Additive Manufacturing of Short Silk Fiber Reinforced PETG Composites

Vijayasankar, K N; Bonthu, Dileep; Doddamani, Mrityunjay; Pati, Falguni

doi:10.1016/j.mtcomm.2022.104772

Cited by 8 publications

(3 citation statements)

References 63 publications

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“…Smaller particles typically result in higher strength and stiffness due to the increased surface area and improved interfacial bonding within the matrix. In the case of HC-PETG30 and HC-PETG50, since hydrochar particles are typically irregular in shape, their distribution within the matrix may also be nonuniform, which can cause the propagation of cracks and decrease the load-bearing capacity of the composite, affecting the mechanical properties of the composite . However, the rigidity, plastic deformation limit, and mechanical strength of activated carbon-infused PETG are ∼30% higher than pure PETG samples as measured by their significantly higher Young’s modulus, yield strength, and ultimate strength, respectively (Figure B).…”

Section: Resultsmentioning

confidence: 99%

“…Recently, PETGa modified version of polyethylene terephthalate (PET)has gained attention as a viable FDM filament due to its high durability, resistance to impact, optical clarity, eco-friendliness, and better layer adhesion . Consequently, PETG is commonly utilized for manufacturing containers, bottles, and medical implants . However, due to challenges in readily integrating bio-waste-derived filler with PETG, recycled PETG composites are less explored (Table ).…”

Section: Introductionmentioning

confidence: 99%

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From Waste to Filament: Development of Biomass-Derived Activated Carbon-Reinforced PETG Composites for Sustainable 3D Printing

Balou

Ahmed

Priye

2023

ACS Sustainable Chem. Eng.

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Fused deposition modeling (FDM) 3D printing not only offers numerous advantages over traditional manufacturing methods but also produces a significant amount of waste in the form of failed prints, support structures, and unused filaments. Thus, there is a need to develop novel and sustainable materials to replace conventional FDM filaments. We report a unique biomass (waste leaves)-derived activated carbon that can be infused with polyethylene terephthalate glycol (PETG) to fabricate a sustainable, cost-effective, and eco-friendly class of 3D printing filaments that enable 3D printing of parts with superior mechanical properties. We investigate the key parameters that influence the chemical, morphological, thermal, surface, and mechanical properties of our biomass-derived hydrochar, activated carbon, and PETG composite filaments. The resulting samples are characterized using Fourier transform infrared spectroscope, X-ray diffraction, scanning electron microscope, contact angle meter, and a universal testing machine. We have observed that while hydrochar can be incorporated with PETG to create biomass-derived filaments, incorporating activated carbon with PETG results in superior filaments. These composites can incorporate an extremely high biomass filler weight percentage while enhancing mechanical strength by over 30%. Our biomass-derived PETG composites were also thermally stable and more hydrophilic than the pure PETG samples. We analyze the mechanism by which activated carbon incorporation increases the PETG composites’ mechanical strength with both physical and chemical techniques. We also demonstrate successful FDM 3D printing of personalized anatomical models and porous cylindrical filter mesh using our biomass-derived PETG composite filaments. Implementing such sustainable principles in the 3D printing industry has the potential to transform it into a restorative and sustainable system while simultaneously minimizing environmental pollution and waste.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

From Waste to Filament: Development of Biomass-Derived Activated Carbon-Reinforced PETG Composites for Sustainable 3D Printing

Balou

Ahmed

Priye

2023

ACS Sustainable Chem. Eng.

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“…Their findings indicated that mechanical properties improved with a higher loading content of wood flour within the PETG matrix, albeit at the expense of reduced thermal conductivity. 11 Penumakala et al (2020) reported that FDM-fabricated PETG exhibited mechanical properties comparable to injection-molded PETG, but these properties diminished with increasing fabrication temperature, highlighting the significance of fabrication temperature in determining the characteristics of 3D-printed PETG. 12 Another study by Szust and Adamski demonstrated that the mechanical properties of FDM-printed PETG were influenced by printing orientation, with the highest tensile strength observed in the z-direction.…”

Section: Introductionmentioning

confidence: 99%

Mechanical, morphological, and dimensional properties of heat-treated fused deposition modeling printed polymeric matrix of polyethylene terephthalate glycol

Kumar,

Singh,

Kumar

et al. 2023

Progress in Rubber, Plastics and Recycling Technology

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This study investigates the impact of heat treatment on the mechanical, morphological, and dimensional properties of polyethylene terephthalate glycol (PETG), a commonly used thermoplastic in 3D printing. Taguchi L25 orthogonal array (OA) was employed to optimize 3D printing parameters, considering factors such as infill percentage (ranging from 20% to 100%), layer height (0.12 mm to 0.28 mm), layer width (0.32 mm to 0.62 mm), and infill pattern. Following ASTM D638 type IV standards, mechanical testing revealed that the optimal printing conditions included a 100% infill percentage, a layer height of 0.16 mm, a layer width of 0.32 mm, and an infill pattern of 5. Specimen 22, produced under these conditions, exhibited a notable stress-bearing capacity of 46.43 ± 1.394 MPa. These results are consistent with previous studies that underscored the significance of high infill percentages and finer layer dimensions in enhancing tensile properties. Subsequently, these optimized specimens were exposed to various heat treatment conditions. It was discovered that heat treatment at 85°C for 15 min yielded the most significant improvements, increasing the stress-bearing capacity to 53.462 ± 1.604 MPa, representing an impressive ∼16% enhancement compared to non-heat-treated specimens. However, this treatment also led to increased brittleness. Morphological analysis using Scanning Electron Microscopy (SEM) further substantiated the findings. Specimens subjected to heat treatment at 85°C exhibited fewer voids and porosities than those printed with lower infill percentages and larger layer dimensions. These observations underscored the importance of adequate infill density and finer printing details for optimizing strength. Regarding dimensional stability, dimensional changes were meticulously measured after heat treatment. Notably, specimens subjected to heat treatment at or near the glass transition temperature (Tg) of PETG experienced the most significant shrinkage. Specimen 6, treated at 85°C, displayed the highest shrinkage, with length and width reductions of 133.30 ± 3.85 mm and 25.90 ± 0.87 mm, respectively.

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The importance of local process conditions on the properties of fused filament fabrication printed polypropylene components

Xu¹,

Huang²,

Schlarb

2023

J of Applied Polymer Sci

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A key characteristic of the manufacture of void free components by 3D printing using fused filament fabrication (FFF) is that this generative process always produces new welded joints between the hot strand leaving the nozzle and the previously deposited and already solidified area. These contact conditions determine the local temperature gradient and the local deformation gradients in the contact. These in turn can have a decisive effect on the morphology and mechanical behavior of the component. In this work, the influence of three different geometric contact conditions under two different machine parameter sets on the morphology and mechanical properties was investigated. The results show that ultimately a parameter simply calculated from the process settings and geometric boundary conditions, the mean contact temperature, is decisive for the properties of the component. If this value is above the melting temperature of the material, quasi‐homogeneous morphologies with decent mechanical properties can be achieved in any case. However, if the mean contact temperature is below the melting temperature, the deformation conditions during strand deposition have a significant influence on morphology and properties. The paper describes this behavior using the example of three contact geometries typically encountered in 3D printing with FFF. The discussed correlations between the morphology and the mechanical properties of the printed FFF samples lead to a better understanding of the process and ultimately to the conclusion that the path generation that is, the slicing strategy should take these facts into account in the future in order to be able to exploit the material‐intrinsic performance potential in 3D printing as well.

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Additive Manufacturing of Short Silk Fiber Reinforced PETG Composites

Cited by 8 publications

References 63 publications

From Waste to Filament: Development of Biomass-Derived Activated Carbon-Reinforced PETG Composites for Sustainable 3D Printing

From Waste to Filament: Development of Biomass-Derived Activated Carbon-Reinforced PETG Composites for Sustainable 3D Printing

Mechanical, morphological, and dimensional properties of heat-treated fused deposition modeling printed polymeric matrix of polyethylene terephthalate glycol

The importance of local process conditions on the properties of fused filament fabrication printed polypropylene components

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