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The effect of melt flow rate and print speed on the density and microcellular structure of 3D printed polylactic acid foams

Kalia, Karun ; Amirkhizi, Alireza ; Ameli, Amir Nobukawa, Shogo ; Kajiwara, Toshihisa ; Ito, Hiroshi ; Kihara, Shin-ichi

AIP Conference Proceedings, 2023, Vol.2884 (1) [Periódico revisado por pares]

Melville: American Institute of Physics

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  • Título:
    The effect of melt flow rate and print speed on the density and microcellular structure of 3D printed polylactic acid foams
  • Autor: Kalia, Karun ; Amirkhizi, Alireza ; Ameli, Amir
  • Nobukawa, Shogo ; Kajiwara, Toshihisa ; Ito, Hiroshi ; Kihara, Shin-ichi
  • Assuntos: Density ; Filaments ; Flow velocity ; Foams ; Fused deposition modeling ; Microspheres ; Microstructure ; Morphology ; Polylactic acid ; Three dimensional printing
  • É parte de: AIP Conference Proceedings, 2023, Vol.2884 (1)
  • Descrição: The purpose of this study was to investigate the effect of flow rate and print speed on the density and microcellular structure of polylactic acid (PLA) foams printed via fused filament fabrication (FFF) process. Unexpanded filaments loaded with thermally expandable microspheres (TEMs), at 2.5 wt.%, were prepared as a feedstock for in-situ foam printing process. Foam samples were printed at three different nozzle-exit flow rate levels (i.e., 55, 85 and 100%) and at three print speed levels (i.e., 5, 25 and 125 mm.s−1) and their density, surface, and internal cellular microstructure were studied. It was found that both process factors have significant effects on the part density, cellular morphology, and mesostructure. With a decrease in the flow rate from 100 to 55%, the part density proportionally decreased from 0.79 to 0.56 g.cm−3. Whereas the part density was relatively high (0.95 g.cm−3) at the high print speed of 125 mm.s−1, low densities (0.67-0.71 g.cm−3) were obtainable at low print speed range of 5-25 mm.s−1. Moreover, the highest cell density was obtained at the medium level of both flow rate and print speed. The correlation between the process factors (flow rate and print speed) and properties (density and cellular microstructure) were explained in terms of the melt residence time inside the heater block as well as the melt volumetric throughput. Overall, at the medium levels of flow rate and print speed, the printed foams provided the lowest density and highest uniformity in the morphology.
  • Editor: Melville: American Institute of Physics
  • Idioma: Inglês
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