Reduction of the residual warpage of fused deposition modeling by negative thermal expansion filler

We investigated the suppression of residual warpage using a negative thermal expansion (NTE) material filler, Zn 1.6 Mg 0.4 P 2 O 7 . To focus on the effect of thermal expansion on residual warpage, we used acrylonitrile-butadiene-styrene, which is an amorphous polymer with a small volume change around the liquid–solid phase transition, as the matrix. Composite pellets were prepared using a kneader, and filaments were produced for fused deposition modeling (FDM) using an extruder. We fabricated a bar-like test piece using a standard FDM machine and measured the warpage deformation using 3D scanning. The experimental results were supported by the finite element method. We also compared similarly sized SiO 2 powders to discuss the advantages of NTE over conventional fillers. The warpage of a 100 mm x 5 mm x 2 mm bar-like test piece was reduced by approximately 75% by introducing Zn 1.6 Mg 0.4 P 2 O 7 at 40 vol%. The effect of Zn 1.6 Mg 0.4 P 2 O 7 at 30 vol% is similar to that of a conventional SiO 2 filler at 40 vol%. Reducing the residual deformation through fillers would reduce energy consumption and simplify the device by avoiding build stage and chamber heating. • Introducing a negative thermal expansion filler to suppress the residual warpage of fused deposition modeling. • The negative thermal expansion material used is Zn 1.6 Mg 0.4 P 2 O 7 . • Warpage of fabricated test pieces was measured and analyzed using 3D scanning and finite element method. • Introducing 40 vol% Zn 1.6 Mg 0.4 P 2 O 7 reduced warpage by approximately 75%. • Zn 1.6 Mg 0.4 P 2 O 7 at 30 vol% showed similar effect to 40 vol% conventional SiO 2 filler.