The utilization of thermosetting waste is a serious issue as it is not recycled commercially due to inherent molecular properties and high technology cost. This research details the study of the mechanical behavior and surface analysis with energy-dispersive X-ray spectroscopy and scanning electron microscope of three-dimensional printed parts of the waste thermosetting polymer, bakelite (BAK) as the reinforcement along with ceramic particles (SiC and Al2O3) in recycled thermoplastic acrylonitrile butadiene styrene matrix for sustainability. The process involves twin-screw extrusion for the preparation of filament, followed by 3D printing of functional prototypes on fused deposition modeling setup. The 3D printed parts prepared with fused deposition modeling were used for the testing of mechanical, thermal, and morphological properties. The results of the present study suggests that for commercial applications recycling of thermoplastic up to 10 wt% can be easily performed without a change in any hardware/ software configuration of the fused deposition modeling setup and the ceramic concentration in thermoplastic-thermosetting blends further led to better mechanical and surface properties.
AltafKQayyumJRaniA, et al.Performance analysis of enhanced 3D printed polymer molds for metal injection molding process. Metals2018; 8: 433.
2.
HuberCAbertCBrucknerF, et al.3D print of polymer bonded rare-earth magnets, and 3D magnetic field scanning with an end-user 3D printer. Appl Phys Lett2016; 109: 162401.
3.
FranchettiMKressC. An economic analysis comparing the cost feasibility of replacing injection molding processes with emerging additive manufacturing techniques. Int J Adv Manuf Technol2017; 88: 2573–2579.
4.
YunusDEShiWSohrabiS, et al.Shear induced alignment of short nanofibers in 3D printed polymer composites. Nanotechnology2016; 27: 495302.
5.
Ranjan N, Singh R and Ahuja IPS. Biocompatible thermoplastic composite blended with HAp and CS for 3D printing. In: Reference module in materials science and materials engineering. New York: Elsevier, 2018.
6.
WangXJiangMZhouZ, et al.3D printing of polymer matrix composites: a review and prospective. Compos Part B: Eng2017; 110: 442–458.
7.
BenwoodCAnsteyAAndrzejewskiJ, et al.Improving the impact strength and heat resistance of 3D printed models: structure, property, and processing correlationships during fused deposition modeling (FDM) of poly(lactic acid). ACS Omega2018; 3: 4400–4411.
8.
LuanCYaoXLiuC, et al.Self-monitoring continuous carbon fiber reinforced thermoplastic based on dual-material three-dimensional printing integration process. Carbon2018; 140: 100–111.
9.
DivyathejMVVarunMRajeevP. Analysis of mechanical behavior of 3D printed ABS parts by experiments. Int J Sci Eng Res2016; 7: 116–124.
10.
LiNLiYLiuS. Rapid prototyping of continuous carbon fiber reinforced polylactic acid composites by 3D printing. J Mater Process Technol2016; 238: 218–225.
11.
DrummerDCifuentes-CuéllarSRietzelD. Suitability of PLA/TCP for fused deposition modeling. Rapid Prototyping J2012; 18: 500–507.
12.
RahimTNATAbdullahAMAkilHM, et al.The improvement of mechanical and thermal properties of polyamide 12 3D printed parts by fused deposition modelling. eXPRESS Polym Lett2017; 11: 963–982.
13.
HanXYangDYangC, et al.Carbon fiber reinforced PEEK composites based on 3D-printing technology for orthopedic and dental applications. J Clin Med2019; 8: 240.
14.
WengZWangJSenthilT, et al.Mechanical and thermal properties of ABS/montmorillonite nanocomposites for fused deposition modeling 3D printing. Mater Des2016; 102: 276–283.
15.
OladapoBIZahediSAAdeoyeAOM. 3D printing of bone scaffolds with hybrid biomaterials. Compos Part B: Eng2019; 158: 428–436.
16.
Le DuigouACastroMBevanR, et al.3D printing of wood fibre biocomposites: from mechanical to actuation functionality. Mater Des2016; 96: 106–114.
17.
WuWYeWWuZ, et al.Influence of layer thickness, raster angle, deformation temperature and recovery temperature on the shape-memory effect of 3D-printed polylactic acid samples. Materials2017; 10: 970.
18.
KalitaSJBoseSHosickHL, et al.Development of controlled porosity polymer-ceramic composite scaffolds via fused deposition modeling. Mater Sci Eng C2003; 23: 611–620.
19.
BlokLGLonganaMLYuH, et al.An investigation into 3D printing of fibre reinforced thermoplastic composites. Addit Manuf2018; 22: 176–186.
20.
YaoTDengZZhangK, et al.A method to predict the ultimate tensile strength of 3D printing polylactic acid (PLA) materials with different printing orientations. Compos Part B: Eng2019; 163: 393–402.
21.
ChenZLiZLiJ, et al.3D printing of ceramics: a review. J Eur Ceram Soc2018; 39: 661–687.
22.
HamidiATadesseY. Single step 3D printing of bioinspired structures via metal reinforced thermoplastic and highly stretchable elastomer. Compos Struct2019; 210: 250–261.
23.
HaoWLiuYZhouH, et al.Preparation and characterization of 3D printed continuous carbon fiber reinforced thermosetting composites. Polym Test2018; 65: 29–34.
24.
JanssenHPetersTBrecherC. Efficient production of tailored structural thermoplastic composite parts by combining tape placement and 3d printing. Procedia CIRP2017; 66: 91–95.
25.
WuWYeWGengP, et al.3D printing of thermoplastic PI and interlayer bonding evaluation. Mater Lett2018; 229: 206–209.
26.
TlegenovYHongGSLuWF. Nozzle condition monitoring in 3D printing. Robot Comput-Integr Manuf2018; 54: 45–55.
27.
LiuSLiYLiN. A novel free-hanging 3D printing method for continuous carbon fiber reinforced thermoplastic lattice truss core structures. Mater Des2018; 137: 235–244.
28.
QuanZSuhrJYuJ, et al.Printing direction dependence of mechanical behavior of additively manufactured 3D preforms and composites. Compos Struct2018; 184: 917–923.
29.
SinghRSinghIKumarR, et al.Waste thermosetting polymer and ceramic as reinforcement in thermoplastic matrix for sustainability: thermomechanical investigations. J Thermoplast Compos Mater2019.
30.
Fabbrocino F, Farina I, Amendola A, et al. Optimal design and additive manufacturing of novel reinforcing elements for composite materials. In: Proceedings of the 7th European congress on computational methods in applied sciences and engineering, Crete, Greece, 2016, pp.5–10.
31.
Fraternali F, Carpentieri G, Montuori R, et al. On the use of mechanical metamaterials for innovative seismic isolation systems. In: Compdyn 2015-Proceedings of the 5th Eccomas thematic conference on computational methods. In: Structural dynamics and earthquake engineering, Crete Island, Greece, 25–27 May 2015, pp.349–358.
32.
Amendola A, Fabbrocino F, Feo L, et al. Dependence of the mechanical properties of pentamode materials on the lattice microstructure. In: ECCOMAS congress 2016–Proceedings of the 7th European congress on computational methods in applied sciences and engineering, Crete Island, Greece, 5–10 June 2016, pp.2134–2150.
