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Enhancing interfacial toughness of 3D printed bi-material polymers via mechanical interlocking and engineered fiber bridging

Laia Farràs Tasias (UGent) , Jules Topart, Stéphane Panier, Francisco A. Gilabert (UGent) and Flavio H. Marchesini (UGent)
(2025) ADDITIVE MANUFACTURING. 100.
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Abstract
Combining materials with distinct properties enables the fabrication of complex structures unattainable with a single material. Hybrid structures, such as those combining stiff and flexible materials, have potential applications in morphing structures, medical prosthetics, and sports goods. The performance of these structures relies heavily on the bonding at the material interface, especially with flat interfaces. Poor bonding can lead to structural failure. This study investigates the bi-material 3D printing of Polylactic Acid (PLA) and Thermoplastic Polyurethane (TPU). PLA is chosen for its environmental friendliness and mechanical properties, while TPU is selected for its flexibility and deformability. The main problem is the weak bonding between PLA and TPU in Fused Filament Fabrication (FFF), often causing failure in the final object. We introduce a methodology to emulate and control the 'fiber bridging' effect occurring in Fiber-Reinforced Polymers (FRP), which enhances interfacial strength. By designing specific patterns and strategically sequencing materials, we create robust mechanical bonds between PLA and TPU. These interface designs significantly increase toughness, improving both bi-directional and unidirectional composites by up to two orders of magnitude. Furthermore, the proposed approach holds potential for application in other multi-material systems, making it a promising strategy for a broader range of material combinations.
Keywords
Multi-material 3D printing, Interlocking mechanisms, Fiber bridging, Mechanical bonding, Interface toughening, FATIGUE DELAMINATION GROWTH, FRACTURE-RESISTANCE, ADHESION, REINFORCEMENT, COMPOSITES, PREDICTION, PLA

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MLA
Farràs Tasias, Laia, et al. “Enhancing Interfacial Toughness of 3D Printed Bi-Material Polymers via Mechanical Interlocking and Engineered Fiber Bridging.” ADDITIVE MANUFACTURING, vol. 100, 2025, doi:10.1016/j.addma.2025.104684.
APA
Farràs Tasias, L., Topart, J., Panier, S., Gilabert, F. A., & Marchesini, F. H. (2025). Enhancing interfacial toughness of 3D printed bi-material polymers via mechanical interlocking and engineered fiber bridging. ADDITIVE MANUFACTURING, 100. https://doi.org/10.1016/j.addma.2025.104684
Chicago author-date
Farràs Tasias, Laia, Jules Topart, Stéphane Panier, Francisco A. Gilabert, and Flavio H. Marchesini. 2025. “Enhancing Interfacial Toughness of 3D Printed Bi-Material Polymers via Mechanical Interlocking and Engineered Fiber Bridging.” ADDITIVE MANUFACTURING 100. https://doi.org/10.1016/j.addma.2025.104684.
Chicago author-date (all authors)
Farràs Tasias, Laia, Jules Topart, Stéphane Panier, Francisco A. Gilabert, and Flavio H. Marchesini. 2025. “Enhancing Interfacial Toughness of 3D Printed Bi-Material Polymers via Mechanical Interlocking and Engineered Fiber Bridging.” ADDITIVE MANUFACTURING 100. doi:10.1016/j.addma.2025.104684.
Vancouver
1.
Farràs Tasias L, Topart J, Panier S, Gilabert FA, Marchesini FH. Enhancing interfacial toughness of 3D printed bi-material polymers via mechanical interlocking and engineered fiber bridging. ADDITIVE MANUFACTURING. 2025;100.
IEEE
[1]
L. Farràs Tasias, J. Topart, S. Panier, F. A. Gilabert, and F. H. Marchesini, “Enhancing interfacial toughness of 3D printed bi-material polymers via mechanical interlocking and engineered fiber bridging,” ADDITIVE MANUFACTURING, vol. 100, 2025.
@article{01JQE55ZSJADFBP873AFP4XWF9,
  abstract     = {{Combining materials with distinct properties enables the fabrication of complex structures unattainable with a single material. Hybrid structures, such as those combining stiff and flexible materials, have potential applications in morphing structures, medical prosthetics, and sports goods. The performance of these structures relies heavily on the bonding at the material interface, especially with flat interfaces. Poor bonding can lead to structural failure. This study investigates the bi-material 3D printing of Polylactic Acid (PLA) and Thermoplastic Polyurethane (TPU). PLA is chosen for its environmental friendliness and mechanical properties, while TPU is selected for its flexibility and deformability. The main problem is the weak bonding between PLA and TPU in Fused Filament Fabrication (FFF), often causing failure in the final object. We introduce a methodology to emulate and control the 'fiber bridging' effect occurring in Fiber-Reinforced Polymers (FRP), which enhances interfacial strength. By designing specific patterns and strategically sequencing materials, we create robust mechanical bonds between PLA and TPU. These interface designs significantly increase toughness, improving both bi-directional and unidirectional composites by up to two orders of magnitude. Furthermore, the proposed approach holds potential for application in other multi-material systems, making it a promising strategy for a broader range of material combinations.}},
  articleno    = {{104684}},
  author       = {{Farràs Tasias, Laia and Topart, Jules and Panier, Stéphane and Gilabert, Francisco A. and Marchesini, Flavio H.}},
  issn         = {{2214-8604}},
  journal      = {{ADDITIVE MANUFACTURING}},
  keywords     = {{Multi-material 3D printing,Interlocking mechanisms,Fiber bridging,Mechanical bonding,Interface toughening,FATIGUE DELAMINATION GROWTH,FRACTURE-RESISTANCE,ADHESION,REINFORCEMENT,COMPOSITES,PREDICTION,PLA}},
  language     = {{eng}},
  pages        = {{12}},
  title        = {{Enhancing interfacial toughness of 3D printed bi-material polymers via mechanical interlocking and engineered fiber bridging}},
  url          = {{http://doi.org/10.1016/j.addma.2025.104684}},
  volume       = {{100}},
  year         = {{2025}},
}
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