Advancing laser transmission welding for additive manufacturing

A study of glass fiber reinforced polypropylene parts

authored by: Julian Kuklik, Matthias Henzler, Richard Staehr, Peter Jaeschke, Stefan Kaierle, Ludger Overmeyer
Abstract: Laser transmission welding (LTW) is a well-established technique for joining high-volume thermoplastic parts, such as automotive injection molded parts. For low-volume, prototype, and custom production, additive manufacturing is an emerging technology for producing complex thermoplastic parts. When compared to injection molding, the additive manufacturing process fused filament fabrication (FFF) results in an inhomogeneous structure with entrapped air within the volume. Additionally, the presence of short glass fibers in the polymer matrix leads to higher radiation scattering during the welding process. This paper presents a fundamental study of the weldability of additively manufactured fiber-reinforced parts. The specimens were fabricated using a FFF process with glass fiber-reinforced polypropylene (GF-PP). The study investigates the influence of layer thickness and line width of the FFF process on the optical transmittance. LTW-experiments were conducted using additively manufactured uncolored and black GF-PP samples. Lap shear test specimens were welded with a different energy per unit length. This research presents a process for welding additively manufactured GF-PP parts that can be used with optimized FFF-parameters to produce high-strength and durable prototypes or spare parts for the automotive industry. This research provides valuable insights into the process parameters and considerations required to achieve robust welds in additively manufactured thermoplastic parts, facilitating broader adoption of LTW in additive manufacturing contexts.
Organisation(s): Institute of Transport and Automation Technology
External Organisation(s): Laser Zentrum Hannover e.V. (LZH)
Institut für integrierte Produktion Hannover (IPH)
Type: Article
Journal: Journal of laser applications
Volume: 36
No. of pages: 6
ISSN: 1042-346X
Publication date: 11.2024
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Electronic, Optical and Magnetic Materials, Atomic and Molecular Physics, and Optics, Biomedical Engineering, Instrumentation
Electronic version(s): https://doi.org/10.2351/7.0001625 (Access: Closed)

BibTeX

@article{4ea8ba5d58764788a5dc69999ebad669,
title = "Advancing laser transmission welding for additive manufacturing: A study of glass fiber reinforced polypropylene parts",
abstract = "Laser transmission welding (LTW) is a well-established technique for joining high-volume thermoplastic parts, such as automotive injection molded parts. For low-volume, prototype, and custom production, additive manufacturing is an emerging technology for producing complex thermoplastic parts. When compared to injection molding, the additive manufacturing process fused filament fabrication (FFF) results in an inhomogeneous structure with entrapped air within the volume. Additionally, the presence of short glass fibers in the polymer matrix leads to higher radiation scattering during the welding process. This paper presents a fundamental study of the weldability of additively manufactured fiber-reinforced parts. The specimens were fabricated using a FFF process with glass fiber-reinforced polypropylene (GF-PP). The study investigates the influence of layer thickness and line width of the FFF process on the optical transmittance. LTW-experiments were conducted using additively manufactured uncolored and black GF-PP samples. Lap shear test specimens were welded with a different energy per unit length. This research presents a process for welding additively manufactured GF-PP parts that can be used with optimized FFF-parameters to produce high-strength and durable prototypes or spare parts for the automotive industry. This research provides valuable insights into the process parameters and considerations required to achieve robust welds in additively manufactured thermoplastic parts, facilitating broader adoption of LTW in additive manufacturing contexts.",
keywords = "additive manufacturing, fused filament fabrication (FFF), glass fiber reinforcement, laser transmission welding, polypropylene, transmissivity, weld seam strength",
author = "Julian Kuklik and Matthias Henzler and Richard Staehr and Peter Jaeschke and Stefan Kaierle and Ludger Overmeyer",
note = "Publisher Copyright: {\textcopyright} 2024 Author(s).",
year = "2024",
month = nov,
doi = "10.2351/7.0001625",
language = "English",
volume = "36",
journal = "Journal of laser applications",
issn = "1042-346X",
publisher = "Laser Institute of America",
number = "4",
}