Printing Filament Research Articles

Stabilizer Effects on the Gelation of Modified Recycled PET for 3D Printing Filament Application

This research identification gel types of the modified-recycled poly (ethylene terephthalate) (modified-rPET) filament, with and without the addition of heat stabilizer Pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate (Irganox®1010). This research also identifies the gel types and studies thermal behavior of the modified-rPET filaments above, by using a hot-stage microscopy, and a differential scanning calorimetry, respectively. rPET flakes were dried to deplete the moisture. Then, they were mixed with additives and heat stabilizer (Irganox®1010) at 0 and 0.5 pph, Then, they were extruded to be compound using twin screw extruder. The compounds were extruded into filament by using filament extruder. The two temperature profiles were used. The first and the second temperature profiles from the feed zone to the die zone were 275-275-275 oC and 290-290-290 oC, respectively. The extrudate of modified-rPET with and without heat stabilizer, were investigated the type of gel and the thermal behavior of the modified-rPET filament. From this preliminary experiment, it was found that the “unmelt-gel” defect was found from the modified-rPET filament, without the addition of Irganox®1010. On the other hand, the “crosslinked gel” defect was found from the modified-rPET filament, with the addition of Irganox®1010. Therefore, the addition of heat stabilizer (Irganox®1010) may cause the “crosslinked gel” significantly. Our future work, we will investigate the effect of another stabilizer and chain extenders on the gelation behavior, to complete this clarification systematically.

Modification of chain extension and crosslinking structures of recycled polyester textile for 3D printing filament

AbstractThe increase in amount of polyester textile waste is contributing to the severity of environmental pollution because polyester cannot be easily recycled. To reduce the limits of its recyclability, a value‐added recycling approach should be explored. This work introduces an approach for recycling polyester textiles into 3D printable filaments. To increase recyclability of polyester textiles, the polyester materials are modified by ADR4468 additive. After the polyester is 3D printed, the sample with 1.0 wt% of ADR4468 shows the highest tensile and compressive strength properties compared with 1.5 and 2.0 wt%, owing to its fewer voids between the printed lines, a fish scale‐like morphology that spreads out, and a higher degree of crystallization. Moreover, the mechanism of modification suggests that ADR4468 extends and crosslinks the polyester chains by ring‐opening reactions of epoxy groups of ADR4468 and forms sea‐island structures. The sea‐island structures of bonded polyester branched cores with tangled polyester shell interface areas and unbonded polyester chain areas performed suitable rheological behaviors to recycle polyester textiles for 3D printable filaments production. The filaments can be used to replace commercially available filaments, offer a sustainable option for consumers, and impact both the polyester textile‐related recycling and 3D printing industries.Highlights An approach is proposed to recycle polyester textiles for 3D printing filament The approach uses a mechanical method to recycle polyester textiles Recycled polyesters were modified by ADR4468 to form core‐shell structures Core‐shell structures were separated by short polyesters(sea‐island structure) The structures met rheological behaviors for 3D printing filament

Pyramid-like magnetic carbon composites device toward tunable and adaptive radar-visible compatible properties

Equipped with intelligent adjustable electromagnetic-visible light compatibility characteristics is of significant importance in military stealth fields. In this work, a tunable microwave absorption and visible light change metamaterial based on polylactic acid (PLA) thermal stimulation was fabricated using 4D printing technology with hydroxylated carbon nanotubes (CNTOH) and carbonyl iron powder (CIP) as active ingredients. The printing filament was synthesized, which exhibited excellent absorption performance with a bandwidth of 5.83 GHz and sufficient shape recovery ability. On this basis, a temperature-dominated shape memory variation cone device was also manufactured and the visible light color-changing coating was sprayed. The microwave absorption performance is adjusted according to the petal angle, achieving a bandwidth variation of 5.9–9.8 GHz. This work confirms the potential exploratory value of the designed shape memory polymer in the field of microwave absorption, and provides unlimited possibilities for designing intelligent controlled stealth materials.

Comparative study of blending techniques in polylactic acid/cellulose nanofibrils green composites for benchtop 3D printing filaments

AbstractAdditive manufacturing for polylactic acid (PLA) reinforced with cellulose nanofibrils (CNF) could unlock fabrication of specialized and user‐specific biomedical devices. However, the process of combining PLA and CNF is challenging and proves complicated with possible irreversible CNF agglomeration and organic solvents leftover, particularly when involving solvent‐casting technique. Direct melt‐blending can mitigate these issues, but there are few reports of a single‐step melting and extrusion process to produce ready‐to‐use 3D printing filaments. This study compares the distribution of CNF fillers within the PLA matrix in PLA/CNF composites made by direct melt‐blending into filaments using a benchtop filament maker, and by solvent‐casting followed by extrusion into filaments. The filaments were 3D‐printed via fused deposition modeling (FDM), followed by tensile testing, morphology, and other characterizations. Uneven filament diameters were observed for the composite filaments prepared via solvent‐casting because of severe agglomeration, resulted in poor printability and tensile properties of filaments and 3D‐printed samples. Direct melt‐blended filament diameters were consistent, resulted in only slight decrease of tensile properties compared to pure PLA, contributing to the highest maximum tensile strength of 3D‐printed sample of 51.47 ± 1.73 MPa at 5% CNF loading. Morphology revealed good integration of CNF into PLA matrix starting at 3% CNF loading. Direct melt‐blending was comparable to the conventional methods, which enables simpler PLA/CNF composite preparation especially for 3D printing.Highlights Better dispersibility achieved by direct melt‐blending than by solvent‐casting. PLA/CNF filaments produced via solvent‐casting suffered severe agglomeration. Direct melt‐blended PLA/CNF5% yielded the highest maximum tensile strength. Morphology reveals good CNF‐PLA integration starting at 3% of CNF loading. Worsened agglomeration causing increased number of voids observed at 10% CNF.

Recyclable hemp hurd fibre-reinforced PLA composites for 3D printing

In this study, 3D printing filaments were produced from hemp hurd fibre-reinforced polylactide (PLA) composites. Hemp hurd microfibres were obtained through alkaline digestion followed by a bleaching treatment and were used to produce PLA-based composites with 20–40 wt% fibre content for fused deposition modelling. Tensile testing of 3D printed composites revealed a gradual increase of Young's modulus with the addition of fibres, reaching a maximum of 7.1 GPa for the 40 wt% composite - a two-fold increase to neat PLA. However, tensile strength was only improved for the 20 wt% formulation, with an increase of 8% in comparison with neat PLA. Nevertheless, the thermo-mechanical properties of the composites were significantly enhanced with the addition of fibres. In addition, physical objects were printed from the recycled filaments to assess their recyclability and printability. It was found that the recycled filaments maintained comparable mechanical properties and printability after three recycling cycles.

Decentralized approach for incorporating waste wind turbine blades into 3D printing filaments using mechanical recycling

AbstractThe increasing awareness in environmental safety has led to rapid development in production of electricity using wind energy with wind turbines. The widespread deployment of wind turbines has outpaced the effective recycling of End‐of‐Life wind turbines. This study explores the potential of mechanically recycling decommissioned wind turbine blades (WTB) as reinforcement material in 3D printing processes. Utilizing mechanical grinding, materials were extracted from the waste blades and subsequently analyzed using Fourier transform infrared spectroscopy, Differential scanning calorimetry, and thermogravimetric analysis to determine optimal processing conditions. The reclaimed materials were then blended with recycled polypropylene through single‐screw extrusion to fabricate tensile test samples via Fused Deposition Modeling. The impact of print orientation on mechanical strength was examined at 0°, 45°, and 90° angles. Morphological analysis was conducted on the fractured specimens to assess the failure characteristics. The findings indicate that samples printed at a 90° orientation exhibited superior mechanical properties, suggesting a viable pathway for incorporating wind turbine waste into sustainable manufacturing cycles.Highlights A decentralized‐mechanical recycling technique to the waste WTB. The necessary material parameters for the operations employed in this study. Reinforced 3D printable filaments from waste WTB. Stronger reinforced filaments obtained from proper fiber alignment.

3D Printing Conductive Filament for Fuel Cell Bipolar Plates

Fuel cell bipolar plates are commonly manufactured from metals and graphite. Utilizing a polymer material, while still adhering to the standards set by the U.S. Department of Energy for bipolar plate electrical conductivity, could greatly reduce production costs and time. 3D printing bipolar plates could have benefits that include weight reductions as well as ease of testing different flowfield designs. However, very few 3D printing filaments are electrically conductive. In this work, samples were printed with Electrifi conductive filament, a copper-polyester composite material. Samples were printed at various conditions to determine optimal print settings for dimensional accuracy and electrical conductivity. Printing parameters such as nozzle temperature, flow rate, and infill pattern were varied to affect sample density and conductivity. Several combinations of print conditions led to conductivities nearing the US DOE technical target for bipolar plate conductivity. SEM imaging was performed to better understand the structure of the Electrifi filament, and an Energy-dispersive X-ray spectroscopy scan provided details on its elemental composition.

Repetitive recycling effects on mechanical characteristics of poly‐lactic acid and PLA/spent coffee grounds composite used for 3D printing filament

AbstractDue to its biodegradability, biocompatibility, and mechanical properties, poly‐lactic acid (PLA) is a leading biomaterial for numerous applications, especially for fused deposition modeling and fused filament fabrication. Nonetheless, the absence of a comprehensive recycling strategy may emerge as a significant source of plastic pollution in the future. Indeed, the polymer undergoes deterioration during melt recycling, resulting in a decrease in some mechanical properties that can compromise recyclability. To improve the properties of recycled PLA, the utilization of organic fillers coming from renewable materials can be considered as a sustainable solution. The objective of this work is then to evaluate the effect of recycling (reprocessing) on a virgin raw material as well as on biocomposites based on spent coffee grounds (incorporating 5% of spend coffee grounds in weight). The different types of filaments are extruded and re‐extruded and characterized under tensile, melt flow index, and hardness tests. The results show that the increase in the number of extrusions whether for virgin PLA or the composite contributes to the diameter fluctuation. Regarding the tensile properties, the rise in the frequency of recycling shows a weakness in the tensile strength and the elongation at break. On the other hand, Young's modulus values exhibit fluctuations. Concerning the addition of the spent coffee grounds filler, no major enhancement is observed in the tensile strength and the elongation at break, which is attributed to the poor adhesion between the matrix and the filler. The recycling process affects the hardness values of PLA, leading to an increase in these values, as well as those of the composite, which can be associated with the increased crystallinity caused by the recycling process and the SCG incorporation.Highlights Recycling and reusability strategy for poly‐lactic acid (PLA) and PLA/spent coffee grounds (SCG) filaments. Assessment of recycling effects on PLA and PLA/SCG. Mechanical characterization through tensile and hardness testing.

Characterization of Commercial and Custom-Made Printing Filament Materials for Computed Tomography Imaging of Radiological Phantoms

In recent years, material extrusion-based additive manufacturing, particularly fused filament fabrication (FFF), has gained significant attention due to its versatility and cost-effectiveness in producing complex geometries. This paper presents the characterization of seven novel materials for FFF and twenty-two commercially available filaments in terms of X-ray computed tomography (CT) numbers, as tissue mimicking materials for the realization of 3D printed radiological phantoms. Two technical approaches, by 3D printing of cube samples and by producing cylinders of melted materials, are used for achieving this goal. Results showed that the CT numbers, given in Hounsfield unit (HU), of all the samples depended on the beam kilovoltage (kV). The CT numbers ranged from +411 HU to +3071 HU (at 80 kV), from −422 HU to +3071 HU (at 100 kV), and from −442 HU to +3070 HU (at 120 kV). Several commercial and custom-made filaments demonstrated suitability for substituting soft and hard human tissues, for realization of 3D printed phantoms with FFF in CT imaging. For breast imaging, an anthropomorphic phantom with two filaments could be fabricated using ABS-C (conductive acrylonitrile butadiene styrene) as a substitute for breast adipose tissue, and ASA-A (acrylic styrene acrylonitrile) for glandular breast tissue.

3D Printable Materials Based on Renewable Polymers from Terpene Alcohols and Calcium Carbide

AbstractThe transition to a sustainable future requires the use of waste‐free technologies for production. Potentially, additive technologies can be a promising approach for accessing circular economy due to the precise amount of feeding materials and the absence of molds. However, the initial feeding materials for additive approaches are often based on non–renewable hydrocarbon sources. This work focused on the use of polymers derived from terpene alcohols to develop a filament suitable for 3D printing. Initially, the vinylation of menthol using calcium carbide was optimized and scaled up, then a series of terpenyl–based vinyl ethers were obtained under optimal conditions. The cationic polymerization of vinyl ethers was also scaled up and resulted in 99 % yield of the polymers, which was subsequently subjected to hot extrusion. The initial terpenol was used as an additive to increase polymer flexibility. The addition of menthol (30 wt %) to polyvinyl menthol led to the suitable filament. Using the filament, a series of objects were 3D printed at 125 °C. The material demonstrated good sinterability and adhesion to glass and shrinkage comparable to that of commercial 3D printing filaments. Furthermore, the polymers obtained were used as additives to enhance the adhesion of commercially available filaments.

Optimization of Glass-Powder-Reinforced Recycled High-Density Polyethylene (rHDPE) Filament for Additive Manufacturing: Transforming Bottle Caps into Sound-Absorbing Material.

Additive manufacturing presents promising potential as a sustainable processing technology, notably through integrating post-consumer recycled polymers into production. This study investigated the recycling of high-density polyethylene (rHDPE) into 3D printing filament, achieved by the following optimal extrusion parameters: 180 °C temperature, 7 rpm speed, and 10% glass powder addition. The properties of the developed rHDPE filament were compared with those of commonly used FDM filaments such as acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) to benchmark the performance of rHDPE against well-established materials in the 3D printing industry, providing a practical perspective for potential users. The resulting filament boasted an average tensile strength of 25.52 MPa, slightly exceeding ABS (25.41 MPa) and comparable to PLA (28.55 MPa). Despite diameter fluctuations, the filament proved usable in 3D printing. Mechanical tests compared the rHPDE filament 3D printed objects with ABS and PLA, showing lower strength but exceptional ductility and flexibility, along with superior sound absorption. A life cycle analysis underscored the sustainability advantages of rHDPE, reducing environmental impact compared to conventional disposal methods. While rHDPE falls behind in mechanical strength against virgin filaments, its unique attributes and sustainability position it as a valuable option for 3D printing, showcasing recycled materials' potential in sustainable innovation.

Multi-walled carbon nanotube-enhanced polyurethane composite materials and the application in high-performance 3D printed flexible strain sensors

Flexile strain sensors hold vast potential for applications in monitoring human motion, enabling human-machine interaction, and facilitating information transfer, etc. However, the available materials and manufacturing techniques for fabricating flexible strain sensors with high sensitivity and extended sensing range still face significant challenges. By utilizing solution casting and twin-screw extrusion techniques, this study prepared high-performance thermoplastic polyurethane/multi-walled carbon nanotube (TPU/MWCNT) nanocomposite 3D printable filaments, and employed material extrusion 3D printing technology to facilely fabricate flexible strain sensors. The 1-pyrene carboxylic acid (PCA)-modified TPU/MWCNT(3 wt%) nanocomposite exhibited outstanding mechanical properties, with a tensile strength of 24.3 ± 0.5 MPa and a fracture elongation of 625.8 ± 12.3 %. The 3D printed TPU/MWCNT(3 wt%)/PCA flexible strain sensors demonstrated amazing sensitivity (GFmax = 10279.95) within a wide strain range (0–300 % strain). The addition of PCA brings the benefits of improved dispersion of MWCNTs in the TPU composite, as well as enhanced thermal stability, and upgraded mechanical and electrical properties under different tensile strains. Meanwhile, the 3D printed samples displayed remarkable durability and reproducibility. Finally, the flexible strain sensors fabricated from this nanocomposite material could accurately perceive human motion, providing great prospects for wearable device applications.

Sustainable polymer reclamation: recycling poly(ethylene terephthalate) glycol (PETG) for 3D printing applications

Due to their versatile properties and wide-ranging applications across various industries, including manufacturing, polymers are indispensable for today’s society. However, polymer-based products significantly impact the environment since many are single-used plastics and require a long time to degrade naturally. A method to attenuate end-of-life polymers’ ill effects is recycling them to bring them again into the production cycle, from grave to cradle. This investigation involves recycling PETG sheets used in face shield production during the COVID-19 outbreak to fabricate 3D printing filaments for FFF. We assessed poly(ethylene terephthalate) glycol (PETG) processability to up to five recycling cycles and obtained filaments with properties adequate for 3D printing. Rheological, thermal, morphological, and mechanical characterization were analyzed to verify the effect of the number of processing cycles on the properties of the polymer. The recycling cycles originated a decrease in viscosity and elasticity, and the gain in molecular mobility resulted, relatively, in solids with a higher degree of crystallinity and prints with more elliptical depositions. The mechanical properties of printed parts fabricated of recycled material were comparable to those from commercial filament, especially after three extrusion cycles. Both extrusion and additive manufacturing processes successfully recycle material into filaments and printed parts, indicating that the proposed methodology is a promising alternative to bring value back to polymers from solid waste.

Flexible support material maintains disc height and supports the formation of hydrated tissue engineered intervertebral discs in vivo.

Mechanical augmentation upon implantation is essential for the long-term success of tissue-engineered intervertebral discs (TE-IVDs). Previous studies utilized stiffer materials to fabricate TE-IVD support structures. However, these materials undergo various failure modes in the mechanically challenging IVD microenvironment. FlexiFil (FPLA) is an elastomeric 3D printing filament that is amenable to the fabrication of support structures. However, no present study has evaluated the efficacy of a flexible support material to preserve disc height and support the formation of hydrated tissues in a large animal model. We leveraged results from our previously developed FE model of the minipig spine to design and test TE-IVD support cages comprised of FPLA and PLA. Specifically, we performed indentation to assess implant mechanical response and scanning electron microscopy to visualize microscale damage. We then implanted FPLA and PLA support cages for 6 weeks in the minipig cervical spine and monitored disc height via weekly x-rays. TE-IVDs cultured in FPLA were also implanted for 6 weeks with weekly x-rays and terminal T2 MRIs to quantify tissue hydration at study endpoint. Results demonstrated that FPLA cages withstood nearly twice the deformation of PLA without detrimental changes in mechanical performance and minimal damage. In vivo, FPLA cages and stably implanted TE-IVDs restored native disc height and supported the formation of hydrated tissues in the minipig spine. Displaced TE-IVDs yielded disc heights that were superior to PLA or discectomy-treated levels. FPLA holds great promise as a flexible and bioresorbable material for enhancing the long-term success of TE-IVD implants.

Recycling, thermophysical characterisation and assessment of low-density polythene waste as feedstock for 3D printing

Low-density polyethene (LDPE) is extensively used in single-end-use food packaging and contributes significantly to global waste plastic. This study addresses this challenge by introducing a sustainable approach to reclaim and valorise waste LDPE from milk packaging by converting them into 3D printing filaments. The process involves extruding shredded LDPE pouches into continuous filaments using a modified thermal extruder. The research comprehensively investigates the effects of two key extrusion parameters, nozzle temperature and screw speed, on the resulting filament's physical and mechanical properties. Characterisation efforts include dimensional analysis, morphological evaluation, chemical integrity assessment, thermal stability analysis, and tensile testing. The results show that filaments remain consistently close to 1.75 mm diameter, which is required by most commercial FDM 3D printers. The filaments are chemically intact, thermally stable, and have high toughness across the range of extrusion parameters. The results and a preliminary demonstration of 3D printing indicate that the LDPE waste can be effectively transformed into consistent filaments that have the potential for 3D printing. A carbon footprint assessment underscores the environmental benefits of this approach, showing substantial reductions in estimated CO2 emissions compared to conventional filament production methods. While challenges related to the quality of printed parts remain, the research opens avenues for optimizing 3D printing parameters and exploring multiple recycling cycles. This work represents a step towards sustainable plastic waste management and offers insights into transforming single-use plastic items into valuable resources.

Manufacturing and testing of pliers to weld 3D printing filaments

Abstract The advent of affordable three-dimensional printers has unlocked new possibilities for small business owners and hobbyists to convert their digital designs into tangible objects. However, during the production process, a lot of material ends up as waste because of improper storage or unused plastic fibers. This paper discusses the existing market products that aim to tackle these issues. Additionally, we introduce a specially designed pair of welding tongs that make it effortless to join plastic fibers utilized in fused deposition modeling printers. The paper presents a prototype of the tongs and provides a summary of the optimal welding temperatures for different printing materials. Finally, the conclusion evaluates the strength of the fibers after the welding process based on the results obtained from a testing mechanism.

New Filaments from Used Disposable Face Masks as an Alternative 3D Printing Filament in the 3D Printing Industry

This study aimed to examine an innovative approach for recycling and repurposing used disposable face masks to create a new 3D printing filament and to compare the mechanical properties of the developed 3D printing filament (DF) with recycled filament (RF) and commercial filament (CF). The development of the new 3D printing filaments involved examining three key pieces of information: (1) optimal melting point ranges, (2) weight, and (3) visual colors for each layer of the face mask. Using an experimental research design, the researchers melted-down disposable face masks to create the filament and analyzed its properties in comparison with RF and CF. No significant differences were identified in terms of strength among CF, RF, and DF types. The findings highlight the potential effectiveness of using disposable face masks as an alternative 3D printing material, contributing to the design and production in the 3D printing industry.

3D printing of continuous metal fiber-reinforced recycled ABS with varying fiber loading

PurposeThe current study aims to develop a 3D-printed continuous metal fiber-reinforced recycled thermoplastic composite using an in-nozzle impregnation technique.Design/methodology/approachRecycled acrylonitrile butadiene styrene (RABS) plastic was blended with virgin ABS (VABS) plastic in a ratio of 60:40 weight proportion to develop a 3D printing filament that was used as a matrix material, while post-used continuous brass wire (CBW) was used as a reinforcement. 3D printing was done by using a self-customized print head to fabricate the flexural, compression and interlaminar shear stress (ILSS) test samples to evaluate the bending, compressive and ILSS properties of the build samples and compared with VABS and RABS-B samples. Moreover, the physical properties of the samples were also analyzed.FindingsUpon three-point bend, compression and ILSS testing, it was found that RABS-B/CBW composite 3D printed with 0.7 mm layer width exhibited a notable improvement in maximum flexural load (Lmax), flexural stress at maximum load (sfmax), flex modulus (Ef) and work of fracture (WOF), compression modulus (Ec) and ILSS properties by 30.5%, 49.6%, 88.4% 13.8, 21.6% and 30.3% respectively.Originality/valueLimited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.

3D Printing Filaments with Electrical Properties: From the Fundamentals of Additive Manufacturing to Recent Trends

3D Printing Filaments with Electrical Properties: From the Fundamentals of Additive Manufacturing to Recent Trends

The Rheology of Polyether Ether Ketone Concentrated Suspensions for Powder Molding and 3D Printing.

The main goal of the work was to use rheological methods for assessing the properties of a composition based on polyether ether ketone (PEEK) to determine the concentration limits of the polymer in the composition and select the optimal content of this composition for powder molding. The rheological properties of highly filled suspensions based on PEEK and paraffin, as well as in paraffin-polyethylene mixtures at various component ratios, were studied. These materials are designed for powder injection molding and 3D printing. Suspensions with a PEEK powder content above 50% are not capable of flow and, with increasing pressure, slide along the surface of the channel. For compositions with a higher content (60 and 70 vol.%) PEEK, independence of the storage modulus from frequency is observed, which is typical for solids and confirms the assignment of such suspensions to elastic-plastic media. The introduction of high-density polyethylene into the composition helps improve the technological properties of suspensions, expanding the range of fluidity, although it leads to an increase in viscosity. In suspensions with a mixed composition of the liquid phase, with increasing temperature, a decrease in the storage modulus is observed at 120 °C and, on the contrary, an increase at 180 °C. The latter may be a consequence of the evaporation of paraffin and the softening of PEEK due to the approach to the glass transition temperature of the polymer. Suspensions with 40% PEEK content have an optimal set of rheological properties for powder injection molding. A 3D printing filament was also obtained from a composition with 40% PEEK, which had good technological properties for FDM 3D printing. Products of satisfactory quality from suspensions with 50% PEEK can be produced by powder injection molding, but not by 3D printing. The selected compositions were used to obtain real PEEK products for practical applications.