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Yan Y, Han M, Jiang Y, Ng ELL, Zhang Y, Owh C, Song Q, Li P, Loh XJ, Chan BQY, Chan SY. Electrically Conductive Polymers for Additive Manufacturing. ACS APPLIED MATERIALS & INTERFACES 2024; 16:5337-5354. [PMID: 38284988 DOI: 10.1021/acsami.3c13258] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/30/2024]
Abstract
The use of electrically conductive polymers (CPs) in the development of electronic devices has attracted significant interest due to their unique intrinsic properties, which result from the synergistic combination of physicochemical properties in conventional polymers with the electronic properties of metals or semiconductors. Most conventional methods adopted for the fabrication of devices with nonplanar morphologies are still challenged by the poor ionic/electronic mobility of end products. Additive manufacturing (AM) brings about exciting prospects to the realm of CPs by enabling greater design freedom, more elaborate structures, quicker prototyping, relatively low cost, and more environmentally friendly electronic device creation. A growing variety of AM technologies are becoming available for three-dimensional (3D) printing of conductive devices, i.e., vat photopolymerization (VP), material extrusion (ME), powder bed fusion (PBF), material jetting (MJ), and lamination object manufacturing (LOM). In this review, we provide an overview of the recent research progress in the area of CPs developed for AM, which advances the design and development of future electronic devices. We consider different AM techniques, vis-à-vis, their development progress and respective challenges in printing CPs. We also discuss the material requirements and notable advances in 3D printing of CPs, as well as their potential electronic applications including wearable electronics, sensors, energy storage and conversion devices, etc. This review concludes with an outlook on AM of CPs.
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Affiliation(s)
- Yinjia Yan
- Frontiers Science Center for Flexible Electronics (FSCFE), Xi'an Institute of Flexible Electronics (IFE), Xi'an Institute of Biomedical Materials and Engineering (IBME), and Ningbo Institute, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an 710072, China
- Institute of Materials Research and Engineering (IMRE), Agency for Science, Technology and Research (A*STAR), 2 Fusionopolis Way, Innovis #08-03, Singapore 138634, Republic of Singapore
| | - Miao Han
- Frontiers Science Center for Flexible Electronics (FSCFE), Xi'an Institute of Flexible Electronics (IFE), Xi'an Institute of Biomedical Materials and Engineering (IBME), and Ningbo Institute, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an 710072, China
- Institute of Materials Research and Engineering (IMRE), Agency for Science, Technology and Research (A*STAR), 2 Fusionopolis Way, Innovis #08-03, Singapore 138634, Republic of Singapore
| | - Yixue Jiang
- Institute of Materials Research and Engineering (IMRE), Agency for Science, Technology and Research (A*STAR), 2 Fusionopolis Way, Innovis #08-03, Singapore 138634, Republic of Singapore
- Department of Materials Science and Engineering, College of Design and Engineering, National University of Singapore, 9 Engineering Drive 1, 117575, Singapore
| | - Evelyn Ling Ling Ng
- Institute of Materials Research and Engineering (IMRE), Agency for Science, Technology and Research (A*STAR), 2 Fusionopolis Way, Innovis #08-03, Singapore 138634, Republic of Singapore
| | - Yanni Zhang
- Frontiers Science Center for Flexible Electronics (FSCFE), Xi'an Institute of Flexible Electronics (IFE), Xi'an Institute of Biomedical Materials and Engineering (IBME), and Ningbo Institute, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an 710072, China
- Institute of Materials Research and Engineering (IMRE), Agency for Science, Technology and Research (A*STAR), 2 Fusionopolis Way, Innovis #08-03, Singapore 138634, Republic of Singapore
| | - Cally Owh
- Institute of Materials Research and Engineering (IMRE), Agency for Science, Technology and Research (A*STAR), 2 Fusionopolis Way, Innovis #08-03, Singapore 138634, Republic of Singapore
- Department of Biomedical Engineering, College of Design and Engineering, National University of Singapore, 9 Engineering Drive 1, 117575, Singapore
| | - Qing Song
- Frontiers Science Center for Flexible Electronics (FSCFE), Xi'an Institute of Flexible Electronics (IFE), Xi'an Institute of Biomedical Materials and Engineering (IBME), and Ningbo Institute, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an 710072, China
| | - Peng Li
- Frontiers Science Center for Flexible Electronics (FSCFE), Xi'an Institute of Flexible Electronics (IFE), Xi'an Institute of Biomedical Materials and Engineering (IBME), and Ningbo Institute, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an 710072, China
| | - Xian Jun Loh
- Institute of Materials Research and Engineering (IMRE), Agency for Science, Technology and Research (A*STAR), 2 Fusionopolis Way, Innovis #08-03, Singapore 138634, Republic of Singapore
| | - Benjamin Qi Yu Chan
- Institute of Materials Research and Engineering (IMRE), Agency for Science, Technology and Research (A*STAR), 2 Fusionopolis Way, Innovis #08-03, Singapore 138634, Republic of Singapore
| | - Siew Yin Chan
- Frontiers Science Center for Flexible Electronics (FSCFE), Xi'an Institute of Flexible Electronics (IFE), Xi'an Institute of Biomedical Materials and Engineering (IBME), and Ningbo Institute, Northwestern Polytechnical University, 127 West Youyi Road, Xi'an 710072, China
- Institute of Materials Research and Engineering (IMRE), Agency for Science, Technology and Research (A*STAR), 2 Fusionopolis Way, Innovis #08-03, Singapore 138634, Republic of Singapore
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Nagengast N, Bay C, Döpper F, Schmidt HW, Neuber C. Thermo-Mechanical Recyclability of Additively Manufactured Polypropylene and Polylactic Acid Parts and Polypropylene Support Structures. Polymers (Basel) 2023; 15:polym15102291. [PMID: 37242864 DOI: 10.3390/polym15102291] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/27/2023] [Revised: 05/07/2023] [Accepted: 05/09/2023] [Indexed: 05/28/2023] Open
Abstract
Polymers have a reputation for several advantageous characteristics like chemical resistance, weight reduction, and simple form-giving processes. The rise of additive manufacturing technologies such as Fused Filament Fabrication (FFF) has introduced an even more versatile production process that supported new product design and material concepts. This led to new investigations and innovations driven by the individualization of customized products. The other side of the coin contains an increasing resource and energy consumption satisfying the growing demand for polymer products. This turns into a magnitude of waste accumulation and increased resource consumption. Therefore, appropriate product and material design, taking into account end-of-life scenarios, is essential to limit or even close the loop of economically driven product systems. In this paper, a comparison of virgin and recycled biodegradable (polylactic acid (PLA)) and petroleum-based (polypropylene (PP) & support) filaments for extrusion-based Additive Manufacturing is presented. For the first time, the thermo-mechanical recycling setup contained a service-life simulation, shredding, and extrusion. Specimens and complex geometries with support materials were manufactured with both, virgin and recycled materials. An empirical assessment was executed through mechanical (ISO 527), rheological (ISO 1133), morphological, and dimensional testing. Furthermore, the surface properties of the PLA and PP printed parts were analyzed. In summary, PP parts and parts from its support structure showed, in consideration of all parameters, suitable recyclability with a marginal parameter variance in comparison to the virgin material. The PLA components showed an acceptable decline in the mechanical values but through thermo-mechanical degradation processes, rheological and dimensional properties of the filament dropped decently. This results in significantly identifiable artifacts of the product optics, based on an increase in surface roughness.
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Affiliation(s)
- Niko Nagengast
- Chair of Biomechanics, Faculty of Engineering, University of Bayreuth, Universitaetsstrasse 9, 95447 Bayreuth, Germany
| | - Christian Bay
- Research Center for Additive Innovations, University of Bayreuth, Universitaetsstrasse 30, 95447 Bayreuth, Germany
- Chair of Manufacturing and Remanufacturing Technology, Faculty of Engineering, University of Bayreuth, Universitaetsstrasse 9, 95447 Bayreuth, Germany
| | - Frank Döpper
- Research Center for Additive Innovations, University of Bayreuth, Universitaetsstrasse 30, 95447 Bayreuth, Germany
- Chair of Manufacturing and Remanufacturing Technology, Faculty of Engineering, University of Bayreuth, Universitaetsstrasse 9, 95447 Bayreuth, Germany
| | - Hans-Werner Schmidt
- Chair of Macromolecular Chemistry, Faculty of Natural Science, University of Bayreuth, Universitaetsstrasse 30, 95447 Bayreuth, Germany
- Bavarian Polymer Institute, University of Bayreuth, Universitaetsstrasse 30, 95447 Bayreuth, Germany
| | - Christian Neuber
- Chair of Macromolecular Chemistry, Faculty of Natural Science, University of Bayreuth, Universitaetsstrasse 30, 95447 Bayreuth, Germany
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Molecular Pathways for Polymer Degradation during Conventional Processing, Additive Manufacturing, and Mechanical Recycling. Molecules 2023; 28:molecules28052344. [PMID: 36903589 PMCID: PMC10004996 DOI: 10.3390/molecules28052344] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/20/2023] [Revised: 02/20/2023] [Accepted: 02/28/2023] [Indexed: 03/06/2023] Open
Abstract
The assessment of the extent of degradation of polymer molecules during processing via conventional (e.g., extrusion and injection molding) and emerging (e.g., additive manufacturing; AM) techniques is important for both the final polymer material performance with respect to technical specifications and the material circularity. In this contribution, the most relevant (thermal, thermo-mechanical, thermal-oxidative, hydrolysis) degradation mechanisms of polymer materials during processing are discussed, addressing conventional extrusion-based manufacturing, including mechanical recycling, and AM. An overview is given of the most important experimental characterization techniques, and it is explained how these can be connected with modeling tools. Case studies are incorporated, dealing with polyesters, styrene-based materials, and polyolefins, as well as the typical AM polymers. Guidelines are formulated in view of a better molecular scale driven degradation control.
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Wang K, Zhang Z, Cai R, Sun G, Cheng P, Peng Y. Improving the mechanical properties of
3D
printed recycled polypropylene‐based composites through adjusting printing temperature. J Appl Polym Sci 2023. [DOI: 10.1002/app.53658] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/24/2023]
Affiliation(s)
- Kui Wang
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic & Transportation Engineering Central South University Changsha China
- ICUBE Laboratory‐CNRS University of Strasbourg Strasbourg France
| | - Zejun Zhang
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic & Transportation Engineering Central South University Changsha China
| | - Ruijun Cai
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic & Transportation Engineering Central South University Changsha China
| | - Guangyu Sun
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic & Transportation Engineering Central South University Changsha China
| | - Ping Cheng
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic & Transportation Engineering Central South University Changsha China
- ICUBE Laboratory‐CNRS University of Strasbourg Strasbourg France
| | - Yong Peng
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic & Transportation Engineering Central South University Changsha China
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Analysis of PLA/PHB Biopolymer Material with Admixture of Hydroxyapatite and Tricalcium Phosphate for Clinical Use. Polymers (Basel) 2022; 14:polym14245357. [PMID: 36559724 PMCID: PMC9784836 DOI: 10.3390/polym14245357] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/27/2022] [Revised: 11/14/2022] [Accepted: 11/30/2022] [Indexed: 12/13/2022] Open
Abstract
One trend in tissue engineering and regenerative medicine is the development of degradable composite polymers. The aim of this study was the comprehensive analysis of Polylactic acid (PLA)/Polyhydroxybutyrate (PHB) + Hydroxyapatite (HA)/Tricalcium phosphate (TCP) material from filament production to mechanical testing of samples with different infills and the production of an implant replacement for an intervertebral disc. Filament Maker-Composer 450 (3devo; Netherlands) was used to produce filaments. Experimental samples and the implant for the intervertebral disc were made using FDM technology using a DeltiQ2 3D printer (Trilab, Czech Republic). Mechanical testing of experimental samples was performed on an Inspekt TABLE 5 kN (Hegewald & Peschke, Nossen, Germany). Microscopic analysis, cytotoxicity test, and filament diameter analysis using descriptive statistics were also part of the focus. The results of the analysis of the diameter of the filament show that the filament meets the prescribed standard. The cytotoxicity test for PLA/PHB + HA/TCP material showed no toxicity. Microscopic analysis showed an even distribution of the ceramic component in the composite polymer. Mechanical testing showed a reduction in mechanical properties with 75% and 50% of the filling of experimental samples. All experimental samples subjected to mechanical testing showed higher tensile and compressive strength values compared to the values of the mechanical properties of vertebral trabecular bones, as reported in the literature. It can therefore be concluded that the material under investigation, PLA/PHB + HA/TCP appears to be a suitable candidate for hard tissue replacement.
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Solid Dispersion Formulations by FDM 3D Printing-A Review. Pharmaceutics 2022; 14:pharmaceutics14040690. [PMID: 35456524 PMCID: PMC9032529 DOI: 10.3390/pharmaceutics14040690] [Citation(s) in RCA: 12] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/19/2022] [Revised: 03/16/2022] [Accepted: 03/18/2022] [Indexed: 01/06/2023] Open
Abstract
Additive manufacturing (AM) is revolutionizing the way medicines are designed, manufactured, and utilized. Perhaps, AM appears to be ideal for the fit-for-purpose manufacturing of medicines in contrast to the several disadvantages associated with the conventional fit-for-all mass production that accounts for less than 50% of pharmacotherapeutic treatment/management of diseases especially among children and elderly patients, as well as patients with special needs. In this review, we discuss the current trends in the application of additive manufacturing to prepare personalized dosage forms on-demand focusing the attention on the relevance of coupling solid dispersion with FDM 3D printing. Combining the two technologies could offer many advantages such as to improve the solubility, dissolution, and oral bioavailability of poorly soluble drugs in tandem with the concept of precision medicine and personalized dosing and to address the dilemma of commercial availability of FDM filaments loaded with Class II and/or Class IV drugs. However, thermal treatment especially for heat-sensitive drugs, regulatory, and ethical obligations in terms of quality control and quality assurance remain points of concern. Hence, a concerted effort is needed between the scientific community, the pharmaceutical industries, the regulatory agencies, the clinicians and clinical pharmacists, and the end-users to address these concerns.
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Abstract
3D printing enables sustainable product innovations through novel design, reduced use of materials, and local manufacturing. Sustainable 3D printing can further be realized using recyclable materials. Cellulose is an abundantly available renewable material. Modified celluloses, such as thermoplastic cellulose esters, are widely used in injection molding applications. The aim of this research was to study the properties of a cellulose-based composite (cellulose acetate propionate (CAP) polymer matrix with 20 wt. % microcellulose) in injection molding and granular extrusion-based 3D printing processes over multiple recycles. The impact of the processing methods on the composite’s properties were investigated. Both injection molded and 3D printed samples were ground with plastic grinding mill to particle sizes below 3 mm after each preparation stage and reused as such in the next process cycle. Morphology, mechanical and thermal properties, and material degradation were analyzed. The thermoplastic cellulose-based compound was found to be directly recyclable for both processes without the need for any additional compounding steps. The polymer matrix was able to withstand at least seven processing cycles without degradation. However, microcellulose was found to be more sensitive to thermal stress. The mechanical and thermal properties of the cellulose-based composites remained close to initial levels throughout.
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Gomes TEP, Cadete MS, Dias-de-Oliveira J, Neto V. Controlling the properties of parts 3D printed from recycled thermoplastics: a review of current practices. Polym Degrad Stab 2022. [DOI: 10.1016/j.polymdegradstab.2022.109850] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/29/2022]
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Fischer KM, Howell AP. Reusability of autoclaved 3D printed polypropylene compared to a glass filled polypropylene composite. 3D Print Med 2021; 7:20. [PMID: 34370133 PMCID: PMC8351346 DOI: 10.1186/s41205-021-00111-x] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/27/2021] [Accepted: 07/15/2021] [Indexed: 11/21/2022] Open
Abstract
Health care waste can be a costly expenditure for facilities as specific disposal methods must be used to prevent the spread of pathogens. If more multi-use medical devices were available, it could potentially relieve some of this burden; however, sterilization between uses is important in preventing disease transmission. 3D printing has the ability to easily create custom medical devices at a low cost, but the majority of filaments utilized cannot survive steam sterilization. Polypropylene (PP) can withstand autoclave temperatures, but is difficult to print as it warps and shrinks during printing; however, a composite PP filament reduces these effects. Commercially available PP and glass filled PP (GFPP) filaments were successfully 3D printed into 30 × 30 × 30 mm cubes with no shrinking or warping and were autoclaved. The 134 °C autoclave temperature was too high as several cubes melted after two to three rounds, but both PP and GFPP cubes displayed minimal changes in mass and volume after one, four, seven, and ten rounds of autoclaving at 121 °C. GFPP cubes autoclaved zero, four, seven, and ten times had significantly smaller average compressive stress values compared to all PP groups, but the GFPP cubes autoclaved once were only less than PP cubes autoclaved zero, seven and ten times. GFPP cubes autoclaved zero, one, four, and seven times also deformed less indicating that the embedded glass fibers provided additional strength. While a single method was found that successfully printed PP and GFPP cubes that were able to survive up to ten rounds of autoclaving, future work should include further investigation into the mechanical properties and increasing the number of autoclave rounds.
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Affiliation(s)
- Kristin M Fischer
- Biology Department, Hampden-Sydney College, PO Box 33, VA, 23943, Hampden Sydney, USA.
| | - Andrew P Howell
- Biochemistry & Molecular Biology Department, Hampden-Sydney College, 23943, Hampden Sydney, VA, USA
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Sustainable Additive Manufacturing: Mechanical Response of Polypropylene over Multiple Recycling Processes. SUSTAINABILITY 2020. [DOI: 10.3390/su13010159] [Citation(s) in RCA: 22] [Impact Index Per Article: 5.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/14/2022]
Abstract
The recycling of polymeric materials has received a steadily growing scientific and industrial interest due to the increase in demand and production of durable and lightweight plastic parts. Recycling of such materials is mostly based on thermomechanical processes that significantly affect the mechanical, as well as the overall physicochemical properties of polymers. The study at hand focuses on the recyclability of Fused Filament Fabrication (FFF) 3D printed Polypropylene (PP) for a certain number of recycling courses (six in total), and its effect on the mechanical properties of 3D printed parts. Namely, 3D printed specimens were fabricated from non-recycled and recycled PP material, and further experimentally tested regarding their mechanical properties in tension, flexion, impact, and microhardness. Comprehensive dynamic scanning calorimetry (DSC), thermogravimetric analysis (TGA), Raman spectroscopy, and morphological investigations by scanning electron microscopy (SEM) were performed for the different 3D printed PP samples. The overall results showed that there is an overall slight increase in the material’s mechanical properties, both in tension and in flexion mode, while the DSC characterization indicates an increase in the polymer crystallinity over the recycling course.
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12
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Synyuk O, Musiał J, Zlotenko B, Kulik T. Development of Equipment for Injection Molding of Polymer Products Filled with Recycled Polymer Waste. Polymers (Basel) 2020; 12:polym12112725. [PMID: 33212991 PMCID: PMC7698543 DOI: 10.3390/polym12112725] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/08/2020] [Revised: 11/05/2020] [Accepted: 11/08/2020] [Indexed: 11/16/2022] Open
Abstract
Polymer waste of light industry and other industries is processed by chemical recycling and mechanical grinding. Modern equipment for polymer waste processing has the following drawbacks: significant energy consumption and reduced performance properties of recycled polymer. New technological processes and equipment for polymer waste recycling have been developed for the manufacture of light industry polymer products with increased performance characteristics. The manufacturing of such products was made possible by the development of the mathematical model, which describes the movement of a mixture of main polymer material and particles of recycled polymer waste in the process of filling a mold cavity. The model, in contrast to the existing models, allows observing the formation of the polymer product structure containing recycled waste particles. Improvement in the performance characteristics of shoe soles made by the injection molding of a mixture of polyvinylchloride and particles of recycled polyvinylchloride was confirmed by experimental tests of breaking strength and fatigue life. The results of these tests can be used in the design of processing equipment to obtain waste particles of the required shape and size and in the design of molds to provide the required concentration and orientation of waste particles in light industry polymer products.
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Affiliation(s)
- Oleg Synyuk
- Department of Machines and Apparatuses, Electromechanical and Power Systems, Khmelnytskyi National University, Instytuts’ka str., 11, 29016 Khmelnytskyi, Ukraine
- Correspondence: (O.S.); (T.K.)
| | - Janusz Musiał
- Faculty of Mechanical Engineering, University of Science and Technology, Kaliskiego 7 Street, 85-789 Bydgoszcz, Poland;
| | - Borys Zlotenko
- Department of Computer Engineering and Electromechanics, Kyiv National University of Technologies and Design, Nemyrovycha-Danchenka Street, 2, 01011 Kyiv, Ukraine;
| | - Tetiana Kulik
- Department of Computer Engineering and Electromechanics, Kyiv National University of Technologies and Design, Nemyrovycha-Danchenka Street, 2, 01011 Kyiv, Ukraine;
- Correspondence: (O.S.); (T.K.)
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13
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H S B, Bonthu D, Prabhakar P, Doddamani M. Three-Dimensional Printed Lightweight Composite Foams. ACS OMEGA 2020; 5:22536-22550. [PMID: 32923813 PMCID: PMC7482239 DOI: 10.1021/acsomega.0c03174] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/01/2020] [Accepted: 08/14/2020] [Indexed: 05/25/2023]
Abstract
The goal of this paper is to enable three-dimensional (3D) printed lightweight composite foams by blending hollow glass microballoons (GMBs) with high density polyethylene (HDPE). To that end, lightweight feedstock for printing syntactic foam composites is developed. The blend for this is prepared by varying the GMB content (20, 40, and 60 volume %) in HDPE for filament extrusion, which is subsequently used for 3D printing. The rheological properties and the melt flow index (MFI) of blends are investigated for identifying suitable printing parameters. It is observed that the storage and loss modulus, as well as complex viscosity, increase with increasing GMB content, whereas MFI decreases. Further, the coefficient of thermal expansion of HDPE and foam filaments decreases with increasing GMB content, thereby lowering the thermal stresses in prints, which promotes the reduction in warpage. The mechanical properties of filaments are determined by subjecting them to tensile tests, whereas 3D printed samples are tested under tensile and flexure tests. The tensile modulus of the filament increases with increasing GMB content (8-47%) as compared to HDPE and exhibit comparable filament strength. 3D printed foams show a higher specific tensile and flexural modulus as compared to neat HDPE, making them suitable candidate materials for weight-sensitive applications. HDPE having 60% by volume GMB exhibited the highest modulus and is 48.02% higher than the printed HDPE. Finally, the property map reveals a higher modulus and comparable strength against injection- and compression-molded foams. Printed foam registered 1.8 times higher modulus than the molded samples. Hence, 3D printed foams have the potential for replacing components processed through conventional manufacturing processes that have limitations on geometrically complex designs, lead time, and associated costs.
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Affiliation(s)
- Bharath H S
- Advanced
Manufacturing Laboratory, Mechanical Engineering, National Institute of Technology, Surathkal, Karnataka 53706, India
| | - Dileep Bonthu
- Advanced
Manufacturing Laboratory, Mechanical Engineering, National Institute of Technology, Surathkal, Karnataka 53706, India
| | - Pavana Prabhakar
- Department
of Civil and Environmental Engineering, University of Wisconsin-Madison, Madison, Wisconsin 53706, United States
| | - Mrityunjay Doddamani
- Advanced
Manufacturing Laboratory, Mechanical Engineering, National Institute of Technology, Surathkal, Karnataka 53706, India
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Jeyachandran P, Bontha S, Bodhak S, Balla VK, Kundu B, Doddamani M. Mechanical behaviour of additively manufactured bioactive glass/high density polyethylene composites. J Mech Behav Biomed Mater 2020; 108:103830. [DOI: 10.1016/j.jmbbm.2020.103830] [Citation(s) in RCA: 18] [Impact Index Per Article: 4.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/08/2020] [Revised: 04/22/2020] [Accepted: 04/23/2020] [Indexed: 12/19/2022]
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15
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Sustainable Additive Manufacturing: Mechanical Response of Acrylonitrile-Butadiene-Styrene over Multiple Recycling Processes. SUSTAINABILITY 2020. [DOI: 10.3390/su12093568] [Citation(s) in RCA: 37] [Impact Index Per Article: 9.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
Abstract
Sustainability in additive manufacturing refers mainly to the recycling rate of polymers and composites used in fused filament fabrication (FFF), which nowadays are rapidly increasing in volume and value. Recycling of such materials is mostly a thermomechanical process that modifies their overall mechanical behavior. The present research work focuses on the acrylonitrile-butadiene-styrene (ABS) polymer, which is the second most popular material used in FFF-3D printing. In order to investigate the effect of the recycling courses on the mechanical response of the ABS polymer, an experimental simulation of the recycling process that isolates the thermomechanical treatment from other parameters (i.e., contamination, ageing, etc.) has been performed. To quantify the effect of repeated recycling processes on the mechanic response of the ABS polymer, a wide variety of mechanical tests were conducted on FFF-printed specimens. Regarding this, standard tensile, compression, flexion, impact and micro-hardness tests were performed per recycle repetition. The findings prove that the mechanical response of the recycled ABS polymer is generally improved over the recycling repetitions for a certain number of repetitions. An optimum overall mechanical behavior is found between the third and the fifth repetition, indicating a significant positive impact of the ABS polymer recycling, besides the environmental one.
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16
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Experiment-Based Process Modeling and Optimization for High-Quality and Resource-Efficient FFF 3D Printing. APPLIED SCIENCES-BASEL 2020. [DOI: 10.3390/app10082899] [Citation(s) in RCA: 33] [Impact Index Per Article: 8.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 01/02/2023]
Abstract
This article reports on the investigation of the effects of process parameters and their interactions on as-built part quality and resource-efficiency of the fused filament fabrication 3D printing process. In particular, the influence of five process parameters: infill percentage, layer thickness, printing speed, printing temperature, and surface inclination angle on dimensional accuracy, surface roughness of the built part, energy consumption, and productivity of the process was examined using Taguchi orthogonal array (L50) design of experiment. The experimental results were analyzed using ANOVA and statistical analysis, and the parameters for optimal responses were identified. Regression models were developed to predict different process responses in terms of the five process parameters experimentally examined in this study. It was found that dimensional accuracy is negatively influenced by high values of layer thickness and printing speed, since thick layers of printed material tend to spread out and high printing speeds hinder accurate deposition of the printed material. In addition, the printing temperature, which regulates the viscosity of the used material, plays a significant role and helps to minimize the dimensional error caused by thick layers and high printing speeds, whereas the surface roughness depends very much on surface inclination angle and layer thickness, which together determine the influence of the staircase effect. Energy consumption and productivity are primarily affected by printing speed and layer thickness, due to their high correlation with build time.
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17
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Ekinci A, Johnson AA, Gleadall A, Engstrøm DS, Han X. Layer-dependent properties of material extruded biodegradable Polylactic Acid. J Mech Behav Biomed Mater 2020; 104:103654. [DOI: 10.1016/j.jmbbm.2020.103654] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/01/2019] [Revised: 01/09/2020] [Accepted: 01/23/2020] [Indexed: 10/25/2022]
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18
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Spoerk M, Holzer C, Gonzalez‐Gutierrez J. Material extrusion‐based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage. J Appl Polym Sci 2019. [DOI: 10.1002/app.48545] [Citation(s) in RCA: 88] [Impact Index Per Article: 17.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/12/2022]
Affiliation(s)
- Martin Spoerk
- Polymer ProcessingMontanuniversitaet Leoben, Otto Gloeckel‐Straße 2 Leoben 8700 Austria
| | - Clemens Holzer
- Polymer ProcessingMontanuniversitaet Leoben, Otto Gloeckel‐Straße 2 Leoben 8700 Austria
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