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Surface topology as non-destructive proxy for tensile strength of plastic parts from filament-based material extrusion

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Abstract

Non-destructive characterization of 3D-printed parts is critical for quality control and adoption of additive manufacturing (AM). The low-cost driver for AM of thermoplastics, typically through material extrusion AM (MEAM), challenges the integration of real-time, operando characterization and control schemes that have been developed for metals. Here, we demonstrate that the surface topology determined from optical profilometry provides information about the mechanical response of the printed part using commercial ABS filaments through calibration-based correlations. The influence of layer thickness on the tensile properties of MEAM ABS was examined. Surface topology was converted into amplitude spectra using fast Fourier transforms. The scatter in the tensile strength of the replicate samples was well represented by the differences in the amplitude of the two fundamental waves that describe the periodicity of the printed roads. These results suggest that information about previously printed layers is transferred to subsequent layers that can be resolved from optical profilometry and offers the potential of a rapid, non-destructive post-print characterization for improved quality control.

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Data availability

The authors declare that the data supporting the findings of this study are available within the paper and its Supplementary Information files. Should any raw data files be needed in another format they are available from the corresponding author upon reasonable request. Source data are provided with this paper.

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Acknowledgements

This work was partially supported by the National Science Foundation under Grant no. CMMI-2011289. The authors acknowledge use of the Penn State Materials Characterization Lab for tensile measurements.

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  1. Department of Materials Science and Engineering, The Pennsylvania State University, University Park, PA, 16802, USA

    Bevan Harbinson

  2. Department of Chemical Engineering, The Pennsylvania State University, University Park, PA, 16802, USA

    Sierra F. Yost & Bryan D. Vogt

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Harbinson, B., Yost, S.F. & Vogt, B.D. Surface topology as non-destructive proxy for tensile strength of plastic parts from filament-based material extrusion. Prog Addit Manuf (2023). https://doi.org/10.1007/s40964-023-00506-8

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