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<p>Objects manufactured via fused filament fabrication (FFF) often suffer from reduced mechanical performance due to weak interlayer bonding and limited adhesion in multi-material parts. To address these limitations, a custom dielectric barrier discharge (DBD) plasma torch is integrated into a commercial FFF printer, enabling in situ atmospheric-pressure plasma treatments during the printing process. These treatments showed a significant enhancement in the fatigue resistance of polyethylene terephthalate glycol (PETG) 3D-printed specimens. Moreover, introducing a small fraction of acetylene into the torch lead to the deposition of plasma-polymerized coating which strongly improved the adhesion between thermoplastic polyurethane (TPU) and polylactic acid&#xa0;(PLA) (from ~ 0.5&#xa0; to ≥ 0.7&#xa0;MPa). This study demonstrates that plasma-assisted FFF is a low-cost, versatile, and easy-to-implement method to enhance mechanical properties of printed objects. It opens promising routes for tailoring interlayer bonding, multi-material integration, and functional coatings in additive manufacturing.</p>

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Integrated plasma torch module for enhanced mechanical properties and multi-material adhesion in FFF 3D printing

  • 期刊论文

  • 发表日期：

    2026年7月14日

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  • Joris Kadok,
  • Thomas Gaulain,
  • Christelle Vergne,
  • Patrick Choquet,
  • Simon Bulou

摘要

Objects manufactured via fused filament fabrication (FFF) often suffer from reduced mechanical performance due to weak interlayer bonding and limited adhesion in multi-material parts. To address these limitations, a custom dielectric barrier discharge (DBD) plasma torch is integrated into a commercial FFF printer, enabling in situ atmospheric-pressure plasma treatments during the printing process. These treatments showed a significant enhancement in the fatigue resistance of polyethylene terephthalate glycol (PETG) 3D-printed specimens. Moreover, introducing a small fraction of acetylene into the torch lead to the deposition of plasma-polymerized coating which strongly improved the adhesion between thermoplastic polyurethane (TPU) and polylactic acid (PLA) (from ~ 0.5  to ≥ 0.7 MPa). This study demonstrates that plasma-assisted FFF is a low-cost, versatile, and easy-to-implement method to enhance mechanical properties of printed objects. It opens promising routes for tailoring interlayer bonding, multi-material integration, and functional coatings in additive manufacturing.