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<p>This research investigates the adhesion characteristics of thermoplastic polyurethane (TPU) and polylactic acid (PLA) composites in 3D printing, focusing on how printing parameters and geometric interlockings affect interfacial adhesion. The study employs various interlocking configurations, mechanical and microscopic testing methods, and a universal testing machine to evaluate the adhesion properties. The findings reveal that penetration and overlapping substantially improve bonding, boosting it nearly fivefold. Microscopic analysis shows a reduced void percentage at junctions, which enhances adhesion through decreased void fraction and increased contact surface area. These results underscore the potential of fused filament fabrication (FFF) technology to improve TPU–PLA composite adhesion and highlight the importance of accurate testing methods. The study further explores the impact of different geometric infusions and interlockings in 3D printed sandwich or bilayer structures of PLA–TPU. The research utilizes a dual-stage experimental design along with comprehensive testing methods, demonstrating that penetration and overlapping substantially improve bonding, minimize void formation, and expand contact surface. The results from Mechanical tensile testing indicate that introducing crevices and penetration structures between two dissimilar materials significantly enhances structural strength. Microscopic validation through scanning electron microscopy reveals that the PLA material exhibits a lower void fraction compared to the TPU material, despite using identical 3D printing parameters for both.</p>

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Optimizing Adhesion in Fused Filament Fabrication-Printed Thermoplastic Polyurethane–Polylactic Acid Composites: Effects of Penetration, Overlapping, and Void Reduction

  • 期刊论文

  • 发表日期：

    2025年10月23日

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  • Benjamin Vins,
  • Ankit Gupta,
  • Samrath Suri,
  • Abhishek Kishor,
  • Aditya Chandrasekar

摘要

This research investigates the adhesion characteristics of thermoplastic polyurethane (TPU) and polylactic acid (PLA) composites in 3D printing, focusing on how printing parameters and geometric interlockings affect interfacial adhesion. The study employs various interlocking configurations, mechanical and microscopic testing methods, and a universal testing machine to evaluate the adhesion properties. The findings reveal that penetration and overlapping substantially improve bonding, boosting it nearly fivefold. Microscopic analysis shows a reduced void percentage at junctions, which enhances adhesion through decreased void fraction and increased contact surface area. These results underscore the potential of fused filament fabrication (FFF) technology to improve TPU–PLA composite adhesion and highlight the importance of accurate testing methods. The study further explores the impact of different geometric infusions and interlockings in 3D printed sandwich or bilayer structures of PLA–TPU. The research utilizes a dual-stage experimental design along with comprehensive testing methods, demonstrating that penetration and overlapping substantially improve bonding, minimize void formation, and expand contact surface. The results from Mechanical tensile testing indicate that introducing crevices and penetration structures between two dissimilar materials significantly enhances structural strength. Microscopic validation through scanning electron microscopy reveals that the PLA material exhibits a lower void fraction compared to the TPU material, despite using identical 3D printing parameters for both.