)ORULGD6WDWH8QLYHUVLW\/LEUDULHV 2020 3D Printed Modular Structures Michelle B. Grand Follow this and additional works at DigiNole: FSU's Digital Repository. For more information, please contact [email protected] THE FLORIDA STATE UNIVERSITY COLLEGE OF ENGINEERING 3D-PRINTED MODULAR STRUCTURES By MICHELLE BRIJANA GRAND A Thesis submitted to the Department of Civil and Environmental Engineering in partial fulfillment of the requirements for graduation with Honors in the Major Degree Awarded: December 2020 The members of the Defense Committee approve the thesis of Michelle Grand defended on 11/19/2020 [Assistant Professor] [Dr. Qian Zhang] Thesis Director [Assistant Professor] [Dr. Rebekah Sweat] Outside Committee Member [Professor] [Dr. Sungmoon Jung] Committee Member [Professor of Practice] [Mr. Sean O. Martin] Committee Member FLORIDA A&M UNIVERSITY — FLORIDA STATE UNIVERSITY COLLEGE OF ENGINEERING 3D-PRINTED MODULAR STRUCTURES By MICHELLE BRIJANA GRAND [email protected] A Thesis submitted to the Department of Civil and Environmental Engineering in partial fulfillment of the requirements for Honors in the Major Submitted: November 2020 TABLE OF CONTENTS List of Tables 5 List of Figures 6 1 Introduction 9 1.1 ResearchObjective............................ 9 1.2 Problem Statement . 10 1.3 Research Scope . 10 1.4 ChapterOverview ............................ 10 2 Literature Review 11 2.1 PlasticRecycling ............................. 11 2.1.1 Motive . 11 2.1.2 Plastic Classifications . 12 Thermoplastics .......................... 13 Thermosets ............................ 15 Additives ............................. 17 IdentificationSystems . 17 2.1.3 Recycling Options . 18 MechanicalRecycling ...................... 18 ChemicalRecycling ....................... 18 EnergyRecovery ......................... 19 2.2 3-D Printing and Construction . 20 2.3 feasibility of 3-D Printed Recycled Plastics . 24 2.3.1 State of Art . 24 2.3.2 Materials and Processes . 24 PET................................ 24 PP................................. 25 HDPE............................... 25 2.3.3 Material Selection . 25 2.3.4 Equipment ............................ 28 2.3.5 Procedure - A Form of Mechanical Recycling . 28 2.4 HDPE applications in the construction industry . 30 2 2.4.1 Aggregate Mixtures . 30 Pavement Base and Subbase . 30 CementituosMixtures . 30 2.4.2 Geotechnical Applications . 31 Geomembranes . 31 geogrids . 31 2.4.3 PipingSystems.......................... 31 2.4.4 Structural Element in Aquaculture Geodesic cages . 32 2.4.5 Other Applications . 32 SepticTank............................ 32 Barriers.............................. 32 Marine Antifoulding . 33 Syntactic Foams . 33 Traffic signs . 34 2.5 LatticesintheIndustry ......................... 35 2.6 Sandwich Panels . 35 2.6.1 Core Types . 35 Corrugated . 35 2.6.2 Honeycombs . 36 2.6.3 Lattice Core . 36 2.7 Polymer Panels . 41 3 Experimental Program 42 3.1 Introduction................................ 42 3.2 Tensile Properties of r-HDPE . 42 3.2.1 background . 42 Stress ............................... 42 Strain ............................... 43 Modulus of Elasticity and Percent Elongation . 43 Poisson’s Ratio . 43 3.2.2 Specimen Preparation . 43 3.2.3 Equipment and Procedure . 44 3.2.4 Results .............................. 46 3.2.5 Analysis and Discussion . 50 3.3 FiniteElementAnalysis ......................... 51 3.3.1 background . 51 3.3.2 Procedure............................. 51 3 ElementOptimization ...................... 52 3.3.3 Results .............................. 54 3.3.4 Analysis and Discussion . 55 3.4 Manufacture . 56 procedure............................. 56 3.5 Summary of Results . 56 3.6 Discussion................................. 58 4 Conclusion 58 5 Future Direction 59 Bibliography 60 4 LIST OF TABLES 2.1 Thermoplastics and Recyclates - Properties . 16 2.2 Polymer 3-D printing Fillament Properties . 27 2.3 Mechanical Properties of Structural Lumber . 32 2.4 Commercially Available Sandwich Panel Cores - Mechanical Proper- ties (d3,E,P) ............................... 41 3.1 Dog-bone Specimen Dimensions . 45 3.2 Tensile Properties of r-HDPE - Results . 50 3.3 Stresses and Deflections of Structures . 55 5 LIST OF FIGURES 2.1 Application of Polymers per Industry (Bodzay and B´anhegyi) . 11 2.2 “Sea of Garbage, Dominican Republic”CNN (2018) . 12 2.3 Voluntary Plastic Container Coding System (Petsko) . 17 2.4 Polymer Life Cycle Muralisrinivasan (2019) . 19 2.5 Aggregate based, gantry 3-D printer Hager et al. (2016) . 21 2.6 Aggregate based, gantry 3-D printer End Product Hager et al. (2016) 21 2.7 Robots complete span of 3D-printed bridge for Amsterdam canal Block (2018) . 21 2.8 6 Bevis Marks Office Canopy, London, UK Ska (2017) . 22 2.9 Facade Panels Made from 3-D Printed Polymer Core Kothe et al. (2020) 22 2.10 3-D Printed Cabin by Dus Architects, Amsterdam Frearson (2016) . 23 2.11 Structure of Retaining Wall Alrubaie et al. (2020) . 33 2.12 Common Corrugated Cores, ? ...................... 36 2.13 Example of a Foldcore, Klett et al. (2017) . 37 2.14 Periodic Honeycombs with Various Cell Shapes, Zhang et al. (2015) 38 2.15 Hierarchical Progression of Hexagonal Honeycomb pattern, Mousanezhad et al. (2015) . 39 2.16 Common Lattice Core Sandwich Panels, Helou and Kara (2017) . 39 2.17 Comparative Analysis on 3d printer Auxetic Patterns., Naboni and Mirante (2016) . 40 3.1 Hot Press Set Up . 44 3.2 Dog-bone specimen dimensions [inches] - Not to scale . 44 3.3 GrippingDevice ............................. 45 3.4 Digital Image Correlation . 46 3.5 TensilePropertiesResults-Specimen1 . 47 3.6 TensilePropertiesResults-Specimen2 . 47 3.7 TensilePropertiesResults-Specimen3 . 48 3.8 TensilePropertiesResults-Specimen4 . 49 3.9 TensilePropertiesResults-Specimen5 . 49 3.10 Quadri-grid Pattern - Not to scale . 51 3.11 Panel Model Isometric View - Not to scale . 52 3.12 Von Misses Stresses on a Single-element per Thickness core . 52 6 3.13 Von Misses Stresses on a Two-element per Thickness core . 53 3.14 Von Misses Stresses on a Three-element per Thickness core . 53 3.15 Von Misses Stresses on a four-element per Thickness core . 53 3.16 Stress v. Element convergence . 54 3.17 Von Misses Stresses on a 1.6mm Wall Thickness Quadri-grid Honey- combCore................................. 54 3.18 Failure Regions of Honeycomb Core . 55 3.19 Filament Extrusion Set Up . 57 3.20 Recycled HDPE Filament - End Product . 57 7 ACKNOWLEDGEMENTS I would like to thank Dr. Lisa Spainhour for encouranging me to pursue this project and continues support. Dr. Qian Zhang and her immeasurable patience and guidance. Dr. Zhang’s students. Dr. Rebekah Sweat for helping manufacture the specimens. Dr. Jung for his infinte Finite Element Analysis knowledge. Steven Squillacote’s support through each and every project conducted at B127. The ma- chine shop guys Tom and Justin. Dr. Hoang. The Garnet and Gold Scholar Society and their IDEA Grant. The Honors in the Major Program. And Ms. Amy Haagard. Special Thanks to Mr. Sean Martin, my advisor, professor, thesis committee member, and mentor; and Dr. Raphael Kampmann for forming my foundation as an engineer. Dedicated to my mother. 8 ABSTRACT The surge of single-use plastics consumption has generated vast volumes of poly- mer waste, threatening water supplies, marine wildlife, and quality of life in low- income communities. Mechanical recycling is suggested as the most sustainable method to reduce polymer pollution because it may extend the life cycle for these products. This study aims to use 3D printing technology as a means to process recycled High-Density Polyethylene (HDPE) to produce honeycomb sandwich core panels. These structures benefit from the lattice design as it can provide greater strength with a relatively low weight nature, and is commonly used in the automo- tive, aerospace, and the architecture industry. Honeycomb sandwich core panel’s wide range of applications may benefit from the transition from directly sourced polymers to a recycled alternative. To test the hypothesis that recycled HDPE may be used as an alternative mate- rial for the fabrication of honeycomb sandwich core panels, the material properties were analyzed through a tensile strength test, geometries were modeled, verified and optimized under Finite Element Analysis, recycled HDPE filament was obtained in the laboratory to produce panels via 3D printing. CHAPTER 1: INTRODUCTION 1.1 Research Objective Excess polymer waste - particularly high density polyethylene (HDPE)- polluting water supplies and threatening ecology’s and communities may be redirected to the consumption cycle by taking shape as sandwich core panels. Sandwich core panels with a lattice core have a high strength to way ration and absorb energy well. These are commonly used for architectural cladding and other type of paneling in the naval and automotive industry. Since this material has been previously observed to have the potential to be reprocessed via 3D printing to manufacture small components and 3D printed honeycomb core panels have been developed and their properties studied, this research aims to cover the ground between this two discoveries. It identifies the potential of recycled HDPE to be used as cladding panel core manufactured by additive manufacturing technology. 9 1.2 Problem Statement By utilizing recycled plastic resin, there is a potential to reduce the polymer waste. This is done so by re-purposing the material with the aid of 3D printing technology to fabricate honeycomb sandwich core panels. If the strength