Fused Particle Fabrication 3-D Printing: Recycled Materials’ Optimization and Mechanical Properties

Woern, Aubrey L.; Byard, Dennis J.; Oakley, Robert B.; Fiedler, Matthew J.; Snabes, Samantha L.; Pearce, Joshua M.

doi:10.3390/ma11081413

Cited by 189 publications

(165 citation statements)

References 55 publications

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“…The particle sizes demonstrated in Figure 10 are small enough to use in a wide array of recyclebots (both commercial and homemade) as well as for direct printing via FPF/FGF as demonstrated in references [58][59][60].…”

Section: Technical Specifications For Particle Size Throughput and mentioning

confidence: 98%

“…Figure 10 shows the resultant particles and particle size distribution, where it is clear that the majority of particles are fines with total areas under 10 mm 2 . These particle sizes are appropriate for the majority of recyclebots as well as direct material extruder-based 3D printers such as the Gigabot X [58][59][60]. Using the initial acoustic measurements, an expansion chamber was designed ( Figure 9) that could be attached to the five-gallon bucket shop vacuum, and a 3D model was produced to utilize PVC and a 3D printable components to reduce noise from the operation of the device.…”

Section: Noise Reductionmentioning

confidence: 99%

“…These fused particle fabrication (FPF) or fused granular fabrication (FGF) 3D printers are becoming established in the academic [49][50][51][52][53][54], maker [55][56][57], and commercial venues (e.g., GigabotX, PartDaddy, Cheetah Pro, David, Erecto-Struder, etc.). FPF/FGF printing is possible with recycled materials [58][59][60], as is using FGF printing of molds for distributed injection molding of larger replicate products [60].…”

Section: Introductionmentioning

confidence: 99%

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Open Source Waste Plastic Granulator

et al. 2019

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In order to accelerate deployment of distributed recycling by providing low-cost feed stocks of granulated post-consumer waste plastic, this study analyzes an open source waste plastic granulator system. It is designed, built, and tested for its ability to convert post-consumer waste, 3D printed products and waste into polymer feedstock for recyclebots of fused particle/granule printers. The technical specifications of the device are quantified in terms of power consumption (380 to 404 W for PET and PLA, respectively) and particle size distribution. The open source device can be fabricated for less than $2000 USD in materials. The experimentally measured power use is only a minor contribution to the overall embodied energy of distributed recycling of waste plastic. The resultant plastic particle size distributions were found to be appropriate for use in both recyclebots and direct material extrusion 3D printers. Simple retrofits are shown to reduce sound levels during operation by 4dB-5dB for the vacuum. These results indicate that the open source waste plastic granulator is an appropriate technology for community, library, maker space, fab lab, or small business–based distributed recycling.

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Section: Technical Specifications For Particle Size Throughput and mentioning

confidence: 98%

Section: Noise Reductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Open Source Waste Plastic Granulator

et al. 2019

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“…Of these enabling technologies, the most advanced is the fused filament fabrication (FFF)-class of desktop 3-D printers that have spawned from the self-replicating rapid prototyper (RepRap) project [62][63][64] . With the distributed manufacturing model, designs are downloaded even in remote areas and are manufactured on demand as needed 65 from readily available (and possibly recycled [66][67][68][69][70][71][72][73][74][75][76][77][78] ) materials. These 3-D printers are, in general, not particularly fast when making products, but with tens of thousands of 3-D printers already strategically deployed all over the world 79 , they have the capacity to fabricate an incredibly diverse and large range of products (growing exponentially) 80 , which have already been shared with open source design licenses.…”

Section: Introductionmentioning

confidence: 99%

A review of open source ventilators for COVID-19 and future pandemics

Pearce

2020

F1000Res

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Coronavirus Disease 2019 threatens to overwhelm our medical infrastructure at the regional level causing spikes in mortality rates because of shortages of critical equipment, like ventilators. Fortunately, with the recent development and widespread deployment of small-scale manufacturing technologies like RepRap-class 3-D printers and open source microcontrollers, mass distributed manufacturing of ventilators has the potential to overcome medical supply shortages. In this study, after providing a background on ventilators, the academic literature is reviewed to find the existing and already openly-published, vetted designs for ventilators systems. These articles are analyzed to determine if the designs are open source both in spirit (license) as well as practical details (e.g. possessing accessible design source files, bill of materials, assembly instructions, wiring diagrams, firmware and software as well as operation and calibration instructions). Next, the existing Internet and gray literature are reviewed for open source ventilator projects and designs. The results of this review found that the tested and peer-reviewed systems lacked complete documentation and the open systems that were documented were either at the very early stages of design (sometimes without even a prototype) and were essentially only basically tested (if at all). With the considerably larger motivation of an ongoing pandemic, it is assumed these projects will garner greater attention and resources to make significant progress to reach a functional and easily-replicated system. There is a large amount of future work needed to move open source ventilators up to the level considered scientific-grade equipment, and even further work needed to reach medical-grade hardware. Future work is needed to achieve the potential of this approach by developing policies, updating regulations, and securing funding mechanisms for the development and testing of open source ventilators for both the current COVID19 pandemic as well as for future pandemics and for everyday use in low-resource settings.

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“…Along with broad distribution and drastic price reduction of FFF machines and consumables, the Rapid Manufacturing is now more and more often replaced with Distributed Manufacturing term, implying the shift from making exclusive products to massive production of commodities [31][32][33][34][35][36][37]. Laying aside FGF machines, operating on polymer pellets or regrind, as described in [38,39], the following tendency can be formulated. While the performance of machines printing with molten polymers has only increased several times since their appearance, the average price of such a machine reduced by several orders of magnitude.…”

Section: Introductionmentioning

confidence: 99%

Desktop Fabrication of Strong Poly (Lactic Acid) Parts: FFF Process Parameters Tuning

Ve¹,

Tavitov²,

Urzhumtcev³

et al. 2019

Preprint

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Current study aims to evaluate the possibilities to increase part strength by optimizing the FFF process parameters. Five different CAD models of parts with same coupling dimensions but different shape inherited from a recent study were converted into test samples with Ultimaker 2 3D printer. The main measure of success was the sample strength, defined as the load at which the first crack in the stressed area of the part appeared. Three different modifications to the FFF process with verified positive effect on interlayer bonding were applied. First modification included raising the extrusion temperature and disabling printed part cooling. Second modification consisted in reduction of the layer thickness. Third modification combined the effects of the first and the second ones. For four out of five shapes tested applied process modifications resulted in significant strengthening of the part. The shape that exhibited the best results was subject to further research by creating special printing mode. The mode included fine-tuning of three technological parameters on different stages of the part fabrication. As result it was possible to increase the part strength by 108% only by tuning printing parameters of the best shape designed with increasing its weight by 8%.

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Fused Particle Fabrication 3-D Printing: Recycled Materials’ Optimization and Mechanical Properties

Cited by 189 publications

References 55 publications

Open Source Waste Plastic Granulator

Open Source Waste Plastic Granulator

A review of open source ventilators for COVID-19 and future pandemics

Desktop Fabrication of Strong Poly (Lactic Acid) Parts: FFF Process Parameters Tuning

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