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Gunputh UF, Williams G, Pawlik M, Lu Y, Wood P. Effect of Powder Bed Fusion Laser Sintering on Dimensional Accuracy and Tensile Properties of Reused Polyamide 11. Polymers (Basel) 2023; 15:4602. [PMID: 38231991 PMCID: PMC10708357 DOI: 10.3390/polym15234602] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/12/2023] [Revised: 11/25/2023] [Accepted: 11/28/2023] [Indexed: 01/19/2024] Open
Abstract
Polyamide 11 (PA11) is a plant-based nylon made from castor beans. Powder bed fusion laser sintering (PBF-LS) is an additive manufacturing process used for PA11 which allows for the reuse of the unsintered powder. The unsintered powder is mixed with virgin powders at different refresh rates, a process which has been studied extensively for most semi-crystalline polyamides. However, there is lack of information on the effect of using 100% reused PA11 powder and the effect of the number of times it is reused on its own, during powder bed fusion laser sintering. This paper investigates the effect of reusing PA11 powder in PBF-LS and the effect of the number of times it is reused on the dimensional accuracy, density and thermal and tensile properties. From the 100% virgin powder to the third reuse of the powder, there is a decrease in powder wastage, crystallinity and tensile strength. These are associated with the polymerisation and cross-linking process of polymer chains, upon exposure to high temperatures. This results in a higher molecular weight and, hence, a higher density. From the fourth reuse to the tenth reuse, the opposite is observed, which is associated with an increase in high-viscosity unmolten particles, resulting in defects in the PBF-LS parts.
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Affiliation(s)
- Urvashi F. Gunputh
- College of Science and Engineering, University of Derby, Quaker Way, Derby DE22 1GB, UK; (G.W.); (M.P.); (Y.L.); (P.W.)
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Tonello R, Conradsen K, Pedersen DB, Frisvad JR. Surface Roughness and Grain Size Variation When 3D Printing Polyamide 11 Parts Using Selective Laser Sintering. Polymers (Basel) 2023; 15:2967. [PMID: 37447613 DOI: 10.3390/polym15132967] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/08/2023] [Revised: 06/06/2023] [Accepted: 06/22/2023] [Indexed: 07/15/2023] Open
Abstract
Selective laser sintering (SLS) is a well-established technology that is used for additive manufacturing. Significant efforts have been made to improve SLS by optimizing the powder deposition, laser beam parameters, and temperature settings. The purpose is to ensure homogeneous sintering and prevent geometric and appearance inaccuracies in the manufactured objects. We evaluated the differences in the surface roughness and grain size of curved objects manufactured by using upcoming SLS technology that features two CO laser sources. Our analysis was carried out on polyamide 11 (PA11), which is a sustainable biobased polymer that has been gaining popularity due to its high-performance properties: its low melting point, high viscosity, and excellent mechanical properties. By using a Taguchi experimental design and analysis of variance (ANOVA), we examined the influence on the surface roughness and grain size of the build setup, the presence of thin walls, and the position of the sample on the powder bed. We found significant differences in some surface roughness and grain size measurements when these parameters were changed.
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Affiliation(s)
- Riccardo Tonello
- Department of Applied Mathematics and Computer Science, Technical University of Denmark, 2800 Kongens Lyngby, Denmark
- Department of Civil and Mechanical Engineering, Technical University of Denmark, 2800 Kongens Lyngby, Denmark
| | - Knut Conradsen
- Department of Applied Mathematics and Computer Science, Technical University of Denmark, 2800 Kongens Lyngby, Denmark
| | - David Bue Pedersen
- Department of Civil and Mechanical Engineering, Technical University of Denmark, 2800 Kongens Lyngby, Denmark
| | - Jeppe Revall Frisvad
- Department of Applied Mathematics and Computer Science, Technical University of Denmark, 2800 Kongens Lyngby, Denmark
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Pandelidi C, Blakis R, Lee KPM, Bateman S, Brandt M, Kajtaz M. Thermal and Oxidative Aging Effects of Polyamide-11 Powder Used in Multi-Jet Fusion. Polymers (Basel) 2023; 15:polym15102395. [PMID: 37242970 DOI: 10.3390/polym15102395] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/12/2023] [Revised: 05/10/2023] [Accepted: 05/15/2023] [Indexed: 05/28/2023] Open
Abstract
The transition of additive manufacturing (AM) from a technique for rapid prototyping to one for manufacturing of near net or net components has been led by the development of methods that can repeatedly fabricate quality parts. High-speed laser sintering and the recently developed multi-jet fusion (MJF) processes have seen quick adoption from industry due to their ability to produce high-quality components relatively quickly. However, the recommended refresh ratios of new powder led to notable amounts of used powder being discarded. In this research, polyamide-11 powder, typically used in AM, was thermally aged to investigate its properties at extreme levels of reuse. The powder was exposed to 180 °C in air for up to 168 h and its chemical, morphological, thermal, rheological, and mechanical properties were examined. To decouple the thermo-oxidative aging phenomena from AM process related effects, such as porosity, rheological and mechanical properties characterisation was performed on compression-moulded specimens. It was found that exposure notably affected the properties of both the powder and the derived compression-moulded specimens within the first 24 h of exposure; however, consecutive exposure did not have a significant effect.
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Affiliation(s)
- Chrysoula Pandelidi
- Centre for Additive Manufacturing, School of Engineering, RMIT University, GPO Box 2476, Melbourne, VIC 3001, Australia
| | - Ryan Blakis
- Centre for Additive Manufacturing, School of Engineering, RMIT University, GPO Box 2476, Melbourne, VIC 3001, Australia
| | - Kok Peng Marcian Lee
- Centre for Additive Manufacturing, School of Engineering, RMIT University, GPO Box 2476, Melbourne, VIC 3001, Australia
| | - Stuart Bateman
- Centre for Additive Manufacturing, School of Engineering, RMIT University, GPO Box 2476, Melbourne, VIC 3001, Australia
| | - Milan Brandt
- Centre for Additive Manufacturing, School of Engineering, RMIT University, GPO Box 2476, Melbourne, VIC 3001, Australia
| | - Mladenko Kajtaz
- Centre for Additive Manufacturing, School of Engineering, RMIT University, GPO Box 2476, Melbourne, VIC 3001, Australia
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Fan D, Liu Y, Wang Y, Wang Q, Guo H, Cai Y, Song R, Wang X, Wang W. 3D printing of bone and cartilage with polymer materials. Front Pharmacol 2022; 13:1044726. [PMID: 36561347 PMCID: PMC9763290 DOI: 10.3389/fphar.2022.1044726] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/15/2022] [Accepted: 11/24/2022] [Indexed: 12/12/2022] Open
Abstract
Damage and degeneration to bone and articular cartilage are the leading causes of musculoskeletal disability. Commonly used clinical and surgical methods include autologous/allogeneic bone and cartilage transplantation, vascularized bone transplantation, autologous chondrocyte implantation, mosaicplasty, and joint replacement. 3D bio printing technology to construct implants by layer-by-layer printing of biological materials, living cells, and other biologically active substances in vitro, which is expected to replace the repair mentioned above methods. Researchers use cells and biomedical materials as discrete materials. 3D bio printing has largely solved the problem of insufficient organ donors with the ability to prepare different organs and tissue structures. This paper mainly discusses the application of polymer materials, bio printing cell selection, and its application in bone and cartilage repair.
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Affiliation(s)
- Daoyang Fan
- Department of Orthopedic, The First Affiliated Hospital of Zhengzhou University, Zhengzhou University, Zhengzhou, China
| | - Yafei Liu
- Department of Orthopedic, The First Affiliated Hospital of Zhengzhou University, Zhengzhou University, Zhengzhou, China
| | - Yifan Wang
- Department of Additive Manufacturing, The First Affiliated Hospital of Zhengzhou University, Zhengzhou, China
| | - Qi Wang
- Department of Pediatrics, The Third Affiliated Hospital of Zhengzhou University, Zhengzhou University, Zhengzhou, China
| | - Hao Guo
- Department of Orthopedic, The First Affiliated Hospital of Zhengzhou University, Zhengzhou University, Zhengzhou, China
| | - Yiming Cai
- Department of Orthopedic, The First Affiliated Hospital of Zhengzhou University, Zhengzhou University, Zhengzhou, China
| | - Ruipeng Song
- Department of Orthopedic, The First Affiliated Hospital of Zhengzhou University, Zhengzhou University, Zhengzhou, China
| | - Xing Wang
- Beijing National Laboratory for Molecular Sciences, Institute of Chemistry, Chinese Academy of Sciences, Beijing, China,University of Chinese Academy of Sciences, Beijing, China,*Correspondence: Weidong Wang, ; Xing Wang,
| | - Weidong Wang
- Department of Orthopedic, The First Affiliated Hospital of Zhengzhou University, Zhengzhou University, Zhengzhou, China,*Correspondence: Weidong Wang, ; Xing Wang,
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Chen J, Zhao L, Zhou K. Multi-Jet Fusion 3D Voxel Printing of Conductive Elastomers. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2022; 34:e2205909. [PMID: 36125341 DOI: 10.1002/adma.202205909] [Citation(s) in RCA: 5] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/29/2022] [Revised: 08/30/2022] [Indexed: 06/15/2023]
Abstract
3D voxel printing enables the fabrication of parts with site-specific materials and properties at voxel-scale resolution, while the current research mainly focuses on the variations in mechanical properties and colors. In this work, the design and fabrication of voxelated conductive elastomers using Multi Jet Fusion 3D voxel printing actualized by a newly developed multifunctional agent (MA) are investigated. The MA, mainly consisting of carbon nanotubes and poly(3,4-ethylenedioxythiophene) polystyrene sulfonate, serves as an infrared-absorbing colorant, a reinforcement, and a conductive filler simultaneously. By controlling the drop-on-demand dispensing of the agents on thermoplastic polyurethane powder, the electrical conductivity across a single printed part can be tailored over a wide range from 10-10 to 10-1 S cm-1 at a voxel resolution of ≈100 µm. Assembly-free strain sensors comprising conductive sensing layers and insulating frames are fabricated to demonstrate the capability of the technique in manufacturing all-printed wearable devices.
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Affiliation(s)
- Jiayao Chen
- HP-NTU Digital Manufacturing Corporate Lab, School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore, 639798, Singapore
- Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore, 639798, Singapore
| | - Lihua Zhao
- HP-NTU Digital Manufacturing Corporate Lab, School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore, 639798, Singapore
- 3D Lab, HP Labs, HP Inc., Palo Alto, CA, 94304, USA
| | - Kun Zhou
- HP-NTU Digital Manufacturing Corporate Lab, School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore, 639798, Singapore
- Singapore Centre for 3D Printing, School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore, 639798, Singapore
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Nanda S, Patra BR, Patel R, Bakos J, Dalai AK. Innovations in applications and prospects of bioplastics and biopolymers: a review. ENVIRONMENTAL CHEMISTRY LETTERS 2022; 20:379-395. [PMID: 34867134 PMCID: PMC8629338 DOI: 10.1007/s10311-021-01334-4] [Citation(s) in RCA: 61] [Impact Index Per Article: 30.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/23/2021] [Accepted: 09/23/2021] [Indexed: 05/22/2023]
Abstract
Non-biodegradable plastics are continually amassing landfills and oceans worldwide while creating severe environmental issues and hazards to animal and human health. Plastic pollution has resulted in the death of millions of seabirds and aquatic animals. The worldwide production of plastics in 2020 has increased by 36% since 2010. This has generated significant interest in bioplastics to supplement global plastic demands. Bioplastics have several advantages over conventional plastics in terms of biodegradability, low carbon footprint, energy efficiency, versatility, unique mechanical and thermal characteristics, and societal acceptance. Bioplastics have huge potential to replace petroleum-based plastics in a wide range of industries from automobiles to biomedical applications. Here we review bioplastic polymers such as polyhydroxyalkanoate, polylactic acid, poly-3-hydroxybutyrate, polyamide 11, and polyhydroxyurethanes; and cellulose-based, starch-based, protein-based and lipid-based biopolymers. We discuss economic benefits, market scenarios, chemistry and applications of bioplastic polymers.
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Affiliation(s)
- Sonil Nanda
- Titan Clean Energy Projects Corporation, Craik, SK Canada
| | - Biswa R. Patra
- Department of Chemical and Biological Engineering, University of Saskatchewan, Saskatoon, SK Canada
| | - Ravi Patel
- Department of Chemical and Biological Engineering, University of Saskatchewan, Saskatoon, SK Canada
| | - Jamie Bakos
- Titan Clean Energy Projects Corporation, Craik, SK Canada
| | - Ajay K. Dalai
- Department of Chemical and Biological Engineering, University of Saskatchewan, Saskatoon, SK Canada
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Kafle A, Luis E, Silwal R, Pan HM, Shrestha PL, Bastola AK. 3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA). Polymers (Basel) 2021; 13:3101. [PMID: 34578002 PMCID: PMC8470301 DOI: 10.3390/polym13183101] [Citation(s) in RCA: 76] [Impact Index Per Article: 25.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/22/2021] [Revised: 09/03/2021] [Accepted: 09/09/2021] [Indexed: 01/08/2023] Open
Abstract
Additive manufacturing (AM) or 3D printing is a digital manufacturing process and offers virtually limitless opportunities to develop structures/objects by tailoring material composition, processing conditions, and geometry technically at every point in an object. In this review, we present three different early adopted, however, widely used, polymer-based 3D printing processes; fused deposition modelling (FDM), selective laser sintering (SLS), and stereolithography (SLA) to create polymeric parts. The main aim of this review is to offer a comparative overview by correlating polymer material-process-properties for three different 3D printing techniques. Moreover, the advanced material-process requirements towards 4D printing via these print methods taking an example of magneto-active polymers is covered. Overall, this review highlights different aspects of these printing methods and serves as a guide to select a suitable print material and 3D print technique for the targeted polymeric material-based applications and also discusses the implementation practices towards 4D printing of polymer-based systems with a current state-of-the-art approach.
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Affiliation(s)
- Abishek Kafle
- Design Lab, Department of Mechanical Engineering, Kathmandu University, Dhulikhel 45200, Nepal; (A.K.); (R.S.)
| | - Eric Luis
- Faculty of Medicine, Macau University of Science and Technology, Avenida Wai Long, Macau SAR, China;
| | - Raman Silwal
- Design Lab, Department of Mechanical Engineering, Kathmandu University, Dhulikhel 45200, Nepal; (A.K.); (R.S.)
| | - Houwen Matthew Pan
- Division of Chemistry and Biological Chemistry, School of Physical and Mathematical Sciences, Nanyang Technological University, 21 Nanyang Link, Singapore 637371, Singapore;
| | - Pratisthit Lal Shrestha
- Design Lab, Department of Mechanical Engineering, Kathmandu University, Dhulikhel 45200, Nepal; (A.K.); (R.S.)
| | - Anil Kumar Bastola
- Centre for Additive Manufacturing (CfAM), School of Engineering, University of Nottingham, Nottingham NG8 1BB, UK
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