Comparing mechanical properties of impact modified polypropylene-copolymer (IMPP) from injection molding (IM) and fused layer modeling (FLM) processes

Abstract

Purpose The purpose of this study was to produce dimensionally accurate and reliable fused layer modeling (FLM) feedstock composed of an impact modified polypropylene matrix, compounded with a cellulose nanofiber (CNF) reinforcement and coupled by a maleic anhydride coupling agent to produce comparable mechanical properties in comparison to the industry-standard method of injection molding (IM). Design/methodology/approach A spray dried CNF (SDCNF) was compounded with the polymer matrix using a masterbatch method. The composite was diluted with neat polymer and extruded into a filament and then printed into standardized mechanical testing samples. For comparison, the filament was chopped and standardized samples were produced with IM. Findings A loss in mechanical properties of up to 30% was observed in FLM samples. If normalized to reflect improved density from a part consolidation method, losses are reduced to 15% or show improvements in the neat polymer matrix. Originality/value Limited research has been done on producing FLM feedstock, reporting mechanical property results based on standardized testing and comparing the same material with IM.