Polymer Composites Based on Polycarbonate (PC) Applied to Additive Manufacturing Using Melted and Extruded Manufacturing (MEM) Technology.

Teofil Jesionowski,Katarzyna Bulanda,Jacek Fal,Łukasz Przeszłowski,Rafał Oliwa,Grzegorz Budzik,Mariusz Oleksy

doi:10.3390/polym13152455

Abstract

As part of the present work, polymer composites used in 3D printing technology, especially in Melted and Extruded Manufacturing (MEM) technology, were obtained. The influence of modified fillers such as alumina modified silica, quaternary ammonium bentonite, lignin/silicon dioxide hybrid filler and unmodified multiwalled carbon nanotubes on the properties of polycarbonate (PC) composites was investigated. In the first part of the work, the polymer and its composites containing 0.5–3 wt.% filler were used to obtain a filament using the proprietary technological line. The moldings for testing functional properties were obtained with the use of 3D printing and injection molding techniques. In the next part of the work, the rheological properties—mass flow rate (MFR) and mechanical properties—Rockwell hardness, Charpy impact strength and static tensile strength with Young’s modulus were examined. The structure of the obtained composites was also described and determined using scanning electron microscopy (SEM). The porosity, roughness and dimensional stability of samples obtained by 3D printing were also determined. On the other hand, the physicochemical properties were presented on the basis of the research results using thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), wide angle X-ray scattering analysis (WAXS) and Fourier Transform infrared spectroscopy (FT-IR). Additionally, the electrical conductivity of the obtained composites was investigated. On the basis of the obtained results, it was found that both the amount and the type of filler significantly affected the functional properties of the composites tested in the study.

Highlights

The Melted and Extruded Manufacturing (MEM) technology is an extrusion method in which structures and models are obtained from filaments composed of thermoplastic polymers, including acrylonitrile-butadiene-styrene (ABS), polylactide (PLA), poly(ethylene terephthalate) (PET), polyamides (PA) and polycarbonates (PC) [7]
The mass flow rate (MFR) index is important for the analysis of the rheological flow properties of the polymer because it significantly affects the properties of the process of obtaining specimens for functional tests [27]
The investigation was performed at a constant temperature of 20 °C for samples in the form of disks 20 mm in diameter

Summary

Introduction

The Melted and Extruded Manufacturing (MEM) technology is an extrusion method in which structures and models are obtained from filaments composed of thermoplastic polymers, including acrylonitrile-butadiene-styrene (ABS), polylactide (PLA), poly(ethylene terephthalate) (PET), polyamides (PA) and polycarbonates (PC) [7]. The resulting thermoplastic parts have poorer mechanical properties compared to traditional manufacturing methods such as injection molding [7] These limitations prompted researchers to develop various types of solutions that will allow obtaining MEM parts with increased strength [7,9]. The authors of [15] presented the possibility of obtaining composites based on poly(ethylene terephthalate)/polycarbonate (GPET/PC) copolymer intended for 3D printing. The introduced fillers were selected to improve the processing properties of PC, including the thermal stability and flowability, while maintaining good mechanical properties of the polymer. The composites obtained in this way will be used for the production of selected machine elements, such as low-power gears in the technology of rapid prototyping and injection molding

Materials

Preparation of the Composite

Sample Preparation

Characterization

Results and Discussion

12. WAXS patterns:

Conclusions