On recyclability of thermosetting polymer and wood dust as reinforcement in secondary recycled ABS for nonstructural engineering applications

Abstract

The management of thermosetting plastic solid waste has become serious issue worldwide due to its highly stable long-chain molecular structure and its recycling is the only way to reduce harmful effects. Also, depletion of natural resources like wood at alarming rate creates worldwide environment issues. In this article, feedstock filament for three-dimensional printing (in nonstructural engineering applications) of thermoplastic composite based on secondary (2°) recycled acrylonitrile butadiene styrene (ABS) as matrix reinforced with waste bakelite powder (BP) (thermosetting) and wood dust (WD) with twin-screw extrusion (TSE) process has been prepared (to impart desired mechanical/thermal/rheological and morphological properties).The results indicated that reinforcement of BP/WD initially increases the melt flow rate (MFR) of composite filament as compared to 2° recycled ABS. However, with increase in percentage of reinforcement beyond a certain limit, the MFR of the composite filaments starts decreasing. The mechanical, rheological, morphological, and thermal properties related to fused filaments prepared by TSE process have been explored in this research work and it has been observed that ABS composite filaments reinforced with 10% by weight of BP possess high peak strength (PS), high energy carrying capacity, more thermal stability, and contains low porosity. Based upon combined optimized extrusion parameter settings for maximizing the PS and percentage break elongation, 10 kg load, 225°C processing temperature, and 70 r min−1 are the best settings for both the composite filaments (ABS + BP, ABS + WD), and the corresponding values for ABS + BP and ABS + WD composite filament are 30.58 MPa (5.15%) and 25.65 MPa (6.05%), respectively.

FDM-based additive manufacturing of recycled thermoplastics and associated composites

“…It was probably due to the high specific heat capacity and less porosity of reinforced Bakelite powder in the ABS matrix. The high specific heat capacity ensures the smooth flow of material in the extruder, exhibiting better mechanical properties [ 9 ].

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“…Enhancing the wear resistance properties by adding ceramic (like Al 2 O 3 and SiC) with BAK Uniform dispersion with 60% infill ratios and 50 mm/s printing speed [ 10 ] 10. 2° R-ABS R-ABS/bakelite powder/wood dust (WD) Particle size: wood dust: 50 µm; BP size was similar to that of WD Twin-screw extruder NA – 30.82 ± 1.7 (90% ABS + 10% BP) 25.66 ± 1.4 (90% ABS + 10% WD) Providing a good thermal interlocking bonding among the polymer particles and enhancing the thermal conductivity of the final material Less porosity noticed [ 9 ] 11. PET White cotton extracted from denim Single screw 1.75 ± 0.15 Prusa i3 NA 1.…”

“…The performance of recycled thermoplastic materials can be improved by incorporating natural or synthetic fillers (i.e., short or continuous). Various reinforcements such as bakelite powder [ 9 , 10 ], ZrO 2 particles [ 11 ], wooden dust [ 9 ], Al 2 O 3 /SiC particles [ 10 , 12 , 13 ], biochar [ 14 ] and clothing fibers [ 15 ] have been used to enhance the stability and structural properties of FDM parts. In most studies, an additive (i.e., short fibers) is added to produce 3D printing composite filaments, requiring specialized and high-cost FDM machines such as Markforged (i.e., Mark Two).…”

On recyclability of thermoplastic ABS polymer as fused filament for FDM technique of additive manufacturing

“…Various researchers focused on preparing composites by reinforcing carbon tubes, glass fibers, aluminium particles, bakelite powder, wood dust, etc. in polymer waste for enhancing, as well as to achieve desired properties (Le Duigou et al , 2016; Chawla et al , 2020). Maurya et al (2019a) investigated that with the addition of polyethylene terephthalate glycol as reinforced material in ABS and PLA matrix, the tensile strength of the composites improved by 70% and 8%, respectively.…”

Integrity and cost evaluation of natural fibers/HDPE composite tailored for piping applications

“…[15][16][17] Recently, researchers have examined various applications of natural fiber reinforced thermoplastics. For instance, physical and rheological properties of biodegradable composites, 18 application of eco-friendly composite materials in automotive industries, 19 non-structural facilities, 20 and biomedical, energy and sports. 21 Other recent studies on natural fibers and natural fiber reinforced plastics are well documented.…”