Recycling Polymer Blend made from Post-used Styrofoam and Polyethylene for Fuse Deposition Modelling

Styrofoam is widely used as packaging material for many applications like home furniture and electrical appliance. Styrofoam is a non-biodegradable material which its disposal causes serious environment issues. This research demonstrates an alternate recycling method of Styrofoam waste by converting it into 3D printing filament for Fused Deposition Modelling (FDM). For this research, the recycled polystyrene (rPS) was extracted from Styrofoam waste and blended with low-density polyethylene (LDPE), then extruded into filament using a filament extruder. The formulated rPS/LDPE blend with different blend ratio exhibited a good printability when the printing temperature and extrusion rate fixed at 240°C and 120%. However, the tensile strength of printed specimens with rPS/LDPE blends were lower than printed specimen with neat rPS. The tensile strength and modulus of printed specimens with rPS/LDPE were decreased due to the increase of LDPE content. The decrease of tensile strength mainly caused by the incompatibility between the rPS and LDPE phases. However, the addition of more LDPE content in the blend enhanced the ductility of rPS/LDPE blends. Furthermore, the increase of LDPE content also increased the thermal stability of rPS/LDPE blends. Overall, the rPS/LDPE blend is a potential alternate material for producing FDM filament.

Recycling Polymer Blend made from Post-used Styrofoam and Polypropylene for Fuse Deposition Modelling

Fuse deposition modelling (FDM) has become a revolutionary manufacturing technology as it offers numerous advantages, including freedom of fabrication, mass customisation, fast prototyping, and cost-effectiveness. Thermoplastic material is commonly used as feedstock for FDM process. The current state of material development, the recycled plastic material also can be used as printing material for FDM machine. Expanded polystyrene (EPS) has been extensively used as packaging materials for many industries but rarely be recycled, as its relatively large volume with minimal weight is unconducive for transportation. This research aimed to utilize EPS waste and turn it into FDM feedstock. This research also aims to enhance the properties of recycled polystyrene (rPS) made from EPS waste by blending it with polypropylene (PP). Different ratios of rPS/PP blends were prepared and extruded into FDM filament using filament extruder. The formulated filaments were printed into specimen using FDM machine. This research found the filament made from rPS/PP blends can be printed into specimen with good printing quality if the nozzle temperature controlled at 240° C with 120 % extrusion rate. With this printing parameter, the specimen printed with rPS/PP blend filament exhibit the greatest adhesion between the deposited layers without any visible voids or gaps. Besides, the printed specimen with rPS/PP blends possess lower tensile strength, but higher tensile modulus as compared to the printed specimen with neat rPS. The addition of more PP decreased both tensile strength and modulus of rPS/PP blends. On the other hand, the rPS/PP blends have higher thermal stability as the PP content increased. Overall, the rPS/PP blends filament shows a great potential as a feedstock material for FDM fabrication.

3D Printed Hygroscopic Programmable Material Systems

ABSTRACTThe paper presents new developments into autonomously responsive architectural systems that adapt to environmental changes using hygroscopic material properties. The presented work expands upon previously developed research by the authors on wood-veneer composite meteorosensitive architectural systems based on the biomimetic transfer of the hygroscopic actuation of plant cones[1,2]. The manipulation parameters, variables and syntactic elements that enabled such meteorosentive architectural systems to be possible, using the hygroscopic qualities of wooden veneer within a weather responsive wood-veneer composite system, are abstracted and transferred into a 3D printed composite system. The fuse deposition modelling approach presented further expands the research field into such autonomous responsive systems by enabling a more complex gradient of functional differentiation within a responsive element while also enabling on-surface complex articulations due to anisotropic conditions. The results indicate that the 3D printed prototype can maintain the ability to operate and respond autonomously and passively to changes in relative humidity, similarly to the wood veneer composite system, by embedding some of the same functional principles within the material itself. The numerically controlled fabrication methodology presented, enabled through 3D printing, looks at designing the “material syntax” as a strategy for functional programming and both formal and functional differentiation. That is, the system can transition within a single composite unit from a support structure to a responsive actuation element variably and multi-directionally. The proof-of-concept functional prototypes presented will situate the functional range of this research.