Startseite Synergistic material extrusion 3D-printing using core–shell filaments containing polycarbonate-based material with different glass transition temperatures and viscosities
Artikel
Lizenziert
Nicht lizenziert Erfordert eine Authentifizierung

Synergistic material extrusion 3D-printing using core–shell filaments containing polycarbonate-based material with different glass transition temperatures and viscosities

  • Fang Peng , Bryan D. Vogt und Miko Cakmak EMAIL logo
Veröffentlicht/Copyright: 2. August 2022
Veröffentlichen auch Sie bei De Gruyter Brill
Manuskript einreichen Informationen für Autor*innen
International Polymer Processing
Aus der Zeitschrift International Polymer Processing Band 37 Heft 4

Abstract

The application of 3D printing of thermoplastics by Material Extrusion (MatEx) has commonly been limited by their poor mechanical strength that results from voids and weak interfaces between printed layers. Here, we demonstrate that core–shell structured filaments made of polycarbonate-based thermoplastics can achieve synergistic improvement in their interfacial bonding from the combination of high-glass transition temperature (T g)/high-viscosity core and low-T g/low-viscosity shell. Tensile strength along the printing direction was enhanced with the core–shell filaments. Layer-interfacial bonding strength as determined by Izod impact tests of the 3D printed parts is significantly improved by using filaments either with only a core–shell T g mismatch or both T g/viscosity core–shell mismatch. The mechanical behavior can be rationalized in terms of improved inter-layer molecule diffusion by a low T g/viscosity shell, better printability at higher temperature due to the core with higher melt strength, and better bulk mechanical strength of high-viscosity/T g core.

Keywords: 3D-printing; coextrusion; filaments; fused deposition modeling
Corresponding author: Miko Cakmak, Department of Polymer Engineering, The University of Akron, Akron, OH, 44325, USA, E-mail:

Current Address: Bryan D. Vogt, Department of Chemical Engineering, The Pennsylvania State University, University Park, PA, 16802, USA

Current Address: Miko Cakmak, Schools of Materials and Mechanical Engineering, Purdue University, West Lafayette, IN, 47907, USA, cakmak@uakron.edu.

Current Adress: Fang Peng, Meta Co., Sunnyvale, CA, 94089, USA

  1. Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.

  2. Research funding: None declared.

  3. Conflict of interest statement: The authors declare no conflicts of interest regarding this article.

References

Ai, J.-R., Peng, F., Joo, P., and Vogt, B.D. (2021). Enhanced dimensional accuracy of material extrusion 3D-printed plastics through filament architecture. ACS Appl. Polym. Mater. 3: 2518–2528, https://doi.org/10.1021/acsapm.1c00110.Suche in Google Scholar

ASTM International (2021). ISO/ASTM 52900:2021; standard terminology for additive manufacturing—general principles—terminology. ASTM International, West Conshohocken, PA, USA.Suche in Google Scholar

Bellehumeur, C., Li, L., Sun, Q., and Gu, P. (2004). Modeling of bond formation between polymer filaments in the fused deposition modeling process. J. Manuf. Process. 6: 170–178, https://doi.org/10.1016/s1526-6125(04)70071-7.Suche in Google Scholar

Chiang, W. and Hwung, D. (1987). Properties of polycarbonate/acrylonitrile-butadiene- styrene blends. Polym. Eng. Sci. 27: 632, https://doi.org/10.1002/pen.760270906.Suche in Google Scholar

Comb, J.W., Priedeman, W.R., and Turley, P.W. (1994). FDM technology process improvements. In: Proceedings of solid freeform fabrication symposium. DTIC Document, pp. 42–49.Suche in Google Scholar

Costanzo, A., Spotorno, R., Candal, M.V., Fernández, M.M., Müller, A.J., Graham, R.S., Cavallo, D., and McIlroy, C. (2020). Residual alignment and its effect on weld strength in material-extrusion 3D-printing of polylactic acid. Addit. Manuf. 36: 101415, https://doi.org/10.1016/j.addma.2020.101415.Suche in Google Scholar

Covestro (2015–2017). Bayblend ® FR3010, Available at: https://solutions.covestro.com/en/products/bayblend/bayblend-fr3010_56968281-00001688?SelectedCountry=US 2016 May 2007.Suche in Google Scholar

Covestro (2019a). Apec® 1895. pp. 2–4, Available at: https://solutions.covestro.com/-/media/covestro/solution-center/products/datasheets/imported/apec/apec-1895_en_56968915-00009063-20763348.pdf.Suche in Google Scholar

Covestro (2019b). Makrolon® 2205. pp. 1–4, Available at: https://solutions.covestro.com/-/media/covestro/solution-center/products/datasheets/imported/makrolon/makrolon-2205_en_56976977-00009642-19212781.pdf.Suche in Google Scholar

Covestro (2021). Makrolon® 3208. pp. 2–4, Available at: https://solutions.covestro.com/-/media/covestro/solution-center/products/datasheets/imported/makrolon/makrolon-3208_en_56978414-05123120-19229217.pdf.Suche in Google Scholar

de Gennes, P.-G. (1971). Reptation of a polymer chain in the presence of fixed obstacles. J. Chem. Phys. 55: 572–579, https://doi.org/10.1063/1.1675789.Suche in Google Scholar

Doi, M. and Edwards, S.F. (1978). Dynamics of concentrated polymer systems. Part 1.—Brownian motion in the equilibrium state. J. Chem. Soc. Faraday Trans. 2: Mol. Chem. Phys. 74: 1789–1801, https://doi.org/10.1039/f29787401789.Suche in Google Scholar

Gardner, R.J. and Martin, J.R. (1979). Humid aging of plastics: effect of molecular weight on mechanical properties and fracture morphology of polycarbonate. J. Appl. Polym. Sci. 24: 1269–1280, https://doi.org/10.1002/app.1979.070240512.Suche in Google Scholar

Haggard, K.W. and Paul, D.R. (2002). Phase behavior of blends of high temperature copolycarbonates with styrene/acrylonitrile copolymers. Polymer (Guildf). 43: 3727–3734, https://doi.org/10.1016/s0032-3861(02)00179-9.Suche in Google Scholar

Han, C.D. and Chin, H.B. (1979). Theoretical prediction of the pressure gradients in coextrusion of non‐Newtonian fluids. Polym. Eng. Sci. 19: 1156–1162, https://doi.org/10.1002/pen.760191605.Suche in Google Scholar

Hart, K.R., Dunn, R.M., and Wetzel, E.D. (2020). Tough, additively manufactured structures fabricated with dual‐thermoplastic filaments. Adv. Eng. Mater. 22: 1901184, https://doi.org/10.1002/adem.201901184.Suche in Google Scholar

Lantada, A.D. and Morgado, P.L. (2012). Rapid prototyping for biomedical engineering: current capabilities and challenges. Annu. Rev. Biomed. Eng. 14: 73–96, https://doi.org/10.1146/annurev-bioeng-071811-150112.Suche in Google Scholar PubMed

Lee, W., Wei, C., and Chung, S.-C. (2014). Development of a hybrid rapid prototyping system using low-cost fused deposition modeling and five-Axis machining. J. Mater. Process. Technol. 214: 2366–2374, https://doi.org/10.1016/j.jmatprotec.2014.05.004.Suche in Google Scholar

McIlroy, C. and Olmsted, P.D. (2017). Disentanglement effects on welding behaviour of polymer melts during the fused-filament-fabrication, method for additive manufacturing. Polymer. 123: 376–391, https://doi.org/10.1016/j.polymer.2017.06.051.Suche in Google Scholar

Mohamed, O.A., Masood, S.H., and Bhowmik, J.L. (2015). Optimization of fused deposition modeling process parameters: a review of current research and future prospects. Adv. Manuf. 3: 42–53, https://doi.org/10.1007/s40436-014-0097-7.Suche in Google Scholar

Peng, F., Zhao, Z., Xia, X., Cakmak, M., and Vogt, B.D. (2018). Enhanced impact resistance of three-dimensional-printed parts with structured filaments. ACS Appl. Mater. Interfaces 10: 16087–16094, https://doi.org/10.1021/acsami.8b00866.Suche in Google Scholar PubMed

Peng, F., Jiang, H., Woods, A., Joo, P., Amis, E.J., Zacharia, N.S., and Vogt, B.D. (2019). 3D printing with core–shell filaments containing high or low density polyethylene shells. ACS Appl. Polym. Mater. 1: 275–285, https://doi.org/10.1021/acsapm.8b00186.Suche in Google Scholar

Pokluda, O., Bellehumeur, C.T., and Vlachopoulos, J. (1997). Modification of frenkel’s model for sintering. AIChE J. 43: 3253–3256, https://doi.org/10.1002/aic.690431213.Suche in Google Scholar

Polychronopoulos, N.D. and Vlachopoulos, J. (2020). The role of heating and cooling in viscous sintering of pairs of spheres and pairs of cylinders. Rapid Prototyp. J. 26: 719, https://doi.org/10.1108/rpj-06-2019-0162.Suche in Google Scholar

Polychronopoulos, N.D., Sarris, I.E., and Vlachopoulos, J. (2021). A viscous sintering model for pore shrinkage in packings of cylinders. Rheol. Acta 60: 397–408, https://doi.org/10.1007/s00397-021-01279-z.Suche in Google Scholar

Prager, S. (1981). The healing process at polymer–polymer interfaces. J. Chem. Phys. 75: 5194, https://doi.org/10.1063/1.441871.Suche in Google Scholar

Seppala, J.E. and Migler, K.D. (2016). Infrared thermography of welding zones produced by polymer extrusion additive manufacturing. Addit. Manuf. 12: 71–769, https://doi.org/10.1016/j.addma.2016.06.007.Suche in Google Scholar PubMed PubMed Central

Standard Terminology for Additive Manufacturing Technologies (2012). Designation F2792-12a, ASTM International.Suche in Google Scholar

Stroop, J. and Stolpe, R. (2006). Prototyping of automotive control systems in a time-triggered environment using flexray. In: Computer aided control system design IEEE International Symposium on intelligent control. IEEE, pp. 2332–2337.10.1109/CACSD.2006.285519Suche in Google Scholar

Sun, Q., Rizvi, G.M., Bellehumeur, C.T., and Gu, P. (2003). Experimental study of the cooling characteristics of polymer filaments in FDM and impact on the mesostructures and properties of prototypes. Solid Free. Fabr. Proc., No. 403: 313–323.Suche in Google Scholar

Vashishtha, V.K., Makade, R., and Mehla, N. (2011). Advancement of rapid prototyping in aerospace industry-a review. Int. J. Eng. Sci. Technol. 3: 2486–2493.Suche in Google Scholar

Yang, F., and Pitchumani, R. (2002). Healing of thermoplastic polymers at an interface under nonisothermal conditions. Macromolecules 35: 3213–3224, https://doi.org/10.1021/ma010858o.Suche in Google Scholar
Received: 2022-03-26
Accepted: 2022-06-19
Published Online: 2022-08-02
Published in Print: 2022-09-27

© 2022 Walter de Gruyter GmbH, Berlin/Boston

Artikel in diesem Heft

  1. Frontmatter
  2. Editorial
  3. Special issue for John Vlachopoulos
  4. Review Article
  5. Calendering of thermoplastics: models and computations
  6. Special Issue Contributions
  7. Film casting of polycarbonate/multi-walled carbon nanotubes composites using ultrasound-assisted twin-screw extruder: experiment and simulation
  8. Effect of mixing conditions and polymer particle size on the properties of polypropylene/graphite nanoplatelets micromoldings
  9. Extrusion foaming of linear and branched polypropylenes – input of the thermomechanical analysis of pressure drop in the die
  10. Improving the thickness distribution of parts with hybrid thermoforming
  11. Synergistic material extrusion 3D-printing using core–shell filaments containing polycarbonate-based material with different glass transition temperatures and viscosities
  12. TPU-based porous heterostructures by combined techniques
  13. Surfactant-free oil-in-oil emulsion-templating of polyimide aerogel foams
  14. Factors determining the flow erosion/part deformation of film insert molded thermoplastic products
  15. The extrusion of EPDM using an external gear pump: experiments and simulations
  16. News
  17. PPS News
https://doi.org/10.1515/ipp-2022-4217
Schlagwörter für diesen Artikel
3D-printing; coextrusion; filaments; fused deposition modeling

Artikel in diesem Heft

  1. Frontmatter
  2. Editorial
  3. Special issue for John Vlachopoulos
  4. Review Article
  5. Calendering of thermoplastics: models and computations
  6. Special Issue Contributions
  7. Film casting of polycarbonate/multi-walled carbon nanotubes composites using ultrasound-assisted twin-screw extruder: experiment and simulation
  8. Effect of mixing conditions and polymer particle size on the properties of polypropylene/graphite nanoplatelets micromoldings
  9. Extrusion foaming of linear and branched polypropylenes – input of the thermomechanical analysis of pressure drop in the die
  10. Improving the thickness distribution of parts with hybrid thermoforming
  11. Synergistic material extrusion 3D-printing using core–shell filaments containing polycarbonate-based material with different glass transition temperatures and viscosities
  12. TPU-based porous heterostructures by combined techniques
  13. Surfactant-free oil-in-oil emulsion-templating of polyimide aerogel foams
  14. Factors determining the flow erosion/part deformation of film insert molded thermoplastic products
  15. The extrusion of EPDM using an external gear pump: experiments and simulations
  16. News
  17. PPS News
Jetzt anmelden und 20% sparen
Institutioneller Zugang
Wie funktioniert Authentifizierung?
Haben Sie eine Idee, wie wir unsere Website verbessern können?
Bitte schreiben Sie uns.
© 2025 De Gruyter Brill
Heruntergeladen am 29.10.2025 von https://www.degruyterbrill.com/document/doi/10.1515/ipp-2022-4217/html
Button zum nach oben scrollen