Extrusion 3D Printing of Polybutyrate-Adipate-Terephthalate-Polymer Composites in the Pellet Form

Fused deposition modelling is a common 3D printing technique used for the freeform fabrication of complex shapes based on polymers. Acrylonitrile butadiene styrene (ABS) is the common material option, though polylactide (PLA) has also proved to be a successful candidate. There is an ever increasing demand to harness new materials as possible candidates for fused deposition. The current research is focused on evaluating polybutyrate-adipate-terephthalate–polymer (PBAT) for fused deposition modelling. Both neat and composite PBAT filled with varying wood flour fillers were experimentally analyzed for 3D printing by extrusion from the pellet forms. The results are positive and the addition of small quantities of the wood flour filler material was found to improve the thixotropic nature of the polymer composite and consequently the inter-strand and inter-layer coalescence.

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Modelling and Investigation of Crack Growth for 3D-Printed Acrylonitrile Butadiene Styrene (ABS) with Various Printing Parameters and Ambient Temperatures

Polymers ◽

10.3390/polym13213737 ◽

2021 ◽

Vol 13 (21) ◽

pp. 3737

Author(s):

Yousef Lafi A. Alshammari ◽

Feiyang He ◽

Muhammad A. Khan

Keyword(s):

3D Printing ◽

Crack Growth ◽

Three Dimensional ◽

Acrylonitrile Butadiene Styrene ◽

Fused Deposition Modelling ◽

Structural Dynamic ◽

Fused Deposition ◽

Nozzle Size ◽

Printing Parameters ◽

Butadiene Styrene

Three-dimensional (3D) printing is one of the significant industrial manufacturing methods in the modern era. Many materials are used for 3D printing; however, as the most used material in fused deposition modelling (FDM) technology, acrylonitrile butadiene styrene (ABS) offers good mechanical properties. It is perfect for making structures for industrial applications in complex environments. Three-dimensional printing parameters, including building orientation, layers thickness, and nozzle size, critically affect the crack growth in FDM structures under complex loads. Therefore, this paper used the dynamic bending vibration test to investigate their influence on fatigue crack growth (FCG) rate under dynamic loads and the Paris power law constant C and m. The paper proposed an analytical solution to determine the stress intensity factor (SIF) at the crack tip based on the measurement of structural dynamic response. The experimental results show that the lower ambient temperature, as well as increased nozzle size and layer thickness, provide a lower FCG rate. The printing orientation, which is the same as loading, also slows the crack growth. The linear regression between these parameters and Paris Law’s coefficient also proves the same conclusion.

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Optimization of Abs 3D-Printing Method and Parameters

European Journal of Engineering Science and Technology ◽

10.33422/ejest.v3i1.160 ◽

1970 ◽

Vol 3 (1) ◽

pp. 44-51

Author(s):

Paweł Żur ◽

Alicja Kołodziej ◽

Andrzej Baier ◽

Grzegorz Kokot

Keyword(s):

3D Printing ◽

Tensile Test ◽

Acrylonitrile Butadiene Styrene ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

Electric Car ◽

University Of Technology ◽

Static Tensile ◽

3D Printed ◽

Printing Method

The paper presents research on the method of 3D-printing ABS (Acrylonitrile butadiene styrene). Series of specimens were 3D-printed in FDM (Fused Deposition Modelling) technology with variable parameters. The influence of the following parameters has been checked: temperature of printing and infill density. Moreover, the material properties of raw, unprocessed ABS have been inspected. The tensile strength of specimens and Young’s modulus have been determined in a static tensile test. Tests were carried out in compliance with the ASTM D638-14 standard. Obtained results were then compared with the material datasheet. Optimum printing method has been defined. The carried out research resulted in optimizing the printing method for ABS vehicle parts applied in Silesian Greenpower electric car. The car has been developed by students of The Silesian University of Technology in Gliwice, Poland as an interfaculty students’ project. Results of the tensile test research have been analysed and discussed and conclusions have been presented in the following article.

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

Journal of Thermoplastic Composite Materials ◽

10.1177/0892705719864623 ◽

2019 ◽

pp. 089270571986462 ◽

Cited By ~ 9

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.

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Application of Fused Deposition Modelling (FDM) Method of 3D Printing in Drug Delivery

Current Pharmaceutical Design ◽

10.2174/1381612822666161026162707 ◽

2017 ◽

Vol 23 (3) ◽

pp. 433-439 ◽

Cited By ~ 48

Author(s):

Jingjunjiao Long ◽

Hamideh Gholizadeh ◽

Jun Lu ◽

Craig Bunt ◽

Ali Seyfoddin

Keyword(s):

Drug Delivery ◽

3D Printing ◽

Low Cost ◽

Three Dimensional ◽

Fused Deposition Modelling ◽

Layer By Layer ◽

Fused Deposition ◽

Accurate Dose ◽

Drug Delivery Devices ◽

3D Printing Technique

Three-dimensional (3D) printing is an emerging manufacturing technology for biomedical and pharmaceutical applications. Fused deposition modelling (FDM) is a low cost extrusion-based 3D printing technique that can deposit materials layer-by-layer to create solid geometries. This review article aims to provide an overview of FDM based 3D printing application in developing new drug delivery systems. The principle methodology, suitable polymers and important parameters in FDM technology and its applications in fabrication of personalised tablets and drug delivery devices are discussed in this review. FDM based 3D printing is a novel and versatile manufacturing technique for creating customised drug delivery devices that contain accurate dose of medicine( s) and provide controlled drug released profiles.

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Evaluation of a rapid prototyping application for stomas

Rapid Prototyping Journal ◽

10.1108/rpj-07-2019-0181 ◽

2020 ◽

Vol 26 (9) ◽

pp. 1525-1533 ◽

Cited By ~ 1

Author(s):

Jose Manuel Sierra ◽

Jose Ignacio Rodríguez ◽

Marta María Villazon ◽

Jose Luis Cortizo ◽

Maria del Rocio Fernandez

Keyword(s):

3D Printing ◽

Acrylonitrile Butadiene Styrene ◽

Experimental Tests ◽

Fused Deposition Modelling ◽

Static Loads ◽

Content Type ◽

Fused Deposition ◽

Collection Device ◽

Low Costs ◽

Butadiene Styrene

Purpose This paper aims to describe the development of an internal waste-collection device for patients who have undergone a colostomy or ileostomy. Its design is based on devices that have been produced by 3D printing with acrylonitrile butadiene styrene. The aim is to find an alternative to the external bags that these patients currently use and to evaluate the properties of the device produced by additive manufacturing. Design/methodology/approach Software for solid modelling has been used, and virtual models allow its visualization and animation, for evaluation, in a simple and fast way. Subsequently, functional prototypes have been developed by a multidisciplinary team, which includes surgeons and engineers, and have been tested to verify their mechanical properties and suitability for function. Findings The project has developed a functional design that has been patented and is in the clinical trials phase. This study demonstrates how 3D printing technologies are the perfect complement to accelerate the design process and build functional prototypes at low costs. The experimental tests regarding cytotoxicity, printing orientation, dynamic and static loads and temperature resistance have demonstrated the validity of the proposed device. Originality/value A device for internal pouch in colostomized patients has been designed, manufactured by fused deposition modelling and validated.

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Influence of Part Orientation on the Surface Roughness in the Process of Fused Deposition Modeling

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.896.29 ◽

2021 ◽

Vol 896 ◽

pp. 29-37

Author(s):

Ján Milde ◽

František Jurina ◽

Jozef Peterka ◽

Patrik Dobrovszký ◽

Jakub Hrbál ◽

...

Keyword(s):

Surface Roughness ◽

3D Printing ◽

Fused Deposition Modeling ◽

Orientation Angle ◽

Acrylonitrile Butadiene Styrene ◽

Lower Surface ◽

Geometrical Model ◽

Fused Deposition ◽

Deposition Modeling ◽

Part Orientation

The article focused on the influence of part orientation on the surface roughness of cuboid parts during the process of fabricating by FDM technology. The components, in this case, is simple cuboid part with the dimensions 15 mm x 15mm x 30 mm. A geometrical model is defined that considers the shape of the material filaments after deposition, to define a theoretical roughness profile, for a certain print orientation angle. Five different print orientations in the X-axis of the cuboid part were set: 0°, 30°, 45°, 60°, and 90°. According to previous research in the field of FDM technology by the author, the internal structure (infill) was set at the value of 70%. The method of 3D printing was the Fused Deposition Modeling (FDM) and the material used in this research was thermoplastic ABS (Acrylonitrile butadiene styrene). For each setting, there were five specimens (twenty five prints in total). Prints were fabricated on a Zortrax M200 3D printer. After the 3D printing, the surface “A” was investigated by portable surface roughness tester Mitutoyo SJ-210. Surface roughness in the article is shown in the form of graphs (Fig.7). Results show increase in part roughness with increasing degree of part orientation. When the direction of applied layers on the measured surface was horizontal, significant improvement in surface roughness was observed. Findings in this paper can be taken into consideration when designing parts, as they can contribute in achieving lower surface roughness values.

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Printing with mechanically interlocked extrudates using a custom bi-extruder for fused deposition modelling

Rapid Prototyping Journal ◽

10.1108/rpj-03-2017-0046 ◽

2018 ◽

Vol 24 (6) ◽

pp. 921-934 ◽

Cited By ~ 8

Author(s):

Mohammad Abu Hasan Khondoker ◽

Asad Asad ◽

Dan Sameoto

Keyword(s):

Cross Sections ◽

Acrylonitrile Butadiene Styrene ◽

Easy Access ◽

Fused Deposition Modelling ◽

Content Type ◽

Immiscible Polymers ◽

Fused Deposition ◽

Functionally Gradient ◽

Different Sources ◽

Butadiene Styrene

Purpose This paper aims to target to print functionally gradient materials (FGM) devices made of immiscible polymers in multi-material fused deposition modelling (FDM) systems. The design is intended to improve adhesion of dissimilar thermoplastics without the need for chemical compatibilization so that filaments from many different sources can be used effectively. Therefore, there is a need to invent an alternative solution for printing multiple immiscible polymers in an FDM system with the desired adhesion. Design/methodology/approach In this study, the authors have developed a bi-extruder for FDM systems which can print two thermoplastics through a single nozzle with a static intermixer to enhance bonding between input materials. The system can also change the composition of extrudates continuously. Findings The uniqueness of this extruder is in its easy access to the internal channel so that a static intermixer can be inserted, enabling deposition of mechanically interlocked extrudates composed of two immiscible polymers. Without this intermixer, the bi-extruder extrudes with simple side-by-side co-extrusion having no mechanical interlocking. The bi-extruder was characterized by printing objects using pairs of materials including polylactic acid, acrylonitrile butadiene styrene and high impact polystyrene. Microscope images of the cross-sections of the extrudates confirm the ability of this bi-extruder to control the composition as desired. It was also found that the mechanically interlocked extrudates composed of two immiscible polymers substantially reduces adhesion failures within and between filaments. Originality/value In this study, the first-ever FDM extruder with a mechanical blending feature next to the nozzle has been designed and used to successfully print FGM objects with improved mechanical properties.

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The Influence of Manufacturing Parameters on the Mechanical Behaviour of PLA and ABS Pieces Manufactured by FDM: A Comparative Analysis

Materials ◽

10.3390/ma11081333 ◽

2018 ◽

Vol 11 (8) ◽

pp. 1333 ◽

Cited By ~ 63

Author(s):

Adrián Rodríguez-Panes ◽

Juan Claver ◽

Ana Camacho

Keyword(s):

Tensile Strength ◽

Mechanical Behaviour ◽

Mechanical Performance ◽

Acrylonitrile Butadiene Styrene ◽

Polymer Materials ◽

Fused Deposition Modelling ◽

Fused Deposition ◽

Layer Orientation ◽

Lower Variability

This paper presents a comparative study of the tensile mechanical behaviour of pieces produced using the Fused Deposition Modelling (FDM) additive manufacturing technique with respect to the two types of thermoplastic material most widely used in this technique: polylactide (PLA) and acrylonitrile butadiene styrene (ABS). The aim of this study is to compare the effect of layer height, infill density, and layer orientation on the mechanical performance of PLA and ABS test specimens. The variables under study here are tensile yield stress, tensile strength, nominal strain at break, and modulus of elasticity. The results obtained with ABS show a lower variability than those obtained with PLA. In general, the infill percentage is the manufacturing parameter of greatest influence on the results, although the effect is more noticeable in PLA than in ABS. The test specimens manufactured using PLA perform more rigidly and they are found to have greater tensile strength than ABS. The bond between layers in PLA turns out to be extremely strong and is, therefore, highly suitable for use in additive technologies. The methodology proposed is a reference of interest in studies involving the determination of mechanical properties of polymer materials manufactured using these technologies.

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Advanced Pharmaceutical Applications of Hot-Melt Extrusion Coupled with Fused Deposition Modelling (FDM) 3D Printing for Personalised Drug Delivery

Pharmaceutics ◽

10.3390/pharmaceutics10040203 ◽

2018 ◽

Vol 10 (4) ◽

pp. 203 ◽

Cited By ~ 63

Author(s):

Deck Tan ◽

Mohammed Maniruzzaman ◽

Ali Nokhodchi

Keyword(s):

3D Printing ◽

Hot Melt Extrusion ◽

Pharmaceutical Products ◽

Fused Deposition Modelling ◽

Melt Extrusion ◽

3D Object ◽

3D Printing Technology ◽

Fused Deposition ◽

Pharmaceutical Applications ◽

Hot Melt

Three-dimensional printing, also known as additive manufacturing, is a fabrication process whereby a 3D object is created layer-by-layer by depositing a feedstock material such as thermoplastic polymer. The 3D printing technology has been widely used for rapid prototyping and its interest as a fabrication method has grown significantly across many disciplines. The most common 3D printing technology is called the Fused Deposition Modelling (FDM) which utilises thermoplastic filaments as a starting material, then extrudes the material in sequential layers above its melting temperature to create a 3D object. These filaments can be fabricated using the Hot-Melt Extrusion (HME) technology. The advantage of using HME to manufacture polymer filaments for FDM printing is that a homogenous solid dispersion of two or more pharmaceutical excipients i.e., polymers can be made and a thermostable drug can even be introduced in the filament composition, which is otherwise impractical with any other techniques. By introducing HME techniques for 3D printing filament development can improve the bioavailability and solubility of drugs as well as sustain the drug release for a prolonged period of time. The latter is of particular interest when medical implants are considered via 3D printing. In recent years, there has been increasing interest in implementing a continuous manufacturing method on pharmaceutical products development and manufacture, in order to ensure high quality and efficacy with less batch-to-batch variations of the pharmaceutical products. The HME and FDM technology can be combined into one integrated continuous processing platform. This article reviews the working principle of Hot Melt Extrusion and Fused Deposition Modelling, and how these two technologies can be combined for the use of advanced pharmaceutical applications.

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3D Printing of Thermo-Sensitive Drugs

Pharmaceutics ◽

10.3390/pharmaceutics13091524 ◽

2021 ◽

Vol 13 (9) ◽

pp. 1524

Author(s):

Sadikalmahdi Abdella ◽

Souha H. Youssef ◽

Franklin Afinjuomo ◽

Yunmei Song ◽

Paris Fouladian ◽

...

Keyword(s):

3D Printing ◽

Three Dimensional ◽

Fused Deposition Modelling ◽

Future Directions ◽

Digital Light Processing ◽

Fused Deposition ◽

Printing Technique ◽

3D Printed ◽

Semi Solid ◽

Selection Of

Three-dimensional (3D) printing is among the rapidly evolving technologies with applications in many sectors. The pharmaceutical industry is no exception, and the approval of the first 3D-printed tablet (Spiratam®) marked a revolution in the field. Several studies reported the fabrication of different dosage forms using a range of 3D printing techniques. Thermosensitive drugs compose a considerable segment of available medications in the market requiring strict temperature control during processing to ensure their efficacy and safety. Heating involved in some of the 3D printing technologies raises concerns regarding the feasibility of the techniques for printing thermolabile drugs. Studies reported that semi-solid extrusion (SSE) is the commonly used printing technique to fabricate thermosensitive drugs. Digital light processing (DLP), binder jetting (BJ), and stereolithography (SLA) can also be used for the fabrication of thermosensitive drugs as they do not involve heating elements. Nonetheless, degradation of some drugs by light source used in the techniques was reported. Interestingly, fused deposition modelling (FDM) coupled with filling techniques offered protection against thermal degradation. Concepts such as selection of low melting point polymers, adjustment of printing parameters, and coupling of more than one printing technique were exploited in printing thermosensitive drugs. This systematic review presents challenges, 3DP procedures, and future directions of 3D printing of thermo-sensitive formulations.

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