Optimization of critical process control parameters in MEX additive manufacturing of high-performance polyethylenimine: energy expenditure, mechanical expectations, and productivity aspects

Abstract

The demand for 3D-printed high-performance polymers (HPPs) is on the rise across sectors such as the defense, aerospace, and automotive industries. Polyethyleneimine (PEI) exhibits exceptional mechanical performance, thermal stability, and wear resistance. Herein, six generic and device-independent control parameters, that is, the infill percentage, deposition angle, layer height, travel speed, nozzle temperature, and bed temperature, were quantitatively evaluated for their impact on multiple response metrics related to energy consumption and mechanical strength. The balance between energy consumption and mechanical strength was investigated for the first time, contributing to the sustainability of the PEI material in 3D printing. This is critical considering that HPPs require high temperatures to be built using the 3D printing method. PEI filaments were fabricated and utilized in material extrusion 3D printing of 125 specimens for 25 different experimental runs (five replicates per run). The divergent impacts of the control parameters on the response metrics throughout the experimental course have been reported. The real weight of the samples varies from 1.06 to 1.82 g (71%), the real printing time from 214 to 2841 s (~ 1300%), the ultimate tensile strength from 15.17 up to 80.73 MPa (530%), and the consumed energy from 0.094 to 1.44 MJ (1500%). The regression and reduced quadratic equations were validated through confirmation runs (10 additional specimens). These outcomes have excessive engineering and industrial merit in determining the optimum control parameters, ensuring the sustainability of the process, and the desired functionality of the products. Graphical Abstract