TY - JOUR

T1 - Advancing laser transmission welding for additive manufacturing

T2 - A study of glass fiber reinforced polypropylene parts

AU - Kuklik, Julian

AU - Henzler, Matthias

AU - Staehr, Richard

AU - Jaeschke, Peter

AU - Kaierle, Stefan

AU - Overmeyer, Ludger

N1 - Publisher Copyright: © 2024 Author(s).

PY - 2024/11

Y1 - 2024/11

N2 - Laser transmission welding (LTW) is a well-established technique for joining high-volume thermoplastic parts, such as automotive injection molded parts. For low-volume, prototype, and custom production, additive manufacturing is an emerging technology for producing complex thermoplastic parts. When compared to injection molding, the additive manufacturing process fused filament fabrication (FFF) results in an inhomogeneous structure with entrapped air within the volume. Additionally, the presence of short glass fibers in the polymer matrix leads to higher radiation scattering during the welding process. This paper presents a fundamental study of the weldability of additively manufactured fiber-reinforced parts. The specimens were fabricated using a FFF process with glass fiber-reinforced polypropylene (GF-PP). The study investigates the influence of layer thickness and line width of the FFF process on the optical transmittance. LTW-experiments were conducted using additively manufactured uncolored and black GF-PP samples. Lap shear test specimens were welded with a different energy per unit length. This research presents a process for welding additively manufactured GF-PP parts that can be used with optimized FFF-parameters to produce high-strength and durable prototypes or spare parts for the automotive industry. This research provides valuable insights into the process parameters and considerations required to achieve robust welds in additively manufactured thermoplastic parts, facilitating broader adoption of LTW in additive manufacturing contexts.

AB - Laser transmission welding (LTW) is a well-established technique for joining high-volume thermoplastic parts, such as automotive injection molded parts. For low-volume, prototype, and custom production, additive manufacturing is an emerging technology for producing complex thermoplastic parts. When compared to injection molding, the additive manufacturing process fused filament fabrication (FFF) results in an inhomogeneous structure with entrapped air within the volume. Additionally, the presence of short glass fibers in the polymer matrix leads to higher radiation scattering during the welding process. This paper presents a fundamental study of the weldability of additively manufactured fiber-reinforced parts. The specimens were fabricated using a FFF process with glass fiber-reinforced polypropylene (GF-PP). The study investigates the influence of layer thickness and line width of the FFF process on the optical transmittance. LTW-experiments were conducted using additively manufactured uncolored and black GF-PP samples. Lap shear test specimens were welded with a different energy per unit length. This research presents a process for welding additively manufactured GF-PP parts that can be used with optimized FFF-parameters to produce high-strength and durable prototypes or spare parts for the automotive industry. This research provides valuable insights into the process parameters and considerations required to achieve robust welds in additively manufactured thermoplastic parts, facilitating broader adoption of LTW in additive manufacturing contexts.

KW - additive manufacturing

KW - fused filament fabrication (FFF)

KW - glass fiber reinforcement

KW - laser transmission welding

KW - polypropylene

KW - transmissivity

KW - weld seam strength

UR - http://www.scopus.com/inward/record.url?scp=85210732721&partnerID=8YFLogxK

U2 - 10.2351/7.0001625

DO - 10.2351/7.0001625

M3 - Article

AN - SCOPUS:85210732721

VL - 36

JO - Journal of laser applications

JF - Journal of laser applications

SN - 1042-346X

IS - 4

M1 - 042011

ER -