Structural Optimization of FDM-Processed ASA Polymer Frames through Acetone Solvent Welding, Variable Infill Strategy, and Layer Orientation: Experimental Validation via Quadcopter Flight Testing

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This is an unedited manuscript accepted for publication and provided as an Article in Press for early access at the author’s request. The article will undergo copyediting, typesetting, and galley proof review before final publication. Please be aware that errors may be identified during production that could affect the content. All legal disclaimers of the journal apply.

Year : 2026 | Volume : 14 | 03 | Page :
    By

    Sunny Nanade,

  • Zarvan Movdawalla,

  1. Assistant Professor, Department of Mechatronics Engineering, Mukesh Patel School of Technology Management & Engineering, SVKM’s NMIMS, Mumbai, Maharashtra, India
  2. Student, Department of Mechanical Engineering, Mukesh Patel School of Technology Management & Engineering, SVKM’s NMIMS, Mumbai, Maharashtra, India

Abstract

Acrylonitrile styrene acrylate (ASA) is an amorphous terpolymer with superior UV resistance compared to acrylonitrile butadiene styrene (ABS), as its acrylate rubber phase lacks photodegradation-prone carbon–carbon double bonds. This study proposes acetone solvent welding as a polymer joining method to produce monolithic structures from FDM-processed ASA components, addressing three processing challenges: achieving structural continuity through polymer chain interdiffusion at solvent-wetted interfaces, correcting thermal warping via post-print geometric correction during welding, and optimizing infill density distribution for maximum strength-to-weight ratio.

Two iterative frame designs were fabricated and tested using quadcopter flight testing as a structural loading platform. Frame 1 (450 g) employed solid (100%) infill landing gears with conventional infill elsewhere, while Frame 2 (443 g) used a strategic variable infill strategy (60–20%) with key layer orientation to exploit FDM polymer anisotropy. A novel warping correction method was developed: acetone-softened ASA components were clamped against a flat granite surface plate during solvent evaporation, achieving geometric correction as polymer chains interdiffused across bond interfaces.

Frame 1 failed structurally within 10 flights, while Frame 2 completed 40+ flights with no structural degradation, no acetone joint separation, and motor mount coplanarity within 0.1 mm tolerance. Despite a 1.5% weight reduction, the optimized design achieved approximately four times greater operational life, demonstrating that polymer volume fraction distribution and layer orientation optimization are superior to uniform high-density infill. These findings provide reproducible guidelines for solvent-welded ASA polymer structures and an effective warping-reduction process without heated build chambers.

Keywords: ASA polymer, Solvent welding, Acetone bonding, Polymer chain interdiffusion, Variable infill, Fused deposition modeling, Thermoplastic processing, Anisotropic polymer properties, Warping mitigation

How to cite this article:
Sunny Nanade, Zarvan Movdawalla. Structural Optimization of FDM-Processed ASA Polymer Frames through Acetone Solvent Welding, Variable Infill Strategy, and Layer Orientation: Experimental Validation via Quadcopter Flight Testing. Journal of Polymer & Composites. 2026; 14(03):-.
How to cite this URL:
Sunny Nanade, Zarvan Movdawalla. Structural Optimization of FDM-Processed ASA Polymer Frames through Acetone Solvent Welding, Variable Infill Strategy, and Layer Orientation: Experimental Validation via Quadcopter Flight Testing. Journal of Polymer & Composites. 2026; 14(03):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=243564


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Ahead of Print Subscription Original Research
Volume 14
03
Received 20/03/2026
Accepted 31/03/2026
Published 12/05/2026
Publication Time 53 Days
3

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