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Thermoplastic Elastomer Filaments and Their Application in 3D Printing

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Thermoplastic Elastomer Filaments and Their Application in 3D Printing 32 elastomery termoplastyczne w technologii druku 3D Agnieszka Przybytek*, Justyna Kucińska-Lipka* 1, Helena Janik* Thermoplastic elastomer filaments and their application in 3D printing The paper provides an overview on the materials used in the 3D printing technology (the Polish and foreign market) with a particular focus on flexible filaments and their possible application in the industry. There are described the techniques of 3D printing and modern filaments available on the market. There is observed the increase of interest in the production of products from filaments based on thermoplastic elastomers (TPE), including the applications in the electronics and medicine, especially in tissue engineering. Ability to modify the physical and mechanical properties of thermoplastic elastomers, combined with their unique elastic and processability properties, opens new possibilities for engineers, designers and bio-engineers. The possibility to use new materials in 3D printing can contribute to faster development of research and accelerates implementation of innovative products. Keywords: 3D printing, flexible filaments, thermoplastic elastomers (TPE), thermoplastic polyurethanes (TPU). Mgr inż. Agnieszka Przybytek ukończyła studia Dr inż. Justyna Kucińska-Lipka ukończyła studia w 2015 roku na Politechnice Gdańskiej (studia w 2003 roku na Wydziale Technologii i Materiało- inżynierskie – Wydział Fizyki Technicznej i Ma- znawstwa (specjalizacja: chemia technologia poli- tematyki Stosowanej, studia magisterskie – Wy- merów) Politechniki Radomskiej. Otrzymała stopień dział Chemiczny). W 2016 roku rozpoczęła studia doktora nauk technicznych (technologia chemiczna) III stopnia na Studium Doktoranckim Wydziału na Wydziale Chemicznym Politechniki Gdańskiej Chemicznego Politechniki Gdańskiej. Obszar w 2007 roku. Obszar zainteresowań: synteza, cha- zainteresowań: nowoczesne materiały polime- rakterystyka i modyfikacja poliuretanów do celów rowe do celów technicznych i medycznych, ich medycznych, a w szczególności przydatnych na rusz- przetwórstwo, charakterystyka oraz formowanie towania tkankowe, biodegradacja polimerów, nowe w celu otrzymania określonych produktów. materiały polimerowe do zastosowań technicznych. Prof. dr hab. inż. Helena Janik ukończyła studia na Wydziale Chemicznym Politechniki Gdańskiej w 1973 roku. W 1989 roku na tej uczelni uzyskała sto- pień doktora nauk technicznych w zakresie technologii chemicznej, a stopień doktora habilitowanego w tej dziedzinie uzyskała w 2006 roku. Tytuł profesora otrzymała w 2012 roku. Obecnie pracuje na stanowisku prof. nadzwyczajnego w Katedrze Technologii Polimerów oraz jest kierownikiem specjalności Techno- logia polimerów, kosmetyków i materiałów funkcjonalnych. Obszar zaintereso- *Polymer Technology Department, Chemical Faculty, Gdansk University wań: synteza, charakterystyka i zastosowanie nowych materiałów polimerowych of Technology, w medycynie i opakowalnictwie z wykorzystaniem przede wszystkim elastome- Narutowicza Street 11/12 80-233 rów uretanowych, poli(kwasu mlekowego), modyfikowanej skrobi termoplastycz- Gdansk, Poland nej, opracowanie nowych kompozycji polimerowo-gumowych. e-mail: [email protected] TOM 20 październik – grudzień 2016 nr 4 elastomery termoplastyczne w technologii druku 3D 33 Termoplastyczne włókna elastomerowe i ich zastosowanie w druku 3D Praca stanowi przegląd dostępnych na rynku krajowym i zagranicznym materiałów używanych w tech- nologii druku 3D. Szczególną uwagę poświęcono elastycznym włóknom (ang. flexible filaments) oraz ich potencjalnemu zastosowaniu w przemyśle. Przedstawiono i oceniono stosowane technologie druku 3D. Scharakteryzowano nowoczesne włókna kompozytowe, ich właściwości i zastosowanie. Opisano także najnowsze doniesienia literaturowe związane z otrzymywaniem nowoczesnych termoplastycznych elastomerów (TPE) do wykorzystania w technologii druku 3D. Na podstawie przeanalizowanych publika- cji zauważono ogromny wzrost zainteresowania wykorzystaniem termoplastycznych poliuretanów (TPU) w przemyśle elektronicznym, medycznym oraz obuwniczym. Dostępne na rynku nowoczesne produkty wykonane przy użyciu drukarek 3D z wykorzystaniem TPU, potwierdzają te doniesienia. Interesujące jest wykorzystanie wodnych dyspersji TPU z możliwą kontrolą bioaktywności do zastosowań w inżynierii tkan- kowej. Dodatek do wodnych dyspersji TPU, biopolimerów lub poli(tlenku etylenu) (PEO) powoduje znacz- ny wzrost ich lepkości. Pozwala to na użycie tego materiału w drukarkach 3D w technologii niskotempera- turowego drukowania (LFDM). Możliwość kontrolowanej zmiany właściwości fizycznych i mechanicznych, wyjątkowa elastyczność, trwałość oraz łatwość przetwórstwa termoplastycznych elastomerów otwierają nowe możliwości wykorzystania druku 3D. Dzięki temu technologia ta przestaje być narzędziem jedynie do prototypowania – umożliwia ona drukowanie materiałów gotowych do użytku na skalę przemysłową. Słowa kluczowe: druk 3D, włókna elastyczne, elastomery termoplastyczne (TPE), termoplastyczne poli- uretany (TPU). 1. Introduction Laser moves automatically sintering the points in space defined by software to form a solid three-dimensional model. Stereolithography (SLA) is based on curing by UV 3D printing is a process that has revolutionized of photosensitive polymeric resins. Fused Deposition the manufacturing industry. This technology is Modeling (FDM) machines work owing to a thin available at our fingertips. It has been using not only filament made from special thermoplastic polymers: by the military, research units or technology advanced through a heated nozzle layer by layer deposition of companies but people at school or home as well. It material creates a 3D object. In Laminated Object is fascinating that nowadays with the only help of Manufacturing (LOM) the layered material (coated a computer and a printer you can quickly create your an adhesive layer) is rolled on the building platform. own idea, project in three dimensions. This technology The feeding roller heats in order to melt the adhesive. has opened a new way for scientists, but also gave Laser is used to draw the geometry of the object. Three- a tool to develop imagination and creative thinking for dimensional printing (3DP) is based on layered powder children and people who have not yet been involved in materials. The process begins with a specific application the field of science and technology. of the powder layer from the tray. This layer is aligned on The most important properties of 3D printing is the work surface platform using the roller. On the thus its precision – it is possible to manufacture a whole prepared powder layer, adhesive is applied, according new range of complicated objects using materials with to a predetermined cross-sectional block. PolyJet (JS) the most diverse properties. Freedom of design, print technology is similar to FDM, except that the head is speed, without wasting materials and the possibility of sprayed on the worktable liquid photopolymer that is household makes this technology very welcome by all curable with UV lamps. According to [1], 3D printing types of industries. processes may be divided into three stages: “Image The main use of 3D printing in most types of acquisition”, “Image post-processing” and described industry appears to be a rapid prototyping (RP). There above “3D printing”. In our opinion it should be add are several technologies using RP for various industrial a stage of “Material selection”. applications. The major prototyping techniques are This paper provides an overview of available summarized in Table 1 [1, 2, 3]. Selective Laser Sintering filaments on the Polish and foreign markets, as well (SLS) is based on a laser as the power source to sinter as an overview of the latest reports associated with the powders (thermoplastics, metal, ceramic, glass, alloys). flexible filaments. nr 4 październik – grudzień 2016 TOM 20 34 elastomery termoplastyczne w technologii druku 3D Table 1. Overview of chosen rapid prototyping techniques Tabela 1. Przegląd wybranych technik szybkiego prototypowania Accuracy Recommended RP technology print/ Advantages Disadvantages Application filaments type price thermoplastic architecture, medicine, dimensional accuracy, SLS (Selective Laser elastomers, composite, price, speed, automotive, aerospace, ++ surface finish, variety of Sintering) glass, metals, alloys surface roughness mechanical engineering, materials, large workspace – powders castings, military, high dimensional accuracy, architecture, medicine, SLA very good surface finish, price, not so archeology, aerospace, +++ photocurable resin (Stereolithography) large workspace,high resistant to UV automotive, mechanical repeatability of products engineering a small amount LOM (Laminated adhesive-coated price, speed, dimensional of material castings, mechanical Object + polymer, paper, accuracy available, surface parts prototypes Manufacturing) cellulose, metal sheets roughness 3DP (Three elastomers, average surface finite element analysis, Dimensional ++ composites, metals, speed, colour, price quality architecture, castings Printing) ceramics – powders high accuracy and a small amount electrical engineering, JS (PolyJet) +++ photocurable resin dimensional tolerance, of material automotive, aerospace speed available architecture, domestics FDM (Fused thermoplastic, price, a large number of speed, average use products, (tools, Deposition ++ elastomers, filaments available surface quality toys, jewelry), medicine, Modeling) composite automotive, electronics (+) – rating
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