Polymer Composites Based on Glycol-Modified Poly(Ethylene Terephthalate) Applied to Additive Manufacturing Using Melted and Extruded Manufacturing Technology (original) (raw)
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As part of the present work, polymer composites used in 3D printing technology, especially in Melted and Extruded Manufacturing (MEM) technology, were obtained. The influence of modified fillers such as alumina modified silica, quaternary ammonium bentonite, lignin/silicon dioxide hybrid filler and unmodified multiwalled carbon nanotubes on the properties of polycarbonate (PC) composites was investigated. In the first part of the work, the polymer and its composites containing 0.5–3 wt.% filler were used to obtain a filament using the proprietary technological line. The moldings for testing functional properties were obtained with the use of 3D printing and injection molding techniques. In the next part of the work, the rheological properties—mass flow rate (MFR) and mechanical properties—Rockwell hardness, Charpy impact strength and static tensile strength with Young’s modulus were examined. The structure of the obtained composites was also described and determined using scanning e...
International Journal of Scientific Research in Engineering and Management (IJSREM), 2023
Material extrusion (ME) or Fused deposition modeling (FDM) is one of the additive manufacturing methods in which the thermoplastic material is heated to the extrusion temperature and then extruded by the nozzle to add layer upon layer to prepare a three-dimensional part. The quality and mechanical properties of the material extruded 3D printed part depends on the selection of process parameter and material used to print any part. So, in the present study, the effect of an individual process parameter such as infill pattern, extrusion temperature and raster angle on the tensile strength of polyethylene terephthalate glycol (PETG) material is observed. It is a thermoplastic material with low cost and higher strength than other polymers. Tensile specimens are 3D printed as per the ASTM standard D638 with different combinations of parameters using the design of experiments and tested using a universal testing machine (UTM). As the outcome of this study, it is observed that the tensile strength increases with an increase in all the selected process parameters. Further, the rectilinear pattern, 240 0C extrusion temperature and 0/+450 raster angle is found to be the optimal set of parameter while the extrusion temperature is obtained as the most influencing parameter using Analysis of Variance (ANOVA).
Poly(ethylene terephthalate) Powder—A Versatile Material for Additive Manufacturing
Polymers, 2019
The 3D printing of articles by the effect of a directed laser beam on a plastic powder is a demanding process, and unlike injection molding, very few polymers work well enough with it. Recently, we reported that poly(ethylene terephthalate) (PET) powder has intrinsically good properties for 3D printing. Basic mechanical properties were shown earlier and it was demonstrated that unfused but heat-exposed PET powder does not degrade quickly allowing good re-use potential. In this work, we conducted a detailed comparison of the mechanical properties of PET and polyamide 12 from different build orientations. PET powders with two different molecular weights were used. With the high molecular weight powder, the processing parameters were optimized, and the printed bars showed little difference between the different orientations, which means there is low anisotropy in mechanical properties of built parts. Based on processing experience of the first powder, the second powder with a lower mol...
2019
Bio-material polylactic acid and poly(butylene adipate-co-terephthalate) were blended to achieve increased ductility of the blend. Cloisite was added to improve the stiffness of the blend. The blends were made into filament suitable for extrusion-based additive manufacturing. Melt flow index of the filament and mechanical properties of the printed bars were tested. Preliminary results showed that the melt flow index increases significantly with cloisite and the modulus of polylactic acid/poly(butylene adipate-co-terephthalate) improved slightly. The notched impact strength of the blend increased with increasing content of cloisite, and it increased significantly after annealing, especially for blends without cloisite.
3D Printing of Polyethylene Terephthalate GlycolSepiolite Composites with Nanoscale Orientation
A fused-deposition modeling (FDM) 3D-printed polyethylene terephthalate glycol (PETG)−sepiolite composite showed effective synergetic mechanical reinforcement in tensile testing compared to an injection-molded composite. The results showed that the addition of 3 phr sepiolite improved the tensile strength of 3D-printed PETG samples by 35.4%, while the tensile strength of injection-molded PETG samples was improved by 7.2%. To confirm these phenomena, FDM PETG−sepiolite composites were investigated by small-angle X-ray scattering to correlate the nanostructures of the composites with their mechanical strengths. The small-angle X-ray scattering data and transmission electron microscopy observations demonstrated that needle-shaped sepiolite particles were aligned in the printing direction. This fine oriented nanostructure formed during 3D printing created a synergistic effect that improved the material properties of the composite. These novel PETG−sepiolite composites with enhanced mechanical properties can be promising materials fabricated via FDM 3D printing.
FDM 3D Printing of Polymers Containing Natural Fillers: A Review of their Mechanical Properties
Polymers
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...
Natural and Synthetic Polymer Fillers for Applications in 3D Printing—FDM Technology Area
Solids
This publication summarises the current state of knowledge and technology on the possibilities and limitations of using mineral and synthetic fillers in the field of 3D printing of thermoplastics. FDM technology can be perceived as a miniaturised variation of conventional extrusion processing (a microextrusion process). However, scaling the process down has an undoubtful drawback of significantly reducing the extrudate diameter (often by a factor of ≈20–30). Therefore, the results produced under conventional extrusion processing cannot be simply translated to processes run with the application of FDM technology. With that in mind, discussing the latest findings in composite materials preparation and application in FDM 3D printing was necessary.
Polymers
Polyethylene terephthalate glycol (PETG) is a thermoplastic formed by polyethylene terephthalate (PET) and ethylene glycol and known for his high impact resistance and ductility. The printability of PETG for fused deposition modelling (FDM) is studied by monitoring the filament temperature using an infra-red camera. The microstructural arrangement of 3D printed PETG is analysed by means of X-ray micro-tomography and tensile performance is investigated in a wide range of printing temperatures from 210 °C to 255 °C. A finite element model is implemented based on 3D microstructure of the printed material to reveal the deformation mechanisms and the role of the microstructural defects on the mechanical performance. The results show that PETG can be printed within a limited range of printing temperatures. The results suggest a significant loss of the mechanical performance due to the FDM processing and particularly a substantial reduction of the elongation at break is observed. The loss ...
Polymers
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...