Local composition control using an active-mixing hotend in fused filament fabrication

Joshua T. Green; Ian A. Rybak; Jonathan J. Slager; Mauricio Lopez; Zachary Chanoi; Calvin M. Stewart; Roger V. Gonzalez

Additive Manufacturing Letters (Dec 2023)

Local composition control using an active-mixing hotend in fused filament fabrication

Joshua T. Green,
Ian A. Rybak,
Jonathan J. Slager,
Mauricio Lopez,
Zachary Chanoi,
Calvin M. Stewart,
Roger V. Gonzalez

Affiliations

Joshua T. Green: Department of Engineering Education and Leadership, College of Engineering, The University of Texas at El Paso, 500W. University Ave., El Paso, TX 79968, USA; Corresponding author.
Ian A. Rybak: Department of Engineering Education and Leadership, College of Engineering, The University of Texas at El Paso, 500W. University Ave., El Paso, TX 79968, USA
Jonathan J. Slager: Department of Mechanical and Nuclear Engineering, School of Engineering and Weapons, United States Naval Academy, 590 Holloway Rd., Annapolis, MD 21402, USA
Mauricio Lopez: Department of Metallurgical, Materials and Biomedical Engineering, College of Engineering, The University of Texas at El Paso, 500W. University Ave., El Paso, TX 79968, USA
Zachary Chanoi: Department of Aerospace and Mechanical Engineering, College of Engineering, The University of Texas at El Paso, 500W. University Ave., El Paso, TX 79968, USA
Calvin M. Stewart: Department of Mechanical and Aerospace Engineering, College of Engineering, The Ohio State University, 201W 19th Avenue, Columbus, OH 43210, USA
Roger V. Gonzalez: Department of Engineering Education and Leadership, College of Engineering, The University of Texas at El Paso, 500W. University Ave., El Paso, TX 79968, USA

Journal volume & issue: Vol. 7
p. 100177

Abstract

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Additive manufacturing with local composition control is uniquely suited for the development and exploration of advanced materials with compositionally graded structures. A fused filament fabrication printer was designed with in situ composition control facilitated by using an active-mixing hotend. Stepper motors drive three filament extruders and a mixing rod in proportions instructed by a print file to control composition and material distribution within extrusions. Composition tailoring was demonstrated by printing specimens with twelve distinct regions each consisting of unique filament mixtures. Local control of composition was demonstrated by printing a variety of specimens with composition gradients having horizontal, vertical, radial, and circumferential orientations. The tensile properties of printed materials were modified by printing with mix ratios of polylactic acid and thermoplastic polyurethane. Eight blend ratios were tested in tension and have tensile moduli ranging from 17.3 to 3480 MPa. These methods demonstrate advanced capabilities that are well suited for manufacturing functionally graded structures.

Published in Additive Manufacturing Letters

ISSN: 2772-3690 (Online)
Publisher: Elsevier
Country of publisher: Netherlands
LCC subjects: Technology: Technology (General): Industrial engineering. Management engineering
Website: https://www.journals.elsevier.com/additive-manufacturing-letters/

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