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Project # 96
Enhanced Interlayer Adhesion in Fused Filament Fabrication via In-Situ Air-Based Annealing
| Team Lead: | Jasraj Singh |
| Other Team Members: | |
| Faculty Advisor(s): | Robert Taylor |
| Department: | MAE |
| Project Type: | REU |
| Title: | Enhanced Interlayer Adhesion in Fused Filament Fabrication via In-Situ Air-Based Annealing |
| Abstract: | Parts produced via Fused Filament Fabrication (FFF) commonly exhibit anisotropic mechanical performance and irregular inter-bead void morphology due to insufficient interlayer chain interdiffusion driven by rapid cooling and steep thermal gradients during deposition. This work presents a novel air-based in-situ annealing system designed to improve layer bonding, promote circular void formation, and reduce anisotropy during printing. The system provides targeted, real-time thermal treatment above the polymer’s glass transition temperature to newly deposited and underlying layers, promoting interlayer bonding, stress relaxation, and potential elimination of the need for a heated chamber in high-temperature material systems. The FFF platform has been upgraded to support high-temperature materials with enhanced extrusion stability and thermal control. Printed structures, including dogbone specimens, are being evaluated for tensile strength, warpage, and microstructural uniformity to quantify the effects of in-process annealing. Preliminary observations suggest that controlled post-deposition heating can significantly improve mechanical performance and structural isotropy. This approach integrates annealing into the FFF workflow, advancing the fabrication of stronger, more dimensionally reliable, and increasingly isotropic thermoplastic components for demanding structural applications. |
| Poster: | View Poster #96 (PDF) |
| Judges Scoring: | Submit Evaluation (judges only) |