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Rheological Changes in Bio-Based Filaments Induced by Extrusion-Based 3D Printing Process.

Antonella Patti1, Stefano Acierno2

  • 1Department of Civil Engineering and Architecture (DICAr), University of Catania, Viale Andrea Doria 6, 95125 Catania, Italy.

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Summary

This study reveals how 3D printing conditions affect bio-based polylactide (PLA) resins. Printing speed and temperature significantly alter material properties, influencing molecular weight and filler network formation in wood-filled PLA.

Keywords:
FDMFFFMEXdegradationnatural fillernozzle temperaturepolylactide acid (PLA)printing speedrheological propertieswood-based composites

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Area of Science:

  • Materials Science
  • Polymer Science
  • Additive Manufacturing

Background:

  • Bio-based polymers like polylactide (PLA) are increasingly used in additive manufacturing.
  • Understanding the impact of processing conditions on material properties is crucial for optimizing 3D printing outcomes.
  • Rheological measurements provide insights into the structural evolution and behavior of polymers during extrusion.

Purpose of the Study:

  • To investigate the effect of extrusion-based 3D printing parameters on the rheological properties of unfilled and wood-filled PLA.
  • To analyze the structural changes in PLA filaments under varying extruder temperatures and printing rates.
  • To assess the degradation kinetics and molecular weight evolution during the 3D printing process.

Main Methods:

  • Rheological measurements, including time sweep tests and specific cycle testing, were performed on pelletized PLA filaments.
  • Unfilled and wood-filled PLA filaments were 3D printed under different extruder temperatures (200 °C and 220 °C) and printing rates.
  • Experimental data of complex viscosity were fitted with linear correlation over time to evaluate degradation kinetics.

Main Results:

  • Temperature changes had a minor effect on the rheological characteristics (storage G' and loss G″ moduli) of unprocessed PLA.
  • For pure PLA, G' slope decreased over time, indicating a shift to lower molecular weight.
  • Wood-filled PLA showed an increased G' slope, suggesting the formation of a filler network. Printing conditions significantly impacted rheological parameters, with lower nozzle temperatures and slower speeds causing greater divergence from unprocessed material properties.

Conclusions:

  • Extrusion-based 3D printing significantly alters the rheological behavior and structural characteristics of both unfilled and wood-filled PLA.
  • Printing speed and temperature are critical parameters that influence molecular weight changes and filler network formation.
  • The study provides insights into material degradation and structural evolution during the 3D printing of bio-based polymers.