Extrusion‐based 3D printing with high‐density polyethylene Birch‐fiber composites

3D Printing of Wood Composites: State of the Art and Opportunities

With the production of wood waste constantly on the increase, questions relating to its recycling and reuse are becoming unavoidable. The reuse of wood and its derivatives can be achieved through the production of composite materials, using wood as a reinforcement or even as the main matrix of the material. Additive manufacturing (also known as 3D printing) is an emerging and very promising process, particularly with the use of bio-based and renewable materials such as wood or its industrial derivatives. The aim of this paper is to present an overview of additive manufacturing processes using wood as a raw material and including industrial solutions. After presenting wood and its waste products, all the additive manufacturing processes using wood or its industrial derivatives will be presented. Finally, for each 3D printing process, this review will consider the current state of research, the industrial solutions that may exist, as well as the main challenges and issues that still need to be overcome.

Material Extrusion Additive Manufacturing with Polyethylene Vitrimers

Polyethylene (PE) is one of the most widely used polymers in conventional polymer manufacturing processes. However, it remains a challenge to use PE in extrusion-based additive manufacturing (AM). Some of the challenges that this material presents include low self-adhesion and shrinkage during the printing process. These two issues lead to higher mechanical anisotropy when compared to other materials, along with poor dimensional accuracy and warpage. Vitrimers are a new class of polymers that have a dynamic crosslinked network, allowing the material to be healed and reprocessed. Prior studies on polyolefin vitrimers suggest that the crosslinks reduce the degree of crystallinity and increase the dimensional stability at elevated temperatures. In this study, high-density polyethylene (HDPE) and HDPE vitrimers (HDPE-V) were successfully processed using a screw-assisted 3D printer. It was demonstrated that HDPE-V were able to reduce shrinkage during the printing process. This shows that 3D printing with HDPE-V will provide better dimensional stability when compared to regular HDPE. Furthermore, after an annealing process, 3D-printed HDPE-V samples showed a decrease in mechanical anisotropy. This annealing process was only possible in HDPE-V due to their superior dimensional stability at elevated temperatures, with minimal deformation above melting temperature.

Research on the Dynamic Response Properties of Nonlethal Projectiles for Injury Risk Assessment

Based on the models already on the market, we have manufactured six types of nonlethal projectiles. We have made convex heads out of polyurethane foam (PUR) filled with mineral fillers like alumina (Al2O3) and montmorillonite (MMT). We chose a suitable holder for nonlethal projectiles. Also, we made a custom industrial model and used CAD modeling in SolidWorks to simulate the deformation of the nonlethal projectiles. The polymeric nonlethal projectile holders were then 3D-printed. We performed a dynamic mechanical analysis (DMA) and discussed the results. Likewise, we conducted ballistic impact experiments on nonlethal projectiles (XM1006) and nonlethal projectiles manufactured that were evaluated using a rigid wall and a pneumatic launcher. Furthermore, we looked at cell structure, the spread of the mean pore diameter, and the particle size distributions of the mineral fillers using scanning electron microscopy (SEM). We evaluated and discussed injury risks from nonlethal impacts. Data on nonlethal projectile lethality and safe impact speed are collected. This study explains how lab studies and real-world practice coexist through nonlethal projectile properties.