scholarly journals Development and Characterization of a 3D Printed Cocoa Bean Shell Filled Recycled Polypropylene for Sustainable Composites

Polymers ◽  
2021 ◽  
Vol 13 (18) ◽  
pp. 3162
Author(s):  
Maria A. Morales ◽  
Alejandro Maranon ◽  
Camilo Hernandez ◽  
Alicia Porras
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Failure Mechanisms ◽  
Industrial Wastes ◽  
Cocoa Bean ◽  
Recycled Polypropylene ◽  
Raster Angle ◽  
3D Printed ◽  
Natural Filler

Natural filler-based composites are an environmentally friendly and potentially sustainable alternative to synthetic or plastic counterparts. Recycling polymers and using agro-industrial wastes are measures that help to achieve a circular economy. Thus, this work presents the development and characterization of a 3D printing filament based on recycled polypropylene and cocoa bean shells, which has not been explored yet. The obtained composites were thermally and physically characterized. In addition, the warping effect, mechanical, and morphological analyses were performed on 3D printed specimens. Thermal analysis exhibited decreased thermal stability when cacao bean shell (CBS) particles were added due to their lignocellulosic content. A reduction in both melting enthalpy and crystallinity percentage was identified. This is caused by the increase in the amorphous structures present in the hemicellulose and lignin of the CBS. Mechanical tests showed high dependence of the mechanical properties on the 3D printing raster angle. Tensile strength increased when a raster angle of 0° was used, compared to specimens printed at 90°, due to the load direction. Tensile strength and fracture strain were improved with CBS addition in specimens printed at 90°, and better bonding between adjacent layers was achieved. Electron microscope images identified particle fracture, filler-matrix debonding, and matrix breakage as the central failure mechanisms. These failure mechanisms are attributed to the poor interfacial bonding between the CBS particles and the matrix, which reduced the tensile properties of specimens printed at 0°. On the other hand, the printing process showed that cocoa bean shell particles reduced by 67% the characteristic warping effect of recycled polypropylene during 3D printing, which is advantageous for 3D printing applications of the rPP. Thereby, potential sustainable natural filler composite filaments for 3D printing applications with low density and low cost can be developed, adding value to agro-industrial and plastic wastes.

scholarly journals Embedding Ultra-High-Molecular-Weight Polyethylene Fibers in 3D-Printed Polylactic Acid (PLA) Parts

Polymers ◽  
2019 ◽  
Vol 11 (11) ◽  
pp. 1825 ◽  
Author(s):  
Amza ◽  
Zapciu ◽  
Eyþórsdóttir ◽  
Björnsdóttir ◽  
Borg
Keyword(s):  
Molecular Weight ◽  
Tensile Strength ◽  
3D Printing ◽  
High Molecular Weight ◽  
Polylactic Acid ◽  
Strength Tests ◽  
Raster Angle ◽  
Uhmwpe Fibers ◽  
3D Printed ◽  
Ultra High Molecular Weight

This study aims to assess whether ultra-high-molecular-weight polyethylene (UHMWPE) fibers can be successfully embedded in a polylactic acid (PLA) matrix in a material extrusion 3D printing (ME3DP) process, despite the apparent thermal incompatibility between the two materials. The work started with assessing the maximum PLA extrusion temperatures at which UHMWPE fibers withstand the 3D printing process without melting or severe degradation. After testing various fiber orientations and extrusion temperatures, it has been found that the maximum extrusion temperature depends on fiber orientation relative to extrusion pathing and varies between 175 °C and 185 °C at an ambient temperature of 25 °C. Multiple specimens with embedded strands of UHMWPE fibers have been 3D printed and following tensile strength tests on the fabricated specimens, it has been found that adding even a small number of fiber strands laid in the same direction as the load increased tensile strength by 12% to 23% depending on the raster angle, even when taking into account the decrease in tensile strength due to reduced performance of the PLA substrate caused by lower extrusion temperatures.

scholarly journals The Direct 3D Printing of Functional PEEK/Hydroxyapatite Composites via a Fused Filament Fabrication Approach

Polymers ◽  
2021 ◽  
Vol 13 (4) ◽  
pp. 545
Author(s):  
Krzysztof Rodzeń ◽  
Preetam K. Sharma ◽  
Alistair McIlhagger ◽  
Mozaffar Mokhtari ◽  
Foram Dave ◽  
...  
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Selective Laser Sintering ◽  
Fused Filament Fabrication ◽  
Bone Apposition ◽  
Innovative Solutions ◽  
3D Printed ◽  
Work Samples ◽  
Viable Approach ◽  
Crystalline Domains

The manufacture of polyetheretherketone/hydroxyapatite (PEEK/HA) composites is seen as a viable approach to help enhance direct bone apposition in orthopaedic implants. A range of methods have been used to produce composites, including Selective Laser Sintering and injection moulding. Such techniques have drawbacks and lack flexibility to manufacture complex, custom-designed implants. 3D printing gets around many of the restraints and provides new opportunities for innovative solutions that are structurally suited to meet the needs of the patient. This work reports the direct 3D printing of extruded PEEK/HA composite filaments via a Fused Filament Fabrication (FFF) approach. In this work samples are 3D printed by a custom modified commercial printer Ultimaker 2+ (UM2+). SEM-EDX and µCT analyses show that HA particles are evenly distributed throughout the bulk and across the surface of the native 3D printed samples, with XRD highlighting up to 50% crystallinity and crystalline domains clearly observed in SEM and HR-TEM analyses. This highlights the favourable temperature conditions during 3D printing. The yield stress and ultimate tensile strength obtained for all the samples are comparable to human femoral cortical bone. The results show how FFF 3D printing of PEEK/HA composites up to 30 wt% HA can be achieved.

Additive technology applied to the realization of K-band microwave terminations: reproducibility improvement

2018 ◽  
Vol 10 (1) ◽  
pp. 3-8
Author(s):  
Azar Maalouf ◽  
Ronan Gingat ◽  
Vincent Laur
Keyword(s):  
3D Printing ◽  
Frequency Band ◽  
Rectangular Waveguide ◽  
Three Dimensional ◽  
Low Density ◽  
Support Material ◽  
Additive Technology ◽  
3D Printed ◽  
K Band

This study examines K-band rectangular waveguide terminations with three-dimensional (3D)-printed loads, and proposes an Asymmetrical Tapered Wedge topology. This geometry shows a good tradeoff between microwave performance and 3D-printing issues (printing directions and support material requirements), thus improving noticeably the reproducibility of the devices. The effect of the density of the 3D-printed load on the reflection parameter of the termination was investigated. Even for a low density, reflection level remained below −27.5 dB between 18 and 26.5 GHz. Reproducibility was demonstrated by the characterization of six loads that were 3D printed under the same conditions. Measurements demonstrate that a maximum reflection parameter level of −33.5 dB can be ensured over the whole frequency band without any post-machining of the 3D-printed devices.

Patterned Magnetorheological Elastomer Developed by 3D Printing

2018 ◽  
Vol 939 ◽  
pp. 147-152 ◽  
Author(s):  
Anil K. Bastola ◽  
Milan Paudel ◽  
Lin Li
Keyword(s):  
Magnetic Field ◽  
3D Printing ◽  
Magnetic Particles ◽  
Layer By Layer ◽  
Carrier Fluid ◽  
Vibration Technique ◽  
Mode Of Operation ◽  
3D Printed ◽  
Mr Effect

This article delineates the characterization of the 3D printed MR elastomer through a forced vibration technique in the squeeze mode of operation. An anisotropic hybrid magnetorheological (MR) elastomer is developed via 3D printing. The 3D printed MR elastomer consists of three different materials; magnetic particles, magnetic particles carrier fluid, and an elastomer. MR fluid filaments are encapsulated layer-by-layer within the elastomer matrix using a 3D printer. When a moderately strong magnetic field is applied, the 3D printed MR elastomer changes its elastic and damping properties. The hybrid 3D printed MR elastomer also shows an anisotropic behavior when the direction of the magnetic field is changed with respect to the orientation of the printed filaments. The relative MR effect is higher when the applied magnetic field is parallel to the orientation of the printed filaments. The maximum change in the stiffness is observed to be 65.2% when a magnetic field of 500 mT is applied to the MR elastomer system. This result shows that the new method, 3D printing could produce anisotropic hybrid MR elastomers or possibly other types.

scholarly journals Design and characterization of a 3D-printed staggered herringbone mixer

BioTechniques ◽  
2021 ◽  
Author(s):  
Vedika J Shenoy ◽  
Chelsea ER Edwards ◽  
Matthew E Helgeson ◽  
Megan T Valentine
Keyword(s):  
3D Printing ◽  
High Throughput ◽  
Low Cost ◽  
Microfluidic Devices ◽  
Device Design ◽  
Replica Molding ◽  
3D Printed ◽  
And Performance ◽  
To Receive

3D printing holds potential as a faster, cheaper alternative compared with traditional photolithography for the fabrication of microfluidic devices by replica molding. However, the influence of printing resolution and quality on device design and performance has yet to receive detailed study. Here, we investigate the use of 3D-printed molds to create staggered herringbone mixers (SHMs) with feature sizes ranging from ∼100 to 500 μm. We provide guidelines for printer calibration to ensure accurate printing at these length scales and quantify the impacts of print variability on SHM performance. We show that SHMs produced by 3D printing generate well-mixed output streams across devices with variable heights and defects, demonstrating that 3D printing is suitable and advantageous for low-cost, high-throughput SHM manufacturing.

scholarly journals The Impact of Defects on Tensile Strength and Modulus of 3D Printed Parts Manufactured by Fused deposition Modeling

2021 ◽  
Author(s):  
Mobina Movahedi
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Research Work ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
3D Printed ◽  
The Impact ◽  
Printing Direction

Additive manufacturing (AM), 3D printing, is defined as a process of depositing materials layer by layer to create three-dimensional printed models, as opposed to subtractive manufacturing methodologies. It has the potential of revolutionizing field of manufacturing, which allows us to create more complex geometries with lower cost and faster speed in comparison to injection molding, compression forming, and forging. Therefore, 3D printing can shorten the design manufacturing cycle, reduce the production cost, and increase the competitiveness. Due to the improvements of processes and advancements of modeling and design, Fused Deposition Modeling (FDM) technologies, a common 3D printing technique, have been involved in wide various applications in the past three decades and numerous studies have been gathered. This research work studies directional properties of FDM 3D printed thermoplastic parts per ASTM D638. Tensile strength and modulus of the coupons along and perpendicular to the printing direction are evaluated. It is observed that FDM 3D printing introduces anisotropic behavior to the manufactured part, e.g. tensile strength of 57.7 and 30.8 MPa for loading along and perpendicular to the printing direction, respectively. FDM 3D printers are not ideal and introduce defects into the manufactured parts, e.g. in the form of missing material, gap. This study investigates the impact of gaps on tensile strength and modulus of 3D printed parts. A maximum reduction of 20% in strength is found for a gap (missing bead) along the loading direction.

scholarly journals The Impact of Defects on Tensile Strength and Modulus of 3D Printed Parts Manufactured by Fused deposition Modeling

2021 ◽  
Author(s):  
Mobina Movahedi
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Fused Deposition Modeling ◽  
Research Work ◽  
Layer By Layer ◽  
Fused Deposition ◽  
Deposition Modeling ◽  
3D Printed ◽  
The Impact ◽  
Printing Direction

Additive manufacturing (AM), 3D printing, is defined as a process of depositing materials layer by layer to create three-dimensional printed models, as opposed to subtractive manufacturing methodologies. It has the potential of revolutionizing field of manufacturing, which allows us to create more complex geometries with lower cost and faster speed in comparison to injection molding, compression forming, and forging. Therefore, 3D printing can shorten the design manufacturing cycle, reduce the production cost, and increase the competitiveness. Due to the improvements of processes and advancements of modeling and design, Fused Deposition Modeling (FDM) technologies, a common 3D printing technique, have been involved in wide various applications in the past three decades and numerous studies have been gathered. This research work studies directional properties of FDM 3D printed thermoplastic parts per ASTM D638. Tensile strength and modulus of the coupons along and perpendicular to the printing direction are evaluated. It is observed that FDM 3D printing introduces anisotropic behavior to the manufactured part, e.g. tensile strength of 57.7 and 30.8 MPa for loading along and perpendicular to the printing direction, respectively. FDM 3D printers are not ideal and introduce defects into the manufactured parts, e.g. in the form of missing material, gap. This study investigates the impact of gaps on tensile strength and modulus of 3D printed parts. A maximum reduction of 20% in strength is found for a gap (missing bead) along the loading direction.

scholarly journals Mechanical properties comparison of PLA, tough PLA and PC 3D printed materials with infill structure – Influence of infill pattern on tensile mechanical properties

2021 ◽  
Vol 1208 (1) ◽  
pp. 012019
Author(s):  
Adi Pandzic ◽  
Damir Hodzic
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Elastic Modulus ◽  
3D Printing ◽  
Material Testing ◽  
Fused Deposition Modelling ◽  
Fused Deposition ◽  
3D Printed ◽  
Printed Materials ◽  
Product Weight

Abstract One of the advantages provided by fused deposition modelling (FDM) 3D printing technology is the manufacturing of product materials with infill structure, which provides advantages such as reduced production time, product weight and even the final price. In this paper, the tensile mechanical properties, tensile strength and elastic modulus, of PLA, Tough PLA and PC FDM 3D printed materials with the infill structure were analysed and compared. Also, the influence of infill pattern on tensile properties was analysed. Material testing were performed according to ISO 527-2 standard. All results are statistically analysed and results showed that infill pattern have influence on tensile mechanical properties for all three materials.

scholarly journals Evaluation of the Mechanical Properties of Porous Thermoplastic Polyurethane Obtained by 3D Printing for Protective Gear

2019 ◽  
Vol 2019 ◽  
pp. 1-10 ◽  
Author(s):  
Hyojeong Lee ◽  
Ran-i Eom ◽  
Yejin Lee
Keyword(s):  
Tensile Strength ◽  
3D Printing ◽  
Thermoplastic Polyurethane ◽  
Three Dimensional ◽  
Protective Equipment ◽  
Shock Absorption ◽  
Protective Gear ◽  
Compression Properties ◽  
Impact Deformation ◽  
3D Printed

Three-dimensional (3D) printing is an efficient and sustainable technology useful in various manufacturing fields. The aim of this study was to investigate the applicability of thermoplastic polyurethane (TPU) as a 3D printing material and the conditions related to the use of TPU as personal protective equipment. The tensile strength, shock absorption, and compressibility were evaluated for different infill and thickness conditions. An increase in the infill rate led to an increase in the tensile strength, regardless of the sample thickness. Similarly, the compression energy increased as the infill increased. Both the shock absorption and compression properties increased as the thickness decreased under identical infill conditions. The actual shock absorption test data were compared to the results of structural analyses, which confirmed the potential for predicting impact deformation through the analysis of the tensile characteristics and the basic properties of a 3D printed material.

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