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Cooperative enhancement of multi-material interface strength by mechanical interlocking structures and FDM path planning

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Abstract

Multi-material additive manufacturing (MMAM) significantly enhances the design flexibility and performance diversity of manufacturing by integrating materials with different characteristics into a single object. However, augmenting the interface strength of MMAM parts is a crucial step in ensuring the overall quality and performance of the components. In this study, we propose a strategy that combines mechanical interlocking structures with FDM path planning to enhance interface strength. To achieve this goal, we designed three mechanical interlocking structures: Dovetail, Hook, and Cross. These structures not only meet the requirements of continuous extrusion processes but also exhibit non-disassemblable characteristics. Taking into account their slicing profiles and the characteristics of their fracture forms, the interface strength was further enhanced during the forming process by adjusting the nozzle’s movement path and controlling the extrusion amount of consumables. The experimental results indicate that, with a layer count of 5 and an embedding distance of 4 mm, all three mechanical interlocking structures exhibit superior tensile performance. Under the collaborative action of path stitching, the interface strength of the three mechanical interlocking structures is enhanced, the Dovetail structure demonstrates a notably superior performance among them, showcasing an average strength limit increase of 304.09% (8.89 MPa). The experimental results not only validate the enhancement of interface strength through the combination of mechanical interlocking structures and FDM path planning but also reveal the relationship between strength limits and contact area. The varied patterns in strength limits resulting from different approaches to increasing the contact area of the two materials provide insights for investigating other structural parameters.

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Funding

This study was supported by the National Natural Science Foundation of China (Grant No. 52175230), the Pilot Project of Fujian Province (Grant No. 2020H0015), and the Natural Science Foundation of Fujian Province (2022J011427).

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Authors and Affiliations

  1. Fujian Provincial Key Laboratory of Special Energy Manufacturing, Xiamen Key Laboratory of Digital Vision Measurement, Huaqiao University, Xiamen, 361021, China

    Bin Liu, Youxin Xu, Wei Cao & Ping Lu

  2. Xiamen Hongfa Electroacoustic Co., Ltd, Xiamen, 361021, China

    Chenghuan Huang

Authors
  1. Bin Liu
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  2. Youxin Xu
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  3. Wei Cao
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Contributions

Bin Liu: investigation, methodology, writing—review and editing, project administration, funding acquisition. Youxin Xu: data curation, methodology, visualization, validation, writing—original draft, writing—review and editing. Wei Cao: investigation, software, validation, writing—original draft. Ping Lu: writing—review and editing, formal analysis, supervision. Chenghuan Huang: conceptualization, supervision.

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Correspondence to Bin Liu.

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Highlights

• Based on the mortise-and-tenon structure of ancient buildings and the biological interlocking mechanism, three mechanical interlocking structures have been designed. They contribute to the improvement of the strength of interfaces with multiple materials.

• Proposed a strategy that combines FDM path planning with interlocking structures, making full use of the characteristics of additive manufacturing for layer-by-layer accumulation. Tailored to the specific characteristics of the slicing contours and failure modes of different mechanical interlocking structures, this strategy achieves a secondary enhancement of the strength of interfaces with multiple materials.

• Explored the relationship between mechanical performance and contact area, observing distinct patterns in the variation of mechanical properties with different methods of altering the contact area.

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Liu, B., Xu, Y., Cao, W. et al. Cooperative enhancement of multi-material interface strength by mechanical interlocking structures and FDM path planning. Int J Adv Manuf Technol 134, 4099–4115 (2024). https://doi.org/10.1007/s00170-024-14398-7

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