Fused Deposition Modeling of Carbon Fiber Reinforced High-Density Polyethylene: Effects on Microstructure and Mechanical Properties

Abstract

Owing to its superior durability, good biocompatibility, and high recycling capability, high-density polyethylene (HDPE) has been widely applied into making prosthetic implants, liquid permeable membranes, corrosion-resistant pipes, etc., and gains its popularity in packaging, consumer goods, and chemical industries. Injection molding and blow molding are two most common conventional processes of making HDPE products. These conventional processes, however, are considered time-consuming and labor-intensive since molds are usually needed prior to fabricating parts. Moreover, manufacturing complex-structured parts (such as lattice and cellular structures) is a challenge for these conventional manufacturing processes. Facing these problems, it is crucial to find a time- and labor-saving process, which can be used to manufacture complicated structures in a cost-effective way. Additive manufacturing (AM) is such a process that needs no mold and is more affordable to create complex and highly customized parts. Among all types of AM processes, fused deposition modeling (FDM), which is primarily designed for thermoplastic materials, seemed to be a benevolent process for fabricating HDPE parts. Based on reported publications, however, it is difficult to print HDPE materials using FDM due to the problems of warping, shrinking, and weak bonding between printed HDPE parts and the substrate. In addition, the FDM-printed HDPE parts can demonstrate defects of porosities and delamination. To improve the printability of FDM, we conducted preliminary experiments and optimized processing parameters. For the first time, we added carbon fiber (CF) into HDPE to make CF-reinforced HDPE composites (CF-HDPE) using FDM and investigated the effects of CF on part quality, microstructure characteristics, and mechanical properties (including tensile properties and dynamic mechanical properties) of CF-reinforced HDPE composites. Experimental results show that the addition of CF was beneficial for not only improving the printability of FDM and quality of printed composite parts, but also for enhancing mechanical properties (such as Young’s Modulus and ultimate tensile strength) of the parts.

Crystallographic Texture Evolution in 3D Printed Polyethylene Reactor Blends

“…Pandit et al investigated carbon-fiber-reinforced HDPE composites to improve printability of HDPE using FDM which otherwise show warping, shrinking, and weak bonding between HDPE and substrate. 39 There have also been studies that confirm the presence of shish kebab structures of UHMWPE fibers prepared by gel spinning 61 − 63 and the formation of shish-kebab structure of UHMWPE during injection molding of UHMWPE/HDPE blends as well as effect of change in UHMWPE molecular weight when melt blended with HDPE. 48 Our previous work investigated crystallographic orientation or texture evolution in UHMWPE during uniaxial tension.…”

“…Understanding the evolution of microstructure and the resultant texture, defined as the preferred alignment of crystallographic orientations in a polycrystalline medium, has been of great interest among the materials community. ,− , Additive manufacturing techniques, especially fused filament fabrication (FFF), also known as fused deposition modeling (FDM), an extrusion-based 3D printing technique, has shown to be very promising to fabricate sustainable customized complex materials. , 3D printing is more customizable and less expensive compared to injection molding. It is also possible to have better control of the process through its parameters like 3D printing speed, orientation, and temperature, thereby obtaining better control of microstructure and hence the resultant properties …”

“…There are numerous studies involving the microstructure of HDPE and UHMWPE and their blends processed through different ways, − as well as X-ray diffraction studies of HDPE or UHMWPE-containing polymers. ,,− There have been studies on the evolution of microstructures in UHMWPE/HDPE blend fibers prepared by melt spinning, control of subinclusion microstructure in ternary blends consisting of HDPE, microstructural characterization of HDPE/polyamide blend through selective laser sintering processing, microstructural evaluation of HDPE along with its other properties after weathering, assessment of microstructure of HDPE post chemical recycling, post reinforcement for use as shielding materials against nuclear radiation, effect of various reinforcements on microstructure of UHMWPE consisting composites, , studies on microstructure of modified UHMWPE and UHMWPE consisting blend foams, and many more. Pandit et al investigated carbon-fiber-reinforced HDPE composites to improve printability of HDPE using FDM which otherwise show warping, shrinking, and weak bonding between HDPE and substrate . There have also been studies that confirm the presence of shish kebab structures of UHMWPE fibers prepared by gel spinning − and the formation of shish-kebab structure of UHMWPE during injection molding of UHMWPE/HDPE blends as well as effect of change in UHMWPE molecular weight when melt blended with HDPE .…”

“…There are numerous studies involving the microstructure of HDPE and UHMWPE and their blends processed through different ways, 39 − 51 as well as X-ray diffraction studies of HDPE or UHMWPE-containing polymers. 15 , 36 , 52 − 60 There have been studies on the evolution of microstructures in UHMWPE/HDPE blend fibers prepared by melt spinning, 15 control of subinclusion microstructure in ternary blends consisting of HDPE, 43 microstructural characterization of HDPE/polyamide blend through selective laser sintering processing, 44 microstructural evaluation of HDPE along with its other properties after weathering, 40 assessment of microstructure of HDPE post chemical recycling, 41 post reinforcement for use as shielding materials against nuclear radiation, 42 effect of various reinforcements on microstructure of UHMWPE consisting composites, 46 , 47 studies on microstructure of modified UHMWPE 50 and UHMWPE consisting blend foams, 51 and many more.…”

Microstructural Characterization and Property of Carbon Fiber Reinforced High-Density Polyethylene Composites Fabricated by Fused Deposition Modeling

“…In addition, CF-reinforced thermoplastic composites are being reported as potential materials to replace traditional thermoplastic polymers and even metals [20]. In a previous investigation, CF concentrations of up to 4 wt.% were considered to investigate its effect on mechanical and dynamic mechanical properties [21]. In the present project, the effects of CF content, with a concentration up to 14%, on surface quality, microstructure characterizations, tensile properties, dynamic mechanical properties, and thermal properties have been analyzed for the first time.…”