Sustainable Additive Manufacturing: Mechanical Response of High-Density Polyethylene over Multiple Recycling Processes

Optimization Course of Titanium Nitride Nanofiller Loading in High-Density Polyethylene: Interpretation of Reinforcement Effects and Performance in Material Extrusion 3D Printing

In this study, titanium nitride (TiN) was selected as an additive to a high-density polyethylene (HDPE) matrix material, and four different nanocomposites were created with TiN loadings of 2.0-8.0 wt. % and a 2 wt. % increase step between them. The mixtures were made, followed by the fabrication of the respective filaments (through a thermomechanical extrusion process) and 3D-printed specimens (using the material extrusion (MEX) technique). The manufactured specimens were subjected to mechanical, thermal, rheological, structural, and morphological testing. Their results were compared with those obtained after conducting the same assessments on unfilled HDPE samples, which were used as the control samples. The mechanical response of the samples improved when correlated with that of the unfilled HDPE. The tensile strength improved by 24.3%, and the flexural strength improved by 26.5% (composite with 6.0 wt. % TiN content). The dimensional deviation and porosity of the samples were assessed with micro-computed tomography and indicated great results for porosity improvement, achieved with 6.0 wt. % TiN content in the composite. TiN has proven to be an effective filler for HDPE polymers, enabling the manufacture of parts with improved mechanical properties and quality.

Evaluation of the Effectiveness of Geogrids Manufactured from Recycled Plastics for Slope Stabilization-A Case Study

This study aimed to investigate the sustainable use of recycled plastics, specifically polypropylene (PP) and high-density polyethylene (HDPE), in the manufacture of geogrids for geotechnical and civil engineering applications. Plastics were collected from a recycling center, specifically targeting containers used for food, cleaning products, and other domestic packaging items. These plastics were sorted according to the Möbius triangle classification system, with HDPE (#2) and PP (#5) being the primary categories of interest. The research methodologically evaluates the mechanical properties of PP/HDPE (0/100, 25/75, 50/50, 75/25 and 100/0% w/w) composites through tensile and flexural tests, exploring various compositions and configurations of geogrids. The results highlight the superiority of pure recycled HDPE processed into 1.3 mm thick laminated yarns and hot air welded for 20 to 30 s, exhibiting a deformation exceeding 60% in comparison to the PP/HDPE composites. Through SolidWorks® Simulation, it was shown that the adoption of a trigonal geogrid geometry optimizes force distribution and tensile strength, significantly improving slope stabilization efficiency. Based on the results obtained, a laboratory-scale prototype geogrid was developed using an extrusion process. The results underscore the importance of careful composite design and yarn configuration selection to achieve the desired mechanical properties and performance in geogrid applications. It emphasizes the potential of recycled plastics as a viable and environmentally friendly solution for stabilizing slopes, contributing to the reduction in plastic waste and promoting sustainable construction practices.

High-Density Polyethylene/Carbon Black Composites in Material Extrusion Additive Manufacturing: Conductivity, Thermal, Rheological, and Mechanical Responses

High-density polyethylene polymer (HDPE) and carbon black (CB) were utilized to create HDPE/CB composites with different filler concentrations (0.0, 2.0, 4.0, 6.0, 8.0, 10.0, 16.0, 20.0, and 24.0 wt.%). The composites were extruded into filaments, which were then utilized to fabricate 3D-printed specimens with the material extrusion (MEX) method, suitable for a variety of standard mechanical tests. The electrical conductivity was investigated. Furthermore, thermogravimetric analysis and differential scanning calorimetry were carried out for all the HDPE/CB composites and pure HDPE. Scanning electron microscopy in different magnifications was performed on the specimens' fracture and side surfaces to investigate the morphological characteristics. Rheological tests and Raman spectroscopy were also performed. Eleven different tests in total were performed to fully characterize the composites and reveal connections between their various properties. HDPE/CB 20.0 wt.% showed the greatest reinforcement results in relation to pure HDPE. Such composites are novel in the MEX 3D printing method. The addition of the CB filler greatly enhanced the performance of the popular HDPE polymer, expanding its applications.

Advancing Plastic Recycling: Challenges and Opportunities in the Integration of 3D Printing and Distributed Recycling for a Circular Economy

The concept of the circular economy has emerged as a promising solution to address the mounting concerns surrounding plastic waste and the urgent need for sustainable resource management. While conventional centralized recycling remains a common practice for plastic waste, centralized facilities may prove inadequate in handling the ever-increasing volumes of plastic waste generated globally. Consequently, exploring alternative recycling methods, such as distributed recycling by additive manufacturing, becomes paramount. This innovative approach encompasses actively involving communities in recycling practices and promotes a circular economy. This comprehensive review paper aims to explore the critical aspects necessary to realize the potential of distributed recycling by additive manufacturing. In this paper, our focus lies on proposing schemes that leverage existing literature to harness the potential of distributed recycling by additive manufacturing as an effective approach to plastic waste management. We explore the intricacies of the recycling process, optimize 3D printing parameters, address potential challenges, and evaluate the mechanical properties of recycled materials. Our investigation draws heavily from the literature of the last five years, as we conduct a thorough critical assessment of DRAM implementation and its influence on the properties of 3D printing structures. Through comprehensive analysis, we reveal the potential of recycled materials in delivering functional components, with insights into their performance, strengths, and weaknesses. This review serves as a comprehensive guide for those interested in embracing distributed recycling by additive manufacturing as a transformative approach to plastic recycling. By fostering community engagement, optimizing 3D printing processes, and incorporating suitable additives, it is possible to collectively contribute to a more sustainable future while combatting the plastic waste crisis. As progress is made, it becomes essential to further delve into the complexities of material behavior, recycling techniques, and the long-term durability of recycled 3D printed components. By addressing these challenges head-on, it is feasible to refine and advance distributed recycling by additive manufacturing as a viable pathway to minimize plastic waste, fostering a circular economy and cultivating a cleaner planet for generations to come.

Material Characterization of Polypropylene and Polystyrene Regarding Molecular Degradation Behavior

During the processing of thermoplastics, polymers are subjected to high stress. As a result of this stress, the polymer chains break, leading to a lower molar mass. This further leads to a lower viscosity of the plastic melt and, eventually, to poorer mechanical properties of the manufactured plastic product. Especially in the context of recycling plastics, this poses a challenge to process technology and product properties. This work aims is to provide a prediction of the material degradation under known stress, so that, for example, a process design that is gentle on the material can be carried out. In order to be able to predict material degradation under a load, a test stand for defined material degradation was designed. The test stand allows for material damaging under a defined temperature, shear rate and residence time. At the same time, the test stand can be used to measure the viscosity, which is used to describe the degradation behavior, since the viscosity correlates with the molar mass. The measured decrease in viscosity under stress can be used to predict material damage under the influencing variables of temperature, shear rate and residence time by means of a test plan and a suitable mathematical description of the measured data. The mathematical description can thus be integrated into simulation environments for plastics processing, so that a simulation of the material degradation can be carried out, if necessary also taking the viscosity reduction into account.

Innovative, simple, and green: A sample preparation method based on 3D printed polymers

The present study evaluates the capability of fifteen 3D printed thermoplastic polymers as novel stationary phases for the extraction of forty-three physicochemically diverse analytes from fortified human oral fluid samples. Prototype extraction devices were prepared in 96-well plate-compatible format using fused deposition modeling 3D printer. The sample preparation was performed with 5-step protocol utilizing 96-well plates and semiautomated benchtop shaker. All resulting extracts were analyzed via high-performance liquid chromatography (operated in reversed-phase gradient elution mode) and tandem mass spectrometry (with electrospray ionization and triple quadrupole mass spectrometer). Exceptionally favorable results were observed for three polymer types: polyamide 6 (reinforced with 15% carbon fiber), LAYFOMM-60 (polyurethane with water-soluble polyvinyl alcohol), and S-FLEX 90A (thermoplastic polyurethane). Furthermore, this study also introduces an automated and repeatable 3D printing method for the fast fabrication of high-throughput, and highly selective sample preparation devices, most of which are ready-to-use without any additional processing or chemical functionalization. As such, the proposed printing method represents a significant step towards the introduction of novel polymeric stationary phases for analytical sample preparation, thus providing laboratory personnel with a method that is safer and more convenient, while minimizing negative environmental impacts.

Thermo-Mechanical Recyclability of Additively Manufactured Polypropylene and Polylactic Acid Parts and Polypropylene Support Structures

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.

Additive Manufacturing of Polyolefins

Polyolefins are semi-crystalline thermoplastic polymers known for their good mechanical properties, low production cost, and chemical resistance. They are amongst the most commonly used plastics, and many polyolefin grades are regarded as engineering polymers. The two main additive manufacturing techniques that can be used to fabricate 3D-printed parts are fused filament fabrication and selective laser sintering. Polyolefins, like polypropylene and polyethylene, can, in principle, be processed with both these techniques. However, the semi-crystalline nature of polyolefins adds complexity to the use of additive manufacturing methods compared to amorphous polymers. First, the crystallization process results in severe shrinkage upon cooling, while the processing temperature and cooling rate affect the mechanical properties and mesoscopic structure of the fabricated parts. In addition, for ultra-high-molecular weight polyolefins, limited chain diffusion is a major obstacle to achieving proper adhesion between adjunct layers. Finally, polyolefins are typically apolar polymers, which reduces the adhesion of the 3D-printed part to the substrate. Notwithstanding these difficulties, it is clear that the successful processing of polyolefins via additive manufacturing techniques would enable the fabrication of high-end engineering products with enormous design flexibility. In addition, additive manufacturing could be utilized for the increased recycling of plastics. This manuscript reviews the work that has been conducted in developing experimental protocols for the additive manufacturing of polyolefins, presenting a comparison between the different approaches with a focus on the use of polyethylene and polypropylene grades. This review is concluded with an outlook for future research to overcome the current challenges that impede the addition of polyolefins to the standard palette of materials processed through additive manufacturing.

MEX 3D Printed HDPE/TiO2 Nanocomposites Physical and Mechanical Properties Investigation

Aiming to develop more robust, mechanically advanced, Fused Filament Fabrication (FFF) materials, High-Density Polyethylene (HDPE) nanocomposites were developed in the current research work. Titanium Dioxide (TiO2) was selected as filler to be incorporated into the HDPE matrix in concentration steps of 0.5, 2.5, 5, and 10 wt.%. 3D printing nanocomposite filaments were extruded in ~1.75 mm diameter and used to 3D print and test tensile and flexion specimens according to international standards. Reported results indicate that the filler contributes to increasing the mechanical strength of the virgin HDPE at certain filler and filler type concentrations; with the highest values reported to be 37.8% higher in tensile strength with HDPE/TiO2 10 wt.%. Morphological and thermal characterization was performed utilizing Scanning Electron Microscopy (SEM), Raman, Thermogravimetric Analysis (TGA), and Differential Scanning Calorimetry (DSC), while the results were correlated with the available literature.

Mechanical Performance of Fused Filament Fabricated and 3D-Printed Polycarbonate Polymer and Polycarbonate/Cellulose Nanofiber Nanocomposites

In this study, nanocomposites were fabricated with polycarbonate (PC) as the matrix material. Cellulose Nanofiber (CNF) at low filler loadings (0.5 wt.% and 1.0 wt.%) was used as the filler. Samples were produced using melt mixing extrusion with the Fused Filament Fabrication (FFF) process. The optimum 3D-printing parameters were experimentally determined and the required specimens for each tested material were manufactured using FFF 3D printing. Tests conducted for mechanical performance were tensile, flexural, impact, and Dynamic Mechanical Analysis (DMA) tests, while images of the side and the fracture area of the specimens were acquired using Scanning Electron Microscopy (SEM), aiming to determine the morphology of the specimens and the fracture mechanism. It was concluded that the filler’s ratio addition of 0.5 wt.% created the optimum performance when compared to pure PC and PC CNF 1.0 wt.% nanocomposite material.

Sustainable Additive Manufacturing: Mechanical Response of Polyethylene Terephthalate Glycol over Multiple Recycling Processes

The continuous demand for thermoplastic polymers in a great variety of applications, combined with an urgent need to minimize the quantity of waste for a balanced energy-from-waste strategy, has led to increasing scientific interest in developing new recycling processes for plastic products. Glycol-modified polyethylene terephthalate (PETG) is known to have some enhanced properties as compared to polyethylene terephthalate (PET) homopolymer; this has recently attracted the interest from the fused filament fabrication (FFF) three-dimensional (3D) printing community. PET has shown a reduced ability for repeated recycling through traditional processes. Herein, we demonstrate the potential for using recycled PETG in consecutive 3D printing manufacturing processes. Distributed recycling additive manufacturing (DRAM)-oriented equipment was chosen in order to test the mechanical and thermal response of PETG material in continuous recycling processes. Tensile, flexure, impact strength, and Vickers micro-hardness tests were carried out for six (6) cycles of recycling. Finally, Raman spectroscopy as well as thermal and morphological analyses via scanning electron microscopy (SEM) fractography were carried out. In general, the results revealed a minor knockdown effect on the mechanical properties as well as the thermal properties of PETG following the process proposed herein, even after six rounds of recycling.