Design of a hybrid high-throughput fused deposition modeling system for circular economy applications

Tanay Kuclourya; Roberto Monroy; Miguel Castillo; David Baca; Rafiq Ahmad; Tanay Kuclourya; Roberto Monroy; Miguel Castillo; David Baca; Rafiq Ahmad

doi:10.3934/ctr.2022010

Clean Technologies and Recycling

2022, Volume 2, Issue 4: 170-198. doi: 10.3934/ctr.2022010

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Research article Special Issues

Design of a hybrid high-throughput fused deposition modeling system for circular economy applications

Laboratory of Intelligent Manufacturing, Design and Automation (LIMDA), Department of Mechanical Engineering, University of Alberta, 9211 116 Street, Edmonton, AB T6G 1H9, Canada

Received: 06 August 2022 Accepted: 30 September 2022 Published: 13 October 2022

In recent years, recycling of plastics has opened several doors of advancements in the field of additive manufacturing (AM). The process of fused deposition modelling (FDM) has already been utilized for reprocessing waste plastics into filaments and finally printing them into useful products. Yet another concept of extrusion additive manufacturing (EAM) is gaining lots of attention. In this work, a screw assisted system based on EAM is designed and installed alongside a pre-existing FDM system. This system is referred to as the direct FDM (DFDM) system throughout this work. The DFDM system used operates with a 1.75 mm nozzle and has the ability of giving a high throughput. The focus of this work is to use this hybrid system (combination of FDM and DFDM systems) to print both virgin as well as recycled plastics. The scope of this work is to use one technology (either FDM or DFDM) at a time and to use both simultaneously for multi-material printing in future. After several trials of printing and setting up some printing parameters, the proposed system has been able to print with virgin as well as recycled PLA.
- AM,
- FDM,
- EAM,
- DFDM,
- throughput,
- hybrid,
- PLA
Citation: Tanay Kuclourya, Roberto Monroy, Miguel Castillo, David Baca, Rafiq Ahmad. Design of a hybrid high-throughput fused deposition modeling system for circular economy applications[J]. Clean Technologies and Recycling, 2022, 2(4): 170-198. doi: 10.3934/ctr.2022010

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Abstract

In recent years, recycling of plastics has opened several doors of advancements in the field of additive manufacturing (AM). The process of fused deposition modelling (FDM) has already been utilized for reprocessing waste plastics into filaments and finally printing them into useful products. Yet another concept of extrusion additive manufacturing (EAM) is gaining lots of attention. In this work, a screw assisted system based on EAM is designed and installed alongside a pre-existing FDM system. This system is referred to as the direct FDM (DFDM) system throughout this work. The DFDM system used operates with a 1.75 mm nozzle and has the ability of giving a high throughput. The focus of this work is to use this hybrid system (combination of FDM and DFDM systems) to print both virgin as well as recycled plastics. The scope of this work is to use one technology (either FDM or DFDM) at a time and to use both simultaneously for multi-material printing in future. After several trials of printing and setting up some printing parameters, the proposed system has been able to print with virgin as well as recycled PLA.

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