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Olejarczyk M, Gruber P, Gazińska M, Krokos A, Ziółkowski G, Szymczyk-Ziółkowska P, Grochowska E, Kurzynowski T. New powder reuse schema in laser-based powder bed fusion of polymers. WASTE MANAGEMENT (NEW YORK, N.Y.) 2024; 187:11-21. [PMID: 38968860 DOI: 10.1016/j.wasman.2024.06.030] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/02/2024] [Revised: 06/14/2024] [Accepted: 06/30/2024] [Indexed: 07/07/2024]
Abstract
The laser-based powder bed fusion of polymers (PBF-LB/P) process often utilizes a blend of powders with varying degrees of degradation. Specifically, for polyamide 12, the traditional reuse schema involves mixing post-processed powder with virgin powder at a predetermined ratio before reintroducing it to the process. Given that only about 15% of the powder is utilized in part production, and powders are refreshed in equal proportions, there arises a challenge with the incremental accumulation of material across build cycles. To mitigate the consumption of fresh powder relative to the actual material usage, this study introduces the incorporation of recycled material into the PBF-LB/P process. This new powder reuse schema is presented for the first time, focusing on the laser sintering process. The characteristics of the recycled powder were evaluated through scanning electron microscopy, differential scanning calorimetry, X-ray diffraction, particle size distribution, and dynamic powder flowability assessments. The findings reveal that waste powders can be effectively reused in PBF-LB/P to produce components with satisfactory mechanical properties, porosity levels, dimensional accuracy, and surface quality.
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Affiliation(s)
- Michał Olejarczyk
- Faculty of Mechanical Engineering, Department of Laser Technologies, Automation and Production Organization, Wroclaw University of Science and Technology, Wyb. Wyspiańskiego 27, 50-370 Wrocław, Poland.
| | - Piotr Gruber
- Faculty of Mechanical Engineering, Department of Laser Technologies, Automation and Production Organization, Wroclaw University of Science and Technology, Wyb. Wyspiańskiego 27, 50-370 Wrocław, Poland
| | - Małgorzata Gazińska
- Faculty of Chemistry, Department of Engineering and Technology of Polymers, Wroclaw University of Science and Technology, Wyb. Wyspiańskiego 27, 50-370 Wrocław, Poland
| | - Anna Krokos
- Faculty of Chemistry, Department of Engineering and Technology of Polymers, Wroclaw University of Science and Technology, Wyb. Wyspiańskiego 27, 50-370 Wrocław, Poland
| | - Grzegorz Ziółkowski
- Faculty of Mechanical Engineering, Department of Laser Technologies, Automation and Production Organization, Wroclaw University of Science and Technology, Wyb. Wyspiańskiego 27, 50-370 Wrocław, Poland
| | - Patrycja Szymczyk-Ziółkowska
- Faculty of Mechanical Engineering, Department of Laser Technologies, Automation and Production Organization, Wroclaw University of Science and Technology, Wyb. Wyspiańskiego 27, 50-370 Wrocław, Poland
| | - Emilia Grochowska
- Faculty of Mechanical Engineering, Department of Laser Technologies, Automation and Production Organization, Wroclaw University of Science and Technology, Wyb. Wyspiańskiego 27, 50-370 Wrocław, Poland
| | - Tomasz Kurzynowski
- Faculty of Mechanical Engineering, Department of Laser Technologies, Automation and Production Organization, Wroclaw University of Science and Technology, Wyb. Wyspiańskiego 27, 50-370 Wrocław, Poland
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Sesseg JP, Fischer S, Schmid HJ. Influence of flow agent in laser sintering powders on powder behavior and critical process steps. POWDER TECHNOL 2023. [DOI: 10.1016/j.powtec.2023.118400] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 03/08/2023]
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Alo OA, Otunniyi IO, Mauchline D. Correlation of reuse extent with degradation degree of PA 12 powder during laser powder bed fusion and mechanical behavior of sintered parts. POLYM ENG SCI 2022. [DOI: 10.1002/pen.26191] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Affiliation(s)
- Oluwaseun A. Alo
- Department of Chemical and Metallurgical Engineering Vaal University of Technology South Africa
| | - Iyiola O. Otunniyi
- Department of Chemical and Metallurgical Engineering Vaal University of Technology South Africa
| | - David Mauchline
- Technology Transfer and Innovation Vaal University of Technology South Africa
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Pochivalov KV, Basko AV, Lebedeva TN, Ilyasova AN, Guseinov SS, Kudryavtsev YV. Thermodynamically-informed approach to the synthesis of 3D printing powders from the mixtures of polyamide 12 with benzyl alcohol. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117685] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/17/2022]
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