The route to achieve isotropy in 3D printing parts via Fused Filament Fabrication with Advanced Semicrystalline Thermoplastics

School of Engineering, Ulster University, York St, Belfast BT15 1ED, Northern Ireland, UK

^* Corresponding author: kp.rodzen@ulster.ac.uk

Abstract

This review investigates the challenges of Additive Manufacturing using commodity, engineering, and advanced materials, both amorphous and semicrystalline. It explains the reasons behind the weaker mechanical performance of semicrystalline materials compared to amorphous polymers used in the 3D printing process. The performance of 3D printing is discussed to demonstrate the current position of additive manufacturing as one of the promising techniques meeting the requirements of the 5.0 Industrial Revolution, particularly in terms of delivering personalized products. The differences between amorphous and semicrystalline materials on a macromolecular level, including the strength of the single bond in the polymer backbone chain and the effect of electron donation to the backbone, are discussed. Interlayer imperfections are classified into several groups: moisture in the feedstock filament, inconsistent filament diameter, shrinkage of the deposited materials, and, most importantly, crystallization kinetics of semicrystalline materials. Finally, insights on how to achieve properties closer to an isotropic body when advanced semicrystalline materials are printed, in order to overcome layer-layer defects, are provided.