Multi-layer Metallization of Polymer Materials via Thermal Spray

With the emerging prevalence of 3D printed polymer materials for rapid prototyping, there is an increasing demand for a similar ease and quickness in producing metallic and multi-material components. One such approach is through the metallization of printed polymer parts using thermal spray, where thick deposits can be quickly and economically deposited. However, technical challenges include management of residual stress of the deposit, assessing the adhesion strength of sprayed metal onto polymers, and potential thermal degradation of polymer substrates from molten droplet impingement during spraying.

This presentation will discuss the methodologies used to accomplish successful metallization of polymer substrates (e.g., ABS, HDPE) including in-situ measurements of substrate deflection for calculation of residual stress, mechanisms and quantification of adhesion between polymers and sprayed metal, and optimization of spray processing and material layering.