Large-scale 3D printers for additive manufacturing: design considerations and challenges

Shah, Jesika J.; Snider, Barry; Clarke, Tim; Kozutsky, S.; Lacki, M.; Hosseini, Ali

doi:10.1007/s00170-019-04074-6

Cited by 119 publications

(54 citation statements)

References 12 publications

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“…There have been several studies using FGF to print recycled materials with large FGF machines. 62 Here, a small printer was tested that could be an additional option to the well-established FFF general consumer market.…”

Section: Discussionmentioning

confidence: 99%

Mechanical Properties of Direct Waste Printing of Polylactic Acid with Universal Pellets Extruder: Comparison to Fused Filament Fabrication on Open-Source Desktop Three-Dimensional Printers

Alexandre

Sanchez

Boudaoud

et al. 2020

3D Printing and Additive Manufacturing

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Fused filament fabrication (FFF) is the most common and widespread additive manufacturing (AM) technique, but it requires the formation of filament. Fused granular fabrication (FGF), where plastic granules are directly three-dimensional (3D) printed, has become a promising technique for the AM technology. FGF could be a key driver to promote further greening of distributed recycling thanks to the reduced melt solidification steps and elimination of the filament extruder system. However, only large-scale FGF systems have been tested for technical and economic viability of recycling plastic materials. The objective of this work is to evaluate the performance of the FFF and FGF techniques in terms of technical and economical dimensions at the desktop 3D printing scale. Recycled and virgin polylactic acid material was studied by using five different types of recycling feedstocks: commercial filament, pellets, distributed filament, distributed pellets, and shredded waste. The results showed that the mechanical properties from the FGF technique using same configurations showed no statistical differences to FFF samples. Nevertheless, the granulometry could have an influence on the reproducibility of the samples, which explains that the critical factor in this technology is to assure the material input in the feeding system. In addition, FGF costs per kg of material were reduced to less than 1 e/kg compared with more than 20 e/kg for commercial recycled filament. These results are encouraging to foster FGF printer diffusion among heavy users of 3D printers because of reducing the cost associated to the filament fabrication while ensuring the technical quality. This indicates the possibility of a new type of 3D printing recycled plastic waste that is more likely to drive a circular economy and distributed recycling.

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Section: Discussionmentioning

confidence: 99%

Mechanical Properties of Direct Waste Printing of Polylactic Acid with Universal Pellets Extruder: Comparison to Fused Filament Fabrication on Open-Source Desktop Three-Dimensional Printers

Alexandre

Sanchez

Boudaoud

et al. 2020

3D Printing and Additive Manufacturing

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“…3D printing market is one of the fastest growing sectors. It is expected that by 2021 it will see over 23% market growth comparing to 2016, reaching over 10 mld USD (Shah et al 2019 ). 3D printing is a relatively new technology that has become very popular in the last few years.…”

Section: Commercial Polymers For 3d Printingmentioning

confidence: 99%

“…Simplicity and low costs have contributed to the fact that it is primarily used in prototyping and small-scale productions. In recent years, the use of 3D printing has become more popular in various industrial sectors, with the aerospace, military, automotive, medical, and construction industries increasingly taking advantage of it (Shah et al 2019 ).…”

Section: Commercial Polymers For 3d Printingmentioning

confidence: 99%

3D printing filament as a second life of waste plastics—a review

Mikula

Skrzypczak

Izydorczyk

et al. 2020

Environ Sci Pollut Res

264

111

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In recent times, the issue of plastic recycling has become one of the leading issues of environmental protection and waste management. Polymer materials have been found an application in many areas of daily life and industry. Along with their extended use, the problem of plastic wastes appeared because, after withdrawal from use, they became persistent and noxious wastes. The possibility of reusing polymeric materials gives a possibility of valorization-a second life-and enables effective waste utilization to obtain consumable products. The 3D printing market is a well-growing sector. Printable filaments can be made from a variety of thermoplastic materials, including those from recycling. This paper focuses on a review of the available literature on the production of filaments for 3D printers from recycled polymers as the alternative to present approach of central selective collection of plastics. The possibility of recycling of basic thermoplastic materials and the impact of processing on their physicochemical and mechanical properties were verified (Lanzotti et al. 2019). In addition, commercially available filaments produced from recycled materials and devices which allow self-production of filaments to 3D printing from plastic waste were reviewed.

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“…Large-scale printers are a relative newcomer to AM and are helping voyage the path between lab-scale experimentation and industrial production capabilities. Whereas typical 3D-printers are benchtop size (average of~8 cubic centimeters), these large-scale printers typically possess build volumes of 1 cubic meter or larger, with some systems like the big area additive manufacturing (BAAM) printer from Cincinnati Incorporated (Harrison, OH, USA) occupying a much larger build volume of 35.5 cubic meters [ 100 ]. As mentioned earlier, these systems utilize a pellet-fed extruder.…”

Section: Challenges and Opportunities In 3d Printing Of Wood Compomentioning

confidence: 99%

“…The presence of wood and lignocellulosic-based fillers can results in poor adhesion due to a lack of polymer entanglement, crystallization problems, and heterogenous dispersion, which were all discussed previously in their relevant sections. To overcome these issues, large-scale printers rely on tunable screws during the extrusion, heated beds, dual-printing heads, and environmental control, as well as extensive trial and error using test prints [ 100 ].…”

Section: Challenges and Opportunities In 3d Printing Of Wood Compomentioning

confidence: 99%

Material Extrusion Additive Manufacturing of Wood and Lignocellulosic Filled Composites

et al. 2020

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Wood and lignocellulosic-based material components are explored in this review as functional additives and reinforcements in composites for extrusion-based additive manufacturing (AM) or 3D printing. The motivation for using these sustainable alternatives in 3D printing includes enhancing material properties of the resulting printed parts, while providing a green alternative to carbon or glass filled polymer matrices, all at reduced material costs. Previous review articles on this topic have focused only on introducing the use of natural fillers with material extrusion AM and discussion of their subsequent material properties. This review not only discusses the present state of materials extrusion AM using natural filler-based composites but will also fill in the knowledge gap regarding state-of-the-art applications of these materials. Emphasis will also be placed on addressing the challenges associated with 3D printing using these materials, including use with large-scale manufacturing, while providing insight to overcome these issues in the future.

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Large-scale 3D printers for additive manufacturing: design considerations and challenges

Cited by 119 publications

References 12 publications

Mechanical Properties of Direct Waste Printing of Polylactic Acid with Universal Pellets Extruder: Comparison to Fused Filament Fabrication on Open-Source Desktop Three-Dimensional Printers

Mechanical Properties of Direct Waste Printing of Polylactic Acid with Universal Pellets Extruder: Comparison to Fused Filament Fabrication on Open-Source Desktop Three-Dimensional Printers

3D printing filament as a second life of waste plastics—a review

Material Extrusion Additive Manufacturing of Wood and Lignocellulosic Filled Composites

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