Local thermal activation for a combined thermoforming and 3D-printing process
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Timo Reindl
Timo ReindlInstitut für Kunststofftechnik, University of Stuttgart, Stuttgart, GermanySearch for this author in:
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Lars Schmohl
Abstract
In this contribution, the use of upcycled filaments for the functionalization of technical thermoformed components using additive manufacturing is investigated. In particular, small series applications in the automotive sector are being addressed. A high-quality plastic filament is obtained from the off-cuts of the thermoforming process and used in a robot-based process to print on and thus functionalize the thermoformed components. This involves adapted path planning, which allows printing on multi-axis curved free-form surfaces with an articulated robot. The resulting process combination of thermoforming and additive manufacturing offers a circular material flow and allows a reduction in waste and total energy consumption while simultaneously increasing the possible shape variety and component complexity. This creates an alternative to the injection molding process with its high tool costs, especially for small series and complex component shapes. In addition, the homogenization of the materials used has positive long-term effects on recyclability at the end of the product life cycle. In realizing the combined process, the adhesive bond of the printed structures to the thermoformed base component is particularly important for the mechanical properties of the finished part. If the bond at the interfaces is insufficient, forces cannot be transferred from functional elements like screw bosses, ribs and honeycomb structures to the base component and vice versa. Therefore, local thermal activation plays a crucial role in the 3D-printing process to ensure sufficient polymer chain movement and entanglement across the boundary layer.
Acknowledgments
We would like to thank the Institute for Control Engineering of Machine Tools and Manufacturing Units at the University of Stuttgart and SE-Kunststoffverarbeitung GmbH & Co. KG, Langenargen for the successful cooperation and for providing the test materials.
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Research ethics: Not applicable.
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Informed consent: Not applicable.
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Author contributions: All authors have accepted responsibility for the entire content of this manuscript and approved its submission.
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Use of Large Language Models, AI and Machine Learning Tools: None declared.
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Conflict of interest: The authors state no conflict of interest.
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Research funding: The results presented here were obtained as part of the research project 35597/01-21/2 funded by the German Federal Environmental Foundation (DBU).
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Data availability: The datasets generated and/or analyzed during the current study are available from the corresponding author on reasonable request.
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Articles in the same Issue
- Frontmatter
- Editorial
- PPS2024 Ferrol: advances and perspectives in polymer processing
- Research Articles
- Applying network theory to the modeling of multilayer flows in slot dies: a use case for symbolic regression-based co-extrusion prediction models
- Multiscale polyethylene fiber – bacterial nanocellulose composites through combined laser fusion and bacterial in situ synthesis
- Novel approach to produce reinforced plastic weld seams using an additive friction stir welding process
- Local thermal activation for a combined thermoforming and 3D-printing process
- A new recycling strategy for airbag waste
- Highly electro-conductive PEDOT based thermoplastic composites: effect of filler form factor on electrical percolation threshold
- Cavity balance improvement for injection molded parts via automated flow leader generation
- Application of artificial intelligence techniques to select the objectives in the multi-objective optimization of injection molding
- Modeling melt conveying and power consumption of conveying elements in co-rotating twin-screw extruders
