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Additive Manufacturing of Mechanically Isotropic Thin Films and Membranes via Microextrusion 3D Printing of Polymer Solutions
- Manjot SinghManjot SinghDepartment of Industrial and Systems Engineering, Virginia Tech, Blacksburg, Virginia 24061, United StatesMore by Manjot Singh
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- Alexander P. HaringAlexander P. HaringDepartment of Industrial and Systems Engineering and Macromolecules Innovation Institute, Virginia Tech, Blacksburg, Virginia 24061, United StatesMore by Alexander P. Haring
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- Yuxin TongYuxin TongDepartment of Industrial and Systems Engineering, Virginia Tech, Blacksburg, Virginia 24061, United StatesMore by Yuxin Tong
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- Ellen CesewskiEllen CesewskiDepartment of Industrial and Systems Engineering and Department of Materials Science and Engineering, Virginia Tech, Blacksburg, Virginia 24061, United StatesMore by Ellen Cesewski
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- Edwin BallEdwin BallDepartment of Chemical and Biomolecular Engineering, Clemson University, Clemson, South Carolina 29634, United StatesMore by Edwin Ball
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- Ross JasperRoss JasperDepartment of Chemical and Biomolecular Engineering, Clemson University, Clemson, South Carolina 29634, United StatesMore by Ross Jasper
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- Eric M. DavisEric M. DavisDepartment of Chemical and Biomolecular Engineering, Clemson University, Clemson, South Carolina 29634, United StatesMore by Eric M. Davis
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- Blake N. Johnson*Blake N. Johnson*E-mail: [email protected]. Tel: (540) 231-0755. Fax: (540) 231-3322.Department of Industrial and Systems Engineering, Macromolecules Innovation Institute, Department of Materials Science and Engineering and Department of Chemical Engineering, Virginia Tech, Blacksburg, Virginia 24061, United StatesMore by Blake N. Johnson
Abstract
Polymer extrusion additive manufacturing processes, such as fused filament fabrication (FFF), are now being used to explore the fabrication of thin films and membranes. However, the physics of molten polymer extrusion constrains achievable thin film properties (e.g., mechanical isotropy), material selection, and spatial control of film composition. Herein, we present an approach for fabrication of functional polymer thin films and membranes based on the microextrusion printing of polymer solutions, which we refer to as “solvent-cast printing” (SCP). Constructs fabricated via SCP exhibited a 43% reduction in anisotropy of tensile strength relative to those fabricated using FFF. The constructs fabricated via SCP exhibited a lesser extent of visible layering defects relative to those fabricated by FFF. Further, the swelling dynamics of the films varied depending on the membrane fabrication technique (i.e., SCP vs manual drop casting). The opportunity for expanding material selection relative to FFF processes was demonstrated by printing poly(benzimidazole), a high-performance thermoplastic with high glass-transition temperatures (Tg ∼ 400 °C). Results from this work indicate that our new approach could facilitate the manufacture of mechanically isotropic thin films and membranes using currently unprintable high-performance thermoplastics.
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