Additive manufacturing of flexible electrically conductive polymer composites via CNC-assisted fused layer modeling process

Kumar, Narendra; Jain, Prashant K.; Tandon, Puneet; Pandey, Pulak M.

doi:10.1007/s40430-018-1116-6

Cited by 57 publications

(39 citation statements)

References 28 publications

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“…The study here provided further evidence that such machines could be used for recycled materials, as PC is a more challenging printing polymer because of its higher temperatures and higher strengths (e.g., if bed adhesion is sub-optimal and the print begins to deform, a PC print will often fail because of mechanical contact with the print head more often than weaker polymers like ABS). There is thus considerable future work to begin to apply PME/FPF printing to composites (ideally made from waste) such as for conductive materials [93] and flexible materials [94]. The results of both this study and previous studies on FGF and PME/FPF infer this type of 3D printing will play a larger role in the additive manufacturing industry in the future.…”

Section: Discussionmentioning

confidence: 90%

Mechanical Properties and Applications of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing

et al. 2019

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Past work has shown that particle material extrusion (fused particle fabrication (FPF)/fused granular fabrication (FGF)) has the potential for increasing the use of recycled polymers in 3D printing. This study extends this potential to high-performance (high-mechanical-strength and heat-resistant) polymers using polycarbonate (PC). Recycled PC regrind of approximately 25 mm2 was 3D printed with an open-source Gigabot X and analyzed. A temperature and nozzle velocity matrix was used to find useful printing parameters, and a print test was used to maximize the output for a two-temperature stage extruder for PC. ASTM type 4 tensile test geometries as well as ASTM-approved compression tests were used to determine the mechanical properties of PC and were compared with filament printing and the bulk virgin material. The results showed the tensile strength of parts manufactured from the recycled PC particles (64.9 MPa) were comparable to that of the commercial filament printed on desktop (62.2 MPa) and large-format (66.3 MPa) 3D printers. Three case study applications were investigated: (i) using PC as a rapid molding technology for lower melting point thermoplastics, (ii) printed parts for high temperature applications, and (iii) printed parts for high-strength applications. The results show that recycled PC particle-based 3D printing can produce high-strength and heat-resistant products at low costs.

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Section: Discussionmentioning

confidence: 90%

Mechanical Properties and Applications of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing

et al. 2019

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“…The capability of the latter method to simultaneously 3D print the functional (e.g., strain sensor) and the structural part has recently become an object of significant research interest [35,36]. In particular, fused deposition modeling (FDM) techniques have been rapidly improved in recent years, making it possible to easily co-print functional and structural materials at low cost [36,37,38,39].…”

Section: Introductionmentioning

confidence: 99%

Dynamic Measurements Using FDM 3D-Printed Embedded Strain Sensors

Maurizi

Slavič

Cianetti

et al. 2019

Sensors

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3D-printing technology is opening up new possibilities for the co-printing of sensory elements. While quasi-static research has shown promise, the dynamic performance has yet to be researched. This study researched smart 3D structures with embedded and printed sensory elements. The embedded strain sensor was based on the conductive PLA (Polylactic Acid) material. The research was focused on dynamic measurements of the strain and considered the theoretical background of the piezoresistivity of conductive PLA materials, the temperature effects, the nonlinearities, the dynamic range, the electromagnetic sensitivity and the frequency range. A quasi-static calibration used in the dynamic measurements was proposed. It was shown that the temperature effects were negligible, the sensory element was linear as long as the structure had a linear response, the dynamic range started at ∼ 30 μ ϵ and broadband performance was in the range of few kHz (depending on the size of the printed sensor). The promising results support future applications of smart 3D-printed systems with embedded sensory elements being used for dynamic measurements in areas where currently piezo-crystal-based sensors are used.

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“…Fused granular fabrication (FGF) or the more generic fused particle fabrication (FPF) (indicating any size or shape of polymer feedstock) have been developed and designs are flourishing in maker communities [19][20][21] as well as in industry with commercialized printers [21][22][23][24][25][26]. Academia has also taken a keen interest in the technology [27,28] for virgin [29] and recycled materials [30,31] including multi-head [32], industrial robot adaptations [33], electronics printing [34], flexible materials printing [35], and biopolymer printing [36]. To date, however, only a small subset of the thermoplastic materials capable of being printed by such systems have been investigated.…”

Section: Introductionmentioning

confidence: 99%

3-D Printable Polymer Pelletizer Chopper for Fused Granular Fabrication-Based Additive Manufacturing

Woern

Pearce

2018

Inventions

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Although distributed additive manufacturing can provide high returns on investment, the current markup on commercial filament over base polymers limits deployment. These cost barriers can be surmounted by eliminating the entire process of fusing filament by three-dimensional (3-D) printing products directly from polymer granules. Fused granular fabrication (FGF) (or fused particle fabrication (FPF)) is being held back in part by the accessibility of low-cost pelletizers and choppers. An open-source 3-D printable invention disclosed here allows for precisely controlled pelletizing of both single thermopolymers as well as composites for 3-D printing. The system is designed, built, and tested for its ability to provide high-tolerance thermopolymer pellets with a number of sizes capable of being used in an FGF printer. In addition, the chopping pelletizer is tested for its ability to chop multi-materials simultaneously for color mixing and composite fabrication as well as precise fractional measuring back to filament. The US$185 open-source 3-D printable pelletizer chopper system was successfully fabricated and has a 0.5 kg/h throughput with one motor, and 1.0 kg/h throughput with two motors using only 0.24 kWh/kg during the chopping process. Pellets were successfully printed directly via FGF as well as indirectly after being converted into high-tolerance filament in a recyclebot.

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Additive manufacturing of flexible electrically conductive polymer composites via CNC-assisted fused layer modeling process

Cited by 57 publications

References 28 publications

Mechanical Properties and Applications of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing

Mechanical Properties and Applications of Recycled Polycarbonate Particle Material Extrusion-Based Additive Manufacturing

Dynamic Measurements Using FDM 3D-Printed Embedded Strain Sensors

3-D Printable Polymer Pelletizer Chopper for Fused Granular Fabrication-Based Additive Manufacturing

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