ORCID

https://orcid.org/0009-0002-0360-606X

Year

2026

Season

Summer

Paper Type

Master's Thesis

College

College of Arts and Sciences

Degree Name

Master of Science in Material Science & Engineering (MS)

Department

Biology

Committee Chairperson

Dr. M. Laura Habegger

Second Advisor

Dr. Grant Bevill

Third Advisor

Dr. Jutima Simsiriwong

Fourth Advisor

Dr. Brian Wingender

Abstract

Material jetting additive manufacturing (MJAM) enables the fabrication of multimaterial components with fine spatial control, allowing the combination of rigid and compliant photopolymers in a single print. However, limited understanding of shear behavior at rigid-compliant interfaces continues to constrain structural reliability in MJAM parts. Therefore, the goal of this study was to characterize the apparent shear strength and failure behavior of rigid-compliant MJAM interfaces through modified lap-shear testing. Samples were fabricated on a Stratasys J35 Pro 3D printer using rigid and compliant photopolymers and printed in two orientations: Vertical, where both photopolymers are deposited before curing, and Horizontal, where one polymer is cured before deposition of the second. Two bonded overlap lengths, one-half and one-quarter the ASTM-recommended length, corresponding to 6.35 mm and 3.175 mm, respectively, were evaluated. Shear strength of the rigid-compliant interface was tested on a Mark-10 ESM303 test frame equipped with an M5-500 load cell, following a modified version of ASTM D3163-01. Failure modes and post-failure surface morphology were examined through video analysis and optical microscopy, respectively. A two-factor Welch-James robust analysis of variance identified a significant main effect of print orientation on apparent shear strength, while overlap length and the print-orientation-by-overlap-length interaction were not statistically significant. Holm-adjusted post hoc pairwise Welch’s t-tests showed that Vertical samples had significantly higher apparent shear strength than Horizontal samples at both overlap lengths. The Vertical 6.35 group averaged 1714.5 kPa compared to 1174.5 kPa for the Horizontal 6.35 group, while the Vertical 3.175 group averaged 1735.0 kPa compared to 1141.1 kPa for the Horizontal 3.175 group. The post hoc tests did not identify a significant difference between overlap lengths within either print orientation. Supplementary analyses showed that total energy was significantly affected by print orientation, overlap length, and their interaction, whereas strain at failure was significantly affected by overlap length but not print orientation or their interaction. Failure progression was orientation dependent: Horizontal samples exhibited interfacial separation prior to void-driven failure, whereas Vertical samples developed voids in the bulk compliant material at the overlap prior to interfacial failure and delamination. Overlap length primarily affected later-stage behavior, with some 6.35 samples undergoing secondary rigid backing fracture after substantial compliant-material damage and delamination, while the 3.175 samples completed void-driven separation without backing fracture. Crack-stretch markings were observed across all samples, while river markings and parallel delamination bands occurred more frequently in Vertical samples. These findings indicate that print orientation had a greater effect on rigid-compliant interface performance in shear than the tested overlap lengths and should be considered when designing MJAM parts with critical rigid-compliant interfaces.

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