Production of spherical wax and polyolefin microparticles by melt emulsification for additive manufacturing

Fanselow, Stephanie; Emamjomeh, Seyed Ehsan; Wirth, Karl‐Ernst; Schmidt, Jochen; Peukert, Wolfgang

doi:10.1016/j.ces.2015.11.019

Cited by 49 publications

(41 citation statements)

References 36 publications

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“…Other polymers, for example, PBT and PA12 powders, have also been produced through this meltbased method by employing different matrix phases and solvents. [152,153]…”

Section: (24 Of 54)mentioning

confidence: 99%

“…Melt-based Melt emulsification/Coextrusion PP [133] PE [152] PBT [152] PA12 [153] • Spherical particle shape…”

Section: Solution-basedmentioning

confidence: 99%

“…Commercial homo-PP is mostly isotactic (iPP), due to the higher crystallinity, melting temperature (≈160 °C) and modulus achievable; many studies investigating the use of SLS for PP have also focused on iPP. [130,148,152,181] To address the brittle nature of iPP (strain at break of 1-7% for SLS specimens), ethylene has been incorporated into the polymer backbone to form PP copolymers that exhibit much higher toughness (strain at break of 75-400%). [141,182] The melting temperature of PP varies with the tacticity and ethylene content in the polymer chain, where lower tacticity and higher ethylene content generally leads to lower melting temperatures.…”

Section: (28 Of 54)mentioning

confidence: 99%

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Recent Progress on Polymer Materials for Additive Manufacturing

Tan

Zhu

Zhou

2020

Adv Funct Materials

490

238

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Additive manufacturing (AM) is the process of printing 3D objects in a layer-by-layer manner. Polymers and their composites are some of the most widely used materials in modern industries and are of great interest in the field of AM due to their vast potential for various applications, especially in the medical, aerospace, and automotive industries. Many studies have been conducted to develop new polymer materials for AM techniques, which include vat photopolymerization, material jetting, powder bed fusion, material extrusion, binder jetting, and sheet lamination. Although several reviews on the development of polymer materials for AM have been published, most of them only focus on a specific application, process, or type of material. Therefore, this article serves to provide a comprehensive review on the progress in polymer material development for AM techniques. It begins with an introduction to different AM techniques, followed by highlighting the progress of their development. Material requirements, notable advances in newly developed materials and their potential applications are discussed in detail and summarized. This review concludes by identifying the major challenges currently encountered in using AM for polymer materials and providing insights into the valuable opportunities it presents, in hopes of spurring further development in this field.

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“…Other polymers, for example, PBT and PA12 powders, have also been produced through this meltbased method by employing different matrix phases and solvents. [152,153]…”

Section: (24 Of 54)mentioning

confidence: 99%

“…Melt-based Melt emulsification/Coextrusion PP [133] PE [152] PBT [152] PA12 [153] • Spherical particle shape…”

Section: Solution-basedmentioning

confidence: 99%

Section: (28 Of 54)mentioning

confidence: 99%

See 1 more Smart Citation

Recent Progress on Polymer Materials for Additive Manufacturing

Tan

Zhu

Zhou

2020

Adv Funct Materials

490

238

View full text Add to dashboard Cite

show abstract

“…The authors also showed some preliminary results on blends of PBT and polyethylene glycol (PEG). The production of spherical polypropylene particles via melt blending with hexadecane was described by Fanselow et al [24,25], however no parts were produced with the obtained powder.…”

Section: Introductionmentioning

confidence: 99%

Production and Processing of a Spherical Polybutylene Terephthalate Powder for Laser Sintering

2019

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This work describes the production of a spherical polybutylene terephthalate (PBT) powder and its processing with selective laser sintering (SLS). The powder was produced via melt emulsification, a continuous extrusion-based process. PBT was melt blended with polyethylene glycol (PEG), creating an emulsion of spherical PBT droplets in a PEG matrix. Powder could be extracted after dissolving the PEG matrix phase in water. The extrusion settings were adjusted to optimize the size and yield of PBT particles. After classification, 79 vol. % of particles fell within a range of 10–100 µm. Owing to its spherical shape, the powder exhibited excellent flowability and packing properties. After powder production, the width of the thermal processing (sintering) window was reduced by 7.6 °C. Processing of the powder on a laser sintering machine was only possible with difficulties. The parts exhibited mechanical properties inferior to injection-molded specimens. The main reason lied in the PBT being prone to thermal degradation and hydrolysis during the powder production process. Melt emulsification in general is a process well suited to produce a large variety of SLS powders with exceptional flowability.

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“…In general, the stability of melt emulsions can be divided into two stages: first, the liquid droplets must be stabilized in the emulsion (emulsion stability) to prevent coalescence [23]; second, after the dispersed wax droplets are solidified, the suspension stability is influenced by phase separation (flotation) and changes in particle size distribution (aggregation and/or Ostwald ripening) ( Figure 1).…”

mentioning

confidence: 99%

Inter-Correlation among the Hydrophilic–Lipophilic Balance, Surfactant System, Viscosity, Particle Size, and Stability of Candelilla Wax-Based Dispersions

2018

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Owing to a decrease in mineral oil resources, it is crucial to develop packaging materials based on renewable resources. Hence, a water vapor-barrier coating is developed as a natural wax-based dispersion. This dispersion should be stable over the storage time. In this study, the physical stability of a wax-based melt dispersion was analyzed (24 h and 21 days after production), and instability phenomena such as agglomeration, coalescence, and flotation were identified. Furthermore, the inter-correlations among the particle size, viscosity of the continuous phase, physical stability, surfactant chemistry, and hydrophilic–lipophilic balance value were characterized. Particle sizes were described by volume/surface mean d3,2, volume moment mean d4,3, and number mean d1,0 diameter, as well as the span of the volume and number distribution. Stability was characterized by the flotation rate, emulsion stability index, and Turbiscan stability index. Coalescence and agglomeration were not observed after the solidification of the wax particles. A significant correlation was observed for the emulsion stability index, with d3,2, and for flotation rate, with d1,0, d4,3, and viscosity as well, with d1,0, d3,2. Surfactants with hydrophilic–lipophilic balance values of 11–13.5 seem to be the most suitable for stabilizing candelilla wax-in-water suspensions. Particles were smaller, and wax suspensions were better stabilized using Tween 20 and Span 20, compared with Tween 80 and Span 80.

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Production of spherical wax and polyolefin microparticles by melt emulsification for additive manufacturing

Cited by 49 publications

References 36 publications

Recent Progress on Polymer Materials for Additive Manufacturing

Recent Progress on Polymer Materials for Additive Manufacturing

Production and Processing of a Spherical Polybutylene Terephthalate Powder for Laser Sintering

Inter-Correlation among the Hydrophilic–Lipophilic Balance, Surfactant System, Viscosity, Particle Size, and Stability of Candelilla Wax-Based Dispersions

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