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A Low-Cost Process for Fabricating Reinforced 3D Printing Thermoplastic Filaments
Mohamed Hassanien1, Maen Alkhader1, Bassam A Abu-Nabah1
1Department of Mechanical Engineering, American University of Sharjah, Sharjah P.O. Box 26666, United Arab Emirates.
Polymers
|January 21, 2023
Summary
Researchers developed a low-cost method to create reinforced filaments for 3D printing using fused deposition modeling (FDM). This technique enhances material properties like stiffness and strength, expanding the capabilities of desktop 3D printers.
Area of Science:
- Materials Science
- Additive Manufacturing
- Polymer Engineering
Background:
- Desktop fused deposition modeling (FDM) printers are widely adopted but have limitations in material processing.
- A lack of low-cost fabrication techniques for reinforced filaments hinders the expansion of FDM applications.
- Existing methods are often expensive or inaccessible for widespread institutional and individual use.
Purpose of the Study:
- To propose and demonstrate a low-cost method for fabricating reinforced filaments using desktop FDM extruders.
- To enhance the utility of FDM printers by enabling the use of non-organic reinforcing particles.
- To address the gap in accessible techniques for producing reinforced filaments.
Main Methods:
- A novel low-cost solution was developed to coat thermoplastic pellets with reinforcing particles.
- Coated pellets were then extruded into filaments using a desktop single-screw extruder.
- Polylactic acid (PLA) filaments reinforced with dune sand and silicon carbide were fabricated and tested.
Main Results:
- Fabricated filaments showed improved stiffness (up to 4.5%) and tensile strength (up to 8%) at low reinforcement levels (< 2 wt%).
- Microstructural analysis confirmed the successful incorporation of reinforcing particles.
- The produced reinforced filaments were successfully used to fabricate 3D parts via FDM printing.
Conclusions:
- The proposed low-cost process effectively fabricates reinforced filaments suitable for desktop FDM printing.
- This method expands the range of processable materials for FDM, enhancing part performance.
- The technique is versatile, capable of incorporating various types of reinforcing particles.
