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Minimizing defects in extrusion-based additive manufacturing through controlled filament spreading and overlapping.

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Bibliographic Details
Title: Minimizing defects in extrusion-based additive manufacturing through controlled filament spreading and overlapping.
Authors: Yoon, Heedong1 (AUTHOR), Azimi Yancheshme, Amir1 (AUTHOR), Butler, Rhys1 (AUTHOR), Palmese, Giuseppe R.1 (AUTHOR), Alvarez, Nicolas J.1 (AUTHOR) nja49@drexel.edu
Source: Colloids & Surfaces A: Physicochemical & Engineering Aspects. Sep2025, Vol. 720, pN.PAG-N.PAG. 1p.
Subjects: Three-dimensional printing, Fibers, Supply & demand, Curing
Abstract: Extrusion-based 3D printing of thermoset resins is in high demand to manufacture large-format, high-performance parts. However, the uncontrolled spreading of individual filaments presents significant challenges in maintaining the dimensional accuracy of printed structures. Additionally, inter-filament voids that form between deposited filaments can significantly impair the mechanical properties of the printed parts. This study demonstrates how controlling filament spreading and line spacing can mitigate these voids and preserve the fidelity of the printed parts. We employed photocurable colloidal suspension inks to investigate the impact of curing kinetics, spontaneous filament spreading, and relative positioning on the shape and defect size of printed parts. Using a novel experimental setup, we tracked the 3D structure and spreading behavior of deposited filaments. Our results show that there is an optimal line spacing between adjacent filaments which is a function of the spreading of the first deposited filament, that minimizes the voids between subsequent filaments. Furthermore, we identified an optimal deposition strategy for multiple filaments, ensuring a uniform and nearly defect-free structure. By applying this approach across successive layers, we were able to reduce inter-layer voids and achieve a nearly uniform print. The optimization strategy developed in this work improves dimensional accuracy and reduces the voids between filaments, allowing for the fabrication of parts with mechanical properties comparable to monolithic structures. This optimization criterion can be integrated into existing vectorization software, enabling automatic adjustment of filament positions based on individual filament spreading behavior. [Display omitted] [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
Description
Abstract:Extrusion-based 3D printing of thermoset resins is in high demand to manufacture large-format, high-performance parts. However, the uncontrolled spreading of individual filaments presents significant challenges in maintaining the dimensional accuracy of printed structures. Additionally, inter-filament voids that form between deposited filaments can significantly impair the mechanical properties of the printed parts. This study demonstrates how controlling filament spreading and line spacing can mitigate these voids and preserve the fidelity of the printed parts. We employed photocurable colloidal suspension inks to investigate the impact of curing kinetics, spontaneous filament spreading, and relative positioning on the shape and defect size of printed parts. Using a novel experimental setup, we tracked the 3D structure and spreading behavior of deposited filaments. Our results show that there is an optimal line spacing between adjacent filaments which is a function of the spreading of the first deposited filament, that minimizes the voids between subsequent filaments. Furthermore, we identified an optimal deposition strategy for multiple filaments, ensuring a uniform and nearly defect-free structure. By applying this approach across successive layers, we were able to reduce inter-layer voids and achieve a nearly uniform print. The optimization strategy developed in this work improves dimensional accuracy and reduces the voids between filaments, allowing for the fabrication of parts with mechanical properties comparable to monolithic structures. This optimization criterion can be integrated into existing vectorization software, enabling automatic adjustment of filament positions based on individual filament spreading behavior. [Display omitted] [ABSTRACT FROM AUTHOR]
ISSN:09277757
DOI:10.1016/j.colsurfa.2025.136879