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Barath Sundaravadivelan1, Dharneedar Ravichandran2, Anna Dmochowska3

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Researchers explored using pulverized coal as a sustainable reinforcement in 3D printing inks. Adding just 2 wt% coal significantly improved material strength, demonstrating a novel application for this abundant resource.

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Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Sustainable Engineering

Background:

  • Coal, traditionally used for energy, faces environmental scrutiny, prompting searches for alternative applications.
  • Global sustainability trends are reducing coal consumption, but its abundance necessitates exploring new uses.
  • Direct Ink Writing (DIW) 3D printing offers potential for novel material fabrication.

Purpose of the Study:

  • To investigate the feasibility of using pulverized coal as a reinforcement in DIW 3D printing.
  • To develop a coal-reinforced thermosetting resin ink suitable for 3D printing.
  • To evaluate the mechanical properties and printability of the developed coal-based composite.

Main Methods:

  • Formulating a thermosetting resin ink with pulverized coal (250 μm) as reinforcement and carbon black as a viscosity modifier.
  • Designing the ink for shear-thinning behavior crucial for DIW 3D printing.
  • 3D printing ASTM standard specimens to assess mechanical properties (tensile and flexural).

Main Results:

  • A 2 wt% concentration of coal in the ink significantly enhanced tensile properties by 35% and flexural properties by 12.5%.
  • The coal-reinforced ink exhibited essential shear-thinning behavior for uniform and continuous printing.
  • Successful printing of various geometries demonstrated the practical application of coal as a 3D printing reinforcement.

Conclusions:

  • Pulverized coal can be effectively utilized as a sustainable reinforcement in DIW 3D printing.
  • This research presents a viable pathway for repurposing coal into advanced materials.
  • The findings open new avenues for sustainable manufacturing and novel applications of coal-derived composites.