TY - JOUR A1 - Kuettner, Andreas A1 - Raths, Max A1 - Fischer, Samuel A1 - Laumer, Tobias T1 - Heat staking of polymer parts generated by fused layer modeling JF - The International Journal of Advanced Manufacturing Technology N2 - Heat staking is a joining technology by which thermoplastic pins are formed by force and temperature to create a form- and force-fitting connection between components. This paper examines the characteristics of 3D printed pins in comparison to conventionally turned pins for heat staking applications. The 3D printed pins are created using fused layer modeling, with variations in horizontal and vertical building directions, as well as different layer thicknesses. The study investigates the impact of significant factors on the heat staking process, including the forming force and temperature. Tensile tests, micrographs, and micro-CT measurements were conducted to determine the properties of the heat-staked joints. Additionally, a stage plan was developed to enhance the understanding of the forming process of both printed and conventionally turned materials. The findings suggest that, under specific process parameters, 3D printed pins exhibit comparable strength to conventionally manufactured pins. The research also demonstrates that the anisotropy resulting from the layer-by-layer construction of the pins significantly influences the strength of the connection. Furthermore, the study reveals that 3D printed pins exhibit good forming accuracy during the heat staking process, and the cavities formed during printing can be substantially reduced. KW - Heat staking KW - Additive manufacturing KW - 3D printing KW - Material qualification KW - Polycarbonate (PC) KW - Fused layer modeling (FLM) Y1 - 2023 U6 - https://doi.org/10.1007/s00170-023-11850-y PB - Springer Nature ER -