Abstract:This paper presents the development of a new Wood Plastic Composite (WPC) material for Fused Deposition Modeling (FDM) feedstocks. In this study, a biodegradable polymer matrix (POLYACTIDE, PLA) was mixed with natural wood flour (WF) by Brabender mixer, and the samples produced by injection molding machine. The effect of wood was investigated as a filler material in composite FDM feedstock and the detailed formulations of compounding ratio by weight percentage. Based on results obtained, it was found that, com… Show more
“…The primary manufacturing processes for wood-plastic composites are extrusion, injection molding, and compression molding or thermoforming (pressing). Newer manufacturing processes for WPCs include additive manufacturing via fused layer modeling and laser sintering [8][9][10][11].…”
Wood-plastic composites (WPCs) are a form of composite combining wood-based elements with polymers. The processes for manufacturing WPCs include extrusion, injection molding, and compression molding or thermoforming (pressing). Newer manufacturing processes for WPCs include additive manufacturing via fused layer modeling and laser sintering. An important constraint for polymers used in WPCs is requiring process conditions (melt temperature, pressure) that will not thermally degrade the wood filler. Wood degrades around 220°C; thus, generalpurpose polymers like polyethylene and poly vinyl chloride are typically used for manufacturing WPCs. Wood fibers are inherently hydrophilic because of the hydroxyl groups contained in the cellulose and hemicellulose molecular chains. Thus, modification of the wood fiber via chemical or physical treatments is very critical to making improved WPCs. The most abundant profiles made from wood-plastic composites are boards or lumber used in outdoor decking applications. Although early WPC products were mainly extruded for profiled sections, nowadays, many injected parts made of WPC are being introduced for various industries, including electrical casings, packaging, daily living supplies, and civil engineering applications. Mold and mildew and color fading of WPCs tend to be the durability issues of prime importance for WPCs. Most recent research on WPC durability focuses on studies to better understand the mechanisms contributing to various degradation issues as well as methods to improve durability. Most WPC products in the USA are utilized in building materials with few exceptions for residential and commercial building applications, which means that building codes are the most important national rules for the WPC manufacturers. New developments are being made especially in the area of nano additives for WPCs including nanocellulose. Recently, the trend of patent registrations for WPCs has shifted to new products or applications instead of the materials itself.
“…The primary manufacturing processes for wood-plastic composites are extrusion, injection molding, and compression molding or thermoforming (pressing). Newer manufacturing processes for WPCs include additive manufacturing via fused layer modeling and laser sintering [8][9][10][11].…”
Wood-plastic composites (WPCs) are a form of composite combining wood-based elements with polymers. The processes for manufacturing WPCs include extrusion, injection molding, and compression molding or thermoforming (pressing). Newer manufacturing processes for WPCs include additive manufacturing via fused layer modeling and laser sintering. An important constraint for polymers used in WPCs is requiring process conditions (melt temperature, pressure) that will not thermally degrade the wood filler. Wood degrades around 220°C; thus, generalpurpose polymers like polyethylene and poly vinyl chloride are typically used for manufacturing WPCs. Wood fibers are inherently hydrophilic because of the hydroxyl groups contained in the cellulose and hemicellulose molecular chains. Thus, modification of the wood fiber via chemical or physical treatments is very critical to making improved WPCs. The most abundant profiles made from wood-plastic composites are boards or lumber used in outdoor decking applications. Although early WPC products were mainly extruded for profiled sections, nowadays, many injected parts made of WPC are being introduced for various industries, including electrical casings, packaging, daily living supplies, and civil engineering applications. Mold and mildew and color fading of WPCs tend to be the durability issues of prime importance for WPCs. Most recent research on WPC durability focuses on studies to better understand the mechanisms contributing to various degradation issues as well as methods to improve durability. Most WPC products in the USA are utilized in building materials with few exceptions for residential and commercial building applications, which means that building codes are the most important national rules for the WPC manufacturers. New developments are being made especially in the area of nano additives for WPCs including nanocellulose. Recently, the trend of patent registrations for WPCs has shifted to new products or applications instead of the materials itself.
“…Natural fibers such as cellulose have been previously used in thermoplastic or thermoset matrices . These composites have been processed both using traditional manufacturing methods (including compression molding, extrusion, injection molding, and resin transfer molding) and 3D printing (e.g., wood fibers in thermoplastic matrices). However, combining the natural fibers with highly processed synthetic polymers often requires chemical treatment of the fiber surfaces to improve fiber–matrix interaction.…”
Many ancient Chinese structures, such as portions of the Great Wall, use a unique mortar that derives from glutinous rice (commonly called “sticky rice”). Unlike other types of rice, sticky rice is rich in amylopectin with negligible amylose. Inspired by the long‐term stability of the amylopectin‐based mortars in ancient structures, sticky rice (SR)‐based materials for 3D printing are developed. Heat causes amylopectin gelatinization, during which molecular branches open to form a large network of gel balls. This causes a merger of the granules and improved interaction between the matrix and fillers. To enhance the mechanical properties, cotton fibers are included, ≈11 µm in diameter. During amylopectin gelatinization, secondary fibers emerge from the primary fibers, creating a complex two‐level fiber network. Both the fibers and matrix constitute a 3D printable fiber composite consisting entirely of natural, inexpensive, and scalable components. The processing steps make no use of any non‐natural materials or hazardous chemicals. A systematic design of experiments is conducted to understand the effect of processing parameters on the mechanical properties. Scalability by printing low‐density cellular materials is demonstrated. Finally, it is shown that SR composites are more resilient than common thermoplastic composites when subjected to flame, heat, or ultraviolet light.
“…This composition of the wood-plastic composite has been shown to have increased mechanical properties. 34–36 Figure 7.CAD model of the wood panel connector (in SketchUp software).Figure 8.Different wood panel connectors made by 3D printing (brown color, wood-plastic composite and white color, ABS): (a) sample with errors in printing; (b–c) properly printed samples; (d) wood-composite filament with the sample printed by using it.…”
Section: Resultsmentioning
confidence: 99%
“…This composition of the wood-plastic composite has been shown to have increased mechanical properties. [34][35][36] The upper left image in Figure 8 shows the printed element which was not properly printed, and with many errors: surplus of deposited material, very low accuracy of dimensions, and with very rough ragged surfaces. This was the first printed element and the consequence of improperly selected parameters of the FDM process.…”
Section: Fdm Technology For Furniture Elements and Toolsmentioning
Additive manufacturing technologies enable rapid prototyping of different parts, according to the three-dimensional model software solution. This paper presents some aspects of fused deposition modeling technology and its application in the wood industry. The fused deposition modeling technology was initially developed for three-dimensional printing of plastic parts, whereas acrylonitrile butadiene styrene and polylactic acid plastics filament are commonly applied. Possibilities for application of different composites with fused deposition modeling in the wood industry are reviewed and presented in this paper. Several industrial applications were considered also, from aspects of material durability, mechanical strength, low cost, and customization. Directions of further research have been discussed, considering graphene and carbon nanotubes as composite reinforcement materials and bio-organic composites with wooden particles or fibers mixed into the polymer matrix. Development of new composites for use with the fused deposition modeling technology is promising area taking into account that new low-cost extruders are already commercially available, as a support to fused deposition modeling device. Three-dimensional printing is very convenient for investigation of different custom-made composite materials, as well as custom shapes of final parts, starting from powders, their mixing, drawing of composite material filament, which are further used for three-dimensional printing with solidification and fabrication of custom-made products. New composites for fused deposition modeling, made of wood and plastic combinations were experimentally investigated for use as functional and customized elements of furniture. Obtained results strongly indicated that both new composite materials and fused deposition modeling printing can be efficiently used for broad customization from aspects of material properties and product shapes, thus enabling low-cost fabrication of small series of complex furniture elements, especially fixtures or clamp tools.
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