Large-scale 3D-printing of Biopolymers Natural Fibertastic Dr. Ir. - PowerPoint PPT Presentation

Large-scale 3D-printing of Biopolymers Natural Fibertastic Dr. Ir. Albert ten Busschen (Poly Products) 22 September 2020, Bergen op Zoom SeaBioComp Partnership Part of the Interreg 2 Seas programme which is part financed by the European Regional Development Fund SeaBioComp is cofinanced by DISCLAIMER: The content of this presentation represents the views of the author only and is his/her sole responsibility; it cannot be considered to reflect the views of the Interreg 2 Seas programme and/or the European Regional Development Fund or any other body of the European Union.

Contents - FDM-printing of thermoplastics - Process parameters and properties - Biopolymers for 3D-printing - Mechanical properties - Printing of products - Eco-efficiency

FDM-printing of thermoplastics - FDM: Fused Deposition Modelling - Molten thermoplastic through nozzle (1) - Layer by layer build-up of product (2) - Nozzle moves in X-Y-plane - Build-plate (3) moves in Z-direction - Raw material: filament or granulate

FDM-printing of thermoplastics Large-scale FDM-printer of Poly Products (based on granulate)

Process parameters and properties Machine build-up - Granulate dryer - Isolated build chamber - Vertical extruder - Melt-pump - Heated nozzle - CNC-driven portal structure - Build-plate 2 x 4 m Principle: extruder - melt pump - nozzle

Process parameters and properties Relevant parameters during printing - Pre-drying of polymer granulate (temperature and time) - Temperature of extruder-zones, meltpump and nozzle - Temperature of build chamber - Extruder output (kg/hr) Φ - Horizontal speed of printing v (m/hr) - Layer thickness t (m) - Layer width W (m) - Nozzle opening diameter d (m)

Process parameters and properties Preparation of printing: making a sliced model Slicing is not the same as with small scale printing Preferably no support and large overhangs Overhangs (> 45 degrees) require infills for stability Infills are to be avoided: additional material/weight Printing with 5 to 20 mm walls: much hot material Time is needed between each layer: cooling down

Process parameters and properties Optimum: minimizing travel moves between walls Pausing causes ‘oozing’ because of viscoelasticity Can be solved by optimizing the travel path

Process parameters and properties Z-axis movement: stepwise or spiralizing Spiralizing does not give a seam However, sometimes stepwise can’t be avoided

Process parameters and properties Sliced model versus real print

Process parameters and properties Properties of 3D-printed reference material Recycled PETG with 30% (wt) short glass fibre (rPETG-GF30) Test specimens made from sides of thin-walled printed cubes

Process parameters and properties Tensile strength of printed rPETG-GF30 80 70 Print direction (0) Tensile strength (MPa) 60 Perpendicular to print direction (90) 50 40 30 20 10 0 Strength perpendicular to print direction is relatively low

Biopolymers for 3D-printing Bio-Polymer Full name Type T m ( ° ° C) ° ° PP Poly Propylene Polyolefine 150 PET Poly Ethylene Terephtalate Polyester 260 PLA Poly Lactic Acid Polyester 165 PEF Poly Ethylene Furanoate Polyester 220 PHB Poly Hydroxy Butyrate Polyester 175 TPS Thermo Plastic Starch Polysacharide 150 PBS Poly Butylene Succinate Polyester 100 Natural Fibers (NF) withstand maximum 170 ° C long-term and 200 ° C short-term Therefore, PET and PEF are not suitable for NF-reinforcement

Biopolymers for 3D-printing For the SeaBioComp project two biopolymers have been selected: TPS: Solanyl C8201 (Supplier: Rodenburg Plastics) PLA: Purapol L130 (Supplier: Corbion – formerly PURAC) Properties from the technical data-sheets (TDS): Property Symbol Unit Solanyl C8201 Purapol L130 E-modulus E GPa 1.7 3.5 Tensile strength MPa 30 50 σ Strain at yield % 5 5 ε Density kg/m 3 1300 1240 ρ Glass Transition Temperature T g ° C 57 55-60 Melt Temperature T m ° C 140-160 175

Mechanical properties Comparison of initial properties and after 3D-printing (in print-direction, 0 ° ): Property initial (TDS) Symbol Unit Solanyl C8201 Purapol L130 E-modulus E GPa 1.7 3.5 Tensile strength MPa 30 50 σ Strain at yield % 5 5 ε Property after printing (0 ° ° ) ° ° E-modulus E GPa 0.6 1.8 Tensile strength MPa 13 38 σ Strain at yield % 2.4 2.5 ε The mechanical properties have been lowered by the 3D-printing process.

Printing of products Application in berthing structures: fender profiles Berthing structure in a harbour (De Klerk Waterbouw)

Printing of products Principle of vertical fender on quay wall Cross-section

Printing of products First design, printed with TPS, scale 1:2

Printing of products Inproved design, printed with rPETG-GF30 Test to failure F max = 67 to 90 kN Promising results Three samples printed (300 mm) Mechanical test at De Klerk Waterbouw

Printing of products Printing fender designs with TPS and PLA Printed with TPS Printed with PLA - Extrusion at 160 ° C - Extrusion at 200 ° C - Nozzle 6 mm - Nozzle 6 mm - Wall-thickness 10 mm - Wall-thickness 12 mm

Printing of products Further improvement of fender design Optimised cross-section Bottom and joggle - Elastic for ship collision - Bottom for top-filling of core - Inner space for energy absorbers - Joggle for piling up profiles - Easy mounting on exiting quay - Flexible for different lengths

Printing of products Printing fender samples with TPS-NF - Material Solanyl C8201 with 20% (wt) hemp fibers (NF) TPS-NF granulate Printing square tube (test)

Printing of products Two prototype fender profiles of TPS-NF Parameter Value Extruder temperature 165 ° C Nozzle diameter (opening) 8.0 mm Layer thickness (t) 2.4 mm Layer width (W) 11.0 mm (installed) 13.3 mm (measured) Printing speed (v) 2.3 mm/min 138 m/hr Extruder output ( Φ ) 4.86 kg/hr 3D-printing parameters Two parts of TPS-NF piled up

Eco-efficiency Eco-efficiency of 3D-printing biopolymer composites When compared with traditional composite products: - No models/moulds needed for product shape - Practically no spillage during production - Use of bio-based materials (renewable) - End-of-Life products can be recycled (circularity) Double sustainable: bio-based (renewable) + recyclable (circular)

Eco-efficiency Comparison: production of 10 composite products product surface 6 m 2 , single-walled (6 mm) Traditional GRP 3D-printing TPS-NF Model needed? YES NO Mould making from model? YES NO Lead time model and mould 6 weeks 0 Raw materials Fossil-based Bio-based (renewable) 1800 kg/m 3 1100 kg/m 3 Compound density Production spillage Ca. 10 % Ca. 1 % Production time of 1 product 1 working day 5 hours Labour/machine time 13 hours 5 hours Trimiing spillage Ca. 10 % Ca. 1 % Products weight 65 kg 40 kg End-of-Life (EoL) Not recyclabe Recyclable (circular)

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