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Experimental Validation of a Micro-Extrusion Set-Up with In-Line Rheometry for the Production and Monitoring of

João Sousa¹, Paulo F Teixeira¹, Loïc Hilliou¹

¹Institute for Polymers and Composites, University of Minho, 4800-058 Guimarães, Portugal.

|August 26, 2023

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This study validates an in-line micro-rheometer and extrusion line for 3D printing filaments. The validated micro-setup enables material characterization and 3D printing with high-quality results.

Area of Science:

Materials Science
Polymer Engineering
Rheology

Background:

3D printing requires precise control over filament properties.
In-line monitoring of material behavior during extrusion is crucial for quality control.
Small-scale material processing is essential for rapid prototyping and characterization.

Purpose of the Study:

To validate an in-line micro-slit rheometer for real-time rheological measurements.
To assess a micro-extrusion line for producing 3D printing filaments from small material quantities.
To establish a comprehensive micro-setup for material characterization and filament production.

Main Methods:

Development and assessment of a micro-extrusion line with controlled throughput and melt temperature.

Keywords:

3D printing cyclic olefin copolymer micro-extrusion slit rheometer

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Characterization of the in-line micro-slit rheometer using low-density polyethylene (LDPE) and cyclic olefin copolymer (COC).

Comparison of in-line rheological data with off-line measurements from rotational and capillary rheometers.

Production of COC filaments and subsequent 3D printing for tensile testing.

Main Results:

The micro-extrusion line demonstrated stable operation with throughputs of 0.045-0.15 kg/h and temperature control within 1°C.
The in-line micro-slit rheometer showed excellent agreement with off-line rheological data, validating its performance.
COC was observed not to follow the Cox-Merz rule under the tested conditions.
High-quality filaments with <6% diameter variation were produced and successfully used for 3D printing test specimens.

Conclusions:

The integrated micro-extrusion and rheometer system is validated for in-line monitoring and filament production.
The micro-setup enables efficient rheological mapping of materials for 3D printing applications.
This technology facilitates the development and optimization of materials for additive manufacturing using minimal sample sizes.