Polylactic acid and high‐density polyethylene blend: Characterization and application in additive manufacturing

A Hierarchical Nano to Micro Scale Modelling of 3D Printed Nano-Reinforced Polylactic Acid: Micropolar Modelling and Molecular Dynamics Simulation

Fused deposition modelling (FDM) is an additive manufacturing technique widely used for rapid prototyping. This method facilitates the creation of parts with intricate geometries, making it suitable for advanced applications in fields such as tissue engineering, aerospace, and electronics. Despite its advantages, FDM often results in the formation of voids between the deposited filaments, which can compromise mechanical properties. However, in some cases, such as the design of scaffolds for bone regeneration, increased porosity can be advantageous as it allows for better permeability. On the other hand, the introduction of nano-additives into the FDM material enhances design flexibility and can significantly improve the mechanical properties. Therefore, modelling FDM-produced components involves complexities at two different scales: nanoscales and microscales. Material deformation is primarily influenced by atomic-scale phenomena, especially with nanoscopic constituents, whereas the distribution of nano-reinforcements and FDM-induced heterogeneities lies at the microscale. This work presents multiscale modelling that bridges the nano and microscales to predict the mechanical properties of FDM-manufactured components. At the nanoscale, molecular dynamic simulations unravel the atomistic intricacies that dictate the behaviour of the base material containing nanoscopic reinforcements. Simulations are conducted on polylactic acid (PLA) and PLA reinforced with silver nanoparticles, with the properties derived from MD simulations transferred to the microscale model. At the microscale, non-classical micropolar theory is utilised, which can account for materials' heterogeneity through internal scale parameters while avoiding direct discretization. The developed mechanical model offers a comprehensive framework for designing 3D-printed PLA nanocomposites with tailored mechanical properties.

Evaluation of Thermal Decomposition Kinetics of Poly (Lactic Acid)/Ethylene Elastomer (EE) Blends

The influences of ethylene-based elastomer (EE) and the compatibilizer agent ethylene-butyl acrylate-glycidyl methacrylate (EBAGMA) on the thermal degradation of PLA/EE blends were evaluated by the thermal degradation kinetics and thermodynamic parameters using thermogravimetry. The presence of EE and EBAGMA synergistically improved the PLA thermal stability. The temperature of 10% of mass loss (T10%) of PLA was around 365 °C, while in the compatibilized PLA/EE blend, this property increased to 370 °C. The PLA average activation energy (Ea¯) reduced in the PLA/EE blend (from 96 kJ/mol to 78 kJ/mol), while the presence of EBAGMA in the PLA/EE blend increased the Ea¯ due to a better blend compatibilization. The solid-state thermal degradation of the PLA and PLA/EE blends was classified as a D-type degradation mechanism. In general, the addition of EE increased the thermodynamic parameters when compared to PLA and the compatibilized blend due to the increase in the collision rate between the components over the thermal decomposition.

Blending of Low-Density Polyethylene and Poly(Butylene Succinate) (LDPE/PBS) with Polyethylene-Graft-Maleic Anhydride (PE-g-MA) as a Compatibilizer on the Phase Morphology, Mechanical and Thermal Properties

It is of significant concern that the buildup of non-biodegradable plastic waste in the environment may result in long-term issues with the environment, the economy and waste management. In this study, low-density polyethylene (LDPE) was compounded with different contents of poly(butylene succinate) (PBS) at 10-50 wt.%, to evaluate the potential of replacing commercial plastics with a biodegradable renewable polymer, PBS for packaging applications. The morphological, mechanical and thermal properties of the LDPE/PBS blends were examined in relation to the effect of polyethylene-graft-maleic anhydride (PE-g-MA) as a compatibilizer. LDPE/PBS/PE-g-MA blends were fabricated via the melt blending method using an internal mixer and then were compression molded into test samples. The presence of LDPE, PBS and PE-g-MA individually in the matrix for each blend presented physical interaction between the constituents, as shown by Fourier-transform infrared spectroscopy (FTIR). The morphology of LDPE/PBS/PE-g-MA blends showed improved compatibility and homogeneity between the LDPE matrix and PBS phase. Compatibilized LDPE/PBS blends showed an improvement in the tensile strength, with 5 phr of compatibilizer providing the optimal content. The thermal stability of LDPE/PBS blends decreased with higher PBS content and the thermal stability of compatibilized blends was higher in contrast to the uncompatibilized blends. Therefore, our research demonstrated that the partial substitution of LDPE with a biodegradable PBS and the incorporation of the PE-g-MA compatibilizer could develop an innovative blend with improved structural, mechanical and thermal properties.

Partial Biodegradable Blend with High Stability against Biodegradation for Fused Deposition Modeling

This research presents a partial biodegradable polymeric blend aimed for large-scale fused deposition modeling (FDM). The literature reports partial biodegradable blends with high contents of fossil fuel-based polymers (>20%) that make them unfriendly to the ecosystem. Furthermore, the reported polymer systems neither present good mechanical strength nor have been investigated in vulnerable environments that results in biodegradation. This research, as a continuity of previous work, presents the stability against biodegradability of a partial biodegradable blend prepared with polylactic acid (PLA) and polypropylene (PP). The blend is designed with intended excess physical interlocking and sufficient chemical grafting, which has only been investigated for thermal and hydrolytic degradation before by the same authors. The research presents, for the first time, ANOVA analysis for the statistical evaluation of endurance against biodegradability. The statistical results are complemented with thermochemical and visual analysis. Fourier transform infrared spectroscopy (FTIR) determines the signs of intermolecular interactions that are further confirmed by differential scanning calorimetry (DSC). The thermochemical interactions observed in FTIR and DSC are validated with thermogravimetric analysis (TGA). Scanning electron microscopy (SEM) is also used as a visual technique to affirm the physical interlocking. It is concluded that the blend exhibits high stability against soil biodegradation in terms of high mechanical strength and high mass retention percentage.

Partial Biodegradable Blend for Fused Filament Fabrication: In-Process Thermal and Post-Printing Moisture Resistance

Despite the extensive research, the moisture-based degradation of the 3D-printed polypropylene and polylactic acid blend is not yet reported. This research is a part of study reported on partial biodegradable blends proposed for large-scale additive manufacturing applications. However, the previous work does not provide information about the stability of the proposed blend system against moisture-based degradation. Therefore, this research presents a combination of excessive physical interlocking and minimum chemical grafting in a partial biodegradable blend to achieve stability against in-process thermal and moisture-based degradation. In this regard, a blend of polylactic acid and polypropylene compatibilized with polyethylene graft maleic anhydride is presented for fused filament fabrication. The research implements, for the first time, an ANOVA for combined thermal and moisture-based degradation. The results are explained using thermochemical and microscopic techniques. Scanning electron microscopy is used for analyzing the printed blend. Fourier transform infrared spectroscopy has allowed studying the intermolecular interactions due to the partial blending and degradation mechanism. Differential scanning calorimetry analyzes the blending (physical interlocking or chemical grafting) and thermochemical effects of the degradation mechanism. The thermogravimetric analysis further validates the physical interlocking and chemical grafting. The novel concept of partial blending with excessive interlocking reports high mechanical stability against moisture-based degradation.

Anisotropic solid-state PLA foaming templated by crystal phase pre-oriented with 3D printing: Cell supporting structures with directional capillary transfer function

Bones represent a superb biomaterial that combines high mechanical stiffness with nutrition delivery to its osteocyte cells through the microscopical Haversian canals and bone canaliculi. Such structure is hard to...

Recent progress of preparation of branched poly(lactic acid) and its application in the modification of polylactic acid materials

Poly (lactic acid) (PLA) with branched structure has abundant terminal groups, high melt strength, good rheological properties, and excellent processability; it is a new research and application direction of PLA materials. This study mainly summarizes the molecular structure design, preparation methods, basic properties of branched PLA, and its application in modified PLA materials. The structure and properties of branched PLA prepared by ring-opening polymerization of monomer, functional group polycondensation, and chain extender in the processing process were introduced. The research progress of in situ formation of branched PLA by initiators, multifunctional monomers/additives through dynamic vulcanization, and irradiation induction was described. The effect of branched PLA on the structure and properties of linear PLA materials was analyzed. The role of branched PLA in improving the crystallization behavior, phase morphology, foaming properties, and mechanical properties of linear PLA materials was discussed. At the same time, its research progress in biomedicine and tissue engineering was analyzed. Branched PLA has excellent compatibility with PLA, which has important research value in regulating the structure and properties of PLA materials.

Effects of In-Process Temperatures and Blending Polymers on Acrylonitrile Butadiene Styrene Blends

Acrylonitrile butadiene styrene (ABS) is a renowned commodity polymer for additive manufacturing, particularly fused deposition modelling (FDM). The recent large-scale applications of 3D-printed ABS require stable mechanical properties than ever needed. However, thermochemical scission of butadiene bonds is one of the contemporary challenges affecting the overall ABS stability. In this regard, literature reports melt-blending of ABS with different polymers with high thermal resistance. However, the comparison for the effects of different polymers on tensile strength of 3D-printed ABS blends was not yet reported. Furthermore, the cumulative studies comprising both blended polymers and in-process thermal variables for FDM were not yet presented as well. This research, for the first time, presents the statistical comparison of tensile properties for the added polymers and in-process thermal variables (printing temperature and build surface temperature). The research presents Fourier transform infrared spectroscopy (FTIR) and thermogravimetric analysis (TGA) to explain the thermochemical reasons behind achieved mechanical properties. Overall, ABS blend with PP shows high tensile strength (≈31 MPa) at different combinations of in-process parameters. Furthermore, some commonalities among both blends are noted, i.e., the tensile strength improves with increase of surface (bed) and printing temperature.

Partial Polymer Blend for Fused Filament Fabrication with High Thermal Stability

The materials for large scale fused filament fabrication (FFF) are not yet designed to resist thermal degradation. This research presents a novel polymer blend of polylactic acid with polypropylene for FFF, purposefully designed with minimum feasible chemical grafting and overwhelming physical interlocking to sustain thermal degradation. Multi-level general full factorial ANOVA is performed for the analysis of thermal effects. The statistical results are further investigated and validated using different thermo-chemical and visual techniques. For example, Fourier transform infrared spectroscopy (FTIR) analyzes the effects of blending and degradation on intermolecular interactions. Differential scanning calorimetry (DSC) investigates the nature of blending (grafting or interlocking) and effects of degradation on thermal properties. Thermogravimetric analysis (TGA) validates the extent of chemical grafting and physical interlocking detected in FTIR and DSC. Scanning electron microscopy (SEM) is used to analyze the morphology and phase separation. The novel approach of overwhelmed physical interlocking and minimum chemical grafting for manufacturing 3D printing blends results in high structural stability (mechanical and intermolecular) against thermal degradation as compared to neat PLA.