Additive Manufacturing of Three-Phase Syntactic Foams Containing Glass Microballoons and Air Pores

Singh, Ashish Kumar; Deptula, Alexander; Anawal, Rajesh; Doddamani, Mrityunjay; Gupta, Nïkhil

doi:10.1007/s11837-019-03355-5

Cited by 36 publications

(12 citation statements)

References 28 publications

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“…Quite similar behavior was also reported in another study of the same group using hollow glass micro‐balloons (GMBs) where void fractions up to 30% were obtained. [ 61d,63 ] Similar to the previous study, the tensile and flexural mechanical properties of the printed structures were not improved by the addition of GMBs due to the formation of voids and air gaps between the printed layers ( Figure ). This is because the final density of the printed cellular structures is still quite high despite the high contents of low‐density microspheres.…”

Section: Routes To Generate Cellular Structures By Additive Manufactu...supporting

confidence: 81%

Foam 3D Printing of Thermoplastics: A Symbiosis of Additive Manufacturing and Foaming Technology

et al. 2022

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Due to their light‐weight and cost‐effectiveness, cellular thermoplastic foams are considered as important engineering materials. On the other hand, additive manufacturing or 3D printing is one of the emerging and fastest growing manufacturing technologies due to its advantages such as design freedom and tool‐less production. Nowadays, 3D printing of polymer compounds is mostly limited to manufacturing of solid parts. In this context, a merged foaming and printing technology can introduce a great alternative for the currently used foam manufacturing technologies such as foam injection molding. This perspective review article tackles the attempts taken toward initiating this novel technology to simultaneously foam and print thermoplastics. After explaining the basics of polymer foaming and additive manufacturing, this article classifies different attempts that have been made toward generating foamed printed structures while highlighting their challenges. These attempts are clustered into 1) architected porous structures, 2) syntactic foaming, 3) post‐foaming of printed parts, and eventually 4) printing of blowing agents saturated filaments. Among these, the latest approach is the most practical route although it has not been thoroughly studied yet. A filament free approach that can be introduced as a potential strategy to unlock the difficulties to produce printed foam structures is also proposed.

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Section: Routes To Generate Cellular Structures By Additive Manufactu...supporting

confidence: 81%

Foam 3D Printing of Thermoplastics: A Symbiosis of Additive Manufacturing and Foaming Technology

et al. 2022

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“…The same group also 3D printed composites from the cenosphere filled filaments and tested for compressive properties at various strain rates. The printed composites were lighter due to the presence of lightweight cenosphere and exhibited higher modulus at all strain rates [ 129 ].…”

Section: Reinforcements In 3d Printed Partsmentioning

confidence: 99%

An Overview of Additive Manufacturing of Polymers and Associated Composites

2020

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Additive manufacturing is rapidly evolving and opening new possibilities for many industries. This article gives an overview of the current status of additive manufacturing with polymers and polymer composites. Various types of reinforcements in polymers and architectured cellular material printing including the auxetic metamaterials and the triply periodic minimal surface structures are discussed. Finally, applications, current challenges, and future directions are highlighted here.

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“…[25][26][27] Thermoplastic matrix syntactic foams offer flexibility in manufacturing and have been successfully produced using techniques such as injection molding, [28] compression molding, [14] and additive manufacturing. [15,29,30] But the strength and modulus of these foams cannot be increased beyond a certain limit which reduces the applicability of thermoplastic syntactic foams in strength driven applications. There is a trade-off between the ease of manufacturing and mechanical performance of these foams.…”

Section: Introductionmentioning

confidence: 99%

Effect of expanded glass particle size on compressive properties of vinyl ester syntactic foams

et al. 2022

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The most common fillers for syntactic foam development are glass microballoons or fly ash cenospheres. However, the need for improved properties and reduced cost requires exploring other possibilities. In this work, syntactic foams of vinyl ester resin reinforced with expanded glass particles (EG) were fabricated and compressive properties of the composites were studied. The foam EGS was reinforced with smaller particles of size 0.04–0.125 mm in 15, 30, and 45 vol.% and EGL had larger particles of size 0.25–0.5 mm in 15 and 30 vol.%. Compression testing reveals that 45 vol.% smaller particles enhance the modulus of the EGS foam by up to 48% with a 3.4% reduction in yield strength compared to neat resin. Strain rate sensitivity was observed in both the modulus and yield strength values for all composites. Composite EGS with 15 and 30 vol.% filler showed better strength and modulus than the neat resin at 0.01 s−1 strain rate, which is an overall improvement in the material. When compared with the literature data, the foams made in the present work have the highest compressive strength and modulus for the same density.

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Additive Manufacturing of Three-Phase Syntactic Foams Containing Glass Microballoons and Air Pores

Cited by 36 publications

References 28 publications

Foam 3D Printing of Thermoplastics: A Symbiosis of Additive Manufacturing and Foaming Technology

Foam 3D Printing of Thermoplastics: A Symbiosis of Additive Manufacturing and Foaming Technology

An Overview of Additive Manufacturing of Polymers and Associated Composites

Effect of expanded glass particle size on compressive properties of vinyl ester syntactic foams

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