Miaozi Huang, Yao Xu, Alois K. Schlarb

• It is known from the literature that freedom from macroscopic defects (voids) is an essential prerequisite for good mechanical properties of 3D-printed components manufactured using fused filament fabrication. The present study further shows that the morphology and mechanical properties of void free components are significantly influenced by the choice of process parameters. Components that were printed at low temperatures and high speeds show fair and inhomogeneous supermolecular morphology, clearly visible weld seams and a special flow-induced staggered structure of the individual strands laid-up. At higher magnification in the optical microscope, transcrystalline structures are visible starting from the contact area between the strands, that is, crystallization has started at the interface between the strands and is moving forward towards the center of the strands. In contrast, the samples printed at high temperatures and low speeds show a homogeneous supermolecular morphology with overall larger spherulites and a higher degree of crystallinity and compared to the specimens printed with the low temperature/high speed-set much better mechanical properties. A numerical simulation of the temperature at the contact point of the strand emerging from the hot nozzle and the cooled strand neighbor agrees well with the measured behavior. The thermal simulation thus enables the temperature to be calculated at any point in time in the welding contact and thus access to the local thermal conditions during joining, cooling and the formation of the morphology.