Low cost 3D printing of metals using filled polymer pellets

Martin, Vincent; Witz, Jean-François; Frederic, Gillon; Najjar, Denis; Quaegebeur, Philippe; Bénabou, Abdelkader; Hecquet, Michel; Berté, Emmanuel; Lesaffre, François; Meersdam, Matthieu; Auzene, Delphine

doi:10.1016/j.ohx.2022.e00292

Cited by 19 publications

(14 citation statements)

References 70 publications

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“…A custom compression screw can also be used to improve extrusion characteristics and could be manufactured using an open source grinder [109] . Other pellet extruders in the academic and maker community such as the Universal Pellet Extruder [110] , GigabotX Pellet Extruder [34] and even a metal filled polymer pellet extruder [111] have demonstrated the successful use of smaller scale extrusion screws without the use of complicated instrumentation involved in a traditional injection molding process. Jamming of pellets either in the hopper of a pellet extruder or barrel is a common as noted in [30] , [51] , [111] .…”

Section: Validation and Characterizationmentioning

confidence: 99%

“…Other pellet extruders in the academic and maker community such as the Universal Pellet Extruder [110] , GigabotX Pellet Extruder [34] and even a metal filled polymer pellet extruder [111] have demonstrated the successful use of smaller scale extrusion screws without the use of complicated instrumentation involved in a traditional injection molding process. Jamming of pellets either in the hopper of a pellet extruder or barrel is a common as noted in [30] , [51] , [111] . This is due to the vertical feed of pellets into the hopper which causes pellets to free fall down the channel of the screw and clog.…”

Section: Validation and Characterizationmentioning

confidence: 99%

See 1 more Smart Citation

Hangprinter for large scale additive manufacturing using fused particle fabrication with recycled plastic and continuous feeding

Rattan¹,

Nauta²,

Romani³

et al. 2023

HardwareX

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Section: Validation and Characterizationmentioning

confidence: 99%

Section: Validation and Characterizationmentioning

confidence: 99%

Hangprinter for large scale additive manufacturing using fused particle fabrication with recycled plastic and continuous feeding

Rattan¹,

Nauta²,

Romani³

et al. 2023

HardwareX

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“…The most used AM for metal materials (in powder, wire, sheet forms, etc.) [49,50] is the laser based, namely, selective laser sintering (SLS) or full melting and bonding (selective laser melting, (SLM)); powder bed fusion, laser metal deposition (LMD); directed energy deposition (DED). These AM machine systems use laser beam to manufacture high precision and low-cost complex high-performance materials.…”

Section: Laser Based Additive Manufacturingmentioning

confidence: 99%

Enhancing industry 5.0 goals through laser based additively Manufactured High-Performance Metals

Nyamekye,

Westman,

Tepponen

2023

IOP Conf. Ser.: Mater. Sci. Eng.

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In the current industry 4.0 (I4.0) and emerging Industry 5.0 (I5.0) eras, the integration of digitalization and sustainable goals is driving nature-centric and human-centric products. The production of these products are also creating digital supply chain that boosts agility and resiliency in operations, management, and supply chain interlinks. Additive manufacturing (AM), an element of I4.0, for instance, offers an integrated connection of all process steps and value chains using computer-based designing, data-driven simulations, cloud-based processing, storing, and managing software along seamless digital threads to create agile and resilient supply chain. The integration of AM and other I4.0 technologies enables greater flexibility offering intrinsic sustainable, human-centric and resilience advantages. Laser based additive manufacturing (LBAM), one of the subcategories of AM, offers opportunities to manufacture new intricate and conventionally impractical metal product designs in an ecological and economic competitive stance. High performance metals (HPMs) suited for high-stress and corrosive demanding applications are tough to machine and prone to thermal cracking in case of welding. Conventionally difficult and lengthy to manufacture yet unavoidable HPMs such as nickel alloys and titanium alloys are effortlessly possible via LBAM. Different industrial sectors that utilize these grades of metal alloys continue to adopt AM for the offered design flexibility for achieving goals such as customization, lightweight, on-demand manufacturing, raw material efficiency and cost saving. This study uses literature review and manufacturing case studies to demonstrate the flexibility and digital nature of LBAM towards I5.0 goals. The study objectively highlights the promising responsiveness of AM in the eventuality of supply disruptions that may be caused by sudden changes. The novelty of the study lies in the pragmatic emphasis on the potentials of LBAM and paired I4.0 technologies in revolutionizing the industry towards industry 5.0 goals. The study shows how I4.0 elements can be paired to enable operational efficiencies, lower carbon emissions, and foster sustainability in promoting I5.0 transformation. This study offers a fundamental understanding of the role of LBAM in the advancement of sustainability, human-centricity, and resilience.

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“…In PBAM, polymers in the form of granules instead of filaments are fed in small single-screw extruders (SSEs) to allow for material deposition and solidification. 1,2,[13][14][15][16][17][18][19][20][21] Such extrusion-based AM (EAM) overcomes limitations of filament-based AM, allowing applications for soft and brittle polymers that can be more challenging to 3D print. 22,23 The cost of the pellet feedstock material is also lower compared to the filament counterpart 23 and EAM allows to bypass the filament production extrusion process so that less degradation of the material is expected.…”

Section: Introductionmentioning

confidence: 99%

“…A competitive less mature additive manufacturing (AM) technique, as mainly developed in the last two decades, is(PBAM). In PBAM, polymers in the form of granules instead of filaments are fed in small single‐screw extruders (SSEs) to allow for material deposition and solidification 1,2,13–21 . Such extrusion‐based AM (EAM) overcomes limitations of filament‐based AM, allowing applications for soft and brittle polymers that can be more challenging to 3D print 22,23 .…”

Section: Introductionmentioning

confidence: 99%

Comparing pellet‐ and filament‐based additive manufacturing with conventional processing for ABS and PLA parts

Gala

Ceretti

Fiório

et al. 2022

J of Applied Polymer Sci

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More recently pellet‐based additive manufacturing or so‐called micro‐extrusion has become more popular for final polymeric part production. In the present work, it is evaluated how pellet‐based AM (PBAM) performs for its extrudates and specimens compared to the more established fused filament fabrication technique, considering both commercial acrylonitrile butadiene styrene polymer and poly(lactic acid) pellets and filaments as feedstocks. For benchmarking purposes, a comparison with conventional techniques, that is, single screw extrusion and injection molding, is also included. To support the performance interpretation a theoretical analysis is conducted regarding the melting finalization point as well as void measurements and Fourier transfer infrared spectroscopic analysis for degradation effects are included. It is demonstrated that for the extrudates comparable results are obtained among the different manufacturing techniques, whereas for the specimens the situation is dissimilar. It is highlighted that PBAM/ME has a large market potential implementation, provided that its operating settings are further optimized.

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Low cost 3D printing of metals using filled polymer pellets

Cited by 19 publications

References 70 publications

Hangprinter for large scale additive manufacturing using fused particle fabrication with recycled plastic and continuous feeding

Hangprinter for large scale additive manufacturing using fused particle fabrication with recycled plastic and continuous feeding

Enhancing industry 5.0 goals through laser based additively Manufactured High-Performance Metals

Comparing pellet‐ and filament‐based additive manufacturing with conventional processing for ABS and PLA parts

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