Shape memory polymers (SMP) are used in the 3D printing field for different applications such as soft robotics or medical devices. Although this technology has expanded the capabilities of additive manufacturing, there still exists fundamental questions regarding the optimum condition for manufacturing these 3D printed parts. Various factors play a crucial role in the final quality of printed parts, such as deposition orientation, percentage infill, or environmental conditions. In this paper, we study the effect of humidity on commercially available SMPs (NinjaFlex©) at both micro- and macro-scale. By performing a 3-dimensional computational fluid dynamic model for the printing environment, it is found there are significant temperature and humidity fluctuations around the hot-end and printing bed. Macro-scale characterization through ASTM D638 tensile testing shows that for humidity levels higher than 60% there is 5-10% reduction in the strength of material (ultimate strength and tangent modulus). This study is verified by micro-scale characterization performed with atomic force microscopy on thin-films. It is shown that in addition to the effect of humidity on the stiffness of materials, there is an effect on the loss moduli of the matter as well. As humidity increases, these polymers become more viscoelastic. Simultaneously, it is shown higher humidity levels cause increased micro-level surface roughness, which can be the cause for the strength reduction for higher humidities.

Atomic Force Microscopy (AFM) is no longer used as a nanotechnology tool responsible for topography imaging. However, it is widely used in different fields to measure various types of material properties, such as mechanical, electrical, magnetic, or chemical properties. One of the recently developed characterization techniques is known as loss tangent. In loss tangent AFM, the AFM cantilever is excited, similar to amplitude modulation AFM (also known as tapping mode); however, the observable aspects are used to extract dissipative and conservative energies per cycle of oscillation. The ratio of dissipation to stored energy is defined as tanδ. This value can provide useful information about the sample under study, such as how viscoelastic or elastic the material is. One of the main advantages of the technique is the fact that it can be carried out by any AFM equipped with basic dynamic AFM characterization. However, this technique lacks some important experimental guidelines. Although there have been many studies in the past years on the effect of oscillation amplitude, tip radius, or environmental factors during the loss tangent measurements, there is still a need to investigate the effect of excitation frequency during measurements. In this paper, we studied four different sets of samples, performing loss tangent measurements with both first and second eigenmode frequencies. It is found that performing these measurements with higher eigenmode is advantageous, minimizing the tip penetration through the surface and therefore minimizing the error in loss tangent measurements due to humidity or artificial dissipations that are not dependent on the actual sample surface.

Purpose The purpose of this study is to design and develop an environmentally controlled enclosure for commercial three-dimensional (3D) printers. Design/methodology/approach Computational fluid dynamics (CFD) simulations and experimental testing investigated various designs for environmentally controlled enclosures. CFD simulations provided the necessary information to select the optimal and feasible design, whereas experimental testing validated the CFD simulation results. An environmentally controlled environment allowed test samples to be printed at several relative humidity (RH) settings (20% RH, 50% RH and 80% RH). The test samples were characterized at both the macro and micro scales. The macroscale characterization was conducted using the static tensile testing procedure, while the microscale polymer material properties were determined using atomic force microscopy. Findings An environmentally controlled enclosure was designed and built to produce airflow in the print region with an average RH uniformity of over 0.70. Three batches of ASTM D638 standard test samples were printed at 20% RH (low RH), 50% RH (mid RH) and 80% RH (high RH). Macroscale characterization showed that the samples printed at lower humidity had statistically significantly higher tangent modulus, ultimate tensile strength and rupture strength. atomic force microscopy studies have also verified these results at the microscale and nanoscale. These studies also showed that a high humidity environment interacts with melted polylactic acid, causing additional surface roughness that reduces the strength of 3D-printed parts. Originality/value There is a need for stronger and higher-quality 3D-printed parts in the additive manufacturing (AM) market. This study fulfills that need by designing and developing an environmentally controlled add-on enclosure for the AM market.