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Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Nondestructive Characterization of Heat and Print-Bonded Multi-Material FDM Interfaces
Author(s) Harshith Kumar Adepu, Partha P. Pandit, Rebecca Anne A. Ang, Luz D. Sotelo
On-Site Speaker (Planned) Harshith Kumar Adepu
Abstract Scope Multi-material fused deposition modeling (FDM) produces interfacial defects including voids and incomplete polymer diffusion, and these interfaces are typically characterized only through destructive mechanical testing. This study applies X-ray computed tomography (CT) and immersion ultrasound to nondestructively quantify interfacial porosity and geometric uniformity in ABS/HIPS cylindrical specimens. Specimens were fabricated by two bonding methods: direct print-bonding at three nozzle temperatures (240°C, 255°C, 270°C) and post-print heat bonding at 215°C. X-ray CT revealed that the heat-bonded sample exhibited substantially lower bulk porosity (0.39%) compared to print-bonded samples (1.39%-3.54%), with porosity increasing as nozzle temperature decreased. However, immersion ultrasound amplitude and time-of-flight C-scans revealed greater spatial variation across the heat-bonded interface, indicating reduced geometric uniformity relative to the printed samples. These results demonstrate a tradeoff between porosity reduction and interfacial uniformity, and highlight the necessity of combining multiple NDE modalities to fully characterize multi-material FDM bond quality.
Proceedings Inclusion? Undecided

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