Abstract
Fused deposition modelling (FDM) is a filament-based rapid prototyping technology that allows new composite materials to be introduced into the FDM process as long as they can be manufactured in feedstock filament form. The purpose of this research was to analyze the rheological behavior of oil palm fiber-reinforced acrylonitrile butadiene styrene (ABS) composites when used as a feedstock material, as well as to determine the best processing conditions for FDM. The composite’s shear thinning behavior was observed, and scanning electron microscopy was used to reveal its composition. The morphological result found that there was a good fiber/matrix adhesion with a 3 wt% fiber loading, as no fiber pullouts or gaps developed between the oil palm fiber and ABS. However, some pores and fiber pullouts were found with a 5 and 7 wt% fiber loading. Next, the rheological results showed that the increment of fiber content (wt%) increased the viscosity. This discovery can definitely be used in the extrusion process for making wire filament for FDM. The shear thinning effect was increased by adding 3, 5, or 7 wt% of oil palm fiber. The non-Newtonian index (n) of the composites increased as the number of shear rates increased, indicating that the fiber loading had a significant impact on the rheological behavior. As the fiber loading increased, the viscosity and shear stress values increased as well. As a result, oil fiber reinforced polymer composites can be used as a feedstock filament for FDM.
Highlights
Rheology tests were successfully performed for the oil palm fiber/acrylonitrile butadiene styrene (ABS) composites with compositions of 0, 3, 5, and 7 wt% at three different die temperatures: 220, 230, and 240 ◦ C
The recommended die temperature for the oil palm composite is 240 ◦ C. This temperature setting was critical for the following step in the fabrication of a wire filament for Fused deposition modelling (FDM) using the extrusion technique
Rheological tests on the oil palm fiber composite samples were carried out using a capillary rheometer to investigate their rheological behaviors through a capillary die
Summary
Additive manufacturing (AM), known as three-dimensional (3D) printing, has gradually gained traction in the manufacturing industry [1,2,3]. It can be utilized to print intricately shaped metallic, polymer, and composite items with a great design flexibility. By. 2020, the market for AM products and services was estimated to exceed $5 billion [4]. FDM is a wire-filament-based method that is frequently used to create functional parts [5,6,7,8,9,10,11]. The impact of the material qualities and mechanical properties of printed parts is critical for their further expansion into FDM. The filament wire is fed into the print head, which allows
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