Journal article
Minimizing defects in extrusion-based additive manufacturing through controlled filament spreading and overlapping
Colloids and surfaces. A, Physicochemical and engineering aspects, Vol.720, 136879
05 Sep 2025
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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.
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Details
- Title
- Minimizing defects in extrusion-based additive manufacturing through controlled filament spreading and overlapping
- Creators
- Heedong YoonAmir Azimi YancheshmeRhys ButlerGiuseppe R. PalmeseNicolas J. Alvarez
- Publication Details
- Colloids and surfaces. A, Physicochemical and engineering aspects, Vol.720, 136879
- Publisher
- Elsevier
- Number of pages
- 9
- Grant note
- Army Research Laboratory, United States: W911NF-17-2-0227, W911NF-24-2-0134 National Science Foundation, United States: CBET-1847140
The authors thank Mr. Mohammad Hassan for his assistance in this work. Research was sponsored by the Army Research Laboratory, United States and was accomplished under Cooperative Agreement Number W911NF-17-2-0227 and W911NF-24-2-0134. The views and conclusions contained in this document are those of the authors and should not be interpreted as representing the official policies, either expressed or implied, of the Army Research Laboratory or the U.S. Government. The U.S. Government is authorized to reproduce and distribute reprints for Government purposes not withstanding any copyright notation herein. NJA was also supported by the National Science Foundation, United States under grant no. CBET-1847140.
- Resource Type
- Journal article
- Language
- English
- Academic Unit
- Chemical and Biological Engineering
- Web of Science ID
- WOS:001491743300001
- Scopus ID
- 2-s2.0-105004672104
- Other Identifier
- 991022053729204721
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- Web of Science research areas
- Chemistry, Physical