Evaluation of various standards of adhesion properties between fused-layer-modeling parts and injection molded parts

• Published in: The Journal of adhesion Vol. 96; no. 1-4; pp. 13 - 32
• Main Authors: Richter, A., Fischer, F., Dilger, K.
• Format: Journal Article
• Language: English
• Published: Taylor & Francis 11-03-2020
• Subjects: Adhesive materials; automotive; boundary layers
• ISSN: 0021-8464; 1563-518X; 1545-5823
• DOI: 10.1080/00218464.2019.1664903

The Fused-Layer-Modeling process is an established process for Additive Manufacturing of polymers and provides many possibilities for the individualization of parts. One of this customization is the individualization of injection molded parts by a direct extrusion method based on Fused-Layer-Modeling. One of the biggest challenges in establishing this bonding process is to workout testing strategies which can help to optimize the bonding area. In general, for Additive Manufacturing there are no existing standards of experimental tests. Most of the time, the standards of related manufacturing technologies like bonding and other joining processes are used and modified for each application. Nonetheless, the opportunity for testing Fused-Layer-Modeling parts is helpful to get useful and repeatable results to investigate interlayer and other mechanical properties.
This paper investigates the strength of the bonding area between Fused-Layer-Modeling parts and injection molded parts. Therefore, we modify two different standards of conventional joining processes and present the results. In the first step, all modifications from the original standard including constructions and dimensions are shown and valued. In the next step, we evaluate the mechanical properties of both bonding partners and material combination. The strength of the bonding is compared against the maximum strength in the z-direction of the Fused-Layer-Modeling part since this is the strength limitation of the layer-by-layer process. In order to guaranty that the specific circumstances of this bonding process are covered and comparable results are realized, we developed new standards.