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Thermo-Mechanical Recyclability of Additively Manufactured Polypropylene and Polylactic Acid Parts and Polypropylene Support Structures

Polymers have a reputation for several advantageous characteristics like chemical resistance, weight reduction, and simple form-giving processes. The rise of additive manufacturing technologies such as Fused Filament Fabrication (FFF) has introduced an even more versatile production process that sup...

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Autores principales: Nagengast, Niko, Bay, Christian, Döpper, Frank, Schmidt, Hans-Werner, Neuber, Christian
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10223719/
https://www.ncbi.nlm.nih.gov/pubmed/37242864
http://dx.doi.org/10.3390/polym15102291
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author Nagengast, Niko
Bay, Christian
Döpper, Frank
Schmidt, Hans-Werner
Neuber, Christian
author_facet Nagengast, Niko
Bay, Christian
Döpper, Frank
Schmidt, Hans-Werner
Neuber, Christian
author_sort Nagengast, Niko
collection PubMed
description Polymers have a reputation for several advantageous characteristics like chemical resistance, weight reduction, and simple form-giving processes. The rise of additive manufacturing technologies such as Fused Filament Fabrication (FFF) has introduced an even more versatile production process that supported new product design and material concepts. This led to new investigations and innovations driven by the individualization of customized products. The other side of the coin contains an increasing resource and energy consumption satisfying the growing demand for polymer products. This turns into a magnitude of waste accumulation and increased resource consumption. Therefore, appropriate product and material design, taking into account end-of-life scenarios, is essential to limit or even close the loop of economically driven product systems. In this paper, a comparison of virgin and recycled biodegradable (polylactic acid (PLA)) and petroleum-based (polypropylene (PP) & support) filaments for extrusion-based Additive Manufacturing is presented. For the first time, the thermo-mechanical recycling setup contained a service-life simulation, shredding, and extrusion. Specimens and complex geometries with support materials were manufactured with both, virgin and recycled materials. An empirical assessment was executed through mechanical (ISO 527), rheological (ISO 1133), morphological, and dimensional testing. Furthermore, the surface properties of the PLA and PP printed parts were analyzed. In summary, PP parts and parts from its support structure showed, in consideration of all parameters, suitable recyclability with a marginal parameter variance in comparison to the virgin material. The PLA components showed an acceptable decline in the mechanical values but through thermo-mechanical degradation processes, rheological and dimensional properties of the filament dropped decently. This results in significantly identifiable artifacts of the product optics, based on an increase in surface roughness.
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spelling pubmed-102237192023-05-28 Thermo-Mechanical Recyclability of Additively Manufactured Polypropylene and Polylactic Acid Parts and Polypropylene Support Structures Nagengast, Niko Bay, Christian Döpper, Frank Schmidt, Hans-Werner Neuber, Christian Polymers (Basel) Article Polymers have a reputation for several advantageous characteristics like chemical resistance, weight reduction, and simple form-giving processes. The rise of additive manufacturing technologies such as Fused Filament Fabrication (FFF) has introduced an even more versatile production process that supported new product design and material concepts. This led to new investigations and innovations driven by the individualization of customized products. The other side of the coin contains an increasing resource and energy consumption satisfying the growing demand for polymer products. This turns into a magnitude of waste accumulation and increased resource consumption. Therefore, appropriate product and material design, taking into account end-of-life scenarios, is essential to limit or even close the loop of economically driven product systems. In this paper, a comparison of virgin and recycled biodegradable (polylactic acid (PLA)) and petroleum-based (polypropylene (PP) & support) filaments for extrusion-based Additive Manufacturing is presented. For the first time, the thermo-mechanical recycling setup contained a service-life simulation, shredding, and extrusion. Specimens and complex geometries with support materials were manufactured with both, virgin and recycled materials. An empirical assessment was executed through mechanical (ISO 527), rheological (ISO 1133), morphological, and dimensional testing. Furthermore, the surface properties of the PLA and PP printed parts were analyzed. In summary, PP parts and parts from its support structure showed, in consideration of all parameters, suitable recyclability with a marginal parameter variance in comparison to the virgin material. The PLA components showed an acceptable decline in the mechanical values but through thermo-mechanical degradation processes, rheological and dimensional properties of the filament dropped decently. This results in significantly identifiable artifacts of the product optics, based on an increase in surface roughness. MDPI 2023-05-12 /pmc/articles/PMC10223719/ /pubmed/37242864 http://dx.doi.org/10.3390/polym15102291 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Nagengast, Niko
Bay, Christian
Döpper, Frank
Schmidt, Hans-Werner
Neuber, Christian
Thermo-Mechanical Recyclability of Additively Manufactured Polypropylene and Polylactic Acid Parts and Polypropylene Support Structures
title Thermo-Mechanical Recyclability of Additively Manufactured Polypropylene and Polylactic Acid Parts and Polypropylene Support Structures
title_full Thermo-Mechanical Recyclability of Additively Manufactured Polypropylene and Polylactic Acid Parts and Polypropylene Support Structures
title_fullStr Thermo-Mechanical Recyclability of Additively Manufactured Polypropylene and Polylactic Acid Parts and Polypropylene Support Structures
title_full_unstemmed Thermo-Mechanical Recyclability of Additively Manufactured Polypropylene and Polylactic Acid Parts and Polypropylene Support Structures
title_short Thermo-Mechanical Recyclability of Additively Manufactured Polypropylene and Polylactic Acid Parts and Polypropylene Support Structures
title_sort thermo-mechanical recyclability of additively manufactured polypropylene and polylactic acid parts and polypropylene support structures
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10223719/
https://www.ncbi.nlm.nih.gov/pubmed/37242864
http://dx.doi.org/10.3390/polym15102291
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