Additive Manufacturing of Polymeric-based Materials: Challenges and Potentials: Characterization and Novel Approaches to Mitigate the Challenges of Polymeric-based Materials in Additive Manufacturing
Program Organizers: Ola Rashwan, Pennsylvania State University- Harrisburg; Matt Caputo, Pennsylvania State University; Daudi Waryoba, Pennsylvania State University; Pedro Cortes, Youngstown State University
Tuesday 8:00 AM
October 11, 2022
Room: 306
Location: David L. Lawrence Convention Center
Session Chair: Matt Caputo, Penn State Shenango; Ola Rashwan, Penn State Harrisburg
8:00 AM
Effects of Ironing on the Surface and Thermo-Mechanical Properties of 3D Printed PLA via Material Extrusion: Matthew Caputo1; Ola Rashwan2; Daudi Waryoba3; Kevin McDade1; 1Penn State Shenango; 2Penn State Harrisburg; 3Penn State DuBois
Additive manufacturing (AM) has shown to provide profound applications in fields of engineering and science by offering design freedom along with versatility in feed-stock material. Polylactic-acid (PLA) is an exceedingly popular biodegradable polymer commonly used in material extrusion printing. As a promising alternative to petroleum based polymers, PLA has found use in several industries due to its bio-compatibility, renew-ability, and good mechanical properties. Several printing parameters in the material extrusion process can alter physical characteristics of a part such as ironing. To date, there is limited information on the effects the ironing process has on 3D printed PLA. This study utilized a fractional factorial design in order to correlate the impact ironing has on the surface morphology and thermo-mechanical properties of 3D printed and ironed PLA. This work reports the surface morphology, surface roughness, and visco-elastic properties, including storage modulus and glass transition temperature, of 3D printed and ironed PLA.
8:20 AM
Characterization of Additive Manufactured Carbon Fiber Composite Using an Original Fracture Toughness Measurement Approach: Allison Rea1; Constantin Solomon1; 1Youngstown State University
Single-edge-notch bending (SENB) specimens made of Onix (composite material of nylon and chopped carbon fiber) were manufactured using fused filament fabrication (FFF) technique. In order to determine the fracture toughness, the ASTM D5045 recommends the measurement of the crack-tip opening displacement (CTOD) using a specialized gauge. This research is proposing an original method of measuring the CTOD by adapting a common strain gauge extensometer, used for elongation measurement in the tensile testing, to the fracture toughness measurement process. In order to attach the strain gauge extensometer to the SENB specimens, specialized extenders were designed and additively manufactured via FFF technique from polylactic acid (PLA). Kinematic analysis of the extenders’ movement during the fracture toughness measurement process was performed in order to determine the CTOD. The paper will present the results on investigating the fracture toughness of carbon fiber composite using the proposed novel method of measuring the crack-tip opening displacement.
8:40 AM
3D Printing of Highly Stretchable Shape Memory Polymer Composites (SMPCs): Kavish Sudan1; Kunal Kate1; Rajiv Malhotra2; 1University of Louisville; 2Rutgers University
Shape memory polymers are structurally active polymers that find application in advanced research fields such as robotic sensors, medical devices, and actuators. However, these materials usually lack structural properties or are only processable via complex cleanroom technologies, restricting their scope of applications. In this work, we utilized an FFF 3D printer for processing in-house developed smart polymer systems and fabricating structures for application in tactile robotics and 4D structures. We developed highly stretchable (> 600%) filaments for a novel shape memory polymer composite and tested their 3D printed parts for the mechanical properties and shape recovery behavior. Additionally, the effect of adding fillers such as carbon fiber and graphene on composite rheology and mechanical properties was analyzed. Furthermore, dynamic mechanical analysis (DMA) was conducted for all the compositions to quantify the shape memory characteristics. Finally, the extent and rate of recovery were also analyzed using the high-speed video capture method.
9:00 AM
Extrusion and Characterization of Compounded rPET 3D Printing Filament: Ola Rashwan1; Zachary Koroneos1; Matthew Caputo2; 1Pennsylvania State University- Harrisburg; 2Penn State Shenango
The continuous increase of polymers in additive manufacturing technology harms the environment and disturbs the ecosystem. This project investigates the extrusion of recycled PET into 3D printing filament. It was expected that if the rPET pellets were compounded with some additives, such as a thermal stabilizer, a chain extender, and an impact modifier, the mechanical properties of the extruded filament would be improved. A twin-screw extruder was used to compound and extrude rPET pellets with the additives into a filament of 1.75 mm in diameter. The standard test specimens were 3D printed and tested according to the ASTM tensile, impact, and flexural test standards. The test results show that the mechanical properties of the compounded rPET are improved compared to the plain recycled PET. This conclusion suggests that the reuse of the waste polymers in 3D Printing technology will make this technology a green manufacturing technology.
9:20 AM Cancelled
Direct Ink Writing of Multi-layered Sensors Embedded Using 3D Printing for Soft Robotics: Akshay Kakar1; Derrick Banerjee1; Konstantinos Sierros1; Edward Sablosky1; 1West Virginia University
Soft robots are the next-generation in robotics, as they provide a higher degree-of-freedom of movement and dexterity. To match the tortuous movements of the soft robots, the development of flexible sensors and methods for embedding the flexible electronics is important to produce the complex, yet bendable complex architectures. Embedding multi-layered sensors enable the soft robots to provide movement information at different depths of their skin, giving it a higher data resolution. In this study, we develop and evaluate methods for direct ink writing of multi-layered strain and temperature sensors embedded in siloxane, using 3D printing. The embedded sensors were evaluated based on sensor print quality, flexibility limits, durability, electromechanical tests including uniaxial tensile and bending, and accuracy of temperature measurements during electromechanical testing.
9:40 AM
Polymeric Composite of Magnetite Iron Oxide Nanoparticles and Their Application in Biomedicine: A Review: Estefani Chichande1; Moises Bustamante2; Emilio Bucio3; 1Universidad Central del Ecuador; 2Universidad Autónoma de México ; 3Universidad Autónoma de México
A broad spectrum of nanomaterials has been investigated for multiple purposes in recent years. Magnetic nanoparticles (MNPs), such as Iron oxide nanoparticles and superparamagnetic iron oxide nanoparticles have received attention because of their physicochemical and magnetic properties and their ease of combination with a polymeric matrix. Furthermore, the arresting of these MNPs into a cross-linked matrix known as hydrogel has attracted significant interest in the biomedical field. Commonly, MNPs act as a reinforcing material for the polymer matrix. In the present work, several methods, such as co-precipitation, polyol, hydrothermal, microemulsion, and sol-gel methods, are reported to synthesize MNPs with controllable physical and chemical properties that suit the required application. Due to the potential of magnetite-based nanocomposites, specifically in hydrogels, processing methods, including physical blending, in situ precipitation, and grafting methods, are exhibited. Moreover, the most common characterization techniques employed to study MNPs and magnetic gel are discussed.
10:00 AM Break
10:20 AM
Fused Deposition Modeling of Natural Carbon-enhanced Composite Filaments for Structural Applications: Logan Veley1; Yahya Al-Majali1; Jason Trembly1; 1Ohio University
This study investigates the development and printability of novel natural carbon-enhanced filament materials. Natural and treated carbon filler from 20 – 50 wt.% was compounded with base polymers of polylactic acid (PLA), polyethylene terephthalate glycol (PETG), polyamide (PA), and high-density polyethylene (HDPE) to produce carbon-plastic composite (CPC) filaments for use in commercially available fused deposition modeling (FDM) printers. Pairing additive manufacturing (AM) advantages with CPC materials at high filler contents provides the opportunity for highly sustainable manufacturing and construction. As-printed and carbonized structures provide an environmentally friendly and economically viable substitute for existing materials used in building/construction, tooling, and metal casting applications. The influence of different types and loading of natural carbon fillers on the thermal, physical, and mechanical properties of the resulting composites will be discussed. The presentation will also discuss initial techno-economic analyses and scalability of the technology for industrial applications.
10:40 AM Question and Answer Period