3D printing of semicrystalline polypropylene: towards eliminating warpage of printed objects

Bachhar, Nirmalya; Gudadhe, Aniket; Kumar, Anil; Andrade, Prem; Kumaraswamy, Guruswamy

doi:10.1007/s12034-020-02097-4

Cited by 40 publications

(37 citation statements)

References 23 publications

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“…The goal of this project was to investigate the sustainability of 3D printed PP and GFPP rectangular objects that have undergone several rounds of steam sterilization via autoclaving to fabricate custom and/or multi-use medical devices. PP was chosen because it had the potential to survive the temperatures needed for autoclaving, but is a more difficult polymer to 3D print because it shrinks and warps during the process [ 13 , 16 , 18 – 20 , 22 , 28 , 31 , 32 ]. PP composites have been gaining traction as the rigidity and stability of PP composites reduces the shrinkage and warpage to varying degrees [ 13 , 14 , 16 – 19 , 21 , 28 , 29 , 31 , 33 , 34 ].…”

Section: Discussionmentioning

confidence: 99%

“…Several manuscripts also used Simplify3D® software to 3D print PP and PP composites [ 18 , 19 , 21 , 22 , 34 ]. Several manuscripts by Spoerk et al also used a 0.6 mm steel nozzle, but the print head temperature was 220 or 230 °C, the print bed temperature was 20 or 70 °C, the layer height was 0.25 mm, and it was printed on a PP plate bed [ 18 , 19 , 21 ].…”

Section: Discussionmentioning

confidence: 99%

“…3D printing also known as additive manufacturing, material extrusion, fused deposition modelling (FDM), and fused filament fabrication (FFF) is when a thermoplastic filament is melted, extruded through a circular nozzle, deposited using a 3-axis system onto a print bed, and the 3D object fabricated layer-by-layer from a computerized model [ 13 – 25 ]. 3D printing is an attractive option for medical device fabrication due to its ability to fabricate potentially inexpensive custom pieces over a relatively short time period; however, the two most common 3D printing filaments, poly(lactic acid) (PLA) and acrylonitrile butadiene styrene (ABS), are not suitable because neither can withstand the necessary temperatures for autoclave sterilization [ 15 , 22 , 23 , 26 – 29 ]. Polypropylene (PP) has been gaining traction as a 3D printing material due its low cost, chemical resistance, moisture stability, high impact strength, and use in medical devices [ 13 , 18 – 20 , 22 , 28 , 30 ].…”

Section: Introductionmentioning

confidence: 99%

“…3D printing is an attractive option for medical device fabrication due to its ability to fabricate potentially inexpensive custom pieces over a relatively short time period; however, the two most common 3D printing filaments, poly(lactic acid) (PLA) and acrylonitrile butadiene styrene (ABS), are not suitable because neither can withstand the necessary temperatures for autoclave sterilization [ 15 , 22 , 23 , 26 – 29 ]. Polypropylene (PP) has been gaining traction as a 3D printing material due its low cost, chemical resistance, moisture stability, high impact strength, and use in medical devices [ 13 , 18 – 20 , 22 , 28 , 30 ]. PP has a melting temperature above the necessary autoclave temperatures; however, 3D printed PP has been shown to warp and shrink during the layer-by-layer fabrication process due to its semicrystalline nature [ 13 , 16 , 18 – 20 , 22 , 28 , 31 , 32 ].…”

Section: Introductionmentioning

confidence: 99%

“…Polypropylene (PP) has been gaining traction as a 3D printing material due its low cost, chemical resistance, moisture stability, high impact strength, and use in medical devices [ 13 , 18 – 20 , 22 , 28 , 30 ]. PP has a melting temperature above the necessary autoclave temperatures; however, 3D printed PP has been shown to warp and shrink during the layer-by-layer fabrication process due to its semicrystalline nature [ 13 , 16 , 18 – 20 , 22 , 28 , 31 , 32 ].…”

Section: Introductionmentioning

confidence: 99%

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Reusability of autoclaved 3D printed polypropylene compared to a glass filled polypropylene composite

Fischer

Howell

2021

3D Print Med

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Health care waste can be a costly expenditure for facilities as specific disposal methods must be used to prevent the spread of pathogens. If more multi-use medical devices were available, it could potentially relieve some of this burden; however, sterilization between uses is important in preventing disease transmission. 3D printing has the ability to easily create custom medical devices at a low cost, but the majority of filaments utilized cannot survive steam sterilization. Polypropylene (PP) can withstand autoclave temperatures, but is difficult to print as it warps and shrinks during printing; however, a composite PP filament reduces these effects. Commercially available PP and glass filled PP (GFPP) filaments were successfully 3D printed into 30 × 30 × 30 mm cubes with no shrinking or warping and were autoclaved. The 134 °C autoclave temperature was too high as several cubes melted after two to three rounds, but both PP and GFPP cubes displayed minimal changes in mass and volume after one, four, seven, and ten rounds of autoclaving at 121 °C. GFPP cubes autoclaved zero, four, seven, and ten times had significantly smaller average compressive stress values compared to all PP groups, but the GFPP cubes autoclaved once were only less than PP cubes autoclaved zero, seven and ten times. GFPP cubes autoclaved zero, one, four, and seven times also deformed less indicating that the embedded glass fibers provided additional strength. While a single method was found that successfully printed PP and GFPP cubes that were able to survive up to ten rounds of autoclaving, future work should include further investigation into the mechanical properties and increasing the number of autoclave rounds.

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Section: Discussionmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Reusability of autoclaved 3D printed polypropylene compared to a glass filled polypropylene composite

Fischer

Howell

2021

3D Print Med

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3D‐Printed Functional Polymers and Nanocomposites: Defects Characterization and Product Quality Improvement

et al. 2022

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There have been continuing efforts toward improving printability and minimizing defects in 3D‐printed functional polymers and polymer nanocomposites (PNCs). While printability is essentially material related, and formation of defects is largely influenced by operational parameters, there is an interconnection between the factors influencing both. It is important to have a comprehensive insight on how these aspects interrelate to increase the prospect of improving part performance and widening the current range of applications of 3D‐printed polymer‐based functional materials. Therefore, this work first reviews various polymer 3D printing techniques and recent advances in 3D‐printed functional polymers and PNCs before discussing characterization and control of common defects in printed parts. Techniques for improving printability of polymer‐based functional materials are then discussed. Some opportunities for further developments in this area are highlighted in respect of polymer blending, immiscible blend nanocomposites, and a specific product development prospect.

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The influence of in situ microfibrillation on the mechanical properties and warpage of low‐density polyethylene/polystyrene composite prepared by fused filament fabrication

Wang,

Yang,

et al. 2024

J of Applied Polymer Sci

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Fused filament fabrication (FFF) has been widely adopted due to its simplicity and cost‐effectiveness. But until now, its application materials are still limited. Polyolefin material is one of the most commonly used plastics. However, low‐density polyethylene (LDPE) is rarely used in FFF due to the inadequate strength of the filaments and the warpage of the printed parts. In this work, polystyrene (PS) is added to LDPE to obtain blend filaments. After that, the filaments are used to validate the possibility of in situ microfibrillation directly in the process. The results show that the addition of PS can significantly improve the bending strength, bending modulus, and hardness without affecting the heat resistance and crystal transition of the composite. Besides, the PS dispersed phase can form microfibers under the influence of the shear field. The formation of microfibers can significantly enhance the mechanical properties of composites. The tensile strength and Young's modulus increase by 140% and 221%, respectively. The warping deformation and surface morphology of printed parts are also improved. This study provides a new idea for utilizing low‐strength polyolefin in 3D printing and achieving performance enhancement.

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3D printing of semicrystalline polypropylene: towards eliminating warpage of printed objects

Cited by 40 publications

References 23 publications

Reusability of autoclaved 3D printed polypropylene compared to a glass filled polypropylene composite

Reusability of autoclaved 3D printed polypropylene compared to a glass filled polypropylene composite

3D‐Printed Functional Polymers and Nanocomposites: Defects Characterization and Product Quality Improvement

The influence of in situ microfibrillation on the mechanical properties and warpage of low‐density polyethylene/polystyrene composite prepared by fused filament fabrication

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