Dimensional Stability of 3D Printed Objects Made from Plastic Waste Using FDM: Potential Construction Applications

Abstract

Construction projects are often challenged by tight budgets and limited time and resources. Contractors are, therefore, looking for ways to become competitive by improving efficiency and using cost-effective materials. Using three-dimensional (3D) printing for shaping materials to produce cost-effective construction elements is becoming a feasible option to make contractors more competitive locally and globally. The process capabilities for 3D printers and related devices have been tightened in recent years with the booming of 3D printing industries and applications. Contractors are attempting to improve production skills to satisfy firm specifications and standards, while attempting to have costs within competitive ranges. The aim of this research is to investigate and test the production process capability (Cp) of 3D printers using fused deposition modeling (FDM) to manufacture 3D printed parts made from plastic waste for use in the construction of buildings with different infill structures and internal designs to reduce cost. This was accomplished by calculating the actual requirement capabilities of the 3D printers under consideration. The production capabilities and requirements of FDM printers are first examined to develop instructions and assumptions to assist in deciphering the characteristics of the 3D printers that will be used. Possible applications in construction are then presented. As an essential outcome of this study, it was noticed that the 3D printed parts made from plastic waste using FDM printers are less expensive than using traditional lightweight non-load bearing concrete hollow masonry blocks, hourdi slab hollow bocks, and concrete face bricks.

Designs, advancements, and applications of three-dimensional printed gyroid structures: A review

“…For FDM-printed recycled PLA gyroid lattice, the total process capability index is verified for the middle, bottom, and top portions, and the greatest Cpk values are found at the bottom level, among all rows. 203 The other possibilities of recycled materials for gyroid lattice include metal (Al–Mg–Sc–Zr, Al–Si–10Mg) are available. The testing samples have been fabricated by combining used and 40% virgin powder that shows almost similar maximum strength and elongation to fracture.…”

A Review of Multi-Material 3D Printing of Functional Materials via Vat Photopolymerization

“…Additive manufacturing or 3D printing of polymers can be generally classified into extrusion-based technologies (fused filament extrusion, direct ink writing), polymer bed sintering, vat photopolymerization-based technologies (stereolithography, digital light processing, liquid crystal display printing, continuous liquid interface printing, two-photon absorption printing), and 3D-volumetric polymerization technologies. Each technology has its own advantages and limitations, and the choice of a processing methodology depends on the feed materials, required printing resolution, printing times, size, performance of the printed materials, and overall cost of fabrication [89][90][91][92].…”

“…Successful completion of the polymerization reaction requires the compatibility with the 3D printing equipment, reactivity of the monomers, and appropriate absorbing characteristics of the photoinitiators and the light source. Furthermore, it is important that the printed architectures are dimensionally stable, possess the required stiffness, durability, and biocompatibility, and can withstand the application pressures, temperatures, and other environmental conditions [89][90][91][92]. Several of the widely used commercial (meth-)acrylates are presented in Figure 18.…”

Development of material extrusion 3D printing compatible tailorable thermoplastic elastomeric materials from acrylonitrile butadiene styrene and styrene‐(ethylene‐butylene)‐styrene block copolymer blends

“…Additive manufacturing technology also eliminates the large investment cost of expensive molds due to its ability to fabricate objects layer‐by‐layer without the need of molds. Additive manufacturing finds its application in various industries such as automotive, medical, electronics, aerospace, construction, and so forth 7–11 . There are various additive manufacturing processes available such as material jetting, 12 powder bed fusion, 13 material extrusion, 14 binder jetting, 15 sheet lamination, 16 and vat photopolymerization 17 .…”

“…Additive manufacturing finds its application in various industries such as automotive, medical, electronics, aerospace, construction, and so forth. [7][8][9][10][11] There are various additive manufacturing processes available such as material jetting, 12 powder bed fusion, 13 material extrusion, 14 binder jetting, 15 sheet lamination, 16 and vat photopolymerization. 17 Among these techniques, the material extrusion-based additive manufacturing (MEAM) is the most commonly used additive manufacturing technique for polymeric materials due to its versatility, convenient production rate, easy and inexpensive process, which makes it economical.…”