Additive manufacturing of heat-sensitive polymer melt using a pellet-fed material extrusion

Zhou, Zuoxin; Salaoru, Iulia; Morris, Peter; Gibbons, Gregory John

doi:10.1016/j.addma.2018.10.040

Cited by 28 publications

(46 citation statements)

References 25 publications

(30 reference statements)

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“…The majority of EAM processes uses a polymer filament, which is forced through a heated nozzle promoting its melting, followed by the continuous deposition of the molten polymer substance as tracks to generate three-dimensional shapes [14]. Next to that, the use of single-screw extruders (SSEs) fed with pellet-shaped polymers is growing [15][16][17][18][19]. SSE-based AM allows the immediate employment of a wide variety of thermoplastic materials such as acrylonitrile butadiene styrene polymer (ABS), poly(lactic acid) PLA, polycarbonate (PC), polyamide (PA), thermoplastic polyurethane (TPU), and styrene-ethylene-butylene-styrene polymer (SEBS), reducing the cost of the feedstock materials [16][17][18][19][20][21].…”

Section: Introductionmentioning

confidence: 99%

“…Next to that, the use of single-screw extruders (SSEs) fed with pellet-shaped polymers is growing [15][16][17][18][19]. SSE-based AM allows the immediate employment of a wide variety of thermoplastic materials such as acrylonitrile butadiene styrene polymer (ABS), poly(lactic acid) PLA, polycarbonate (PC), polyamide (PA), thermoplastic polyurethane (TPU), and styrene-ethylene-butylene-styrene polymer (SEBS), reducing the cost of the feedstock materials [16][17][18][19][20][21]. It allows bypassing multiple manufacturing steps such as the filament extrusion before the AM process, relieving the material to one extrusion cycle and leading to less degradation.…”

Section: Introductionmentioning

confidence: 99%

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Theoretical Evaluation of the Melting Efficiency for the Single-Screw Micro-Extrusion Process: The Case of 3D Printing of ABS

et al. 2020

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One of the challenges for single-screw micro-extrusion or additive manufacturing (AM), thus 3D printing, of polymers is controlling the melting efficiency so that energy and equipment costs can be minimized. Here, a numerical model is presented for AM process design, selecting acrylonitrile–butadiene–styrene (ABS) as viscoelastic reference polymer. It is demonstrated that AM melting is different compared to conventional melting due to variation in extrusion dimensions, leading to a different balance in heating by conduction and viscous heat dissipation as caused by the shearing between the melt layers in the associated film layer near the barrel. The thickness of this melt film layer is variable along the screw length, and it is shown that simplified models assuming an overall average value are too approximate. It is highlighted that the screw frequency, pitch angle and compression ratio are important process parameters to control the point of melt finalization. In addition, the power-law index reflecting the shear thinning nature of the polymer melt is showcased as a key parameter. Moreover, AM process results assuming constant and temperature dependent specific heat capacities and thermal conductivities are compared. The current work opens the door for on-line AM process control, addressing all relevant operating and material parameters.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Theoretical Evaluation of the Melting Efficiency for the Single-Screw Micro-Extrusion Process: The Case of 3D Printing of ABS

et al. 2020

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“…With regard to the commercial large-scale systems, the first equipment was described a year later, in two articles from 2017 [ 63 , 64 ]. As will be shown in Section 4, many new experimental systems for both small- and large-scale applications appeared in the period from 2014 to 2018 [ 15 – 29 , 32 , 34 , 35 , 37 ], which can be related to the high number of publications in the same period. Although the scientific production in the last 2 years decreased, a crescent share of the research was carried out with commercial systems [ 48 , 49 , 51 , 53 , 54 , 65 – 69 , 71 – 73 , 75 ], indicating the consolidation of screw-assisted EAM in the market.…”

Section: Search Resultsmentioning

confidence: 99%

Screw-assisted 3D printing with granulated materials: a systematic review

Netto

Idogava

Santos

et al. 2021

Int J Adv Manuf Technol

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This paper presents a systematic review on extrusion additive manufacturing (EAM), with focus on the technological development of screw-assisted systems that can be fed directly with granulated materials. Screw-assisted EAM has gained importance as an enabling technology to expand the range of 3D printing materials, reduce costs associated with feedstock fabrication, and increase the material deposition rate compared to traditional fused filament fabrication (FFF). Many experimental printheads and commercial systems that use some screw-processing mechanism can be found in the literature, but the design diversity and lack of standard terminology make it difficult to determine the most suitable solutions for a given material or application field. Besides, the few previous reviews have offered only a glimpse into the topic, without an in-depth analysis about the design of the extruders and associated capabilities. A systematic procedure was devised to identify the screw-assisted EAM systems that can print directly from granulated materials, resulting in 61 articles describing different pieces of equipment that were categorized as experimental printheads and commercial systems, for small- and large-scale applications. After describing their main characteristics, the most significant extruder modifications were discussed with reference to the materials processed and performance requirements. In the end, a general workflow for the development of 3D printers based on screw extrusion was proposed. This review intends to provide information about the state-of-the-art screw-assisted EAM and help the academy to identify further research opportunities in the field.

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“…Zhou et al [ 137 ] developed a heat-sensitive polymer polyvinyl alcohol (PVOH) using a material extrusion additive manufacturing method. The fabrication was carried out using a combination of compounding, extrusion, and additive manufacturing.…”

Section: Additive Manufacturing Using Polymersmentioning

confidence: 99%

Additive Manufacturing of Polymer Materials: Progress, Promise and Challenges

et al. 2021

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The use of additive manufacturing (AM) has moved well beyond prototyping and has been established as a highly versatile manufacturing method with demonstrated potential to completely transform traditional manufacturing in the future. In this paper, a comprehensive review and critical analyses of the recent advances and achievements in the field of different AM processes for polymers, their composites and nanocomposites, elastomers and multi materials, shape memory polymers and thermo-responsive materials are presented. Moreover, their applications in different fields such as bio-medical, electronics, textiles, and aerospace industries are also discussed. We conclude the article with an account of further research needs and future perspectives of AM process with polymeric materials.

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Additive manufacturing of heat-sensitive polymer melt using a pellet-fed material extrusion

Abstract: Please refer to published version for the most recent bibliographic citation information. If a published version is known of, the repository item page linked to above, will contain details on accessing it.

Cited by 28 publications

References 25 publications

Theoretical Evaluation of the Melting Efficiency for the Single-Screw Micro-Extrusion Process: The Case of 3D Printing of ABS

Theoretical Evaluation of the Melting Efficiency for the Single-Screw Micro-Extrusion Process: The Case of 3D Printing of ABS

Screw-assisted 3D printing with granulated materials: a systematic review

Additive Manufacturing of Polymer Materials: Progress, Promise and Challenges

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