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Recycled Cellulose Polypropylene Composite Feedstocks for Material Extrusion Additive Manufacturing.

Nicole E Zander1, Jay H Park2, Zachary R Boelter1

  • 1U.S. Army Research Laboratory, Weapons and Materials Research Directorate, Aberdeen Proving Ground, Aberdeen, Maryland 21005, United States.

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|September 10, 2019
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Summary

Recycled plastics like polypropylene can be reinforced with cellulose waste for 3D printing. This green composite feedstock improves stiffness and reduces distortion in additive manufacturing applications.

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Area of Science:

  • Materials Science
  • Polymer Science
  • Additive Manufacturing

Background:

  • Consumer-grade packaging plastics offer potential for additive manufacturing but often exhibit poor mechanical properties and dimensional instability.
  • Reinforcing these recycled plastics with additives can enhance part stiffness and reduce warpage/shrinkage.

Purpose of the Study:

  • To investigate the reinforcement of recycled polypropylene using cellulose waste materials.
  • To develop a green composite feedstock for extrusion-based additive manufacturing.
  • To evaluate the impact of cellulose fillers on the properties of 3D-printed recycled polypropylene.

Main Methods:

  • Recycled polypropylene composites were fabricated with waste paper, cardboard, and wood flour using solid-state shear pulverization.
  • Fourier transform infrared (FTIR) and thermogravimetric analysis (TGA) were used to assess filler content.
  • Dynamic mechanical analysis (DMA) and tensile testing were performed to evaluate mechanical properties.

Main Results:

  • Thermogravimetric analysis confirmed higher filler incorporation in recycled polymer composites compared to virgin polymer composites.
  • Dynamic mechanical analysis revealed a 20-30% increase in storage modulus upon addition of cellulose materials.
  • While tensile strength did not significantly increase at 10 wt% cellulose, the elastic modulus of virgin polypropylene increased by 38%.

Conclusions:

  • Cellulose waste materials can be effectively incorporated into recycled polypropylene to create composite feedstock for additive manufacturing.
  • The addition of cellulose enhances the stiffness and elastic modulus of the printed parts.
  • Interfacial weakness between the filler and the polymer matrix was identified as a limiting factor for tensile strength improvement.