Fused Deposition Modeling of Polyolefins: Challenges and Opportunities

Abstract

Polyolefins are the largest class of commercially available synthetic polymers that are extensively used in a variety of applications from commodities to engineering owing to their low cost of production, good physico‐mechanical properties, light weight, good processability, and recyclability. Compared to conventional molding techniques, fused deposition modeling (FDM)‐based 3D printing is a smart manufacturing technology for thermoplastics due to its low cost, ease of production of complex geometrical parts, rapid prototyping, and scalable customization. FDM 3D printing can be an ideal manufacturing technology for polyolefins to manufacture various complex parts. However, FDM 3D‐printing of polyolefins is challenged bycritical printing problems like high warpage, dimensional inaccuracies, poor bed adhesion, and poor layer‐to‐layer adhesion. In this review, a fundamental understanding of polyolefins and their FDM 3D‐printing process is established, and the recent progress of FDM 3D printing of polyolefins is summarized. Furthermore, strategies to overcome warpage and to improve mechanical strength of the 3D‐printed polyolefins are provided. Finally, future prospectives of FDM 3D‐printing of polyolefins are critically discussed to inspire prospective research in this field. It is believed that this review article can be tremendously useful for research work related to FDM of polyolefin‐based materials.

Direct relationship between crystalline structure and part deformation of polypropylene copolymer parts fabricated by material extrusion additive manufacturing

“…34 On the other hand, polymer chains at higher nozzle temperature exhibit enhanced segmental mobility, which decreases the crystallization rate and favors the relaxation of internal stress and oriented structures. 63 Thus, it is difficult to predict the part deformation associated with the residual thermal stress.…”

Direct ink writing‐based additive manufacturing of styrene‐isoprene‐styrene block copolymer

“…[8][9][10][11][12] The most efficient AM process for solid thermoplastics is material extrusion additive manufacturing, which is based on fused deposition modeling (FDM). 13 Amorphous thermoplastics, such as polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS), are compatible with FDM 3D printer. 14 However, FDM based on conventional filament fabrication is not compatible with soft polymeric materials.…”

“…18 In addition, SIS has good heat and weather resistance. 13 SIS is a commercially available TPE material with numerous applications in the automotive, toy, footwear, and biomedical industries. 29 However, manufacturing SIS products purely depends on conventional molding process, which can be expensive depending on the complexity of the product.…”

“…Depending on the type of material, different AM techniques are used to process it, such as stereolithography, material jetting (such as in direct inkjet), material extrusion, powder‐based fusion (such as in selective laser sintering (SLS)), etc 8–12 . The most efficient AM process for solid thermoplastics is material extrusion additive manufacturing, which is based on fused deposition modeling (FDM) 13 . Amorphous thermoplastics, such as polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS), are compatible with FDM 3D printer 14 .…”

“…These components provide the finished material with superior mechanical strength and balanced flexibility 18 . In addition, SIS has good heat and weather resistance 13 . SIS is a commercially available TPE material with numerous applications in the automotive, toy, footwear, and biomedical industries 29 .…”