Important Criteria for Preparation of 3D Printer Filaments from Polymer Biocomposites (original) (raw)
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In this work, an extrusion-based 3D printing technique was employed for processing of biobased blends of Poly(Lactic Acid) (PLA) with low-cost kraft lignin. In Fused Filament Fabrication (FFF) 3D printing process, objects are built in a layer-by-layer fashion by melting, extruding and selectively depositing thermoplastic fibers on a platform. These fibers are used as building blocks for more complex structures with defined microarchitecture, in an automated, cost-effective process, with minimum material waste. A sustainable material consisting of lignin biopolymer blended with poly(lactic acid) was examined for its physical properties and for its melt processability during the FFF process. Samples with different PLA/lignin weight ratios were prepared and their mechanical (tensile testing), thermal (Differential Scanning Calorimetry analysis) and morphological (optical and scanning electron microscopy, SEM) properties were studied. The composition with optimum properties was selected for the production of 3D-printing filament. Three process parameters, which contribute to shear rate and stress imposed on the melt, were examined: extrusion temperature, printing speed and fiber's width varied and their effect on extrudates' morphology was evaluated. The mechanical properties of 3D printed specimens were assessed with tensile testing and SEM fractography.
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As biodegradable thermoplastics are more and more penetrating the market of filaments for fused deposition modeling (FDM) 3D printing, fillers in the form of natural fibers are convenient: They have the clear advantage of reducing cost, yet retaining the filament biodegradability characteristics. In plastics that are processed through standard techniques (e.g., extrusion or injection molding), natural fibers have a mild reinforcing function, improving stiffness and strength, it is thus interesting to evaluate whether the same holds true also in the case of FDM produced components. The results analyzed in this review show that the mechanical properties of the most common materials, i.e., acrylonitrile-butadiene-styrene (ABS) and PLA, do not benefit from biofillers, while other less widely used polymers, such as the polyolefins, are found to become more performant. Much research has been devoted to studying the effect of additive formulation and processing parameters on the mechanical...
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In recent times, the issue of plastic recycling has become one of the leading issues of environmental protection and waste management. Polymer materials have been found an application in many areas of daily life and industry. Along with their extended use, the problem of plastic wastes appeared because, after withdrawal from use, they became persistent and noxious wastes. The possibility of reusing polymeric materials gives a possibility of valorization—a second life—and enables effective waste utilization to obtain consumable products. The 3D printing market is a well-growing sector. Printable filaments can be made from a variety of thermoplastic materials, including those from recycling. This paper focuses on a review of the available literature on the production of filaments for 3D printers from recycled polymers as the alternative to present approach of central selective collection of plastics. The possibility of recycling of basic thermoplastic materials and the impact of proce...
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Biodegradable and bio-based polymers have raised great attention since sustainable development policies tend to become more and more important with the growing concern for the environment and the decreasing reserve of fossil fuel [1]. The increasing demand for environmentally friendly materials attracted the attention on biopolymers reinforced with cellulose, that is a virtually inexhaustible source of raw material [2] and on new manufacturing ways such as additive manufacturing (AM) [3]. The most diffused AM technology for polymers is Fused Deposition Modelling (FDM), a technique where a filament of thermoplastic polymer is extruded through a nozzle and deposited layer by layer to form the final object with the support of computer aided design. The aim of this work is the development of different kind of thermoplastic biodegradable composites based on commercially available polymers reinforced with cellulose and to study their applicability in fused deposition modeling (FDM). The f...
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The 3D printing technology is a method of converting proposed complex geometric shapes into solid models. One of these methods is the FDM (fused deposition modeling) printing technology as a considerably affordable and the most commonly used method in the world. The purpose of this study is to obtain FDM 3D printer filaments that are as natural as possible, resembling wood and evoking the sensation of wood upon touching through deployment of bio-based plastics and additives. Polylactic acid (PLA) and bio thermoplastic polyurethane (TPU) were used as matrices, and lignin and Arboform, a lignin-based biomaterial, were used as additives. The characteristics of composites achieved through addition of 10% lignin and Arboform to matrices were identified by differential scanning calorimetry (DSC) thermogravimetric analysis (TGA), scanning electron microscopy (SEM), and the tensile test. The effects of some printing parameters on the mechanical characteristics were also determined. Lignin i...
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In the last years, the excessive use of plastic and other synthetic materials, that are generally difficult to dispose of, has caused growing ecological worries. These are contributing to redirecting the world’s attention to sustainable materials and a circular economy (CE) approach using recycling routes. In this work, bio-filaments for the Fused Filament Fabrication (FFF) 3D printing technique were produced from recycled polylactic acid (PLA) and artisanal ceramic waste by an extrusion process and fully characterized from a physical, thermal, and mechanical point of view. The data showed different morphological, thermal, rheological, and mechanical properties of the two produced filaments. Furthermore, the 3D objects produced from the 100% recycled PLA filament showed lower mechanical performance. However, the results have demonstrated that all the produced filaments can be used in a low-cost FFF commercial printer that has been modified with simple hand-made operations in order t...
Cleaner Materials , 2024
The biodegradable natural polymers and fibers could be suggested to revolutionize 3D printing as sustainable, biocompatible, and unique properties in the print matrix for different applications. This review article covers the natural polymers in the form of cellulose, alginate, starch, collagen, silk, chitosan, and gelatin as printing constituent. Furthermore, it includes various natural fibers such as hemp, jute, flax, and bamboo with unique characteristics and advantages in 3D printing. Reinforcements derived from nature have provided better tensile strength, moduli, and flexural properties when infused into polymer matrices, such as PLA, ABS, and PP. Extrusion-based methods, comprising Fused Deposition Modeling (FDM)/Fused Filament Fabrication (FFF), are the most applied techniques of 3D printing for natural-polymer and fiber composites with a principal application in the medical and industrial domains. The future of natural polymers and fibers in 3D printing is becoming very promising despite uniform printability, interfacial adhesion, and mechanical property-related issues. Research in optimizing material composition, processing parameters, and post-processing techniques goes apace to attain the required properties, functionality, and performance. This review provides an outline to researchers and engineers working on 3D printing on the immense potential associated with biodegradable natural polymers and fibers for designing innovative, sustainable, and high-performance products in various applications that contribute to a greener and more sustainable future.
Implementing FDM 3D Printing Strategies Using Natural Fibers to Produce Biomass Composite
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Current environmental concerns have led to a search of more environmentally friendly manufacturing methods; thus, natural fibers have gained attention in the 3D printing industry to be used as bio-filters along with thermoplastics. The utilization of natural fibers is very convenient as they are easily available, cost-effective, eco-friendly, and biodegradable. Using natural fibers rather than synthetic fibers in the production of the 3D printing filaments will reduce gas emissions associated with the production of the synthetic fibers that would add to the current pollution problem. As a matter of fact, natural fibers have a reinforcing effect on plastics. This review analyzes how the properties of the different polymers vary when natural fibers processed to produce filaments for 3D Printing are added. The results of using natural fibers for 3D Printing are presented in this study and appeared to be satisfactory, while a few studies have reported some issues.
Polymers, 2021
Nowadays the use of natural fiber composites has gained significant interest due to their low density, high availability, and low cost. The present study explores the development of sustainable 3D printing filaments based on rice husk (RH), an agricultural residue, and recycled polypropylene (rPP) and the influence of fiber weight ratio on physical, thermal, mechanical, and morphological properties of 3D printing parts. Thermogravimetric analysis revealed that the composite’s degradation process started earlier than for the neat rPP due to the lignocellulosic fiber components. Mechanical tests showed that tensile strength increased when using a raster angle of 0° than specimens printed at 90°, due to the weaker inter-layer bonding compared to in-layer. Furthermore, inter layer bonding tensile strength was similar for all tested materials. Scanning electron microscope (SEM) images revealed the limited interaction between the untreated fiber and matrix, which led to reduced tensile pr...