Recycled plastic filament made from post‐consumer expanded polystyrene and polypropylene for fused filamant fabrication

Chu, Jia Sheng; Koay, Seong Chun; Chan, Ming Yeng; Choo, Hui Leng; Ong, Thai Kiat

doi:10.1002/pen.26144

Cited by 13 publications

(26 citation statements)

References 25 publications

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“…Low MFI in PPP/DC composite filaments indicated the high viscosity and lack of material flow that led to the poor adhesion between adjacent layers and less coalescence during 3D printing of the tensile specimens. Chu et al 24 claimed that the material with low melt viscosity would experience the warping during printing.…”

Section: Resultsmentioning

confidence: 99%

3D polymer composite filament development from post‐consumer polypropylene and disposable chopstick fillers

Tan

Chan

Koay

et al. 2023

Vinyl Additive Technology

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This study focused on the development of three‐dimensional (3D) polymer composite filament made of disposable chopstick (DC) and post‐consumer polypropylene (PPP). The PPP/DC composite parts were printed via fused filament fabrication (FFF) process. The effect of the printing temperature and different DC fiber content on the properties of the 3D printed parts were investigated. The printing temperature of 200–220°C was suitable for these filaments because the printing temperature did not show any thermal degradation, as proven by thermogravimetric analysis. Furthermore, the thermal stability of the 3D filament increased with DC content. The chemical modification with sodium hydroxide (NaOH) was carried out on DC to remove the unwanted organic components by showing changes in peak intensity in the Fourier transform infrared analysis. Moreover, the melt flow index of the composite filaments decreased with increasing of the DC content and caused the composites' viscosity increased. The results show that the optimum printing temperature of 210°C would reduce the warping and gave better tensile properties to the 3D printed parts. Nevertheless, the tensile strength and elongation at break of the 3D printed PPP/DC parts reduced as the DC content increased because the presence of some air gap and fiber pull out on the fracture surface of 3D printed parts, which are in line with the results observed from scanning electron microscopy. However, the tensile strength and elongation at break percentage of all 3D printed PPP/DC composite parts were higher in comparison with the 3D parts printed by commercial wood plastic composite filament.

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Section: Resultsmentioning

confidence: 99%

3D polymer composite filament development from post‐consumer polypropylene and disposable chopstick fillers

Tan

Chan

Koay

et al. 2023

Vinyl Additive Technology

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“…• Chu et al [19] pursued more sustainable FFF using 100% recycled blends of PS and PP. Energy characterization and optimization • Baumers et al [20] provides a review of energy consumption in AM processes, reporting a SEC of 144 kWh/kg for FFF deposition of PC.…”

Section: Injection Moldingmentioning

confidence: 99%

“…Cost, life cycle, and sustainability assessment Luo et al [ 15 ] evaluates environmental impact of rapid tooling methods with a focus on the embodied energy of Keltool versus electroplated, selectively laser sintered plastic molds. Hopkinson et al [ 16 ] compares the cost of injection molding with layer based AM processes, with breakeven quantities of ~700 units for a larger cover and ~8000 for a smaller lever. Peng et al [ 17 ] considers the life cycle of FFF printing, including initial filament extrusion, 3D printing, post‐processing, and transportation. Dev et al [ 18 ] investigates the effect of infill parameters on material usage and properties in FFF. Chu et al [ 19 ] pursued more sustainable FFF using 100% recycled blends of PS and PP. …”

Section: Introductionmentioning

confidence: 99%

Strategic cost and sustainability analyses of injection molding and material extrusion additive manufacturing

Kazmer

Peterson

Masato

et al. 2023

Polymer Engineering & Sci

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Economic and environmental costs are assessed for four different plastics manufacturing processes, including cold and hot runner molding as well as stock and upgraded material extrusion three dimensional (3D) printers. A larger stock 3D printer was found to provide a melting capacity of 14.4 ml/h, while a smaller printer with an upgraded extruder had a melting capacity of 36 ml/h. 3D printing at these maximum melting capacities resulted in specific energy consumption (SEC) of 16.5 and 5.28 kWh/kg, respectively, with the latter value being less than 50% of the lowest values reported in the literature. Even so, analysis of these respective processes found them to be only 2.9% and 3.8% efficient relative to their theoretical minimum energy requirements. By comparison, cold and hot runner molding with an all‐electric machine had SEC of 1.28 and 0.929 kWh/kg, respectively, with efficiencies of 9.9% and 13.6% relative to the theoretical minima. Breakeven analysis considering the cost and carbon footprint of mold tooling found injection molding was preferable at a production quantity of around 70,000 units. Parametric analysis of model inputs indicates that the breakeven quantities are robust with respect to carbon tax incentives but highly dependent on mold costs, labor costs, and part size. Dimensional and mechanical properties of the molded and 3D printed specimens are also characterized and discussed.

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“…For instance, Philip has used FFF technology to 3D print customized pendant and lamp covers. 5 Furthermore, the National Aeronautics and Scape Administration (NASA) also used FFF 3D printer for producing components for the Mars Perseverance Rover. 6 With the FFF method, the need for molds in production has gradually diminished, leading to reduced costs and shorter manufacturing times.…”

Section: Introductionmentioning

confidence: 99%

“…8 Notable successful projects that have utilized plastic waste in 3D printing include the production of Olympic podiums made from plastic bottles during the 2020 Summer Olympics in Tokyo, Japan. 5 However, the availability of wood filament in the market is currently limited to PLA-and PETG-based options. With no options for recycled plastic with natural fiber.…”

Section: Introductionmentioning

confidence: 99%

Effects of corn husk fiber as filler in recycled single‐use polypropylene for fused filament fabrication

Yap,

Chun,

Yeng

et al. 2023

Vinyl Additive Technology

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Fused filament fabrication (FFF) is one of the most popular 3D printing approaches among end‐users due to its lower cost, ease of operation, and wide range of material choices. However, the use of composite filament produced from recycled plastic and agriculture waste is still relatively uncommon. This research focuses on developing composite filament from corn husk fiber (CHF) and recycled single‐use polypropylene for FFF. In this work, neat recycled polypropylene (rPP) and rPP/CHF composites were extruded into filament for FFF printing. It was observed that increasing the CHF content would reduce the print quality of the parts, as visible air gaps and voids were found on the printed surface and within the layers. Nevertheless, these issues were able to be overcome by adjusting the printing temperature and increasing the extrusion percentage during the printing process. The melt flow index results indicate that a higher CHF content would reduce the melt flow of the extruded rPP/CHF composite during printing, potentially affecting the quality of the printed parts. On the other hand, increasing the temperature enhanced the melt flow of the composite, which was beneficial for the printing process. When a small amount of CHF was added to the rPP, the printed part exhibited the highest tensile strength due to the reinforcing effect of the fibers. However, the tensile strength of printed parts using rPP/CHF composite filament decreased with higher CHF content. Additionally, higher CHF content resulted in printed composite parts that were more rigid and stiffer. It also reduced warpage on the printed specimens made with this composite, but it is important to note that warpage of the printed specimen is not directly correlated to crystallinity caused by nucleating effect of CHF. The rPP/CHF composite filament did exhibit earlier thermal degradation due to the addition of more CHF. However, this should not affect the printing process when temperature not beyond 230°C. This study highlights the potential of utilizing single‐use PP and fibers extracted from corn husk as feedstock for 3D printing. The findings expand the possibilities for recycling and employing agricultural waste in sustainable additive manufacturing processes.Highlights Utilizes single‐use PP and CHF in developing composite filaments, contributing to sustainability and reducing plastic waste. This research offers a sustainable approach by utilizing waste materials as feedstock for FFF‐based 3D printing, which able to reduce the environmental pollution caused by disposal of single‐use plastic and promotes recycling practices.

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Recycled plastic filament made from post‐consumer expanded polystyrene and polypropylene for fused filamant fabrication

Cited by 13 publications

References 25 publications

3D polymer composite filament development from post‐consumer polypropylene and disposable chopstick fillers

3D polymer composite filament development from post‐consumer polypropylene and disposable chopstick fillers

Strategic cost and sustainability analyses of injection molding and material extrusion additive manufacturing

Effects of corn husk fiber as filler in recycled single‐use polypropylene for fused filament fabrication

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