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ACS Omega Jun 2024This study aimed to investigate heterogeneous catalytic filaments of calcium oxide (CaO) for fused deposition modeling three-dimensional (3D) printers. The CaO catalysts...
This study aimed to investigate heterogeneous catalytic filaments of calcium oxide (CaO) for fused deposition modeling three-dimensional (3D) printers. The CaO catalysts were blended with acrylonitrile butadiene styrene (ABS) plastic to form catalytic filaments. A single-screw filament extruder was used to prepare the filaments, following which their mechanical properties, thermal properties, morphology, catalytic characteristics in biodiesel production, and reusability were evaluated. In accordance with the results, a maximum CaO catalyst content of 15 wt % was recommended to be blended in the ABS pellet. The hardness and compressive strength of these catalytic filaments were shown to be improved. Subsequently, the catalytic filaments with the highest CaO content (15 wt %) were used to produce methyl ester from pretreated sludge palm oil through the transesterification process. To determine the recommended conditions for achieving the highest purity of methyl ester in biodiesel, the process parameters were optimized. A methyl ester purity of 96.58 wt % and a biodiesel yield of 79.7 wt % could be achieved under the recommended conditions of a 9.0:1 methanol to oil molar ratio, 75.0 wt % catalytic filament loading, and 4.0 h reaction time. Furthermore, the reusability of the 15 wt % CaO catalytic filaments was evaluated in a batch process with multiple transesterification cycles. The results indicated that the purity of methyl ester dropped to 95.0 wt % only after the fourth cycle. The method used in this study for preparing and characterizing CaO catalytic filaments can potentially serve as a novel approach for constructing biodiesel reactors using 3D printing technology.
PubMed: 38947778
DOI: 10.1021/acsomega.4c03063 -
Heliyon Jun 2024Additive manufacturing (AM) has gained significant attention in recent years owing to its ability to fabricate intricate shapes and structures that are often challenging...
Additive manufacturing (AM) has gained significant attention in recent years owing to its ability to fabricate intricate shapes and structures that are often challenging or unattainable using conventional manufacturing techniques. This high-quality development trend entails higher requirements for the structural design of 3D printers. In this study, polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) filaments were fed through a heated extrusion nozzle, which melted the material and deposited it onto a build platform. This study's objectives are high-gravitational material extrusion (HG-MEX) systems development, analyzing the high gravity influences on the flow behavior of materials during extrusion, and understanding the effects of gravitational on material flow and overall extrusion performance. HG-MEX systems have great potential for addressing various challenges in additive manufacturing, such as precise manufacturing. The highlight of the progress is that we developed an HG-MEX system and applied surface science to material extrusion in different gravity. We established a system and obtained results on different gravity, we analyzed the analogy between different gravity phenomena. We analyzed the interplay between the behavior of the fabricated parts and gravity. We analyzed high gravity effects on extrusion processes. The results confirmed the characteristics and feasibility of the developed system. The results suggest that a material extrusion line operating under 15 G conditions resulted in better printing quality compared to one operating under 1 G conditions. This observation implies that high gravity had a positive effect on the extrusion process, leading to improved material extrusion performance.
PubMed: 38947488
DOI: 10.1016/j.heliyon.2024.e32161 -
Polymers Jun 2024The manufacturing method influences the properties of the produced components. This work investigates the influence of manufacturing methods, such as fused deposition...
Influence of the Manufacturing Method (3D Printing and Injection Molding) on Water Absorption and Mechanical and Thermal Properties of Polymer Composites Based on Poly(lactic acid).
The manufacturing method influences the properties of the produced components. This work investigates the influence of manufacturing methods, such as fused deposition modeling (3D printing) and injection molding, on the water absorption and mechanical and thermal properties of the specimens produced from neat bio-based poly(lactic acid) (PLA) polymer and poly(lactic acid)/wood composites. Acrylonitrile butadiene styrene (ABS) acts as the reference material due to its low water absorption and good functional properties. The printing layer thickness is one of the factors that affects the properties of a 3D-printed specimen. The investigation includes two different layer thicknesses (0.2 mm and 0.3 mm) while maintaining uniform overall thickness of the specimens across two manufacturing methods. 3D-printed specimens absorb significantly higher amounts of water than the injection-molded specimens, and the increase in the layer thickness of the 3D-printed specimens contributes to further increased water absorption. However, the swelling due to water absorption in 3D-printed specimens decreases upon increased layer thickness. The tensile, flexural, and impact properties of all of the specimens decrease after water absorption, while the properties improve upon decreasing the layer thickness. Higher porosity upon increasing the layer thickness is the predominant factor. The results from dynamic mechanical analysis and microscopy validate the outcomes. The results from this experimental study highlight the limitations of additive manufacturing.
PubMed: 38931969
DOI: 10.3390/polym16121619 -
Molecules (Basel, Switzerland) Jun 2024The expansive utility of polymeric 3D-printing technologies and demand for high- performance lightweight structures has prompted the emergence of various...
The expansive utility of polymeric 3D-printing technologies and demand for high- performance lightweight structures has prompted the emergence of various carbon-reinforced polymer composite filaments. However, detailed characterization of the processing-microstructure-property relationships of these materials is still required to realize their full potential. In this study, acrylonitrile butadiene styrene (ABS) and two carbon-reinforced ABS variants, with either carbon nanotubes (CNT) or 5 wt.% chopped carbon fiber (CF), were designed in a bio-inspired honeycomb geometry. These structures were manufactured by fused filament fabrication (FFF) and investigated across a range of layer thicknesses and hexagonal (hex) sizes. Microscopy of material cross-sections was conducted to evaluate the relationship between print parameters and porosity. Analyses determined a trend of reduced porosity with lower print-layer heights and hex sizes compared to larger print-layer heights and hex sizes. Mechanical properties were evaluated through compression testing, with ABS specimens achieving higher compressive yield strength, while CNT-ABS achieved higher ultimate compressive strength due to the reduction in porosity and subsequent strengthening. A trend of decreasing strength with increasing hex size across all materials was supported by the negative correlation between porosity and increasing print-layer height and hex size. We elucidated the potential of honeycomb ABS, CNT-ABS, and ABS-5wt.% CF polymer composites for novel 3D-printed structures. These studies were supported by the development of a predictive classification and regression supervised machine learning model with 0.92 accuracy and a 0.96 coefficient of determination to help inform and guide design for targeted performance.
PubMed: 38930802
DOI: 10.3390/molecules29122736 -
Materials (Basel, Switzerland) Jun 2024The integration of recycled polymers into additive manufacturing (AM) processes offers a promising opportunity for advancing sustainability within the manufacturing... (Review)
Review
The integration of recycled polymers into additive manufacturing (AM) processes offers a promising opportunity for advancing sustainability within the manufacturing industry. This review paper summarizes existing research and developments related to the use of recycled materials in AM, focusing on distinct polymers, such as polylactic acid (PLA), polyethylene terephthalate (PET), and acrylonitrile butadiene styrene (ABS), among others. Key topics explored include the availability of recycled filaments on the market, challenges associated with material variability and traceability, and efforts toward establishing ethical product standards and sustainability characterization methodologies. Regulatory considerations and standards development by organizations such as ASTM and ISO are discussed, along with recommendations for future advancements in improving the sustainability of filament recycling and achieving net-zero emissions in AM processes. The collective efforts outlined in this paper underscore the potential of recycled polymers in AM to foster a more sustainable and environmentally friendly manufacturing industry.
PubMed: 38930283
DOI: 10.3390/ma17122915 -
Materials (Basel, Switzerland) Jun 2024The glycolysis process of flexible polyurethane foams containing styrene-acrylonitrile and calcium carbonate as fillers was explored in detail. The use of DABCO as a...
The glycolysis process of flexible polyurethane foams containing styrene-acrylonitrile and calcium carbonate as fillers was explored in detail. The use of DABCO as a catalyst allowed us to reduce the catalyst concentration and the polyurethane-to-glycol mass ratio to 0.1% and 1:1, respectively. The glycolysis process allowed us to obtain a high-purity polyol (99%), which can totally replace raw polyols in the synthesis of new flexible polyurethane foams, maintaining the standard mechanical properties of the original one and modifying the ratio of isocyanates employed to correct the closed cell structure caused by the impurities present in the recovered polyol. This isocyanate mixture was also optimized, resulting in a ratio of 30 and 70% of the isocyanates TDI80 and TDI65, respectively. Additionally, the fillers incorporated in the glycolyzed foams were recovered. Both recovered fillers, styrene-acrylonitrile and calcium carbonate, were fully characterized, showing a quality very similar to that of commercial compounds. Finally, the replacement of commercial fillers by the recovered ones in the synthesis of new polyurethane foams was studied, demonstrating the feasibility of using them in the synthesis of new foams without significantly altering their properties.
PubMed: 38930213
DOI: 10.3390/ma17122844 -
ACS Applied Polymer Materials Jun 2024The processing of an immiscible polymer blend using melt blending (i.e., extrusion) often results in a polymer material with inferior mechanical performance compared...
The processing of an immiscible polymer blend using melt blending (i.e., extrusion) often results in a polymer material with inferior mechanical performance compared with its virgin counterparts. Here, we report and compare the properties of immiscible polymer blends produced from industrial mixed plastic waste from shredder residue comprising at least four different polymers (acrylonitrile butadiene styrene, polystyrene, polypropylene, and polyethylene) and a prior melt-blending step employed. As anticipated, mixed plastic blend produced a prior melt-blending step exhibited a more homogeneous microstructure, resulting in brittleness, poor work of fracture, and single-edge notched fracture toughness with a flat R-curve. Without the intimate polymers mixing arising from melt blending, the resulting mixed plastic blend was found to possess a more heterogeneous concentric ellipsoid microstructure with large single polymer domains. This mixed plastic blend demonstrated progressive failure under uniaxial tensile loading, along with a more ductile single-edge notched fracture toughness response accompanied by a growing R-curve. Digital image correlation and fractographic analysis revealed that melt blending created a large number of incompatible polymer boundaries that acted as stress concentration points, leading to brittleness and earlier onset catastrophic failure. The more heterogeneous mixed plastic blend produced using a prior melt-blending step contains a smaller number of incompatible polymer boundaries. Additionally, the presence of larger single polymer domains also implies that the mechanical characteristics of the single polymer can be exploited in the immiscible mixed plastic blend. Our work opens up a simple pathway to add value to mixed plastic waste from shredder residue for use in engineering applications, diverting them away from landfill or incineration.
PubMed: 38903398
DOI: 10.1021/acsapm.4c00360 -
Materials (Basel, Switzerland) Jun 2024This study investigated how printing conditions influence the fracture behaviour of 3D-printed acrylonitrile butadiene styrene (ABS) under tensile loading....
This study investigated how printing conditions influence the fracture behaviour of 3D-printed acrylonitrile butadiene styrene (ABS) under tensile loading. Dog-bone-shaped ABS specimens were produced using the fusion filament fabrication technique, with varying printing angles. Tensile tests were conducted on pre-notched specimens with consistent pre-notch lengths but different orientations. Optical and scanning electron microscopies were employed to analyse crack propagation in the pre-notched specimens. In order to support experimental evidence, finite element computation was implemented to study the damage induced by the microstructural rearrangement of the filaments when subject to tensile loading. The findings revealed the simple linear correlation between the failure properties including elongation at break and maximum stress in relation to the printing angle for different pre-notch lengths. A more progressive damage was found to support the ultimate performance of the studied material. This experiment evidence was used to build a damage model of 3D-printed ABS that accounts for the onset, growth, and damage saturation. This damage modelling is able to capture the failure properties as a function of the printing angle using a sigmoid-like damage function and a modulation of the stiffness within the raster. The numerical results demonstrated that damage pattern develops as a result of the filament arrangement and weak adhesion between adjacent filaments and explains the diffuse damage kinetics observed experimentally. This study concludes with a topological law relating the notch size and orientation to the rupture properties of 3D-printed ABS. This study supports the idea of tailoring the microstructural arrangement to control and mitigate the mechanical instabilities that lead to the failure of 3D-printed polymers.
PubMed: 38893962
DOI: 10.3390/ma17112699 -
Materials (Basel, Switzerland) May 2024This study investigates the effect of extrusion screw speed and carbon nanotube (CNT) concentration on the thermal, mechanical, and electromagnetic interference...
This study investigates the effect of extrusion screw speed and carbon nanotube (CNT) concentration on the thermal, mechanical, and electromagnetic interference shielding effectiveness (EMI SE) properties of Polycarbonate (PC)/acrylonitrile-butadiene-styrene (ABS) and its polymer nanocomposites (PNCs) by means of design of experiments (DoE) approach. A masterbatch method was employed to obtain the best dispersion of the CNTs throughout the polymer matrix. This study evaluates the thermo-mechanical characterisation of the polymers and PNCs at varying screw speeds to assess filler matrix bonding. The results highlight that CNT concentration has a significant effect on all mechanical properties, while screw speed only affects the Charpy impact strength and flexural properties of the samples. Compounding at 200 rpm has the best flexural and tensile strength, which is attributed to the best filler matrix bonding (highest storage modulus) of the PNCs. The best EMI SE results were obtained at 10 wt.% CNTs. This research contributes valuable insights into the effect of CNT concentration and extrusion screw speed on the mechanical, thermal and EMI SE properties of PC/ABS and its PNCs.
PubMed: 38893888
DOI: 10.3390/ma17112625 -
Materials (Basel, Switzerland) May 2024In this work, a self-lubricating composite was manufactured using a novel hybrid 3D printing/in situ spraying process that involved the printing of an acrylonitrile...
In this work, a self-lubricating composite was manufactured using a novel hybrid 3D printing/in situ spraying process that involved the printing of an acrylonitrile butadiene styrene (ABS) matrix using fused deposition modeling (FDM), along with the in situ spraying of alumina (AlO) and hexagonal boron nitride (hBN) reinforcements during 3D printing. The results revealed that the addition of the reinforcement induced an extensive formation of micropores throughout the ABS structure. Under tensile-loading conditions, the mechanical strength and cohesive interlayer bonding of the composites were diminished due to the presence of these micropores. However, under tribological conditions, the presence of the AlO and hBN reinforcement improved the frictional resistance of ABS in extreme loading conditions. This improvement in frictional resistance was attributed to the ability of the AlO reinforcement to support the external tribo-load and the shearing-like ability of hBN reinforcement during sliding. Collectively, this work provides novel insights into the possibility of designing tribologically robust ABS components through the addition of in situ-sprayed ceramic and solid-lubricant reinforcements.
PubMed: 38893868
DOI: 10.3390/ma17112601