Investigating the influence of bending stiffness and processing parameters on single-leg bending geometries of additively manufactured composites

• Combination of additive manufacturing methods by imprinting PBF-based plates with MEX materials. • Testing of single-leg bending as a ranking of bonding strength of dissimilar material combinations. • Increasing bonding strength for higher nozzle temperatures of hard-soft combination. • Visualisation of bending stiffness on results by high deformations. • Limits of testing soft materials with single-leg bending method due to high flexibility. In less than a decade, additive manufacturing technologies have been developed so successfully that they already produce small and medium-sized lot sizes of prototypes or customised components in the industry. With its new possibilities such as combining materials and technologies, the benefits of different technologies can be merged and broaden future application fields. One way is to print with one technology on a part produced by another. Thus, a thermally bonded part composed of, e.g., selectively sintered and material-extruded components can be created. This combination of technologies was considered in this study to investigate the bonding strength of extrusion-based layers on selectively sintered surfaces and the impact of nozzle temperature, orientation, and thickness of imprinted materials. The extrusion-based layers covered stiff (fibre-reinforced polyamide) and soft (thermoplastic polyurethane) material properties with pre-cracked single-leg bending (SLB) specimens to study their effect on delamination tendencies. This combination of materials and additive manufacturing technologies has not yet been studied for the SLB testing method. The scope of this study is to obtain more information on how relatively hard-hard and hard-soft combinations behave for this special testing method. The results of this testing method were evaluated using two different fracture mechanical approaches to determine the energy release rate. A clear trend towards an improved bonding, thus, higher values, was found for higher nozzle temperatures. Furthermore, a limitation regarding the required bending stiffness of the composites was found. Overall, the single-leg bending testing method enables a relative ranking for material combinations with a certain bending stiffness.