Integrated laser-based powder bed fusion and fused filament fabrication for three-dimensional printing of hybrid metal/polymer objects

Yuan-hui Chueh; Chao Wei; Xiaoji Zhang; Lin Li

doi:10.1016/j.addma.2019.100928

Integrated laser-based powder bed fusion and fused filament fabrication for three-dimensional printing of hybrid metal/polymer objects

Yuan-hui Chueh, Chao Wei, Xiaoji Zhang, Lin Li

Dalton Nuclear Institute

Research output: Contribution to journal › Article › peer-review

Abstract

To produce complex functional devices while eliminating the need for assembly calls for a multi-material additive manufacturing technology. This paper presented a 3D-printing system that integrated fused filament fabrication (FFF) and laser-based powder bed fusion (PBF) to produce hybrid metal and polymer components. The design and operation procedure of the system were introduced. PBF-printed metal and FFF-printed polymer, both of which differ in material properties, were joined through PBF-printed interlocking structures, with their joining strength enhanced by laser heating. The mechanisms and scientific rationale that governed metal/polymer joining were discussed. Tensile and shear tests confirmed good joint strength of the printed metal/polymer components, which were created without adhesives. In addition, metal powder deposition onto the top of polymer substrates through laser melting was demonstrated. Layers of copper (Cu10Sn) were successfully deposited onto the top of a PLA/SS 316L composite substrate; however, their joint strength remained a problem to resolve. Finally, several 3D components consisting of hybrid stainless steel (SS 316L), copper (Cu10Sn) and polymer (PLA, PET) were successfully printed and their potential applications were discussed.

Original language	English
Pages (from-to)	100928
Journal	Additive Manufacturing
Volume	31
Early online date	8 Nov 2019
DOIs	https://doi.org/10.1016/j.addma.2019.100928
Publication status	Published - 1 Jan 2020

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Photon Science Institute
Dalton Nuclear Institute

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10.1016/j.addma.2019.100928

LPRC: Laser Processing Research Centre Impact
Allegre, O. (PI), Crosby, D. (PI), Domingos, M. (PI), Francis, J. (PI), Gillen, D. (PI), Guo, W. (PI), Li, L. (PI), Mativenga, P. (PI), Rogers, B. D. (PI), Whitehead, D. (PI), Wilson, D. (PI), Zhong, S. (PI), Mirhosseini, N. (Researcher), Ouyang, J. (Researcher), Huang, Y. (Researcher), Wei, C. (Researcher), Cheng, D. (PGR student), Suryo Pratomo, E. (PGR student), Zhang, Z. (PGR student), Li, Z. (PGR student), Mo, H. (PGR student), Zhu, M. (PGR student), Li, Q. (PGR student), Liu, W. (PGR student), Wang, L. (PGR student), Guo, H. (PGR student), Heinemann, R. (PI) & Liu, Z. (PI)
1/04/00 → …
Project: Research

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title = "Integrated laser-based powder bed fusion and fused filament fabrication for three-dimensional printing of hybrid metal/polymer objects",

abstract = "To produce complex functional devices while eliminating the need for assembly calls for a multi-material additive manufacturing technology. This paper presented a 3D-printing system that integrated fused filament fabrication (FFF) and laser-based powder bed fusion (PBF) to produce hybrid metal and polymer components. The design and operation procedure of the system were introduced. PBF-printed metal and FFF-printed polymer, both of which differ in material properties, were joined through PBF-printed interlocking structures, with their joining strength enhanced by laser heating. The mechanisms and scientific rationale that governed metal/polymer joining were discussed. Tensile and shear tests confirmed good joint strength of the printed metal/polymer components, which were created without adhesives. In addition, metal powder deposition onto the top of polymer substrates through laser melting was demonstrated. Layers of copper (Cu10Sn) were successfully deposited onto the top of a PLA/SS 316L composite substrate; however, their joint strength remained a problem to resolve. Finally, several 3D components consisting of hybrid stainless steel (SS 316L), copper (Cu10Sn) and polymer (PLA, PET) were successfully printed and their potential applications were discussed.",

author = "Yuan-hui Chueh and Chao Wei and Xiaoji Zhang and Lin Li",

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doi = "10.1016/j.addma.2019.100928",

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T1 - Integrated laser-based powder bed fusion and fused filament fabrication for three-dimensional printing of hybrid metal/polymer objects

AU - Chueh, Yuan-hui

AU - Wei, Chao

AU - Zhang, Xiaoji

AU - Li, Lin

PY - 2020/1/1

Y1 - 2020/1/1

N2 - To produce complex functional devices while eliminating the need for assembly calls for a multi-material additive manufacturing technology. This paper presented a 3D-printing system that integrated fused filament fabrication (FFF) and laser-based powder bed fusion (PBF) to produce hybrid metal and polymer components. The design and operation procedure of the system were introduced. PBF-printed metal and FFF-printed polymer, both of which differ in material properties, were joined through PBF-printed interlocking structures, with their joining strength enhanced by laser heating. The mechanisms and scientific rationale that governed metal/polymer joining were discussed. Tensile and shear tests confirmed good joint strength of the printed metal/polymer components, which were created without adhesives. In addition, metal powder deposition onto the top of polymer substrates through laser melting was demonstrated. Layers of copper (Cu10Sn) were successfully deposited onto the top of a PLA/SS 316L composite substrate; however, their joint strength remained a problem to resolve. Finally, several 3D components consisting of hybrid stainless steel (SS 316L), copper (Cu10Sn) and polymer (PLA, PET) were successfully printed and their potential applications were discussed.

AB - To produce complex functional devices while eliminating the need for assembly calls for a multi-material additive manufacturing technology. This paper presented a 3D-printing system that integrated fused filament fabrication (FFF) and laser-based powder bed fusion (PBF) to produce hybrid metal and polymer components. The design and operation procedure of the system were introduced. PBF-printed metal and FFF-printed polymer, both of which differ in material properties, were joined through PBF-printed interlocking structures, with their joining strength enhanced by laser heating. The mechanisms and scientific rationale that governed metal/polymer joining were discussed. Tensile and shear tests confirmed good joint strength of the printed metal/polymer components, which were created without adhesives. In addition, metal powder deposition onto the top of polymer substrates through laser melting was demonstrated. Layers of copper (Cu10Sn) were successfully deposited onto the top of a PLA/SS 316L composite substrate; however, their joint strength remained a problem to resolve. Finally, several 3D components consisting of hybrid stainless steel (SS 316L), copper (Cu10Sn) and polymer (PLA, PET) were successfully printed and their potential applications were discussed.

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Integrated laser-based powder bed fusion and fused filament fabrication for three-dimensional printing of hybrid metal/polymer objects

Abstract

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LPRC: Laser Processing Research Centre Impact

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