Atmospheric Pressure Plasma Sources for Additive Manufacturing

2023
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Authors: Thomas Neubert; Kristina Lachmann; Lara Schumann; Veysel Zeren; Tim Abraham; Michael Thomas
Published in: Future Automotive Production Conference 2022
Publisher: Springer Fachmedien Wiesbaden

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Abstract

The chapter delves into the application of atmospheric pressure plasma sources for additive manufacturing, specifically focusing on enhancing the surface chemistry and adhesion of 3D-printed polymer components. It introduces a small, robust plasma nozzle based on a micro dielectric barrier discharge (µ-DBD), which is integrated into a commercial FDM 3D printer. The nozzle is designed to treat surfaces before, during, and after the printing process, creating functional groups that increase surface energy and adhesion. Experimental results show significant improvements in wettability, surface energy, and adhesion strength for non-polar polymers like polypropylene. The chapter highlights the potential of this technology for various applications, including the combination of different materials in 3D printing, and discusses future developments such as the use of other process gases and ring-shaped plasma sources for parallel surface treatment.

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Abstract

Adhesion plays a central role in additive manufacturing (AM) processes like Fused Deposition Modelling (FDM). The printed part needs sufficient adhesion to the build plate. The adhesion in between the printed material layers defines the mechanical strength of the component. Post-processing processes such as painting or bonding require good chemical coupling, as does the combination of different materials (FDM of different polymers, integration of metal inserts).

Unfortunately, sufficient adhesion is not given for all material combinations. An interesting and flexible possibility to influence the surface chemistry and thus the chemical bonding are surface functionalization by using atmospheric pressure plasma technologies. These have been used for many years with great success for the surface treatment of polymers. Depending on the plasma parameters used, it is possible to clean and etch surfaces, to functionalise surfaces with reactive chemical groups, to deposit layers or to cross-link polymers. While this is already used for treatment of 2D and 3D substrates in many applications, the integration of new functionalities by plasma into additive manufacturing processes is of great interest. This allows new functionalities to be integrated into 3D-printed components and simplifies further processing.

At the Fraunhofer IST various approaches of small atmospheric pressure plasma sources are under development which can be easily integrated into the additive manufacturing process. Small point-shaped plasma modules for the sequential treatment of defined areas were built-up and integrated into commercially available FDM printers. With these plasma sources, the plasma treatment of defined areas of the components is possible during 3D printing. Integrated plasma sources enable moreover the in-situ treatment of internal surfaces which are subsequently no longer accessible for other treatment processes. This can create new products and expand the scope of additive manufacturing.

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Title: Atmospheric Pressure Plasma Sources for Additive Manufacturing
Authors: Thomas Neubert
Kristina Lachmann
Lara Schumann
Veysel Zeren
Tim Abraham
Michael Thomas
Publisher: Springer Fachmedien Wiesbaden
Book: Future Automotive Production Conference 2022
Print ISBN: 978-3-658-39927-6

Electronic ISBN: 978-3-658-39928-3

Copyright Year: 2023
DOI: https://doi.org/10.1007/978-3-658-39928-3_11

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Atmospheric Pressure Plasma Sources for Additive Manufacturing

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