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Microfoamed Strands by 3D Foam Printing.
Daniele Tammaro1, Massimiliano Maria Villone1, Pier Luca Maffettone1
1Dipartimento di Ingegneria Chimica, dei Materiali e della Produzione Industriale, University of Naples Federico II, P.le Tecchio 80, I-80125 Napoli, Italy.
Polymers
|August 12, 2022
Summary
This study introduces a green 3D foam-printing technology using carbon dioxide (CO2) to create innovative microfoamed strands from polylactic acid. Optimized process parameters yield low foam density and tunable mechanical properties based on crystallinity.
Area of Science:
- Materials Science
- Polymer Engineering
- Sustainable Manufacturing
Background:
- 3D foam-printing technology is emerging, but the foaming mechanism within the printer nozzle requires further understanding and control.
- Developing sustainable methods for producing microfoamed materials is crucial for advanced applications.
Purpose of the Study:
- To investigate the effects of operating parameters in 3D foam-printing on carbon dioxide (CO2) utilization and foaming efficiency.
- To characterize the mechanical properties of microfoamed strands as a function of foam density and crystallinity.
- To develop a model explaining the relationship between mechanical properties, foam density, and polymer crystallinity.
Main Methods:
- Utilized a green and sustainable technology employing CO2 for microfoaming.
- Employed 3D foam-printing to produce strands from bio-based polylactic acid.
- Characterized bubble morphology, foam density, porosity, and polymer crystallinity.
- Measured mechanical properties (elastic modulus) of the foamed strands.
Main Results:
- Achieved low foam densities (e.g., 40 kg/m3) and tunable porosities (macro- to micro-scale) with 15 wt% CO2.
- Demonstrated a linear relationship between CO2 concentration and polymer crystallinity content (5% to 45%).
- Established that the elastic modulus is strongly influenced by crystallinity, leading to a corrected Egli's equation.
Conclusions:
- The study successfully optimized CO2 utilization in 3D foam-printing for innovative microfoamed strands.
- The developed model accurately predicts mechanical properties based on foam density and crystallinity.
- This green technology offers a pathway for producing tailored microfoamed materials from sustainable polymers.
