Microstructure Evaluation and Thermal–Mechanical Properties of ABS Matrix Composite Filament Reinforced with Multi-Walled Carbon Nanotubes by a Single Screw Extruder for FDM 3D Printing

Abstract

This paper reports the synthesis of a new printable ABS–MWCNT composite filament, for use in fused deposition modeling (FDM), using an extrusion technique. Acrylonitrile butadiene styrene (ABS) and multi-walled carbon nanotubes (MWCNTs) were the initial materials used for fabricating the filaments. The MWCNTs were dispersed in ABS resin, then extruded through a single-shaft extruder in filament form, with MWCNT contents of 0.5%, 1%, 1.5%, 2%, 3% or 4% by weight. After extrusion, the diameter of the filaments was about 1.75 mm, making them appropriate for FDM. The as-synthesized filaments were then used in FDM to print out samples, on which tensile tests and other analyses were carried out. The results demonstrate that the sample with 2% MWCNTs had the highest strength value, 44.57 MPa, comprising a 42% increase over that of the pure ABS sample. The morphology and dispersion of MWCNTs in the composite were observed by field emission scanning electron microscopy (FESEM), demonstrating the uniform distribution of MWCNTs in the ABS matrix. The thermal behavior results indicated no significant change in the ABS structure; however, the melt flow index of the filaments decreased with an increase in the MWCNT content.

Instrumented open-source filament extruder for research and education

“…The extrusor system is usually divided into three functional regions: the extrusion system, which is the drill and motor, the feeding zone, with printed designs in general and the heating zone, which is usually with resistances only in the barrel, therefore with only one heating zone. The structural part of the extruder has several types of constructive forms, some designs use printed parts locked into a wooden board, and others use metallic plates [19] , [21] , [22] . However, these machines have little instrumentation, using heater controller and potentiometer for motor control.…”

“…However, in the vertical, it assists the winding system, and in the horizontal, it is responsible for pulling the filament, especially as it gets rigid. The most common designs resemble rolling mills, where the filament passes through rollers connected to a motor [19] , [20] , [21] , [22] , [23] , [24] , [25] , [26] , [27] , [28] , [29] , [30] , [31] , [32] . The winder system is present in all designs of desktop extruders.…”

“…This circuit made it possible, for example, to change the extrusion flow rate in a more stable and accurate way, since it is modified by PWM. These digital signals, in this circuit, are more accurate, regarding repeatability, compared to those with a potentiometer [19] , [20] , [21] , [22] .…”

Enhanced mechanical properties of MWCNT reinforced ABS nanocomposites fabricated through additive manufacturing process

“…The mechanical and electrical characteristics of MWCNT/ABS composites were enhanced in certain limits. After 3 wt.% MWCNTs of dispersion the properties of composites decrease significantly 33 …”

“…After 3 wt.% MWCNTs of dispersion the properties of composites decrease significantly. 33 In this research work MWCNTs /ABS composites with 1, 2, and 3 wt.% MWCNTs reinforcement were prepared with two-time twin screw extruder. The filaments were prepared for FDM-3D printing through filament extruder.…”