Manufacturing of ABS/expanded perlite filament for 3D printing of lightweight components through fused deposition modeling

Abstract

3D printing constitutes a revolutionary technology that experiences continuously expanding applicability to numerous industrial sections. However, the predefined physicochemical, thermal and mechanical properties of existing thermoplastic filaments set strong limitations to the application of 3D printing manufacturing method for the production of functional components with specific properties for demanding applications.In the current study, we investigate the use of expanded perlite microspheres as filler for the production of ABS composite filament through extrusion procedure, and the use of composite filament for printing of dog bone samples on a commercial 3d printer. Various types of composite filaments were produced in terms of expanded perlite granulometry (-90 μm, −212 + 90 μm, −355 + 212 μm and −500 + 355 μm) in different amounts (10, 20 and 40% v/v). The evaluation of the filaments and printed dog bone samples was performed through morphological observation and tensile strength testing. It was shown that only fine expanded perlite grades survived the extrusion procedure, while printing procedure was adversely affected when the filament content in filler exceeded 20% v/v, and printed specimens present defects. When filament content in filler was up to 20% v/v, well-formed dog bone samples of acceptable quality were printed. In these cases, the ultimate strength of dog bone samples was found comparable to the control specimens (ABS only).The results of the current study highlighted the importance of the granulometry and crushing resistance of the lightweight filler towards the successful preparation of composite filament through extrusion process. The use of expanded perlite microspheres is expected to improve the performance of the filler in the specific application, allowing the production of well-formed filament that can be used for 3d printing of lightweight and thermal insulating components for the construction sector.