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Additive Manufacturing with Polymer Composites for Sustainable Applications / BENJAMIN CUMMINGS

Swansea University Author: BENJAMIN CUMMINGS

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DOI (Published version): 10.23889/SUThesis.66887

Abstract

The evolving field of digital manufacturing includes additive manufacturing (AM) that builds computationally sliced parts layer-by-layer. AM popularity continues to grow partially due to its potential to accelerate the transition to a circular economy. This thesis aims to help mitigate waste product...

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Published: Swansea University, Wales, UK 2024
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Davies, M., & Charles, R.
URI: https://cronfa.swan.ac.uk/Record/cronfa66887
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spelling v2 66887 2024-06-24 Additive Manufacturing with Polymer Composites for Sustainable Applications cab384b4e1264165640ab1bedb15256b BENJAMIN CUMMINGS BENJAMIN CUMMINGS true false 2024-06-24 The evolving field of digital manufacturing includes additive manufacturing (AM) that builds computationally sliced parts layer-by-layer. AM popularity continues to grow partially due to its potential to accelerate the transition to a circular economy. This thesis aims to help mitigate waste products using four novel polymer composites designed and developed for use with either fused filament fabrication (FFF) or direct writing (DW). These polymer composites are: 1) Simulation verified and AM printed triply periodic minimal surface lattice structures embedded with heat storage materials. Diamond TPMS geometry bentonite/CaCl2 embedded prints of low packed configuration adsorb <19.1% total dry cylinder weight and reaches 38.3 °C bulk temperature when stacked in an open reactor. 2) Microporous zeolite composites for carbon capture strengthened using novel sacrificial polymer content. Zeolite 13X composite UCS increases from 4.92 (±1.22) to 7.75 (±0.75) MPa with the addition of 4 wt% CSR providing a composite BET surface area of 148 (±17)cm3/g. 3) Printer filaments made from rPP hospital blue wrap previously destined for landfill or incineration. MFI is reduced from 103 (±8) to 45 (±2)g/10mins when increasing SEBS content from 9.1 wt% to 20 wt%. The reduced MFI facilitates filament extrusion and subsequent printing of tensile and impact samples with tensile strength and impact energy absorption up to 22.5 (±1.2) MPa and 14 (±0.8) kJ/m2, respectively. 4) Epoxy matrix composites for;i) weight saving applications and ii) bone-like composite manufacture to improve surgical training and patient communication. Drilled compression strength of bone-like epoxy matrix composites encompassed those of drilled bone compression strength, ranging between a 5 wt% gypsum and 20 wt%hydroxyapatite composite of 2.7 (±0.3) MPa to a 1 wt% PE, 40 wt% GY and 5wt% HA composite of 6.5 (±0.5) MPa. This thesis contributes a furthered understanding of low-cost desktop AM as utilised for local acquisition of custom engineering products that necessitates minimal lead times and transportation. E-Thesis Swansea University, Wales, UK Additive Manufacturing, 3D printing, Materials Science, Polymers, Polymer Composites, Machining, Recycling, Sustainability, Circular Economy, Resource Efficiency, Energy Storage, Carbon Capture, Medical Plastics, CAD, Rubber Toughing, Elastomers, Ceramics. 7 6 2024 2024-06-07 10.23889/SUThesis.66887 A selection of content is redacted or is partially redacted from this thesis to protect sensitive and personal information. COLLEGE NANME COLLEGE CODE Swansea University Davies, M., & Charles, R. Doctoral EngD Materials and Manufacturing Academy (M2A)/ EPSRC doctoral training grant, European Social Fund Materials and Manufacturing Academy (M2A)/ EPSRC doctoral training grant, European Social Fund 2024-06-24T16:31:05.0935948 2024-06-24T16:18:11.2259934 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering BENJAMIN CUMMINGS 1 66887__30742__27841153d88e4f9e98b520a6ef3aafdc.pdf 2023_Cummings_B.final.66887.pdf 2024-06-24T16:22:57.4052540 Output 7060982 application/pdf E-Thesis – open access true Copyright: The Author, Benjamin Cummings, 2023 true eng
title Additive Manufacturing with Polymer Composites for Sustainable Applications
spellingShingle Additive Manufacturing with Polymer Composites for Sustainable Applications
BENJAMIN CUMMINGS
title_short Additive Manufacturing with Polymer Composites for Sustainable Applications
title_full Additive Manufacturing with Polymer Composites for Sustainable Applications
title_fullStr Additive Manufacturing with Polymer Composites for Sustainable Applications
title_full_unstemmed Additive Manufacturing with Polymer Composites for Sustainable Applications
title_sort Additive Manufacturing with Polymer Composites for Sustainable Applications
author_id_str_mv cab384b4e1264165640ab1bedb15256b
author_id_fullname_str_mv cab384b4e1264165640ab1bedb15256b_***_BENJAMIN CUMMINGS
author BENJAMIN CUMMINGS
author2 BENJAMIN CUMMINGS
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publishDate 2024
institution Swansea University
doi_str_mv 10.23889/SUThesis.66887
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
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description The evolving field of digital manufacturing includes additive manufacturing (AM) that builds computationally sliced parts layer-by-layer. AM popularity continues to grow partially due to its potential to accelerate the transition to a circular economy. This thesis aims to help mitigate waste products using four novel polymer composites designed and developed for use with either fused filament fabrication (FFF) or direct writing (DW). These polymer composites are: 1) Simulation verified and AM printed triply periodic minimal surface lattice structures embedded with heat storage materials. Diamond TPMS geometry bentonite/CaCl2 embedded prints of low packed configuration adsorb <19.1% total dry cylinder weight and reaches 38.3 °C bulk temperature when stacked in an open reactor. 2) Microporous zeolite composites for carbon capture strengthened using novel sacrificial polymer content. Zeolite 13X composite UCS increases from 4.92 (±1.22) to 7.75 (±0.75) MPa with the addition of 4 wt% CSR providing a composite BET surface area of 148 (±17)cm3/g. 3) Printer filaments made from rPP hospital blue wrap previously destined for landfill or incineration. MFI is reduced from 103 (±8) to 45 (±2)g/10mins when increasing SEBS content from 9.1 wt% to 20 wt%. The reduced MFI facilitates filament extrusion and subsequent printing of tensile and impact samples with tensile strength and impact energy absorption up to 22.5 (±1.2) MPa and 14 (±0.8) kJ/m2, respectively. 4) Epoxy matrix composites for;i) weight saving applications and ii) bone-like composite manufacture to improve surgical training and patient communication. Drilled compression strength of bone-like epoxy matrix composites encompassed those of drilled bone compression strength, ranging between a 5 wt% gypsum and 20 wt%hydroxyapatite composite of 2.7 (±0.3) MPa to a 1 wt% PE, 40 wt% GY and 5wt% HA composite of 6.5 (±0.5) MPa. This thesis contributes a furthered understanding of low-cost desktop AM as utilised for local acquisition of custom engineering products that necessitates minimal lead times and transportation.
published_date 2024-06-07T16:31:03Z
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score 11.012678

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