Process parameter effects on interlaminar fracture toughness of FDM printed coupons

In Fused Deposition Modeling (FDM), filaments of heated thermoplastic are extruded from a tip that moves in a raster-like motion. Depending on filament material properties and the processing parameters, the extruded beads and the fusion-bond between them could result in anisotropic properties (particularly with regard to strength). In this work, the focus is on characterizing the interlaminar fracture toughness of coupons produced by FDM with varying road-to-road offsets producing positive, zero and negative air gaps between neighboring roads resulting in coupons of varying density (void content). The resulting bond line formation is assessed through measuring and analyzing changes in the mesostructure and the contact attained at the interfaces between the adjoining roads. The bond quality is assessed by evaluating plane-strain fracture toughness using compact tension specimens. Results demonstrate an approximate five-fold increase in fracture toughness with varying air gaps.