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<p>Material Extrusion (MEX) is one of the most widely used Additive Manufacturing (AM) technologies due to its accessibility, versatility, and cost-effectiveness. However, the layer-by-layer and track-by-track nature of MEX printing makes it prone to defects, particularly voids between adjacent material tracks, which negatively impact structural integrity and surface quality. Among these, inter-track voids are the most prevalent in MEX-printed parts. This study investigates an interlaced toolpath strategy for Fused Filament Fabrication (FFF) to mitigate inter-track void formation. Unlike other void-minimisation strategies that rely on thermal post-treatments, laser-assisted deposition, or ultrasonic-enhanced printing, this method is a software-based approach that does not require hardware modifications or post-processing. A series of experiments were conducted using line-based toolpaths with interlaced deposition, varying second-pass extrusion rates and extrusion temperatures. The results demonstrate that the interlaced strategy reduces inter-track porosity by up to 65.5% while maintaining negligible changes in printing time. In addition, increasing the second-pass extrusion temperature by 5&#xa0;°C further reduced porosity while limiting volumetric errors. These findings suggest that interlaced deposition strategies can be integrated into existing toolpaths to enhance print quality and mechanical performance in MEX-based AM. This method offers an effective solution for minimising porosity while maintaining precise material deposition, making it particularly relevant for applications requiring dense infill structures with high precision.</p>

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An interlaced toolpath strategy for void reduction in material extrusion additive manufacturing

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年5月21日

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  • Xiaochen Sun,
  • Maciej Mazur,
  • Chi-Tsun Cheng

摘要

Material Extrusion (MEX) is one of the most widely used Additive Manufacturing (AM) technologies due to its accessibility, versatility, and cost-effectiveness. However, the layer-by-layer and track-by-track nature of MEX printing makes it prone to defects, particularly voids between adjacent material tracks, which negatively impact structural integrity and surface quality. Among these, inter-track voids are the most prevalent in MEX-printed parts. This study investigates an interlaced toolpath strategy for Fused Filament Fabrication (FFF) to mitigate inter-track void formation. Unlike other void-minimisation strategies that rely on thermal post-treatments, laser-assisted deposition, or ultrasonic-enhanced printing, this method is a software-based approach that does not require hardware modifications or post-processing. A series of experiments were conducted using line-based toolpaths with interlaced deposition, varying second-pass extrusion rates and extrusion temperatures. The results demonstrate that the interlaced strategy reduces inter-track porosity by up to 65.5% while maintaining negligible changes in printing time. In addition, increasing the second-pass extrusion temperature by 5 °C further reduced porosity while limiting volumetric errors. These findings suggest that interlaced deposition strategies can be integrated into existing toolpaths to enhance print quality and mechanical performance in MEX-based AM. This method offers an effective solution for minimising porosity while maintaining precise material deposition, making it particularly relevant for applications requiring dense infill structures with high precision.