On the use of high viscosity polymers in the fused filament fabrication process

Purpose - This work aims to provide additional insights regarding the practicability of using conventional materials in the fused filament fabrication (FFF) process. Design/methodology/approach - Two different acrylonitryle butadiene styrene (ABS) grades are studied and compared, aiming to check to what extent the regular ABS developed for conventional polymer processing, with a different rheology than the one provided for the FFF process, can also be used in this process (FFF). Findings - The rheological results show that a general-purpose ABS (ABS-GP) melt is much more viscous and elastic than ABS-FFF. It is clear that using ABS-GP as feedstock material in the FFF process results in poor coalescence and adhesion between the extruded filaments, which has a detrimental effect on the mechanical properties of the printed specimens. Despite its lower performance, ABS-GP can be a good choice if the objective is to produce an aesthetical prototype. If the objective is to produce a functional prototype or a final part, its mechanical performance requirements will dictate the choice. Originality/value - This work provides insightful information regarding the use of high viscosity materials on the 3D printing process.