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3D printing using powder melt extrusion.

Bret M Boyle1, Panupoan T Xiong1, Tara E Mensch1

  • 1Department of Chemistry, Colorado State University, Fort Collins, CO, United States.

Additive Manufacturing
|April 28, 2021
PubMed
Summary
This summary is machine-generated.

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A novel powder melt extrusion (PME) 3D printer head was developed for printing with thermoplastic powders. While PME parts show comparable viscoelastic properties, lower resolution and material feed inconsistency result in reduced print quality and mechanical strength compared to fused filament fabrication.

Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Mechanical Engineering

Background:

  • Current 3D printing technologies are limited by material constraints.
  • Filament-based printing restricts the use of novel powder-based materials.

Purpose of the Study:

  • To design and fabricate a bench-top powder melt extrusion (PME) 3D printer head.
  • To evaluate the performance of the PME printer for 3D printing thermoplastic powders.
  • To compare PME printing with traditional fused filament fabrication (FFF).

Main Methods:

  • Iterative design and fabrication of a PME printer head, modifying funnel shape, auger pressure, and hot end structure.
  • Printing common thermoplastics (PLA, HIPS, ABS) in powder form (< 1 mm) using PME and FFF.
  • Performance evaluation through dynamic mechanical analysis (DMA), dimensional analysis, surface roughness comparison, and tensile testing.
Keywords:
3D printingAdditive manufacturingExtrusion

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Main Results:

  • PME printed objects exhibited comparable viscoelastic properties to FFF printed objects.
  • PME demonstrated lower print resolution (0.8 mm X-Y, 0.1 mm Z) and less consistent material feed than FFF (0.4 mm X-Y, 0.18 mm Z).
  • PME resulted in lower print quality (layer uniformity, structure), reduced tensile strength (49.2 ± 10.7 MPa vs. 57.7 ± 2.31 MPa), and lower Young's moduli (1620 ± 375 MPa vs. 2160 ± 179 MPa) compared to FFF.

Conclusions:

  • The PME method offers a viable platform for rapid prototyping with diverse thermoplastic powders.
  • Further optimization is needed to improve PME's resolution and material feed consistency for enhanced print quality and mechanical performance.
  • PME expands the range of materials that can be utilized in additive manufacturing.