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Modeling Materials Coextrusion in Polymers Additive Manufacturing

Material extrusion additive manufacturing enables us to combine more materials in the same nozzle during the deposition process. This technology, called material coextrusion, generates an expanded range of material properties, which can gradually change in the design domain, ensuring blending or hig...

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Autores principales: Sponchiado, Riccardo, Rosso, Stefano, Dal Fabbro, Pierandrea, Grigolato, Luca, Elsayed, Hamada, Bernardo, Enrico, Maltauro, Mattia, Uccheddu, Francesca, Meneghello, Roberto, Concheri, Gianmaria, Savio, Gianpaolo
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9863070/
https://www.ncbi.nlm.nih.gov/pubmed/36676557
http://dx.doi.org/10.3390/ma16020820
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author Sponchiado, Riccardo
Rosso, Stefano
Dal Fabbro, Pierandrea
Grigolato, Luca
Elsayed, Hamada
Bernardo, Enrico
Maltauro, Mattia
Uccheddu, Francesca
Meneghello, Roberto
Concheri, Gianmaria
Savio, Gianpaolo
author_facet Sponchiado, Riccardo
Rosso, Stefano
Dal Fabbro, Pierandrea
Grigolato, Luca
Elsayed, Hamada
Bernardo, Enrico
Maltauro, Mattia
Uccheddu, Francesca
Meneghello, Roberto
Concheri, Gianmaria
Savio, Gianpaolo
author_sort Sponchiado, Riccardo
collection PubMed
description Material extrusion additive manufacturing enables us to combine more materials in the same nozzle during the deposition process. This technology, called material coextrusion, generates an expanded range of material properties, which can gradually change in the design domain, ensuring blending or higher bonding/interlocking among the different materials. To exploit the opportunities offered by these technologies, it is necessary to know the behavior of the combined materials according to the materials fractions. In this work, two compatible pairs of materials, namely Polylactic Acid (PLA)-Thermoplastic Polyurethane (TPU) and Acrylonitrile Styrene Acrylate (ASA)-TPU, were investigated by changing the material fractions in the coextrusion process. An original model describing the distribution of the materials is proposed. Based on this, the mechanical properties were investigated by analytical and numerical approaches. The analytical model was developed on the simplified assumption that the coextruded materials are a set of rods, whereas the more realistic numerical model is based on homogenization theory, adopting the finite element analysis of a representative volume element. To verify the deposition model, a specific experimental test was developed, and the modeled material deposition was superimposed and qualitatively compared with the actual microscope images regarding the different deposition directions and material fractions. The analytical and numerical models show similar trends, and it can be assumed that the finite element model has a more realistic behavior due to the higher accuracy of the model description. The elastic moduli obtained by the models was verified in experimental tensile tests. The tensile tests show Young’s moduli of 3425 MPa for PLA, 1812 MPa for ASA, and 162 MPa for TPU. At the intermediate material fraction, the Young’s modulus shows an almost linear trend between PLA and TPU and between ASA and TPU. The ultimate tensile strength values are 63.9 MPa for PLA, 35.7 MPa for ASA, and 63.5 MPa for TPU, whereas at the intermediate material fraction, they assume lower values. In this initial work, the results show a good agreement between models and experiments, providing useful tools for designers and contributing to a new branch in additive manufacturing research.
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spelling pubmed-98630702023-01-22 Modeling Materials Coextrusion in Polymers Additive Manufacturing Sponchiado, Riccardo Rosso, Stefano Dal Fabbro, Pierandrea Grigolato, Luca Elsayed, Hamada Bernardo, Enrico Maltauro, Mattia Uccheddu, Francesca Meneghello, Roberto Concheri, Gianmaria Savio, Gianpaolo Materials (Basel) Article Material extrusion additive manufacturing enables us to combine more materials in the same nozzle during the deposition process. This technology, called material coextrusion, generates an expanded range of material properties, which can gradually change in the design domain, ensuring blending or higher bonding/interlocking among the different materials. To exploit the opportunities offered by these technologies, it is necessary to know the behavior of the combined materials according to the materials fractions. In this work, two compatible pairs of materials, namely Polylactic Acid (PLA)-Thermoplastic Polyurethane (TPU) and Acrylonitrile Styrene Acrylate (ASA)-TPU, were investigated by changing the material fractions in the coextrusion process. An original model describing the distribution of the materials is proposed. Based on this, the mechanical properties were investigated by analytical and numerical approaches. The analytical model was developed on the simplified assumption that the coextruded materials are a set of rods, whereas the more realistic numerical model is based on homogenization theory, adopting the finite element analysis of a representative volume element. To verify the deposition model, a specific experimental test was developed, and the modeled material deposition was superimposed and qualitatively compared with the actual microscope images regarding the different deposition directions and material fractions. The analytical and numerical models show similar trends, and it can be assumed that the finite element model has a more realistic behavior due to the higher accuracy of the model description. The elastic moduli obtained by the models was verified in experimental tensile tests. The tensile tests show Young’s moduli of 3425 MPa for PLA, 1812 MPa for ASA, and 162 MPa for TPU. At the intermediate material fraction, the Young’s modulus shows an almost linear trend between PLA and TPU and between ASA and TPU. The ultimate tensile strength values are 63.9 MPa for PLA, 35.7 MPa for ASA, and 63.5 MPa for TPU, whereas at the intermediate material fraction, they assume lower values. In this initial work, the results show a good agreement between models and experiments, providing useful tools for designers and contributing to a new branch in additive manufacturing research. MDPI 2023-01-14 /pmc/articles/PMC9863070/ /pubmed/36676557 http://dx.doi.org/10.3390/ma16020820 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
Sponchiado, Riccardo
Rosso, Stefano
Dal Fabbro, Pierandrea
Grigolato, Luca
Elsayed, Hamada
Bernardo, Enrico
Maltauro, Mattia
Uccheddu, Francesca
Meneghello, Roberto
Concheri, Gianmaria
Savio, Gianpaolo
Modeling Materials Coextrusion in Polymers Additive Manufacturing
title Modeling Materials Coextrusion in Polymers Additive Manufacturing
title_full Modeling Materials Coextrusion in Polymers Additive Manufacturing
title_fullStr Modeling Materials Coextrusion in Polymers Additive Manufacturing
title_full_unstemmed Modeling Materials Coextrusion in Polymers Additive Manufacturing
title_short Modeling Materials Coextrusion in Polymers Additive Manufacturing
title_sort modeling materials coextrusion in polymers additive manufacturing
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9863070/
https://www.ncbi.nlm.nih.gov/pubmed/36676557
http://dx.doi.org/10.3390/ma16020820
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