Characterisation of fusion bonding between filaments of thin 3D printed polyamide 6 using an essential work of fracture method

The extent and quality, i.e. consistency, of the fusion bonding between filaments that occurs during the fused filament fabrication (FFF) process play an important role in determining the mechanical performance of 3D printed polymeric parts. This present research is designed to quantify these parameters of the fusion bonding between individual filaments deposited during the 3D printing process. Polyamide 6 (PA6) specimens were prepared from both 3D printed single-layer and single-filament films. Also, to provide a benchmark material, 3D printed PA6 films prepared by the FFF process were further processed by using compression moulding (CM) to investigate whether the fusion bonding could be enhanced. An essential work of fracture method was employed to evaluate the fusion bonding between the filaments by determining the value of the specific essential work of fracture, we, and the associated experimental reproducibility. The higher value of we, and the relatively low degree of scatter determined for the benchmark material revealed that the extent and quality of fusion bonding attained when using only the FFF process clearly needed to be improved when parts are fabricated for practical applications. To study the effect of temperature on the fusion bonding, the structural detail and fracture surfaces of thin polymer films were studied, with the thermal history of the deposited filaments also being measured using a thermal camera.