrodeposition using a voxel-by-voxel printing technique, is so far very challenging due to the negative standard reduction potential, which leads to hydrogen evolution and unstable printing. In this paper, we demonstrate the stable and successful room temperature (RT) electrochemical printing of Ni micro-architectures by using a newly formulated Ni ink and supporting electrolyte, which were developed through 2D voltammetry and deposition analysis. The micro manufacturing of Ni succeeds at a high deposition speed up to ∼61 nm/s, which is the fastest speed reported so far for microprinting of Ni. 3D printed micropillars feature a heterogeneous nanostructure from ∼13 nm at the center to ∼27 nm at the perimeter. By performing micropillar compression tests, the printed pillars exhibit a high compressive yield-strength of 2.3 ± 0.1 GPa, only ∼15 % lower than 2D processed samples (2.7 ± 0.1 GPa) featuring a homogeneous nanostructure of 27 ± 16 nm. Thus, by deposition of stronger, but less noble metals we show a new pathway to enhance the mechanical robustness of 3D-printed structures, opening up new applications where mechanical rigidity is essential.

Influence of Manufacturing Process on the Conductivity of Material Extrusion Components: A Comparison between Filament- and Granule-Based Processes.

The additive manufacturing of components using material extrusion (MEX) enables the integration of several materials into one component, including functional structures such as electrically conductive structures. This study investigated the influence of the selected additive MEX process on the resistivity of MEX structures. Specimens were produced from filaments and granules of an electrically conductive PLA and filled with carbon nanotubes and carbon black. Specimens were produced with a full-factorial variation of the input variables: extrusion temperature, deposition speed, and production process. The resistivity of the specimens was determined by four-wire measurement. Analysis of the obtained data showed that only the extrusion temperature had a significant influence on the resistivity of the MEX specimens. Furthermore, the impact of the nozzle diameter was evaluated by comparing the results of this study with those of a previous study, with an otherwise equal experimental setup. The nozzle diameter had a significant influence on resistivity and a larger nozzle diameter reduced the mean variance by an order of magnitude. The resistivity was lower for most process parameter sets. As the manufacturing process had no significant influence on the resistivity of MEX structures, it can be selected based on other criteria, e.g., the cost of feedstock.