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

Amza Amza,Björnsdóttir Björnsdóttir,Zapciu Zapciu,Borg Borg,Eyþórsdóttir Eyþórsdóttir

doi:10.3390/polym11111825

Amza Amza, Björnsdóttir Björnsdóttir + Show 3 more

Open Access

https://doi.org/10.3390/polym11111825

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Abstract

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.

Highlights

Since 2009, when patents held by the American company, Stratasys, on fused deposition modeling 3D printing started to expire, this additive manufacturing (AM) process has seen extensive implementation under the recognized name of material extrusion 3D printing (ME3DP)
It was observed that ultra-high-molecular-weight polyethylene (UHMWPE) fibers of 0.16 mm diameter will melt after a pass of the extrusion nozzle at a 45◦ angle when extrusion temperature was above 186 ◦ C
This research aimed at investigating whether ultra-high-molecular-weight polyethylene fibers can be successfully embedded in a thermoplastic matrix during a material extrusion 3D printing process

Summary

Introduction

Since 2009, when patents held by the American company, Stratasys, on fused deposition modeling 3D printing started to expire, this additive manufacturing (AM) process has seen extensive implementation under the recognized name of material extrusion 3D printing (ME3DP). ME3DP is a process where parts are fabricated by depositing layers of material one on top of another, with each layer being made by extruding thermoplastic feedstock that comes in the form of filament or pellets along a predetermined path. The first layer is printed onto a platform which moves in the horizontal plane relative to the extruder. Upon finalizing the first horizontal layer, the extruder moves relative to the platform in a perpendicular direction and proceeds to deposit the horizontal layer.

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