Fused Filament Fabrication 3D Printing of Self-Healing High-Impact Polystyrene Thermoplastic Polymer Composites Utilizing Eco-friendly Solvent-Filled Microcapsules

Shinde, Vinita V.; Taylor, G. Austin; Celestine, Asha‐Dee N.; Beckingham, Bryan S.

doi:10.1021/acsapm.1c01884

Cited by 15 publications

(8 citation statements)

References 67 publications

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“…Furthermore, creating self-healing filaments during 3D printing utilizing solvent-filled microcapsules is a potential future solution. Recently, Shinde et al [170] have successfully created self-healing high impact polystyrene (HIPS) filaments for 3D printing. Doublewalled self-healing microcapsules filled with ethyl phenylacetate solvent were synthesized and coated onto HIPS filaments for 3D printing.…”

Section: Pre-process Treatmentmentioning

confidence: 99%

Recycled, Bio-Based, and Blended Composite Materials for 3D Printing Filament: Pros and Cons—A Review

Nguyen¹,

Vuillaume²,

Hu³

et al. 2023

MSA

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In recent years, additive manufacturing (AM), known as "3D printing", has experienced exceptional growth thanks to the development of mechatronics and materials science. Fused filament deposition (FDM) manufacturing is the most widely used technique in the field of AM, due to low operating and material costs. However, the materials commonly used for this technology are virgin thermoplastics. It is worth noting a considerable amount of waste exists due to failed print and disposable prototypes. In this regard, using green and sustainable materials is essential to limit the impact on the environment. The recycled, bio-based, and blended recycled materials are therefore a potential approach for 3D printing. In contrast, the lack of understanding of the mechanism of interlayer adhesion and the degradation of materials for FDM printing has posed a major challenge for these green materials. This paper provides an overview of the FDM technique and material requirements for 3D printing filaments. The main objective is to highlight the advantages and disadvantages of using recycled, bio-based, and blended materials based on thermoplastics for 3D printing filaments. In this work, solutions to improve the mechanical properties of 3D printing parts before, during, and after the printing process are pointed out. This paper provides an overview on choosing which materials and solutions depend on the specific application purposes. Moreover, research gaps and opportunities are mentioned in the discussion and conclusions sections of this study.

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Section: Pre-process Treatmentmentioning

confidence: 99%

Recycled, Bio-Based, and Blended Composite Materials for 3D Printing Filament: Pros and Cons—A Review

Nguyen¹,

Vuillaume²,

Hu³

et al. 2023

MSA

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“…The materials used for self-healing coatings can respond to thermal, circumstantial pH, ultraviolet (UV) irradiation, electric field, special ions, or other stimuli to repair their own defects and cracks, which is inspired by the self-healing organisms in nature. − The self-healing mechanisms can be categorized to intrinsic healing and extrinsic healing, which depend upon whether there are chemical reactions between the material matrix and the externally embedded components during the healing processes . For instance, during the extrinsic healing process, the healing agents flow to the damage sites and heal the cracks by initiating chemical reactions once racks are formed and break the extrinsic microcapsules. − However, the limited healing times of the microcapsules and poor compatibility between microcapsules and the material matrix inevitably result in a short life and decrease the mechanical abilities of the extrinsic self-healing materials. − …”

Section: Introductionmentioning

confidence: 99%

Satisfactory Tensile Strength and Strain of Recyclable Polyurethane with a Trimaleimide Structure for Thermal Self-Healing and Anticorrosive Coatings

Li,

Zhang,

Cui

et al. 2024

Langmuir

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Bismaleimide (BMI) is often used as the cross-linking reagent in Diels–Alder (D–A)-type intrinsic self-healing materials (DISMs) to promote the connectivity of damaged surfaces based on reversible D–A bond formation on the molecular scale. Until now, although DISMs have exhibited great potential in the applications of various sensors, electronic skin, and artificial muscles, it is still difficult to prepare DISMs with satisfactory self-healing abilities and high tensile strengths and strains at the same time, thus largely limiting their applications in self-healing anticorrosive coatings. Herein, symmetrical trimaleimide (TMI) was successfully synthesized, and trimaleimide-structured D–A self-healing polyurethane (TMI–DA–PU) was prepared via the reversible D–A reaction (cycloaddition of furan and maleimide). As a DISM, TMI–DA–PU exhibits apparently higher self-healing efficiency (98.7%), tensile strength (25.4 MPa), and strain (1378%) compared to bismaleimide-structured D–A self-healing polyurethane (BMI–DA–PU) (self-healing efficiency, 90.2%; tensile strength, 19.3 MPa; strain, 1174%). In addition, TMI–DA–PU shows a high recycling efficiency (>95%) after 4 cycles of recycling. A series of characterizations indicate that TMI provides more monoene rings as the self-healing sites, forms denser cross-linked structures compared to BMI, and is, thus, more appropriate to be used for DISM applications. Moreover, the barrier abilities of coatings can be semi-quantitatively expressed by the impedance value at 0.01 Hz (|Z|0.01 Hz). The |Z|0.01 Hz value of the TMI–DA–PU coating is 3.93 × 109 Ω cm2 on day 0, which is significantly higher than that of the BMI–DA–PU coating (6.76 × 108 Ω cm2 on day 0), indicating that the denser rigid cross-linked structure of TMI results in the small porosity in the TMI–DA–PU coating, thus effectively improving the anticorrosion performance. The construction of DISMs with the structure of TMI demonstrates immense potential in self-healing anticorrosive coatings.

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“…Fused filament fabrication (FFF) is the most commonly used 3D printing method owing to its simple design, minimal waste, minimal footprint, and affordability. , FFF is a popular method in designing new polymeric products used for many packaging, transportation, and biomedical applications. , With the foreseeing increase in the production of biodegradable plastics, estimated at 47% from 2020 to 2025, , FFF of biodegradable polymers has started gaining more interest from academia and industry . From the studies conducted on the 3D printing of conventional polymers, it is well-known that molecular weight, chemical structure, crystallinity, and processing conditions considerably impact the mechanical and physical characteristics of the printed products. , Moreover, appropriate rheological characteristics of printing materials are the main parameter for successful 3D printing processes, not only in polymeric products but also for other applications.…”

Section: Introductionmentioning

confidence: 99%

“…Fused filament fabrication (FFF) is the most commonly used 3D printing method owing to its simple design, minimal waste, minimal footprint, and affordability. 1,2 FFF is a popular method in designing new polymeric products used for many packaging, transportation, and biomedical applications. 3,4 With the foreseeing increase in the production of biodegradable plastics, estimated at 47% from 2020 to 2025, 5,6 FFF of biodegradable polymers has started gaining more interest from academia and industry.…”

Section: ■ Introductionmentioning

confidence: 99%

Effects of Rheological Properties on 3D Printing of Poly(lactic acid) (PLA) and Poly(hydroxy alkenoate) (PHA) Hybrid Materials

Torabi

McGreal

Zarrin

et al. 2023

ACS Appl. Polym. Mater.

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Fused filament fabrication (FFF) has been extensively studied for conventional polymers, but there are few studies that address the processing challenges for biobased, biodegradable polymers such as poly(lactic acid) (PLA) and poly(hydroxy alkenoates) (PHA) in FFF processes. This study has investigated the elongational and shear rheological properties and thermophysical characteristics of PLA/PHA hybrid materials to determine the effects of processing conditions, including nozzle temperatures, bed temperatures, and speeds, on the quality of the PLA/PHA printed products, e.g., adhesion strength and tensile properties. Our findings showed that adding PHA to the composition of the PLA/PHA hybrid material leads to a reduction in shear and extensional viscosities, causing a rise in elongation at break and adhesion strength while showing comparable tensile strength with the PLA samples. In addition to the presence of PHA in the combination of the hybrid materials, processing conditions, including nozzle temperature, bed temperature, and print speed, were found to be effective on the adhesion strength and tensile characteristics of the printed products. Our results suggested that among processing parameters, nozzle temperature has the most significant effect on adhesion strength and tensile characteristics. Samples printed at the nozzle temperature of 215 °C showed an order of magnitude higher adhesion strength and up to 34% enhancement in elongation at break compared to the printed samples at 185 °C. This study sheds light on the significance of the material and processing parameters in obtaining quality products from biobased, biodegradable polymers.

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Fused Filament Fabrication 3D Printing of Self-Healing High-Impact Polystyrene Thermoplastic Polymer Composites Utilizing Eco-friendly Solvent-Filled Microcapsules

Cited by 15 publications

References 67 publications

Recycled, Bio-Based, and Blended Composite Materials for 3D Printing Filament: Pros and Cons—A Review

Recycled, Bio-Based, and Blended Composite Materials for 3D Printing Filament: Pros and Cons—A Review

Satisfactory Tensile Strength and Strain of Recyclable Polyurethane with a Trimaleimide Structure for Thermal Self-Healing and Anticorrosive Coatings

Effects of Rheological Properties on 3D Printing of Poly(lactic acid) (PLA) and Poly(hydroxy alkenoate) (PHA) Hybrid Materials

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