ABANG ISMAWI HASSIM, Dayang Habibah (MY)
SARKAWI, Siti Salina (MY)
NGEOW, Yen Wan (MY)
IBRAHIM, Suhawati (MY)
YONG, Kok Chong (MY)
| CLAIMS 1 . A material for fused deposition modelling, FDM type 3-dimensional, 3D, printer comprising: a) 40.0% to 70.0% of polypropylene, PP by total weight of the material; b) 20.0% to 50.0% of ethylene-vinyl acetate, EVA by total weight of the material; and c) 5.00% to 20.0% of styrene-(ethylene-cobutylene)-styrene polymers- grafted maleic anhydride, SEBS-G by total weight of the material. 2. The material as claimed in claim 1 , further includes additives in an amount ranging between 3.0 % to 10.0 % by total weight of the material. 3. The material as claimed in claim 1 , wherein the PP is used in an amount ranging between 50.0 % to 60.0 % by total weight of the material. 4. The material as claimed in claim 1 , wherein the EVA is used in an amount ranging between 30.0 % to 40.0 % by total weight of the material. 5. The material as claimed in claim 1 , wherein the SEBS-G is used in an amount ranging between 10.0 % to 20.0 % by total weight of the material. 6. A filament for a fused deposition modelling, FDM type 3-dimensional, 3D printer obtained by extruding the material according to claim 1 . |
FIELD OF THE INVENTION
Present invention discloses a material for Fused Deposition Modelling (FDM) type 3- dimensional (3D) printer and a method of preparing thereof.
BACKGROUND OF THE INVENTION
In recent years, 3D printing devices employing the FDM method is widely used in rapid prototyping, common households and educational facilities. Moreover, objects obtained using 3D printing devices are expanded to be used for multiple purposes i.e. medical, automotive, engineering, robotics, fashion, defense etc.
Typically, material prepared using pure polymers such as Polypropylene (PP) are widely used to print 3D parts for product that need to be light, water-tight and durable. However, PP has some limitations as FDM 3D printing material. The semi-crystalline structure of the material causes the 3D printed parts to heavily warp (shrink) upon cooling, making it challenging to 3D print. The warpage issue of PP is critical during printing and need to be solved to obtain a desire 3D parts. As such, it is not easy to adhere to the building platform during the 3D printing process. Also, there is a need to develop flexible filament for FDM 3D printer which results improved elastic properties to making it suitable for practical use. Hence, a material which can overcome the above-mentioned drawbacks is desired.
SUMMARY OF THE INVENTION
Present invention relates to a material for Fused Deposition Modelling (FDM) type 3- dimensional (3D) printer and a method of preparing thereof. The material comprises (i) polypropylene (PP), wherein the PP is used in an amount ranging between 40.0% to 70.0% by total weight of the material, (ii) ethylene-vinyl acetate (EVA), wherein the EVA is used in an amount ranging between 20.0% to 50.0% by total weight of the material and (iii) styrene-(ethylene-cobutylene)-styrene polymers-grafted maleic anhydride (SEBS-G), wherein the SEBS-G is used in an amount ranging between 5.00% to 20.0% by total weight of the material. The material further includes additives, wherein the additives is used in an amount ranging between 3.0% to 5.0% by total weight of the material.
Additional aspects, features and advantages of the invention will become apparent to those skilled in the art upon consideration of the following detailed description of preferred embodiments of the invention in conjunction with the drawings listed below.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The present invention will be fully understood from the detailed description given herein below and the accompanying drawings which is given by way of illustration only, and thus is not limitative of the present invention, wherein:
In the appended drawings:
FIGURE 1 illustrates (a) material of the present invention having PP/EVA24/SEBS-G ratio of 40/50/10 without warpage problem and (b) control PP material with warpage problem.
FIGURE 2 illustrates tensile strength of the material of the present invention having different PP/EVA24/SEBS-G ratio and control PP material.
FIGURE 3 illustrates elongation at break of the material of the present invention having different PP/EVA24/SEBS-G ratio and control PP material.
FIGURE 4 illustrates stress-strain curves of the material of the present invention having 60/30/10 PP/EVA24/SEBS-G ratio and control PP material.
FIGURE 5 illustrates stress-strain curves of the material of the present invention having 50/40/10 PP/EVA24/SEBS-G ratio and control PP material. DETAILED DESCRIPTION OF THE INVENTION
Detailed description of preferred embodiments of the present invention is disclosed herein. It should be understood, however, that the embodiments are merely exemplary of the present invention, which may be embodied in various forms. Therefore, the details disclosed herein are not to be interpreted as limiting, but merely as the basis for the claims and for teaching one skilled in the art of the invention. The numerical data or ranges used in the specification are not to be construed as limiting.
Present invention discloses a material for Fused Deposition Modelling (FDM) type 3- dimensional (3D) printer and a method of preparing thereof.
First aspect of the present invention discusses on a material for FDM type 3D printer, wherein the material comprises polypropylene (PP), ethylene-vinyl acetate (EVA) and Styrene-(ethylene-cobutylene)-styrene polymers-grafted maleic anhydride (SEBS-G). The material further includes additives.
The PP is used in an amount ranging between 40.0% to 70.0% by total weight of the material, preferably between 50.0% to 60.0% by total weight of the material, most preferably 50.0% by total weight of the material.
The EVA is used in an amount ranging between 20.0% to 50.0% by total weight of the material, preferably between 30.0% to 50.0% by total weight of the material, most preferably 40.0% by total weight of the material. The EVA used contain vinyl acetate (VA) content ranging between 17.0% to 30.0% by total weight of the EVA , preferably between 20.0% to 26.0% by total weight of the EVA, most preferably 24.0% by total weight of the EVA. The EVA is modified EVA grafted with maleic anhydride (MA).
The SEBS-G is used in an amount ranging between 5.0% to 20.0% by total weight of the material, preferably between 10.0% to 20.0% by total weight of the material, most preferably 10.0% by total weight of the material.
The additives is used in an amount ranging between 3.0% to 10.0% by total weight of the material, preferably between 3.0% to 5.0% by total weight of the material, most preferably 5.0% by total weight of the material. The additives is selected from the group consisting of filler, pigment, stabilizer and any combinations thereof.
Table 1 shows the chemical components of the material for FDM type 3D printer of the present invention and compositions thereof (as mentioned above).
Table 1 : Chemical components of the material for FDM type 3D printer of the present invention and compositions thereof
The second aspect of the present invention discusses on method of preparing FDM type 3D printing material. The printing material can be obtained in one or more forms including filament, pellet but not limited thereto.
The method comprises the steps of: i. drying PP, EVA and SEBS-G separately as summarized in Table 1 in vacuum oven at a temperature ranging between 65°C to 75°C for a time period ranging between 6 hours to 24 hours to obtain a dried PP, dried EVA and dried SEBS-G; ii. adding dried EVA an amount ranging between 20.0% to 50.0% by total weight of the material, SEBS-G in an amount ranging between 5.00% to 20.0% by total weight of the material and additives in an amount ranging between 3.0% to 10.0% by total weight of the material to the dried PP obtained in step (i) to obtain a blend; iii. mixing the blend obtained in step (ii) at a temperature ranging between 160°C to 190°C a time period ranging between 5 minutes to 7 minutes at a speed of 70 rpm to 80 rpm using rotor speed at a fill factor ranging between 0.70 to 0.75 to obtain a PP blend; iv. crushing the PP blend using pulverizer wherein the pulverizer is pelletizer but not limited thereto to obtain a pelletized PP blend, wherein the pelletized PP blend has a size ranging between 2 mm to 4 mm; and v. feeding the pelletized PP blend obtained in step (iv) for extruding into filament maker at a temperature ranging between 170°C to 190°C for a time period ranging between 2 hours to 4 hours to obtain PP/EVA filament wherein the PP/EVA filament is collected by spinning spool for 3D printing.
The method above is not limited thereto as there are other alternative processes in preparing the filament of the present invention. For example, single/twin screw extruder system/line is used in industrial scale.
The material for FDM type 3D printer is subjected to analysis such as (i) thermal properties and (ii) mechanical properties analysis, details of which are discussed below.
Thermal
The material for FDM type 3D printer of the present invention and control material for FDM type 3D printer having different PP/EVA24/SEBS-G ratio is analysed based on the thermal analysis. The thermal properties for both material of the present invention and control material having different PP/EVA24/SEBS-G ratio is summarized in Table 2.
Table 2: Thermal properties of the material for FDM type 3D printer of the present invention and control material for FDM type 3D printer having different PP/EVA24/SEBS-G ratio
The results in Table 2 shows, material for FDM type 3D printer of the present invention having PP/EVA24/SEBS-G ratio of 40/50/10 has the lowest crystallinity. As a result, using material for FDM type 3D printer of the present invention having PP/EVA24/SEBS-G ratio of 40/50/10 warpage problem during printing process can be reduced. FIGURE 1(a) illustrates (a) material for FDM type 3D printer of the present invention having PP/EVA24/SEBS-G ratio of 40/50/10 without warpage problem. Meanwhile, FIGURE 1(b) illustrates a control material for FDM type 3D printer with warpage problem. Mechanical properties analysis
The material for FDM type 3D printer of the present invention for FDM type 3D printer having different PP/EVA24/SEBS-G ratio and control material is analyzed based on the mechanical properties i.e. tensile strength and elongation at break.
FIGURE 2, FIGURE 3, FIGURE 4 and FIGURE 5 show the outcome of mechanical properties of the materials for FDM type 3D printer as mentioned above. The results obtained show that material for FDM type 3D printer of the present invention having PP/EVA24/SEBS-G ratio of 40/50/10 has the highest tensile strength and elongation at break compared to the control material and other blends ratio for FDM type 3D printer. FIGURE 4 and FIGURE 5 show the present invention has higher ductility compared to control sample. High ductility indicates that a material is able to absorb more energy which leads to improved toughness.
The material for FDM type 3D printer of the present invention is applicable for the manufacturing of FDM type 3D printing material but not limited thereto.
As a whole, the results obtained in the present invention shows that the material for FDM type 3D printer of the present invention can be used to develop a material for FDM type 3-dimensional 3D printer which can overcome the warpage problem during printing process with improved tensile strength, elongation at break and appropriate thermal properties.
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises", "comprising", “including” and “having” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups therefrom.
The method, steps, processes and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. The use of the expression “at least” or “at least one” suggests the use of one or more elements, as the use may be in one of the embodiments to achieve one or more of the desired objects or results.
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