Otto Glöckel-Straße 2, A-8700 Leoben, Tel.: +43 3842 402 3501

kv@unileoben.ac.at

www.kunststofftechnik.at

29.09.2016

Schuschnigg Stephan

Novel Compounds for FFF

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Additive Manufacturing with Polymers

Polymers highest volume

SLS 38% with PA and Metals

FFF 31%

SLA 14%

80% of professional uses AM for

Product development

Prototyping

Proof of concept

They care for

Material cost

Consistency of the machines

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Fused Filament Fabrication

Filament based

Heated die

Melt extrusion

Layered deposition

Thermoplastic material

Low viscous

High stiffness

Temperature range

PRODUCT

Pro

cessin

g

Material

Desi

gn

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Filaments used today

ABS

PLA

HIPS

PVA

PA12

ASA

PC

PETG

Flexible

Filled Polymers

Wood

Metal

Magnetic

Conductive

Mineral Fillers

Ceramic

Reinforced

[1]

[2]

[3]

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Goal for NextGen3D

3D printing of polyolefin compounds

Characterization of available filaments

Advantages of polyolefins

Better impact strength

Higher temperature resistance

No moisture absorption

Compounding special polyolefins with

Lower shrinkage

Better mechanical properties

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Shrinkage

pvT

Cooling mode

50 100 150 200 250

1.00

1.05

1.10

1.15

1.20

1.25

Filled PP with glass bubbles

Rela

tive s

peci

fic

volu

me

Temperature in °C

Available filaments:

PLA white

ABS transparent

PP black

PP white

Granules:

PP 1

PP 2

PP 3

PP 4

PP 5

PP 6

PE

HDPE

PP Glass Bubble

PE

PP

PLA

ABS

200 bar

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Filament Tensile Tests

0 1 2 3 4 5

0

5

10

15

20

25

Fila

me

nt te

nsile

str

ess in

MP

a

Filament tensile strain in %

PP random Copolymer

Glass Bubble 30 vol.%

DMean

=22 µm

no compatibilizer

maleic anhydride >0.9 %

maleic anhydride >1.0 %

maleic anhydride >1.8 %

Pure PP

700% Strain at break

40 MPa Stress

Young's Module 450-500 MPa

1% MA

Young's Module 667 MPa

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Filled Systems Metals

CopperFill by ColorFabb PLA/PHA with ~36 vol.% copper [4]

Massod [5] PA 40 vol.% iron for direct tooling

Nikazad [6] ABS with 5-40 vol.% iron

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Viscosity depending on loading

[7] 0.1 1 10 100 1000 10000

1

10

100

Binder (PP+wax)

10 vol% 62 vol%

20 vol% 64 vol%

30 vol% 66 vol%

40 vol% 68 vol%

50 vol% 70 vol%

60 vol% 72 vol%

Vis

cosi

ty in P

a·s

Shear rate in s-1

T=170°C

2

1n2

0 1

Van den Brule and Jongschaap [8]

3

1

m

3

1

mm0

1

8

91

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Filled Systems Ceramics

Laybrick chalk and co-polyester [9]

Loading >50 vol.% ceramics in polymer, wax, plasticizer, elastomer, tackifier [10, 11]

Goal ± 1% deviation to the CAD dimensions

Linear shrinkage 8-12 % while debinding, sintering

Ceramfacturing 77 wt% Ceramic, Backbone and Soluble Binder

Debinding in solvent

Sintering

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Conclusion

Many new materials

Mostly PLA and ABS

Filled systems

Quality of the filament

Good printing parameters

Compounds

Highly filled with metallic, magnetic, ceramic powders

Polyolefin compounds, blends

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Literature

1. http://www.alphacam.de/3d-drucker/fdm-3d-drucker/fdm-materialien/nylon-12.html

2. http://jelwek.pl/pl/akcesoria/90-jelwek-watch.html

3. https://markforged.com/part-of-the-week-october-23-2015-carl-calabrias-composite-wheel-tensioner-jig/

4. http://colorfabb.com/copperfill

5. Masood, S.; Song, W.: Development of new metal/polymer materials for rapid tooling using Fused deposition modelling, Materials & Design 25 (7), 2004, S. 587–594

6. Nikzad, M.; Masood, S.H.; Sbarski, I.: Thermo-mechanical properties of a highly filled polymeric composites for Fused Deposition Modeling, Materials & Design 32 (6), 2011, S. 3448–3456

7. Gonzalez-Gutierrez, J.; Đuretek, I.; Kukla, C., et al.: Models to Predict the Viscosity of Metal Injection Molding Feedstock Materials as Function of Their Formulation, Metals 6 (6), 2016, S. 129; first published; Kukla, C.; Duretek, I.; Holzer, C.: Modelling of rheological behaviour of 316L feedstocks with different powder loadings and binder compositions. In Proceedings of the Euro PM2014 Congress and Exhibition, Salzburg, Austria, 21–24 September 2014.

8. Brule, B.H.A.A. van den; Jongschaap, R.J.J.: Modeling of concentrated suspensions, Journal of Statistical Physics 62 (5-6), 1991, S. 1225–1237

9. http://www.orbi-tech.de

10. Lombardi, J.L.; Hoffman, R.A.; Waters, J.A., et al.: Issues associated with EFF & FDM ceramic filled feedstock formulation, In: Proceedings Solid Freeform Fabrication Symposium, 1997, S. 457–464

11. Onagoruwa, S.; Bose, S.; Bandyopadhyay, A.: Fused deposition of ceramics (FDC) and composites, Pro SFF, Texas, 2001, S. 224–231

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Thank you very much for your attention

© Foto Freisinger

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