Effect of Bead Geometry and Layer Time on Microstructure and Thermomechanical Properties of Large-Format Polymer Composites

Large-format additive manufacturing (LFAM) is a manufacturing process in which high volumes of material are extruded in a layer-by-layer fashion to create large structures with often complex geometries. The Loci-One system, operated and developed by Loci Robotics Inc., is an LFAM-type system that was used to print single-bead walls of 20% by weight carbon fiber reinforced acrylonitrile butadiene styrene (CF-ABS) using various print parameter inputs. This study observed the influence of bead width and layer time on thermomechanical performance via material characterization techniques that accounted for the complex microstructure of LFAM parts to develop a better understanding of parameter-structure-property relationships. Printed parts were characterized by measuring the coefficient of thermal expansion (CTE) and interlayer strength. Near the edges of the printed beads, microscopy revealed a "thinning effect" experienced by a shell composed primarily of highly oriented fiber as the bead width was increased; however, this effect was diminished with a higher shear rate. The CTE results demonstrated the influence of mesostructure on the thermomechanical response. Increased shear rates were expected to lower CTE in the x-direction due to a higher ratio of fiber oriented in the print direction, but this relationship was not always observed. For the larger bead widths printed at higher shear rates, the randomly oriented fiber at the core dominated the thermomechanical response and increased CTE overall in the x-direction. A heat transfer model was developed for this work to determine how much time was required for the deposited bead to cool to the glass transition temperature. Interlayer strength results revealed a rapid decrease once the printed layer time exceeded the time required for the extrudate to cool below the glass transition temperature.