Sustainability aspects of composite filament fabrication for 3D printing applications

Tadi, Siva Prasad; Maddula, Shanmuka Srinivas; Mamilla, Ravi Sankar

doi:10.1016/j.rser.2023.113961

Cited by 17 publications

(5 citation statements)

References 114 publications

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“…The present findings compliment previous work where there is a growing body of literature seeking to achieve green innovation in 3D printing. Beyond drug delivery, green innovation for 3D printing has explored the possibility of both recycling and upcycling feedstocks . Other research has explored the potential of using 3D printing materials that can sequester carbon from the environment, thereby minimizing its impact .…”

Section: Discussionmentioning

confidence: 99%

“…Beyond drug delivery, green innovation for 3D printing has explored the possibility of both recycling and upcycling feedstocks. 39 Other research has explored the potential of using 3D printing materials that can sequester carbon from the environment, thereby minimizing its impact. 40 Studies into the use of artificial intelligence (AI) have also been investigated, whereby AI can minimize the wasteful practice of trial-and-error and for preventative maintenance.…”

Section: Discussionmentioning

confidence: 99%

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Cold Laser Sintering of Medicines: Toward Carbon Neutral Pharmaceutical Printing

Elbadawi,

Li,

Ghosh

et al. 2024

ACS Sustainable Chem. Eng.

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Selective laser sintering (SLS) is an emerging threedimensional (3D) printing technology that uses a laser to fuse powder particles together, which allows the fabrication of personalized solid dosage forms. It possesses great potential for commercial use. However, a major drawback of SLS is the need to heat the powder bed while printing; this leads to high energy consumption (and hence a large carbon footprint), which may hinder its translation to industry. In this study, the concept of cold laser sintering (CLS) is introduced. In CLS, the aim is to sinter particles without heating the powder bed, where the energy from the laser, alone, is sufficient to fuse adjacent particles. The study demonstrated that a laser power above 1.8 W was sufficient to sinter both KollicoatIR and Eudragit L100-55-based formulations at room temperature. The cold sintering printing process was found to reduce carbon emissions by 99% compared to a commercial SLS printer. The CLS printed formulations possessed characteristics comparable to those made with conventional SLS printing, including a porous microstructure, fast disintegration time, and molecular dispersion of the drug. It was also possible to achieve higher drug loadings than was possible with conventional SLS printing. Increasing the laser power from 1.8 to 3.0 W increased the flexural strength of the printed formulations from 0.6 to 1.6 MPa, concomitantly increasing the disintegration time from 5 to over 300 s. CLS appears to offer a new route to laser-sintered pharmaceuticals that minimizes impact on the environment and is fit for purpose in Industry 5.0.

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Section: Discussionmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

Cold Laser Sintering of Medicines: Toward Carbon Neutral Pharmaceutical Printing

Elbadawi,

Li,

Ghosh

et al. 2024

ACS Sustainable Chem. Eng.

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“…and metal-coated fillers (with or without a metal core) [ 6 ]. The insulating polymer matrix in CPCs offers flexibility, low cost, low density, corrosion resistance and high specific strength, as well as the production of complex shapes through various environmentally friendly technologies, such as 3D printing [ 7 , 8 , 9 , 10 ], injection molding [ 11 ] and compression molding [ 12 ].…”

Section: Introductionmentioning

confidence: 99%

Surface Modification of Copper-Based Flakes for Conductive Polymer Composites

Mihelčič,

Oseli,

Rojac

et al. 2024

Polymers

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The physical properties as well as thermal and electrical stability of copper particles can be improved by surface protection, which mainly depends on the coating material. Our study was, therefore, focused on the rheological, thermal, mechanical and electrical characterization of polymer composites by comparing uncoated (Cu), silver-coated (Cu@Ag) and silica-coated (Cu@Si) copper flakes in low-density polyethylene at various volume concentrations (up to 40%). Interactions among particles were investigated by rheological properties, as these indicate network formation (geometrical entanglement), which is important for mechanical reinforcement as well as establishing an electric pathway (electrical percolation). The results showed that geometrical and electrical percolation were the same for Cu and Cu@Si, ~15%, while, surprisingly, Cu@Ag exhibited much lower percolation, ~7.5%, indicating the fusion of the Ag coating material, which also decreased crystal growth (degree of crystallinity). Furthermore, the magnitude of the rheological and mechanical response remained the same for all investigated materials, indicating that the coating materials do not provide any load transfer capabilities. However, they profoundly affect electron transfer, in that, Cu@Ag exhibited superior conductivity (74.4 S/m) compared to Cu (1.7 × 10−4 S/m) and Cu@Si (1.5 × 10−10 S/m). The results obtained are important for the design of advanced polymer composites for various applications, particularly in electronics where enhanced electrical conductivity is desired.

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“…Ceramics are unusable for applications in extremely low or high temperatures due to their brittle behavior. Another problem that occurs is the segregation of ceramic powders in VAT photopolymerization processes such as stereolithography (SLA) [17][18][19][20][21].…”

Section: Introductionmentioning

confidence: 99%

Mechanical Performance of Recycled 3D Printed Sustainable Polymer-Based Composites: A Literature Review

Kyriakidis,

Kladovasilakis,

Pechlivani

et al. 2024

J. Compos. Sci.

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The development of efficient waste valorization strategies has emerged as an important field in the overall efforts for alignment with the environmental goals that have been set by the European Union (EU) Green Deal regarding the development of sustainable circular economy models. Additive manufacturing has emerged as a sustainable method for secondary life product development with the main advantages of it being a form of net-zero waste production and having the ability to successfully transport complex design to actual products finding applications in the industry for rapid prototyping or for tailored products. The insertion of eco-friendly sustainable materials in these processes can lead to significant reduction in material footprints and lower energy demands for the manufacturing process, helping achieve Sustainable Development Goal 12 (SDG12) set by the EU for responsible production and consumption. The aim of this comprehensive review is to state the existing progress regarding the incorporation of sustainable polymeric composite materials in additive manufacturing (AM) processes and identify possible gaps for further research. In this context, a comprehensive presentation of the reacquired materials coming from urban and industrial waste valorization processes and that are used to produce sustainable composites is made. Then, an assessment of the printability and the mechanical response of the constructed composites is made, by taking into consideration some key thermal, rheological and mechanical properties (e.g., viscosity, melting and degradation temperature, tensile and impact strength). Finally, existing life cycle analysis results are presented regarding overall energy demands and environmental footprint during the waste-to-feedstock and the manufacturing processes. A lack of scientific research was observed, regarding the manifestation of novel evaluation techniques such as dynamic mechanical analysis and impact testing. Assessing the dynamic response is vital for evaluating whether these types of composites are adequate for upscaling and use in real life applications.

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Sustainability aspects of composite filament fabrication for 3D printing applications

Cited by 17 publications

References 114 publications

Cold Laser Sintering of Medicines: Toward Carbon Neutral Pharmaceutical Printing

Cold Laser Sintering of Medicines: Toward Carbon Neutral Pharmaceutical Printing

Surface Modification of Copper-Based Flakes for Conductive Polymer Composites

Mechanical Performance of Recycled 3D Printed Sustainable Polymer-Based Composites: A Literature Review

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