Purpose - This study aims to quantify the ultimate tensile strength and the nominal strain at break (f) of printed parts made from polylactic acid (PLA) with a Replicating Rapid prototyper (Rep-Rap) 3D printer, by varying three important process parameters: layer thickness, infill orientation and the number of shell perimeters. Little information is currently available about mechanical properties of parts printed using open-source, low-cost 3D printers. Design/methodology/approach - A computer-aided design model of a tensile test specimen was created, conforming to the ASTM:D638. Experiments were designed, based on a central composite design. A set of 60 specimens, obtained from combinations of selected paramers, was printed on a Rep-Rap Prusa I3 in PLA. Testing was performed using a JJ Instruments - T5002-type tensile testing machine and the load was measured using a load cell of 1,100 N. Findings - This study investigated the main impact of each process parameter on mechanical properties and the effects of interactions. The use of a response surface methodology allowed the proposition of an empirical model which connects process parameters and mechanical properties. Even though results showed a high variability, additional ideas on how to understand the impact of process parameters are suggested in this paper. Originality/value - On the basis of experimental results, it is possible to obtain practical suggestions to set common process parameters in relation to mechanical properties. Experiments discussed in the present paper provide a variety of data and insight regarding the relationship among the main process parameters and the stiffness and strength of fused deposition modeling-printed parts made from PLA. In particular, this paper underlines the shortage in existing literature concerning the impact of process parameters on the elastic modulus and the strain to failure for the PLA. The experimental data produced show a good degree of compliance with analytical formulations and other data found in literature

Centralized waste plastic recycling is economically challenging, yet distributed recycling and additive manufacturing (DRAM) offers a path that provides consumers with direct economic incentives to recycle. This study explores the technical pathways for DRAM of complex polymer composites using a case study of windshield wiper blades, which are a thermopolymer composite made up of a soft (flexible) and hard material. The distributed manufacturing methods ran from mechanical grinding to fused granular fabrication, heated syringe printing, 3-D printed molds coupled to injection molding and filament production in a recyclebot to fused filament fabrication. The particle size, angle of repose, thermal and rheological properties are characterized for the two sub-materials to define the conditions for the extrusion. A successful pathway was found and the mechanical properties of the resultant components were quantified.Finally, the means to convert scrap windshield wiper blades into useful, high-value, bespoke biomedical products of fingertip grips for hand prosthetic was demonstrated. This study showed that the DRAM model of materials recycling can be used to improve the variety of solutions for a circular economy.

Purpose Recent advancements of 3D printing technology have brought forward the interest for this technique in many engineering fields. This study aims to focus on mechanical properties of the polylactic acid (PLA) feeding material under different thermal conditions for a typical fusion deposition of 3D printer system. Design/methodology/approach Specimens were tested under static loading within the range 20ºC to 60ºC considering different infill orientations. The combined effect of temperature and filament orientation is investigated in terms of constitutive material parameters and final failure mechanisms. The difference between feeding system before and post-3D printing was also assessed by mechanical test on feeding filament to verify the thermal profile during the deposition phase. Findings The results in terms of Young’s modulus, ultimate tensile strength (UTS), strain at failure (εf) and stress at failure (σf) are presented and discussed to study the influence of process settings over the final deposited material. Fracture surfaces have been investigated using an optical microscope to link the phenomenological interpretation of the failure with the micro-mechanical behaviour. Experimental results show a strong correlation between stiffness and strength with the infill orientation and the temperature values. Moreover, a relevant effect is related to deformed geometry of the filament approaching glass transition region of the polymer according to the deposition orientation. Research limitations/implications The developed method can be applied to optimise the stiffness and strength of any 3D-printed composite according to the infill orientation. Practical implications To avoid the failure of specimens outside the gauge length, a previously proposed modification to the geometry was adopted. The geometry has a parabolic profile with a curvature of 1,000 mm tangent to the middle part of the specimen. Originality/value Several authors have reported the stiffness and strength of 3D-printed parts under static and ambient temperature for different build parameters. However, there is a lack of literature on the combination of the latter with the temperature effects on the mechanical properties which this paper covers.

In service, railway tracks must withstand the transverse and longitudinal forces that are caused by running vehicles and thermal loads. The mechanical design that adopts any of the track models available in the technical literature requires that the strength of the track is fully characterised. In this paper, the results of an experimental research activity on the sleeper–ballast resistance along the lateral and the longitudinal directions are reported and discussed. In particular, the work is aimed at identifying the strength contributions offered by the base, the ballast between the sleepers, and the ballast shoulder to the global resistance of the track in the horizontal plane. These quantities were experimentally determined by means of an ad hoc system designed by the authors. Field tests were carried out on a series of track sections that were built to simulate scenarios in which the ballast was removed from the crib and/or the shoulder. The results of this study indicate that the strength percent contributions from the crib, the sleeper base, and the shoulder are, respectively, equal to about 50%, 25%, and 25% in the lateral direction, and 60%, 30%, and 10% in the longitudinal direction. Moreover, the comparison of the acquired data with literature results reveals that a detailed knowledge about the testing conditions and the activated ballast failure mechanisms is needed in order to correctly use the test data for the design purpose.