Material developer Kai Parthy proposes a new extrusion technique to increase the strength of FFF-printed objects. The so-called T-shape extrusion uses overlapping filament strands to significantly improve layer adhesion. The method could be particularly advantageous for porous or fiber-reinforced materials.
In conventional FFF printing processes, layers are deposited layer by layer, whereby the connection between the layers is often a weak point. T-shaped extrusion profiles allow each filament strand to overlap its neighbor by more than 50 %. This interlocking of the strands is intended to reduce delamination and improve the mechanical properties of the printed object.
Parthy originally developed the technology to optimize the layer adhesion of its special Growlay filament. This material contains micropores that are subsequently created by rinsing with water. This tends to cause the printed layers to swell, which in some cases can lead to the objects breaking. This problem could be reduced by strengthening the connection between the layers using T-profiles.
In addition to porous materials, classic filaments such as PLA and fiber-reinforced plastics also benefit from the technology. The degree of overlap can be specifically controlled via the overflow factor, i.e. through deliberate over-extrusion. In addition, further modifications to the extrusion cross-sections could be possible if the angle of attack of the hotend is varied. This could lead to non-planar surfaces and optimized overhangs.
However, the software remains a challenge. There is currently no slicer that can automatically generate T-shape profiles. The development of corresponding algorithms would be necessary to make this technology accessible to users.
Contact: kai.parthy@gmail.com
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