On mechanical and surface properties of electro-active polymer matrix-based 3D printed functionally graded prototypes

2020 ◽  
pp. 089270572090767 ◽  
Author(s):  
Ravinder Sharma ◽  
Rupinder Singh ◽  
Ajay Batish
Keyword(s):  
3D Printing ◽  
Mechanical Testing ◽  
Surface Properties ◽  
Polymer Matrix ◽  
Mechanical Performance ◽  
Surface Hardness ◽  
Functionally Graded ◽  
Density Level ◽  
Fused Deposition ◽  
3D Printed

This research article reports the mechanical and surface properties of 3D printed electro-active polymer (EAP) matrix-based functionally graded prototypes with fused deposition modeling. The standard tensile specimens (per ASTM D-638-type IV) have been 3D printed using in-house developed feedstock filament. The EAP, polyvinyl diene fluoride (PVDF)-based matrix, has been used with the reinforcement of barium titanate (BT) and graphene (Gr) in this study. The fixed proportion of the polymer matrix composite comprising PVDF (78 wt%) + Gr (2 wt%) + BT (20 wt%) has been selected for 3D printing of smart polymer matrix. The results of mechanical testing suggested that the 3D printing of parts performed at 50 mm/s infill speed; infill angle of 45° at maximum density level (100%) has shown better mechanical strength (peak strength 42.98 MPa and break strength 40.70 MPa). The result of surface hardness has shown strong correlation with observed tensile properties. The microphotographs of fractured surfaces revealed that the parts fabricated at highest density have minimum porosity, resulting into better mechanical performance as compared to parts fabricated at lower density level. Further the results of mechanical testing have been supported by 3D rendered images and surface roughness profile.

Multimaterial printing and characterization for mechanical and surface properties of functionally graded prototype

2019 ◽  
Vol 233 (19-20) ◽  
pp. 6741-6753 ◽  
Author(s):  
Sudhir Kumar ◽  
Rupinder Singh ◽  
TP Singh ◽  
Ajay Batish
Keyword(s):  
Polylactic Acid ◽  
Surface Properties ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Three Dimensional ◽  
Surface Hardness ◽  
Functionally Graded ◽  
Three Dimensional Printing ◽  
Fused Deposition ◽  
Dimensional Printing

In this work, an effort has been made for multimaterial three-dimensional printing of functionally graded prototypes of polylactic acid matrix (tensile specimens as per ASTM D638 type IV) followed by characterization of mechanical and surface properties. The work is an extension of previous reported studies on twin-screw extrusion process for the preparation of multimaterial wires as feedstock filaments in possible three-dimensional printing applications. The results of the study suggest that the highest peak strength (46.28 MPa) and break strength (41.65 MPa) was obtained for multimaterial three-dimensional printed samples at infill density 100%, infill angle 45°, and infill speed of 90 mm/s on commercial open source fused deposition modeling setup. Further surface hardness measurements performed on two extreme surfaces (top surface comprising magnetite (Fe3O4)-reinforced polylactic acid and bottom with polylactic acid without any reinforcement) revealed that the hardness for the bottom layer was more than the hardness for the top layer. From fractured surface analysis (using photomicrographs), it has been observed that the three-dimensional printed samples with low infill density resulted into more void formation due to which the performance while mechanical testing was poor in comparison to samples printed with higher infill density. The results are also supported by rendered images of photomicrographs, which revealed that high roughness value of samples printed with low infill density was also one of the reasons for poor mechanical performance of multimaterial three-dimensional printed functionally graded prototypes.

Use of polymer concrete for large-scale 3D printing

2021 ◽  
Vol 27 (3) ◽  
pp. 465-474
Author(s):  
Martin Krčma ◽  
David Škaroupka ◽  
Petr Vosynek ◽  
Tomáš Zikmund ◽  
Jozef Kaiser ◽  
...  
Keyword(s):  
3D Printing ◽  
Large Scale ◽  
Mechanical Performance ◽  
Construction Material ◽  
Polymer Concrete ◽  
Fused Deposition Modelling ◽  
Cast State ◽  
Content Type ◽  
Fused Deposition ◽  
3D Printed

Purpose This paper aims to focus on the evaluation of a polymer concrete as a three-dimensional (3D) printing material. An associated company has developed plastic concrete made from reused unrecyclable plastic waste. Its intended use is as a construction material. Design/methodology/approach The concrete mix, called PolyBet, composed of polypropylene and glass sand, is printed by the fused deposition modelling process. The process of material and parameter selection is described. The mechanical properties of the filled material were compared to its cast state. Samples were made from castings and two different orientations of 3D-printed parts. Three-point flex tests were carried out, and the area of the break was examined. Computed tomography of the samples was carried out. Findings The influence of the 3D printing process on the material was evaluated. The mechanical performance of the longitudinal samples was close to the cast state. There was a difference in the failure mode between the states, with cast parts exhibiting a tougher behaviour, with fractures propagating in a stair-like manner. The 3D-printed samples exhibited high degrees of porosity. Originality/value The results suggest that the novel material is a good fit for 3D printing, with little to no degradation caused by the process. Layer adhesion was shown to be excellent, with negligible effect on the finished part for the longitudinal orientation. That means, if large-scale testing of buildability is successful, the material is a good fit for additive manufacturing of building components and other large-scale structures.

scholarly journals 3D-Printable PP/SEBS Thermoplastic Elastomeric Blends: Preparation and Properties

Polymers ◽  
2019 ◽  
Vol 11 (2) ◽  
pp. 347 ◽  
Author(s):  
Shib Banerjee ◽  
Stephen Burbine ◽  
Nischay Kodihalli Shivaprakash ◽  
Joey Mead
Keyword(s):  
3D Printing ◽  
Carbon Black ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Polymeric Materials ◽  
Fused Deposition ◽  
3D Printed ◽  
Injection Molded ◽  
Preferential Location

Currently, material extrusion 3D printing (ME3DP) based on fused deposition modeling (FDM) is considered a highly adaptable and efficient additive manufacturing technique to develop components with complex geometries using computer-aided design. While the 3D printing process for a number of thermoplastic materials using FDM technology has been well demonstrated, there still exists a significant challenge to develop new polymeric materials compatible with ME3DP. The present work reports the development of ME3DP compatible thermoplastic elastomeric (TPE) materials from polypropylene (PP) and styrene-(ethylene-butylene)-styrene (SEBS) block copolymers using a straightforward blending approach, which enables the creation of tailorable materials. Properties of the 3D printed TPEs were compared with traditional injection molded samples. The tensile strength and Young’s modulus of the 3D printed sample were lower than the injection molded samples. However, no significant differences could be found in the melt rheological properties at higher frequency ranges or in the dynamic mechanical behavior. The phase morphologies of the 3D printed and injection molded TPEs were correlated with their respective properties. Reinforcing carbon black was used to increase the mechanical performance of the 3D printed TPE, and the balancing of thermoplastic elastomeric and mechanical properties were achieved at a lower carbon black loading. The preferential location of carbon black in the blend phases was theoretically predicted from wetting parameters. This study was made in order to get an insight to the relationship between morphology and properties of the ME3DP compatible PP/SEBS blends.

Magnetic Field-Assisted 3D Printing of Limpet Teeth Inspired Polymer Matrix Composite With Compression Reinforcement

2021 ◽  
Vol 144 (4) ◽  
Author(s):  
Dylan Joralmon ◽  
Evangeline Amonoo ◽  
Yizhen Zhu ◽  
Xiangjia Li
Keyword(s):  
Magnetic Field ◽  
3D Printing ◽  
Polymer Matrix ◽  
Mechanical Performance ◽  
Polymer Matrix Composites ◽  
Cost Effective ◽  
Industrial Applications ◽  
Mechanical Reinforcement ◽  
3D Printed ◽  
Geometric Morphology

Abstract Lightweight and cost-effective polymer matrix composites (PMCs) with extraordinary mechanical performance will be a key to the next generation of diverse industrial applications, such as aerospace, electric automobile, and biomedical devices. Limpet teeth made of mineral-polymer composites have been proved as nature’s strongest material due to the unique hierarchical architectures of mineral fiber alignment. Here, we present an approach to build limpet teeth inspired structural materials with precise control of geometric morphologies of microstructures by magnetic field-assisted 3D printing (MF-3DP). α-Iron (III) oxide-hydroxide nanoparticles (α-FeOOHs) are aligned by the magnetic field during 3D printing and aligned α-FeOOHs (aFeOOHs) bundles are further grown to aligned goethite-based bundles (aGBs) by rapid thermal treatment after printing. The mechanical reinforcement of aGBs in PMCs can be modulated by adjusting the geometric morphology and alignment of α-FeOOHs encapsulated inside the 3D printed PMCs. In order to identify the mechanical enhancement mechanism, physics-based modeling, simulation, and tests were conducted, and the results further guided the design of bioinspired goethite-based PMCs. The correlation of the geometric morphology of self-assembled α-FeOOHs, curing characteristics of α-FeOOHs/polymer composite, and process parameters were identified to establish the optimal design of goethite-based PMCs. The 3D printed PMCs with aGBs show promising mechanical reinforcement compared with PMCs without aGBs. This study opens intriguing perspectives for designing high strength 3D printed PMCs on the basis of bioinspired architectures with customized configurations.

An Experimental Investigation of the Effects of Gamma Radiation on 3D Printed ABS for In-Space Manufacturing Purposes

2016 ◽  
Author(s):  
Behzad Rankouhi ◽  
Fereidoon Delfanian ◽  
Robert McTaggart ◽  
Todd Letcher
Keyword(s):  
Mechanical Properties ◽  
Fused Deposition Modeling ◽  
Mechanical Performance ◽  
Space Station ◽  
Surface Hardness ◽  
Low Earth Orbit ◽  
Radiation Environment ◽  
Control Group ◽  
Fused Deposition ◽  
3D Printed

The following work is presented as a preliminary study on the effects of gamma irradiation on mechanical properties of Acrylonitrile Butadiene Styrene (ABS) as an in-space 3D printing feedstock to investigate the forthcoming possibilities of this technology for future space exploration missions. 3D printed testing samples were irradiated at different dosages from 1 to 1400 kGy (1 Gray (Gy) = 1 J/kg = 100 rad) using a Cobalt-60 gamma irradiator to simulate space radiation environment. Testing samples were manufactured using Fused Deposition Modeling (FDM) with a Makerbot Replicator 2x 3D printer. The correlation between the mechanical properties of irradiated samples and accumulated radiation dosage were evaluated by a series of tensile and flexural tests. Furthermore, Shore hardness tests were conducted to evaluate changes in surface hardness of irradiated parts. Finally, results were compared with a control group of samples. Findings showed a significant decrease in mechanical performance and noticeable changes in appearance of the parts with accumulated dosage of 1000 kGy and higher. However, for dosages below 10 kGy, samples showed no significant decrease in mechanical performance or change in appearance. These results were used to predict the life of a 3D printed part on board the International Space Station (ISS), on Low Earth Orbit (LEO) satellites, in deep space and long duration missions.

Magnetic Field Assisted 3D Printing of Limpet Teeth Inspired Polymer Matrix Composite With Compression Reinforcement

2021 ◽  
Author(s):  
Dylan Joralmon ◽  
Evangeline Amonoo ◽  
Yizhen Zhu ◽  
Xiangjia Li
Keyword(s):  
Magnetic Field ◽  
3D Printing ◽  
Polymer Matrix ◽  
Mechanical Performance ◽  
Polymer Matrix Composites ◽  
Cost Effective ◽  
Industrial Applications ◽  
Mechanical Reinforcement ◽  
3D Printed ◽  
Geometric Morphology

Abstract Lightweight and cost-effective polymer matrix composites (PMCs) with extraordinary mechanical performance will be a key to the next generation of diverse industrial applications such as aerospace, electric automobile, and biomedical devices. Limpet teeth made of mineral-polymer composites have been proved as nature’s strongest material due to the unique hierarchical architectures of mineral fiber alignment. Here, we present an approach to build limpet teeth inspired structural materials with precise control of geometric morphologies of microstructures by magnetic field-assisted 3D printing (MF-3DP). α-Iron (III) oxide-hydroxide nanoparticles (α-FeOOHs) are aligned by the magnetic field during 3D printing and aligned α-FeOOHs bundles are further grown to aligned goethite-based bundles (aGBs) by rapid thermal treatment after printing. The mechanical reinforcement of goethite-based fillers in PMCs can be modulated by adjusting the geometric morphology and alignment of mineral particles encapsulated inside the 3D printed PMCs. In order to identify the mechanical enhancement mechanism, physics-based modeling, simulation, and tests were conducted and the results further guided the design of bioinspired goethite-based PMCs. The correlation of the geometric morphology of self-assembled α-FeOOHs, curing characteristics of α-FeOOHs/polymer composite, and process parameters were identified to establish the optimal design of goethite-based PMCs. The 3D-printed PMCs with aGBs show promising mechanical reinforcement. This study opens intriguing perspectives for designing high strength 3D printed PMCs on the basis of bioinspired architectures with customized configurations.

Investigations on 3D printed thermosetting and ceramic-reinforced recycled thermoplastic-based functional prototypes

2019 ◽  
pp. 089270571986462 ◽  
Author(s):  
Rupinder Singh ◽  
Ranvijay Kumar ◽  
Inderpreet Singh
Keyword(s):  
Mechanical Properties ◽  
3D Printing ◽  
Surface Hardness ◽  
Acrylonitrile Butadiene Styrene ◽  
Experimental Investigations ◽  
Fused Deposition Modelling ◽  
Ceramic Particles ◽  
Fused Deposition ◽  
Thermoplastic Matrix ◽  
3D Printed

The 3D printing of thermoplastic polymers (both virgin and reinforced with metal/ceramic particles) has been widely explored in recent past with fused deposition modelling (FDM) process. But hitherto very little has been reported on 3D printing of thermoplastics polymers with reinforcement of thermosetting polymers and ceramic particles. This article is an extension of work reported on thermo-mechanical investigations on waste thermosetting polymer bakelite and ceramic (silicon carbide and aluminium oxide) as reinforcement in recycled acrylonitrile butadiene styrene (ABS) thermoplastic matrix for sustainability. The study reports the experimental investigations on mechanical (tensile), morphological, surface hardness and thermal stability analysis of 3D printed functional prototype as tensile specimen (as per ASTM D 638). In the present case study, it has been ascertained that composition/proportion of thermoplastic matrix has a significant role in controlling the mechanical properties, whereas other input process parameters of FDM are insignificant. The results of the study suggest that thermosetting and ceramic-reinforced ABS thermoplastic-based 3D printed parts have mechanical properties at par with unreinforced ABS.

scholarly journals Evaluation of Tensile Properties and Damage of Continuous Fibre Reinforced 3D-Printed Parts

2018 ◽  
Vol 774 ◽  
pp. 161-166 ◽  
Author(s):  
Octavio Andrés González-Estrada ◽  
Alberto Pertuz ◽  
Jabid E. Quiroga Mendez
Keyword(s):  
3D Printing ◽  
Tensile Properties ◽  
Mechanical Performance ◽  
Volume Fraction ◽  
Three Dimensional ◽  
Tensile Tests ◽  
Fused Deposition Modelling ◽  
Printing Process ◽  
Fused Deposition ◽  
3D Printed

Three-dimensional (3D) printing technology has been traditionally used for the production of prototypes. Recently, developments in 3D printing using Fused Deposition Modelling (FDM) and reinforcement with continuous fibres (fiberglass and carbon fibre), have allowed the manufacture of functional prototypes, considerably improving the mechanical performance of the composite parts. In this work, we characterise the elastic tensile properties of fibre reinforced specimens, considering the variation of several parameters available during the printing process: fibre orientation, volume fraction, fill pattern, reinforcement distribution. Tensile tests were performed according to ASTM D638 to obtain Young’s modulus and ultimate strength for different material configurations available during the printing process. We also perform a fractographic analysis using Scanning Electron Microscopy (SEM) to give an insight of the failure mechanisms present in the specimens.

scholarly journals 3D Printing On-Water Sports Boards with Bio-Inspired Core Designs

Polymers ◽  
2020 ◽  
Vol 12 (1) ◽  
pp. 250 ◽  
Author(s):  
Aref Soltani ◽  
Reza Noroozi ◽  
Mahdi Bodaghi ◽  
Ali Zolfagharian ◽  
Reza Hedayati
Keyword(s):  
3D Printing ◽  
Fused Deposition Modeling ◽  
Performance Enhancement ◽  
Close Relation ◽  
Honeycomb Structure ◽  
Functionally Graded ◽  
Core Structure ◽  
Fused Deposition ◽  
3D Printed ◽  
Water Sports

Modeling and analyzing the sports equipment for injury prevention, reduction in cost, and performance enhancement have gained considerable attention in the sports engineering community. In this regard, the structure study of on-water sports board (surfboard, kiteboard, and skimboard) is vital due to its close relation with environmental and human health as well as performance and safety of the board. The aim of this paper is to advance the on-water sports board through various bio-inspired core structure designs such as honeycomb, spiderweb, pinecone, and carbon atom configuration fabricated by three-dimensional (3D) printing technology. Fused deposition modeling was employed to fabricate complex structures from polylactic acid (PLA) materials. A 3D-printed sample board with a uniform honeycomb structure was designed, 3D printed, and tested under three-point bending conditions. A geometrically linear analytical method was developed for the honeycomb core structure using the energy method and considering the equivalent section for honeycombs. A geometrically non-linear finite element method based on the ABAQUS software was also employed to simulate the boards with various core designs. Experiments were conducted to verify the analytical and numerical results. After validation, various patterns were simulated, and it was found that bio-inspired functionally graded honeycomb structure had the best bending performance. Due to the absence of similar designs and results in the literature, this paper is expected to advance the state of the art of on-water sports boards and provide designers with structures that could enhance the performance of sports equipment.

Biodegradable 3D Printed Polymer Microneedles for Transdermal Drug Delivery

2018 ◽  
Author(s):  
Michael A. Luzuriaga ◽  
Danielle R. Berry ◽  
John C. Reagan ◽  
Ronald A. Smaldone ◽  
Jeremiah J. Gassensmith
Keyword(s):  
Drug Delivery ◽  
3D Printing ◽  
Transdermal Drug Delivery ◽  
Fused Deposition Modeling ◽  
Fused Deposition ◽  
Modeling Software ◽  
Deposition Modeling ◽  
3D Printed ◽  
Microfabrication Technique ◽  
Mechanical Strengths

Biodegradable polymer microneedle (MN) arrays are an emerging class of transdermal drug delivery devices that promise a painless and sanitary alternative to syringes; however, prototyping bespoke needle architectures is expensive and requires production of new master templates. Here, we present a new microfabrication technique for MNs using fused deposition modeling (FDM) 3D printing using polylactic acid, an FDA approved, renewable, biodegradable, thermoplastic material. We show how this natural degradability can be exploited to overcome a key challenge of FDM 3D printing, in particular the low resolution of these printers. We improved the feature size of the printed parts significantly by developing a post fabrication chemical etching protocol, which allowed us to access tip sizes as small as 1 μm. With 3D modeling software, various MN shapes were designed and printed rapidly with custom needle density, length, and shape. Scanning electron microscopy confirmed that our method resulted in needle tip sizes in the range of 1 – 55 µm, which could successfully penetrate and break off into porcine skin. We have also shown that these MNs have comparable mechanical strengths to currently fabricated MNs and we further demonstrated how the swellability of PLA can be exploited to load small molecule drugs and how its degradability in skin can release those small molecules over time.

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