Improving the filament weld-strength of fused filament fabrication products through improved interdiffusion

Fused Filament Fabrication (FFF) is a popular additive manufacturing technique where molten polymer filament is applied in a raster pattern, layer by layer, to obtain the work piece. A necessary consequence of this method is a pronounced mechanical anisotropy of the product; the interface between the filaments is weaker compared to the filament itself. The strength of this interface is governed by the reptation theory which postulates a more efficient interpenetration of polymeric surfaces with decreasing polymer viscosity. This relationship was utilized in this work to modify a polycarbonate-acrylonitrile butadiene styrene polymer blend to produce FFF work pieces with less mechanical anisotropy, independent of printer settings. The tensile strength ratio of the printed interface to bulk tensile strength could be increased from 41% to 95%. Though the absolute bulk tensile strength decreases slightly, this method presents an easy and effective way to address the mechanical problems inherent in the FFF-method.