PMID- 32923813
OWN - NLM
STAT- PubMed-not-MEDLINE
LR  - 20200928
IS  - 2470-1343 (Electronic)
IS  - 2470-1343 (Linking)
VI  - 5
IP  - 35
DP  - 2020 Sep 8
TI  - Three-Dimensional Printed Lightweight Composite Foams.
PG  - 22536-22550
LID - 10.1021/acsomega.0c03174 [doi]
AB  - The goal of this paper is to enable three-dimensional (3D) printed lightweight 
      composite foams by blending hollow glass microballoons (GMBs) with high density 
      polyethylene (HDPE). To that end, lightweight feedstock for printing syntactic 
      foam composites is developed. The blend for this is prepared by varying the GMB 
      content (20, 40, and 60 volume %) in HDPE for filament extrusion, which is 
      subsequently used for 3D printing. The rheological properties and the melt flow 
      index (MFI) of blends are investigated for identifying suitable printing 
      parameters. It is observed that the storage and loss modulus, as well as complex 
      viscosity, increase with increasing GMB content, whereas MFI decreases. Further, 
      the coefficient of thermal expansion of HDPE and foam filaments decreases with 
      increasing GMB content, thereby lowering the thermal stresses in prints, which 
      promotes the reduction in warpage. The mechanical properties of filaments are 
      determined by subjecting them to tensile tests, whereas 3D printed samples are 
      tested under tensile and flexure tests. The tensile modulus of the filament 
      increases with increasing GMB content (8-47%) as compared to HDPE and exhibit 
      comparable filament strength. 3D printed foams show a higher specific tensile and 
      flexural modulus as compared to neat HDPE, making them suitable candidate 
      materials for weight-sensitive applications. HDPE having 60% by volume GMB 
      exhibited the highest modulus and is 48.02% higher than the printed HDPE. 
      Finally, the property map reveals a higher modulus and comparable strength 
      against injection- and compression-molded foams. Printed foam registered 1.8 
      times higher modulus than the molded samples. Hence, 3D printed foams have the 
      potential for replacing components processed through conventional manufacturing 
      processes that have limitations on geometrically complex designs, lead time, and 
      associated costs.
CI  - Copyright (c) 2020 American Chemical Society.
FAU - H S, Bharath
AU  - H S B
AD  - Advanced Manufacturing Laboratory, Mechanical Engineering, National Institute of 
      Technology, Surathkal, Karnataka 53706, India.
FAU - Bonthu, Dileep
AU  - Bonthu D
AD  - Advanced Manufacturing Laboratory, Mechanical Engineering, National Institute of 
      Technology, Surathkal, Karnataka 53706, India.
FAU - Prabhakar, Pavana
AU  - Prabhakar P
AD  - Department of Civil and Environmental Engineering, University of 
      Wisconsin-Madison, Madison, Wisconsin 53706, United States.
FAU - Doddamani, Mrityunjay
AU  - Doddamani M
AD  - Advanced Manufacturing Laboratory, Mechanical Engineering, National Institute of 
      Technology, Surathkal, Karnataka 53706, India.
LA  - eng
PT  - Journal Article
DEP - 20200826
PL  - United States
TA  - ACS Omega
JT  - ACS omega
JID - 101691658
PMC - PMC7482239
COIS- The authors declare no competing financial interest.
EDAT- 2020/09/15 06:00
MHDA- 2020/09/15 06:01
PMCR- 2020/08/26
CRDT- 2020/09/14 05:56
PHST- 2020/07/01 00:00 [received]
PHST- 2020/08/14 00:00 [accepted]
PHST- 2020/09/14 05:56 [entrez]
PHST- 2020/09/15 06:00 [pubmed]
PHST- 2020/09/15 06:01 [medline]
PHST- 2020/08/26 00:00 [pmc-release]
AID - 10.1021/acsomega.0c03174 [doi]
PST - epublish
SO  - ACS Omega. 2020 Aug 26;5(35):22536-22550. doi: 10.1021/acsomega.0c03174. 
      eCollection 2020 Sep 8.