Lignin (LIG) is a natural biopolymer containing antioxidants. To see if these properties would carry through after serving as a coating for PLA pellets and then being 3D printed, the researchers placed the material into an extruder at 200 ◦C. Their suppositions proved correct as not only did the filament work successfully, but it passed on antioxidants.
“A wound healing model compound, curcumin (CUR), was applied in the surface of the mesh and its diffusion was studied,” stated the researchers. “It was observed that the dimensions of the meshes affected the permeation rate of CUR. Accordingly, the design of the mesh could be modified according to the patient’s needs.”
Photographs of: PLA and PLA coated pellets (A); LIG and TC containing PLA filaments (B); LIG and TC containing 1 cm × 1 cm squares prepared using 3D printing (C); and different shapes printed using the filament containing 2% (w/w) LIG (D).
The use of PLA is popular for many reasons, beginning with its percieved biodegradability factor, and lack of toxicity. Suitable for FFF 3D printing, the vegetable-based filament can be combined with other molecules and has shown increasing merit for medical applications, especially in accelerating healing of wounds. This type of study has not been expansive previously, however, harnessing the power of lignin’s antioxidant and antimicrobial properties. Lignin is of interest as an extremely abundant polymer that the researchers contend is highly unexploited. It is an affordable material to acquire and use, and useful in a variety of other applications currently.
Scheme of the different meshes produced using FFF.
The researchers used different types of mesh with a 2 percent combination of LIG in the PLA, along with curcumin (CUR) applied in the material and diffused. They discovered better effectiveness with the meshes when using a size of 1mm. The research team also found that the release rate was delayed if they used both the mesh and a soluble PVA film, printed with the mesh on an FDM 3D printer with a dual extruder. The PVA film may also function in dual capacity as it not only delays the release of CUR, but also keeps the wound moist.
“A potential scenario for this material is as a wound dressing material due to the antioxidant activity of the composite material that can contribute to wound closure. Due to the low price of 3D printing equipment and its versatility, these materials can be used in hospitals to print wound dressings for patients on demand,” concluded the researchers.
“Due to the enhanced cell proliferation on antioxidant materials [16], these materials can be used for tissue culture applications or even for regenerative medicine. Due to the versatility of FFF, complex geometries can be prepared such as scaffolds. However, before this type of materials can be implanted into humans, the safety of lignin-based materials should be evaluated. It has been reported before that LIG-based materials are biocompatible [45] but more studies should be performed.”
3D printing continues to make substantial impacts in the medical arena, innovating for better ways to heal wounds, along with improving drug-delivery systems, and assisting in tissue regeneration. What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.
Experimental setup used to measure drug diffusion trough the 3D printed meshes (A); photographs of the 3D printed meshes made of PLA and 2% (w/w) LIG (B); and CUR release through 1.5 mm (C) and 1 mm (D) 3D printed meshes (n = 3).
Long-lasting, rechargeable lithium-ion (Li-ion) batteries have a high energy density and low self-discharge, and are finding their way into aerospace and military applications, among others. As the demand for energy consumption rises at the same time the pressure for reducing our usage of fossil fuels is, our society is working hard to find innovative ways of manufacturing energy storage devices.
The abstract reads, “We demonstrate that a graphene content of 20 wt. % exhibits sufficient conductivity and critically, effective 3D printability for the rapid manufacturing of 3D printed freestanding anodes (3DAs); simplifying the components of the Li‐ion battery negating the need for a copper current collector. The 3DAs are physicochemically and electrochemically characterised and possess sufficient conductivity for electrochemical studies. Critically, it is found that if the 3DAs are used in Li‐ion batteries the specific capacity is very poor but can be significantly improved through the use of a chemical pre‐treatment. Such treatment induces an increased porosity, which results in a 200‐fold increase (after anode stabilisation) of the specific capacity (ca. 500 mAh g−1 at a current density of 40 mA g−1). This work significantly enhances the field of additive manufacturing/3D printed graphene based energy storage devices demonstrating that useful 3D printable batteries can be realised.”
Many researchers are working with novel nanomaterials like carbon nanotubes and graphene for the purposes of 3D printing novel energy storage devices, such as Li-based batteries, as the technology can be used to create structures with a large surface area – helpful when it comes to energy capabilities. This particular team used FDM (extrusion-based) technology to create Li-ion anodes out of bespoke 3D printable graphene/PLA filaments. They also performed electrochemical and physicochemical characterization, to make sure that the graphene content was optimized for controlling the conductivity, electrochemical activity, and 3D printability of their 3D printed freestanding anodes, or 3DAs.
The researchers stated that “…this approach simplifies the components of the Li‐ion battery negating the need for a copper current collector.”
The team used Autodesk Fusion 360 to create the 3D printed designs for this work – a circular disc electrode, 1.0 mm thick, with a range of diameters – and printed them at 190 °C, with a direct drive extruder, on a ZMorph 3D printer. The 3D printable graphene/PLA filaments were made with a range of 1, 5, 15, 20 and 40 wt.% graphene nanoplatelets, which were validated using thermogravimetric analysis (TGA).
Physicochemical characterisation and optical images of the graphene/PLA powders, respective filaments and 3DAs. A: Thermogravimetric analysis, B: Resistivity vs. graphene content, C: TEM analysis of 20 wt. % graphene/PLA, D: 3D printing process of the 3DAs (for electrochemical characterisation), E: Raman (inset) and Raman Mapping of the 3DA.
“In brief, the fabrication of graphene/PLA filaments containing percentages over 20 wt. % are extremely brittle and highly unreproducible in terms of both homogeneity, printability and structural integrity; additionally filaments with a wt. % of graphene below 10 % did not offer sufficient percolation (i. e. high resistivity),” the researchers wrote.
“Therefore, we have found that 15–20 % is the optimal wt. % when one is considering graphene nanoplatelets…where the resistivity decreases and conductivity increases.”
After they optimized the graphene content, the team used the filament with 20 wt. % graphene to 3D print test anodes for more physicochemical characterization. They also completed a Raman analysis on the anodes, as well as an XPS analysis; the latter involved taking high-resolution scans “over the C 1s and O 1s photoelectron peaks,” which were broad and strangely shaped. The analysis showed that PLA was present in two forms, at roughly the same levels, as in the graphene/PLA samples.
“In summary, XPS analysis reveals that the high volume of graphene within the graphene/PLA filament is fully dispersed within the PLA creating a conductive pathway throughout the sample, thus corroborating with aforementioned electrochemical and physicochemical characterisation,” the researchers wrote.
SEM images of a typical graphene 3DA pre‐ and post‐NaOH chemical treatment displaying their respective charge‐discharge profiles. The setup used to test the anodes is simpler over traditional coin cells as no copper current collector is required.
Finally, the team evaluated the energy capabilities of the 3DAs in a Li-ion battery setup, and found that that the graphene 3DAs have a relatively low electrochemical response. To further understand, they analyzed the graphene 3DA’s topography, which showed that its surface doesn’t have good porosity for wetting electrolytes. By introducing a simple chemical pre‐treatment of NaOH to the 3DAs for 24 hours, the researchers were able to induce porosity and get past this limitation.
To further understand, they used X-ray diffraction to analyze the crystalline structure of the graphene/PLA both before and after this pre-treatment, explaining that the SEM images and XRD patterns show that the material didn’t lose its 3D structure, “but now offers an excellent electrochemical behaviour/performance.”
“…we suggest that the graphene incorporated within the 3DA, is predominantly graphene‐like in its electrochemical behaviour, and that the increased surface area of the graphene nanoplatelets within the composite provide the improved energy outputs,” the researchers stated. “The results presented herein enhances the field of additive manufacturing/3D printed graphene‐based energy storage devices with the utilisation of a tailorable graphene/PLA filament, and with a simple chemical treatment of the 3D printed anode can exhibit a 200‐fold increase within the specific capacity (after anode stabilisation).”
The team determined that the 3D printed freestanding anodes with a 20 wt. % graphene content had the most effective 3D printability and conductivity.
“The results presented herein significantly enhance the field of additive manufacturing/3D printed graphene based energy storage devices demonstrating that useful 3D printable batteries can be realised,” the paper concluded.
Co-authors are Dr. Christopher W. Foster, Dr. Guo‐Qiang Zou, Yunling Jiang, Dr. Michael P. Down, Dr. Christopher M. Liauw, Alejandro Garcia‐Miranda Ferrari, Prof. Xiaobo Ji, Prof. Graham C. Smith, Prof. Peter J. Kelly, and Prof. Craig E. Banks.
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We’re starting off today’s 3D Printing News Briefs with a product launch announcement – 3YOURMIND launched the full version of its Agile MES software software this week at AMUG 2019. Moving on, Sintratec will present its latest SLS 3D printer at RAPID + TCT next month in Detroit, Tiamet3D has joined Ultimaker’s material alliance program, and Sciaky entered into an agreement with KTM Consultants. Xometry just announced some important certifications, and nScrypt is 3D printing titanium parts. Moving on to the world of art and theatre, the Zurich Opera House is 3D printing props, and artist Andrea Salvatori worked with WASP to create a 3D printed art collection.
3YOURMIND Launched Agile Manufacturing Execution System (MES) Software
After spending five years providing order management systems to scale for some of the industry’s AM leaders, 3YOURMIND has finally moved its software solutions to a production environment with the launch of its Agile Manufacturing Execution System (MES) earlier this week at AMUG 2019. The software uses smart part prioritization, rapid scheduling, order tracking, and custom AM workflow creation to improve machine utilization and make production more efficient, and an Early Access Program (EAP) allowed the company to receive direct feedback on its Agile MES software from representatives at companies like EOS and Voestalpine. The next step will be working to finalize machine connectivity.
“For Agile Manufacturing, the Agile MES will need to both GET and PUSH data from all major AM machines and post-processing systems. We are already integrating the data from several vendors into our software and expect to support all major machines,” explained 3YOURMIND’s CEO Stephan Kühr. “Receiving and processing machine data allows us to provide the documentation that is needed for quality assurance and to increase the repeatability of additive manufacturing. Pushing data directly to machines will be the key to automating production.”
Sintratec Showcasing New SLS 3D Printer at RAPID + TCT
A few months ago, Swiss SLS 3D printer manufacturer Sintratec introduced its scalable, modular Sintratec S2. Now, the company will be presenting the printer in the US for the first time next month at RAPID + TCT in Detroit, which will also be Sintratec’s first time attending the massive event. What makes the Sintratec S2 stand out is its closed-loop workflow, as the complete system covers every process with its three modules: the Laser Sintering Station (LSS), the Material Core Unit (MCU), and the Material Handling Station (MHS). The 3D printer offers quick material changes, a 4K camera for print monitoring, improved ergonomics, and effective heat distribution through its cylindrical printing area and ring lamps.
“The Sintratec S2 will boost the design of applications and gives the user the opportunity to set foot in small series production as well. And that for an unusually attractive price-performance ratio,” said Sintratec CEO Dominik Solenicki.
“With the Sintratec S2 solution we will be opening new opportunities for companies of any size.”
The price for the Sintratec S2 starts at $39,900, and you can see it for yourself at Sintratec’s booth 1753 at RAPID + TCT from May 20-23.
Tiamet 3D Joins Ultimaker’s Material Alliance Program
Last year, Dutch 3D printing specialist Tiamet 3D, founded in late 2014, worked with Finland-based Carbodeon to develop the first nanodiamond-enhanced 3D printing filaments, which went on the market in September. Now the company has joined Ultimaker as a partner in its Material Alliance Program. Together, the two will offer end-users simple one click downloads of Tiamet’s ULTRA Diamond material profile, which is now available on Ultimaker’s Cura software. This collaboration is formally backed by Tiamet’s manufacturing partner Mitsubishi Chemical Performance Polymers (MCPP Netherlands).
Reid Larson, the Director and Co-Founder of Tiamet 3D, told us about some of the highlighted specs of its ULTRA Diamond material, including no additional nozzle wear, 6300 mpa stiffness, low moisture absorption and friction, improved thermal conductivity, and twice “the temperature resistance of normal PLA, Annealed goes to 125C HDT.” You can purchase one kg of ULTRA Diamond filament for €59.
Sciaky Increasing Sales Efforts Through New Agreement
In an effort to increase the sales efforts of its Electron Beam Additive Manufacturing (EBAM) solutions in Australia, the Middle East, and New Zealand, Sciaky, Inc. has entered into an agreement with KTM Consultants, founded by metallurgist Trent Mackenzie in 2015. In terms of sheer work envelope, Sciaky’s massive EBAM systems are the industry’s most widely scalable metal 3D printing solution, able to produce parts ranging from 8 inches to 19 feet at gross deposition rates of up to 25 lbs of metal an hour. Additionally, its Interlayer Real-time Imaging and Sensing System (IRISS) is the metal 3D printing market’s only real-time adaptive control system capable of sensing and digitally self-adjusting its deposition.
“I was immediately drawn to Sciaky’s EBAM technology because of its unique and robust capabilities. Industrial manufacturers of large metal parts need to explore the significant advantages that technologies like EBAM offer. It is truly a game-changer,” said Mackenzie.
Xometry Announces New Industry Certifications
Digital manufacturing marketplace Xometry announced that it has just received ISO 9001:2015 and AS9100D certifications – some of the most rigorous, widely-recognized quality management designations in the industry. ISO 9001 helps organizations meet the needs and expectations of their customers in terms of quality management, while AS9100 meets customer demands in the exacting aerospace and defense industries. The company went through a major audit as part of the process, and its achievement definitely reflects how committed Xometry is to providing quality.
“We are thrilled to receive this designation. Our team members have a passion for providing great customer service while following the disciplines that give our customers peace of mind regarding on-time delivery, quality, and continuous improvement. It is yet another step towards achieving industry “best in class” status and being able to meet the expanded needs of our customers,” stated Xometry COO Peter Goguen.
nScrypt Develops Proprietary Method for 3D Printing Titanium
nScrypt 3D printed titanium gear, dogbone, and block
Florida manufacturer nScrypt, which develops high-precision Micro-Dispensing and Direct Digital Manufacturing equipment and solutions, is now focusing on repeatable 3D printing of metals for the medical, defense, and aerospace industries. The company has created a proprietary method for 3D printing titanium parts, which tests have shown display densities comparable to wrought parts. This method could easily work with other metals as well, such as copper, Inconel, and stainless steel, and nScrypt’s Factory in a Tool (FiT) systems can finish or polish areas with high tolerance features using its integrated precision nMill milling head. nScrypt’s Brandon Dickerson told us that the company expects to release more details on this later in 2019.
“The parts were printed with our SmartPump Micro-Dispensing tool head, which runs on any of our systems,” Dickerson told 3DPrint.com. “The parts shown in the photos were printed on our DDM (Direct Digital Manufacturing) system, also known as our Factory in a Tool (FiT) system, which can run 5 tool heads at the same time, including our Micro-Dispensing, Material Extrusion, micro-milling, and pick-and-place tool heads. The parts were sintered after the build and the current densities are in the high 90% range. We expect our system to appeal to customers who want to do Direct Digital Manufacturing and need strong metal parts, but cannot build them with a powder bed system (for example, if the geometry would trap powder inside) or prefer not to use a powder bed system (for example, if they want a cleaner system).”
Zurich Opera House 3D Printing Props with German RepRap
Finished tutu for “The Nutcracker”, which was produced with the help of the x400 3D printer
Switzerland’s largest cultural institution, the Zurich Opera House, puts on over 300 performances a year, but the behind-the-scenes magic happens in the studios and workshops, where the props and costumes are made. The opera house uses the x400 3D printer from German RepRap, with assistance from Swiss reseller KVT- Fastening, to support its creative work by fabricating props and molds. This affords the institution more creativity and flexibility, as they can design objects to their exacting needs in 3D modeling programs, which also helps save on time and money. The opera house currently uses PLA, which is easy to handle, offers a variety of colors, and is flame retardant – very important in a theatrical setting.
“Often, the wishes and ideas of costume and stage designers are very diverse and sometimes extraordinary. It often happens that props are not available in the way designers have it in their minds. This is where the 3D printer is perfect for,” said Andreas Gatzka, director of theater sculpture at the Zurich Opera House.
“There are a lot of great benefits. Special wishes of stage and costume designers can be realized quickly as well as a short-term change of the objects, for example larger, smaller, longer, shorter, or whatever is needed.”
3D Printed Art Collection
Artist Andrea Salvatori 3D printed the eye-catching pieces for his new collection, titled Ikebana Rock’n’Roll, using the Delta WASP 40100 Clay 3D printer – designed by WASP to be used by ceramic and clay artists. The collection just opened on stage at THE POOL NYC in Milan last week, and will be available to view until May 31st. With these 3D printed vases, Salvatori wanted to use “a miscellany of ceramic insertions” to mess with the high quality shapes 3D printing can achieve by adding asymmetry.
“The process of depositing the material and setting the spheres is a central theme in the Ikebana Rock’n’Roll collection, to the point of convincing Salvatori to name the works “Composition 40100”, as if they originated from a musical dialogue of the most varied tones. The artist upsets the algorithm reiterated slavishly by the machine with imperfect musical accents, the result from time to time of spontaneous actions and reasoned processes,” WASP wrote in a blog post.
“The ikebanes, proposed by Andrea Salvatori in the exhibition, transcend the experimental limits of an abstract investigation, representing a concrete territory in which 3D printing and ceramic art co-exist synergistically. The Master challenges the confrontation with the public, becoming also in this sector, precursor of a new genre in which WASP feels itself fully represented.”
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Process scheme for obtaining mono-and bi-filler filaments for a FDM 3D printer on the base of PLA, GNP and MWCNTs.
Researchers from all over the world have come together to further the study of materials science in 3D printing, with their findings recently published in ‘PLA/Graphene/MWCNT Composites with Improved Electrical and Thermal Properties Suitable for FDM 3D Printing Applications.’ While there may be a variety of different polymeric materials available today for 3D printing, polylactic acid (PLA) is a preferred medium due to its natural qualities (plant-based), biodegradability, and its bio-absorbable qualities.
Many users see PLA as the ‘greener’ choice, and today it is highly desirable for manufacturing in a wide range of applications, including:
Packaging
Pharmaceuticals
Textiles
Engineering
Automotive
Biomedical
Tissue Engineering
“3D printing has been promising,” state the authors. “However, its mechanical performance as well as electrical and thermal properties must be improved in order to expand the application fields.”
The use of nanofillers to bolster the properties of PLA is common, imbuing it with higher strength mechanically, allowing for better conductivity, and stability and bioactivity too. Both carbon nanotubes (CNT) and graphene are used, with promising results as they show the ability to tune critical properties for higher performance; in fact, CNTs offer an enormous number of benefits, but especially in adding stability, whether mechanically, electrically, thermally, or chemically—obviously making them candidates for multifunctional materials. We do wish to point out that Carbon Nanotubes pose a severe health risk and that inhaling fumes from carbon nanotubes may give you cancer.
Polymer composites containing graphene also add dimensional stability, prevent microcracks from occurring, and improve the barrier above the matrix polymer.
“Recently, graphene and functionalized graphene were utilized in composites containing different fillers, and the combination of fillers have shown synergy effect in terms of the mechanical properties, thermal and electrical conductivities, and super capacitance,” state the researchers. “It was found that combining together two nanofillers, such as carbon nanotubes and graphene, leads to the formation of a co-supporting network of both fillers.”
In 3D printing, these types of materials offer better strength and conductivity, and improved printability, and are generally added to the polymer matrix by solution mixing, melt blending, or in situ polymerization. Following are the materials used:
Industrial Graphene NanoPlates, GNP (supplied by TimeNano, Chengdu, China), with purity, 90 wt.%; number of layers <30; thickness <30 nm; diameter/median size 5–7 μm; aspect ratio: ~230/165, specific surface area, m2/g: 1.42 m2/g, as well as Industrial Grade OH-Functionalized Carbon Nanotubes (multi-walled carbon nanotubes) (MWCNTs) (TimeNano, produced by CVD method) with purity, 95 wt.% OH 2.48% content; size (outer D = 10–30 nm, inner D = 5–10 nm, length = 10–30 μm); aspect ratio: ~1000; specific surface area 110 m2/g; density 2.1 g/cm3; electrical conductivity S = 100 S/cm.
The authors reported that when using the maximum amount of filler content (6 wt.%), conductivity increased by almost 7-8 decades for mono-filler systems, in comparison to pure PLA; however, the effect was more obvious in PLA/MWCNT composites. Bi-filler composites with PLA/MWCNT/GNP also show electrical conductivity due to a synergetic effect—and those values are higher than those of the mono-filler systems.
Scanning Electron Microscopy (SEM) images of cryo-fractured surfaces of the mono-filler composites, containing (a) 6 wt.% multi-walled carbon nanotubes (MWCNT) and (b) 6 wt.% of graphene nanoplates (GNP) and bi-filler composites, containing (c) 1.5% GNP/1.5% MWCNT and (d) 3% GNP/3% MWCNT, respectively at magnification 20,000×.
“Thermal transport in obtained PLA/GNP composites is a thriving area of research thanks to graphene’s extraordinary heat conductivity properties and its potential for use in thermal management applications,” concluded the authors. “The obtained composites can be considered an excellent electrical and heat conductor for a variety of applications.”
Thermal conductivity and thermal diffusivity vs. GNP and MWCNT filler content for two (PLA/GNP and PLA/MWCNT) and bi-filler (PLA/GNP/MWCNT) composites.
PLA is one of the most popular and versatile materials used in 3D printing, often preferred over other polymers like ABS because it is vegetable-based and assumed to be biodegradable (most variants of PLA are not compostable and . Researchers have performed numerous studies centered around its uses, to include effectiveness of recycled forms of PLA, new filament formulations, and innovation for applications like satellite antennas. What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.
Advanced materials company NatureWorks, headquartered in Minnesota and jointly owned by Cargill and chemical producer PTT Global Chemical in Thailand, is the world’s leading manufacturer of Ingeo material, a PLA biopolymer. Much of the PLA used in 3D printing comes from Natureworks. Valued due to their unique functional properties, Ingeo materials are used in multiple products, ranging from coffee capsules and tea bags to appliances, industrial tools and jigs, and 3D printing filament. Now, the company announced its latest PLA grade – an Ingeo formulation meant to reduce problems with breakaway 3D printing support material on dual extrusion systems.
Ingeo 3D450 provides a clean, fast mechanical breakaway of support structures, which leads to professional parts made with high precision and finish quality. The material also helps ensure an improvement in productivity, and a decrease in post-processing time as well.
“There was a significant reduction in part cleaning times, about 10 times faster than using PLA supports. 3D450 prints faster than soluble support materials,” stated Voodoo Manufacturing, one of several partners that are beta testing the new Ingeo grade for NatureWorks. “Additionally, we have been able to lower the support roof to model spacing, which results in better bottom-part quality.”
The new break-away material formulation was designed to work with the Ingeo 3D series of grades that the company developed for the professional 3D printing market, such as 3D850 and 3D870. Ingeo 3D450 can print and cool with no signs of warping, at 3D printing speeds of up to 100 mm per second, and even across larger sections of support structures, which is quite a feat.
“MatterHackers PRO Series Breakaway Support, using Ingeo 3D450, works well offering clean printed surfaces and clean breakaway material,” stated beta tester MatterHackers. “It is more convenient than other, dissolvable, support offerings. There was no residue on the hot-end, and we found no filament or printing issues.”
Ingeo 3D450 is able to decrease, and even eliminate, those pesky buildability and speed issues that can sometimes occur when you’re using water soluble support materials, such as high-impact polystyrene (HIPS) or polyvinyl alcohol (PVA). This new grade actually has a longer, more stable shelf life than these other materials, in addition to significantly less moisture sensitivity during the 3D printing process, and is also very compatible with large-format 3D printers.
In addition, because Ingeo 3D450 breakaway supports don’t need a solvent bath to be removed from a 3D printed part, users won’t need to worry about the typical size constraints when they need to submerse a build with PVA supports in the water. Having searched high and low in my kitchen cabinets a few months ago to find a container that was deep enough to completely submerge a tall eagle I’d printed with a lot of PVA support material, this sounds great to me.
“Our team liked the increased brittleness,” said Slant 3D, another beta tester. “It was easier to break through grid supports. It flowed smoothly and consistently.”
Battery isolator cover printed by IC3D with Ingeo 3D450 supports before and after removal.
There are plenty of applications for NatureWorks’ new Ingeo 3D450 support material, including patterns for investment metal casting, complex industrial parts like fixtures, architectural and retail models, and the battery isolator cover that IC3D completed as a beta tester for the material.
IC3D said, “D450 printed perfectly flat. There was zero warping or bending.”
You can now purchase filament made with Ingeo 3D450 from 3D-Fuel and MatterHackers. NatureWorks, and its sales channel partners in the US, Europe, and Asia are selling resin in 25-kg and 750-kg quantities.
Next week at the Additive Manufacturing Users Group (AMUG) Conference in Chicago, Titan Robotics will be demonstrating the Ingeo 3D450 filament, made by 3D-Fuel, on its new Atlas hybrid filament and direct pellet extrusion printing system. The demonstration will take place on Monday, April 1st from 10 am to 2 pm at Titan’s booth #78.
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3D printing, as well as 4D printing, have opened up an ever-expanding realm of hardware, software, and unique methods for constructing complex geometries. Along with that though also comes a vast array of materials which is continually growing—but many researchers and engineers still use the old standbys like ABS and PLA.
Efforts to recycle 3D printed items are a constant source of study too, as researchers worry about the amount of plastic that could be left sitting in landfills, even if it is eventually biodegradable, as is the case with PLA. In ‘A comparison between mechanical properties of specimens 3D printed with virgin and recycled PLA,’ Italian researchers Antonio Lanzottia, Massimo Martorelli, Saverio Maietta, Salvatore Gerbino, Francesco Penta, and Antonio Gloria further explore the realities of using recycled PLA for functional parts.
An image of the filament extrusion
PLA is popular in comparison to ABS because it is a bio based polymer. The authors point out that composting the material is probably not a very realistic solution due to the amount of time it takes parts to degrade. But, what if we could recycle PLA? How feasible is this and how does this affect the material? What happens to mechanical strength of material that has been recycled—especially if it has been recycled repeatedly:
“Specifically, it has been proved that the use of a filament recycled twenty times through an extrusion-based process minimally affected the tensile strength and modulus of PLA,” state the researchers. “In addition, a study on recycled polypropylene blends in injection moulding procedure was performed and an appropriate blending ratio of virgin and recycled polymer was assessed, showing that the decrease in the mechanical properties of devices fabricated from recycled polymers may be improved optimizing the process parameters during the injection moulding.”
Further studies also showed that weakening in mechanical properties was minimal in recycled PLA, motivating the authors to form an intense study comparing both virgin PLA and recycled PLA, testing both interlaminar properties and short-beam strength. PLA samples were printed at 200°C using a Prusa I3, with a .4 mm nozzle. The first set was tested, then ground up and recycled with a homemade extruder into 1.75 mm material. It was then used to make new samples for mechanical property testing.
Schematic representation of the experimental setup – horizontal shear load diagram (adapted from ASTM D2344)
The researchers included three different recycling phases, with testing for short-beam strength on both virgin and recycled material. They noted that the PLA recycled once and even twice over was not ‘significantly’ affected in short-beam strength, but after that it did experience substantial degradation. In the samples that had been recycled three times, there was ‘great variability.’
In conclusion, the researchers offered more specific data:
“The one-time and twice recycled specimens showed a short-beam strength (106.8 ± 9.0 MPa and 108.5 ± 9.9 MPa, respectively) which was similar to that of the virgin specimens (119.1 ± 6.6 MPa). However, a third recycling process negatively affected the values of the short-beam strength also producing a great variability in the results (75.0 ± 16.2 MPa).”
3D printing, in existence since the 80s, has only just begun to really hit its stride—and the study of materials science has become of substantial interest to many, whether they are interested in using PLA or recycled materials to create items like energy storage devices, prosthetics, sustainable thermoplastics, and so much more. What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.
Fashion and sustainability are two words that feel as antonyms nowadays. The mass production of clothing and ethically doubtful methods of manufacture give one of the biggest economic forces one of the top rankings of the most polluting sectors. This creates a negative social influence and climatic impact that makes obvious the need for a change to make fashion great again. This issue is not new and many people are working towards a better future. And although the changes come slowly, the mentality and so with it the industry is moving towards a healthier direction.
3D printing on textiles, one of the innovative methods in fashion industry. 3D printer at Fabricademy. Credit: Anastasia Pistofidou
One of those people who believe in the need for a change in fashion is Anastasia Pistofidou. She is a Greek architect specialized in digital fabrication technologies. Based in Barcelona, currently works as director of the FabTextile research lab and Fabricademy, a new textile and technology academy. The FabTextile project offers an “Open sourcing fashion production for a global innovation ecosystem.”. It is a research platform that seeks a new approach in the fashion industry through the use of technologies as 3D printing or CNC milling.
Taken for FabTextile website:
In Fab Textiles we are developing and implementing a new approach on to how create, produce and distribute fashion elements, by using distributed manufacturing infrastructures and knowledge networks.Fab Textiles offers a cross-disciplinary education and research platform, where production and culture through advanced technologies are making impact in the way we think and act towards the fashion industry.
3D printed top. Credit: Anastasia Pistofidou
As we have mentioned in other posts, the use of 3D printing in the textile sector is opening a new scope that is oriented towards improving the present landscape of fashion. Although we are still making baby steps before we graduate to major achievements, there are some interesting ways that 3D printing can add to fashion. Some of the positive things 3D printing could bring this field is the possibility of creating tailored garments that waste less material. The capacity to produce locally and improve distribution systems, saving transportation costs and pollution are other benefits. Also, the idea of open source fashion is quite interesting and could shift the way we design clothes, enhancing the customization of pieces to fit personal needs while making fashion more of a collective endeavor.
We asked Anastasia some questions in order to learn more.
Which 3D printers do you use?
We use various 3D printers using FDM technology, mainly BCN and Prusa.
What materials can you print?
We can print in TPU, PLA, Filaflex, nylon.
How would I work with you if I was a fashion designer?
You can make your sketches and patterns in paper and we can 3D model and 3D print them.
Why is what you do important?
Because it is a completely new production process and it used 3D models that are digital and not physical patterns on paper. you can also design directly in 3D, not necessarily in a flat pattern. You can send your 3D file anywhere to be printed, without having to ship garments
In use since at least the 4th century AD, dichroic glass displays different colors depending on how it’s being viewed. Now, Dutch scientists have produced the effect in a material that can be used to create 3D-printed objects – and it’s not just a novelty, as it could have practical applications.
A team of researchers at Wageningen University started with regular polyvinyl alcohol (PVA), which is a widely-available polymer commonly used as a 3D printing medium. To this they added gold nanoparticles of varying sizes – not much of the gold was needed, as it ended up constituting only 0.07 percent of the resulting composite material’s weight.
Sometimes 3D printing may seem to be almost too good to be true, offering what can sometimes be astounding benefits in affordability, production of speed, self-sustainability, and savings in materials and labor. The downsides are few, but as with the use of any machinery, the topic of safety should always present. And although physical hazards may be few in 3D printing, toxicity to humans has been in question for years—in connection with both the materials being used and particle emissions.
As Qian Zhang, a PhD student at Georgia Institute of Technology, asserts in her recent dissertation, ‘Particle Emissions from Consumer Level 3D Printers,’ concerns continue regarding 3D printing emissions in closed environments (which would be the norm in most cases) such as the workplace, classroom, and home. Zhang’s research was comprehensive, focusing on ABS and PLA in terms of particle emissions and their dangers to the public.
Overall, as Zhang points out, ABS and PLA are the most common forms of materials used with 3D printing although many other alternative sources are beginning to gain traction too, from metal to wood—and a growing multitude of other options. ABS is used due to affordability, good strength, stiffness, and more, while PLA (although less stable and not as strong) is thought of as being more environmentally friendly due to its plant-based origins, allowing for more recycling options. Zhang considered these materials specifically, along with FDM 3D printers at the desktop level that may emit particles and volatile organic compounds (VOCs or total volatile organic compounds, TVOCs) into the air, along with gas phase pollutants.
Previous studies showed that ABS usually emitted more particles; in fact, perhaps as much as ‘one to two orders of magnitude higher’ than PLA. As the researcher points out, particle emissions can vary due to other reasons such as:
Types of environment
Air mixing and air rate
Measurement instrumentation
Calculation methods regarding particles
Particle number (a), surface area (b) and mass (c) emissions for ABS filament d green color on printer A for 3 objects taking about 1 hr, 4 hr and 7 hr to print. Each bar indicates the emission (TP) from one print object; colors indicate different particle size ranges. Values on the colored bars are the ratios of emissions from such particle size range over total emissions.
Carbon and oxygen were the ‘most abundant elements’ found in particle emissions, along with small amounts of metals. ABS filaments were also known to emit styrene and ethylbenzene, while PLA filaments have been known to emit lactide, lactic acid and methyl-methacrylate. The research shows that overall, VOC concentrations may be above normal limits in offices, but environmental variables such as heating, and air-conditioning, may be responsible for lowering levels of toxins substantially. Ultrafine particles are extremely mobile and may cover a large surface area, and in humans can affect the entire respiratory tract, as well as organs and cells, via transportation through the bloodstream.
“The existing results revealed the potential health effects for 3D printer emissions, while more toxicity assessments using multiple methods need to be applied and compared in order to have a broader understanding of the particle emission toxicity,” states Zhang.
Testing included an examination of the following:
Methods
Printer operating conditions
Printer brands
Filament materials
Brands and colors
Extrusion and build plate temperatures
“Applying an existing test method to 3D printers gives insight for development of a standard test method for 3D printers and provides a database for assessing emission limits. Furthermore, it might provide insights for 3D printer and filament manufacturers to produce low emitting products and develop effective mitigation methods,” says Zhang.
Particle emissions tend to be greater as a 3D printing job begins, mainly comprised of ultrafine particles and nanoparticles.
“For shorter print jobs, these aerosol dynamic processes may never reach steady state before printing ends, whereas for longer jobs, concentrations of various sizes can remain relatively constant after about 1 hour of printing (for this condition), indicating the processes of particle formation, vapor-condensational growth, coagulation and loss reach a steady state,” states Zhang.
“Compared to number concentration profiles, the surface area and mass concentrations both take longer to reach a maximum. The large number of newly formed particles contributes little to surface area or mass, but as printing continues to supply vapors, particle growth by condensation of vapors leads to a rise in surface area and mass concentrations.”
Printer brands and filaments especially did make a big difference when using ABS, while in terms of PLA the 3D printer used had the most effect. ABS numbers turned out to be up to 3 to 104 times that of PLA yields, but Zhang points out that variations differ regarding 3D printer brands, and mass basis of particles should be taken into account also.
“A consistency among various methods showed that PLA emitted particles induced similar levels of responses at much lower doses than ABS-emitted particles, indicating PLA emitted particles are more toxic on a particle mass basis. However, calculations for the overall exposure showed ABS filaments may be more harmful due to their much higher emissions. Overall, 3D printers are sources of high levels of ultrafine particles, which are potentially harmful for their users. Therefore, the emissions should be regulated and mitigate,” concluded the research.
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Time series of particle number concentrations averaged over various particle size ranges on log scale (a), total particle concentrations on linear scale (b), evolution of size distributions (c) and average particle number distributions during the printing period separated into 5 time intervals (d). The print condition was ABS filament brand a, red color, using printer A; the printing period was 47 min, identified by the vertical lines.
Long time print job time series of particle number concentrations (a) and size distributions (b) for ABS filament, brand d, green color, on printer A; the printing period was 7 hr 4 min, identified by the vertical lines.
It’s safe to say that in Ohio at least, winter is here with a vengeance. But while I’m already sick of the ice and snow that come part and parcel with the season, I do actually like winter for another, very different reason: the movies. We are now deep in awards show season, with the Golden Globes and the Critics’ Choice Movie Awards in the rear-view mirror, the SAG Awards this weekend, and the 91st Academy Awards coming up at the end of February. Even though I’m a little salty that not a single female director was nominated this year, I’m looking forward to once again taking over the television for the night (sorry, husband!) on February 24th and following along with the televised awards ceremony to look at all of the amazing dresses and see who gets to take home an Oscar.
But the Academy Awards aren’t just about glamorous red carpet looks, or even about celebrating and acknowledging the work of excellent actors, directors, and writers in making great films. They are also about awarding the achievements of those who work behind the scenes with cutting-edge, modern technology…like 3D printing.
3D printing has also been used to help make multiple Academy Award-nominated movies in recent years. Designer and Shapeways community member Igor Knezevic was part of the Art Department team for the movie Passengers, which was nominated for an Academy Award for Best Production Design in 2017. In the same year, the stop-motion film Kubo and the Two Strings was nominated at the Oscars for Best Animated Feature Film and Best Achievement in Visual Effects, winning the latter award. Oregon-based animation studio LAIKA used 3D printing to make two characters for the movie – a 400 lb, 16-foot-tall Skeleton Demon puppet and the flying Moonbeast, which was the studio’s first fully 3D printed character.
This year, another movie that utilized 3D printing techniques during production was once again nominated for an Academy Award.
Oscar-winning director Damien Chazelle was at the helm for the 2018 film First Man, a biographical drama that counts Steven Spielberg as an executive producer and stars Ryan Gosling as astronaut Neil Armstrong in the years leading up to the groundbreaking Apollo 11 spaceflight that resulted in man walking on the moon for the first time. Coincidentally, this week marks the 50th anniversary of that amazing moment in history when Armstrong uttered those famous words on the surface of the moon: that’s one small step for man, one giant leap for mankind.
The movie, which also stars Claire Foy as Armstrong’s wife Janet, is a biopic spanning the years 1961-1969 and explores the sacrifices that Armstrong, his family, and the nation, had to face during and leading up to the dangerous space mission. According to IMDB, Armstrong’s sons Mark and Rick said that the film was “the most accurate portrayal” they’d seen of their parents.
“A look at the life of the astronaut, Neil Armstrong, and the legendary space mission that led him to become the first man to walk on the Moon on July 20, 1969,” IMDB wrote about the movie.
During production for First Man, the team called on large-scale 3D printing company BigRep for help in creating a scale replica of the Apollo 11 capsule, along with some other iconic replicas as well.
The film’s production team used the massive BigRep ONE 3D printer for the job, and had two of the systems running for six months, around the clock every day, in order to finish the job in time.
All of this hard work resulted in some very lifelike 3D printed replicas from a major moment in American aerospace history.
3DPrint.com asked Michel David, a BigRep 3D Printing Specialist, some questions about the company’s work in Hollywood, including what materials were used to create the 3D printed historical replicas.
David told us, “BigRep provided mainly PLA (translucent) – named “Berliner luft”.
We also wanted to know about the amount of post-processing work that had to be completed before the 3D printed replicas were ready for their close-ups.
“The film industry is no stranger to post processing, so I am sure there was a lot involved,” David told 3DPrint.com. “However, the time and expense saving lies in the geometry generation and construction as it is more efficient in this case than traditional modeling methods due to the accuracy of the 3D prints.”
An important aspect of any manufacturing job, whether it’s making a movie or making airplane cabin components, is sticking to the budget. So we also asked David if using BigRep’s 3D printers helped save on the cost of fabricating the replicas for the film.
“Yes, much more affordable,” David told us. “With so much manual work involved in traditional model making, it can end up being a significant expense in the long run for production.”
First Man was nominated for four Academy Awards, all in the technical categories: Best Achievement in Sound Editing, Best Achievement in Sound Mixing, Best Achievement in Production Design, and Best Achievement in Visual Effects.
The film is up against some stiff competition, such as Black Panther, Ready Player One, and Bohemian Rhapsody, another biopic. I know who I’ll be rooting for come February 24th.
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As innovation in materials grows into a vast science—especially within the 3D and 4D printing realms, medical patients of today and the future can look forward to improved, patient-specific care. Researchers from Queen’s University Belfast study the implications and potential with enhanced PLA in ‘Antioxidant PLA Composites Containing Lignin for 3D Printing Applications: A Potential Material for Healthcare Applications.’
