A New Generation of Bio-Composite Thermoplastic Filaments for a More Sustainable Design of Parts Manufactured by FDM
Abstract
:1. Introduction
2. Materials and Methods
2.1. Bio-Plastic Compounds Fabrication
2.2. Performance Evaluation
- Manufacturing capability: this property was evaluated considering melting temperatures, filament surface roughness, density, and retraction behaviour, considered as longitudinal moulding shrinkage. In all the bio-composite materials, the melting temperature was evaluated by Differential scanning calorimetry (DSC), according to standard ISO 11357. The density was estimated at 23 °C, according to standard ISO 1183. The longitudinal moulding shrinkage was measured at 23 °C, according to standard ASTM D 995.
- Roughness: the average value of this characteristic was measured for an object printed with these new bio-composite materials and compared it with that of an object printed with pristine PLA and with Acrilonitrile-butadiene-stirene (ABS).
- Mechanical properties: the elastic modulus, the yield strength, the yield elongation, the ultimate stress, and the ultimate elongation were evaluated. The elastic modulus was evaluated at 23 °C by using a dynamic mechanical analyzer (DMA Q800, TA Instruments), according to standard ISO 527. The yield and elongation strength together with the ultimate stress and elongation were estimated by a static mechanical machine (Instron 5569), setting a displacement rate equal to 10 mm/min. All mechanical properties were tested at 23 °C, according to standard ISO 527.
3. Results and Discussion
3.1. Manufacturing Capability
3.2. Roughness
3.3. Mechanical Properties
- HEMP (Hempt fillers 20%): this material has excellent tensile strength, thanks to the high presence of silicon contained in the hemp shives. This is a result not obtainable even with hemp fiber or wood sawdust. The elastic modulus is more than double if compared to ABS (+115%) and PLA (+133%). Moreover, the yield strength remains almost constant in comparison with ABS, but it increases significantly when compared to PLA (+16%) (see Figure 5).
- WEED (Powder from hemp leaf fillers 20%): again, it results in a relevant increment of the elastic modulus. However, both yield stress and ultimate stress are smaller than ABS and PLA. In addition, this material undergoes a very high plastic deformation. This is due to cannabinoids, which give much plasticity to the material. The starting ABS or PLA have a percentage of elongation at break equal to about 3% [25]. Adding 20% of hemp leaf powder, this percentage reaches about 9%.
- TOMATO (Cherry tomatoes fillers 20%): the performances in terms of ultimate stress and ultimate elongation are very similar to pristine PLA and ABS. However, the TOMATO elastic modulus is about +20% higher than ABS and PLA. Moreover, ABS shows a higher yield stress (about +30%) compared to the TOMATO composite.
- CAROB (Carob flour fillers 20%): due to the high temperatures of the die, contained sugar becomes caramel, which gives the final material a noticeable elongation approaching the yield point. In fact, although most of its mechanical properties are similar to ABS and PLA, CAROB has a percentage of elongation at break which reaches more than a 20% value due to the addition of carob flour.
- PRUNED (Orange pruning fillers 20%): material has shown excellent resistance to plastic deformation and failure compared to PLA (+25% and +42%, respectively) while the elastic modulus is similar. In this case, its mechanical properties are very comparable to ABS with the exception of yield elongation that is closer to PLA values.
- HEMP: filler gives excellent surface touch properties, breathability, and wood effect (Figure 4c).
- WEED: this material has a characteristic natural green colour, which makes it very suitable for the production of domestic objects.
- TOMATO filler gives a vivid red colour.
- CAROB filler gives a characteristic reddish/brownish colour and a shiny appearance.
- PRUNED: this material has a characteristic brownish colour.
4. Applications to Biomedical Devices
4.1. Neck Orthosis
4.2. Laryngoscope
5. Conclusions
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Material | Relative Humidity | Shape | Particle Size (µm) |
---|---|---|---|
HEMP | 6% | Spherical-like | 130 |
WEED | 4% | Spherical-like | 150 |
TOMATO | 4% | Spherical | 100 |
CAROB | 4% | Spherical | 130 |
PRUNED | 4% | Spherical | 100 |
Drying Granules | 10 h in a Vacuum Oven at 90 °C |
---|---|
Barrel temperature | 160–170 °C |
Mold temperatures | 30 °C |
Screw speed | 300 rpm |
Injection speed | Slow |
Material | Density (g/cm3) | Melting Temperature (°C) | Filament Surface Roughness (µm) | Molding Shrinkage (%) | Melt Volume Rate (cm3/10’) | Melt Flow Rate (g/10’) | Flexural Modulus (MPa) |
---|---|---|---|---|---|---|---|
PLA | 1.350 | 172.5 | 3.0 | 0.32 | 18.2 | 21.0 | 3200 |
HEMP | 1.256 | 145.0 | 3.5 | 0.23 | 21.3 | 24.0 | 3833 |
WEED | 1.265 | 150.5 | 3.2 | 0.28 | 76.0 | 86.9 | 3455 |
TOMATO | 1.240 | 155.0 | 3.2 | 0.28 | 89.0 | 100.0 | 3220 |
CAROB | 1.290 | 140.0 | 2.5 | 0.22 | 68.2 | 76.0 | 3560 |
PRUNED | 1.220 | 150.0 | 2.8 | 0.27 | 110.0 | 124.0 | 3300 |
Layer height (mm) | 0.25 |
Infill ratio (%) | 50 |
Nozzle diameter (mm) | 0.6 |
Printing speed (mm/s) | 60 |
Printing temperature (°C) | 200 |
Material | Colour | Elastic Modulus (MPa) | Yield Stress (MPa) | Yield Elongation (%) | Ultimate Stress (MPa) | Ultimate Elongation (%) |
---|---|---|---|---|---|---|
ABS | 2060 | 45.1 | 1.0 | 38.0 | 3.0 | |
PLA | 1900 | 35.9 | 2.0 | 26.4 | 3.8 | |
HEMP | Wood | 4420 | 41.8 | 1.5 | 33.6 | 3.5 |
WEED | Green | 3887 | 32.0 | 1.3 | 19.5 | 8.8 |
TOMATO | Red | 2450 | 34.0 | 1.7 | 30.2 | 3.1 |
CAROB | Reddish/Brownish | 2260 | 31.2 | 1.9 | 22.1 | 25 |
PRUNED | Brownish | 2500 | 44.1 | 2.0 | 37.0 | 2.5 |
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Calì, M.; Pascoletti, G.; Gaeta, M.; Milazzo, G.; Ambu, R. A New Generation of Bio-Composite Thermoplastic Filaments for a More Sustainable Design of Parts Manufactured by FDM. Appl. Sci. 2020, 10, 5852. https://doi.org/10.3390/app10175852
Calì M, Pascoletti G, Gaeta M, Milazzo G, Ambu R. A New Generation of Bio-Composite Thermoplastic Filaments for a More Sustainable Design of Parts Manufactured by FDM. Applied Sciences. 2020; 10(17):5852. https://doi.org/10.3390/app10175852
Chicago/Turabian StyleCalì, Michele, Giulia Pascoletti, Massimiliano Gaeta, Giovanni Milazzo, and Rita Ambu. 2020. "A New Generation of Bio-Composite Thermoplastic Filaments for a More Sustainable Design of Parts Manufactured by FDM" Applied Sciences 10, no. 17: 5852. https://doi.org/10.3390/app10175852
APA StyleCalì, M., Pascoletti, G., Gaeta, M., Milazzo, G., & Ambu, R. (2020). A New Generation of Bio-Composite Thermoplastic Filaments for a More Sustainable Design of Parts Manufactured by FDM. Applied Sciences, 10(17), 5852. https://doi.org/10.3390/app10175852