Maximizing the strength of fused-deposition ABS plastic parts

Fused-Deposition (FD) creates parts using robotic extrusion of a semi-liquid polymer fiber, which molecularly bonds with neighboring fibers via thermal-diffusion bonding. The strength of the part depends on the bulk polymer strength, the mesostructure (fiber layout, void geometry, extent of fiber bonding), and the fiber-to-fiber bond strength. The influence of these factors on the mechanical strength of FD-ABS plastic parts is reported along with the FD process variable settings for maximum strength. Substantial increases in transverse strength are achieved at the optimal settings and additional increases can be achieved by post-fabrication annealing.