Material Science of 3D Printing Filaments Milwaukee 3D Meet Up Coex3D

Topics Filament Manufacturing Upstream Extrusion Down Stream Polymer Science 101 Monomers Morphology Melt Behavior Filaments Discussion

Filament Manufacturing

Resin Drying Critical steps in resin processing Hydrophilic resins needs to be dried to make 3D filament PLA, PET, PC, PA, PVOH are highly Hydrophilic ABS slightly Hydrophilic Filament Manufacturing Up-Stream Processing

Resin Drying Filament Manufacturing Up-Stream Processing

Color Feeders Color concentrates Additives Throat Mixers Magnet Filament Manufacturing Up-Stream Processing

Filament Manufacturing Real Extruders Extruder Elements Zone Heated Barrel Screw Screen Pack Breaker Plate

Filament Manufacturing Real Extruders Process Conditions on Extruders Melt Temperature Melt Pressure RPMs Motor Load

Filament Manufacturing Real Extruders Extruder Screws Feeding Melting Compression Mixing Material Specific

Filament Manufacturing Water Quench Water Bath Filaments are often water quenched Molten phase to solid phase Methods are often trade secret feet water cooling

Filament Manufacturing Filament Orientation

Filament Manufacturing Laser Micrometer

Filament Manufacturing Spooling

Filament Manufacturing Packaging

Polymer Science for 3D Printers

Polymer Science 101 for 3D Printers Plastic vs. Polymer Plastic Plastics are polymers which, under appropriate conditions of temperature and pressure, can be molded or shaped. Polymer A large molecule formed by the chemical union of five or more identical combining units called monomers

Polymers Science 101 Monomers Number of monomers (Molecular Weight) influences viscosity and strength properties (wax RU, PP 7,000 – 24,000 RU) Types and location of the monomer influence polymer chemical and mechanical properties

Polymers Science 101 Morphology

Polymers Science 101 Melt Behavior - Viscosity Viscosity Melt Index Test (MI or MFR) Temp & Weight 3D Printing Filaments are typically injection molding resin grades 10+g/10 220°C 10kg Lower MI or MFR would require more force on filament advance Intrinsic viscosity (IV) is used to measure viscosity for polymers like PET

Polymers Science 101 Melt Behavior – Melting Temps Thermal Transitions Glass Transition – Amorphous materials flow, they do not melt Melting Point – The temp at which a crystalline structure transitions to a liquid Amorphous structure

3D Printing Filaments

Polymer Science 101 Polylactide (PLA) - General Polylactide (PLA) Biopolymer - derived from corn Relatively clean resin Condensation reaction Translucent Translucent Blue

Polymer Science 101 Polylactide Polylactide (PLA) Morphology Semi-crystalline polymers Filament production method and colorants will change crystalinity levels Resin has a Tg 55-60°C & Tm of °C Different processing temps on printer (≈220°C) Melt Behavior MFR: 6 g/10 min (210°C & 2.16 Kg) Monomer Latic Acid Density: 1.24 g/cc

Polymer Science 101 ABS Acrylonitrile Butadiene Styrene Derived from 3 monomers Monomers % - Properties Not a clean resin to extrude Opaque

Polymer Science 101 ABS Acrylonitrile Butadiene Styrene (ABS) Morphology Amorphous Grade dependent Tg 100°C - 130°C Melt Behavior MFR: 1.1 g/10 min (200° C & 5 Kg) MFR: 13 g/10 min (220° C & 10 Kg) Monomer Acrylonitrile, Styrene & Butadiene Density: 1.03 g/cc

Polymer Science 101 PVOH PVOH Water soluble polymer Commonly used in 3D Printing for structural elements that are dissolved after print is complete Narrow gap between PVOH melting temp and thermal degradation – run as cool as possible Keep Dry when not in use

Polymer Science 101 CX-Glass & CoPET CX-Glass (Developmental) Glass like polymer Extremely clean polymer Morphology Amorphous Melt Behavior MFR: 13 g/10 min (220° C & 10 Kg) Clear Heated bed required CoPET (Developmental) Copolyester polymer Clean polymer Morphology Amorphous Melt Behavior MFR: 10 g/10 min (220° C & 10 Kg) Clear

Polymer Science 101 CX-Glass & CoPET

Thank You If you would like a copy of the presentation just drop me an at Or