EFFECT OF FUSED DEPOSITION MODELING (FDM) 3D PRINTING ON PROPERTIES OF PRINTED POLYLACTIC ACID (PLA)

2.2.1.1 Stereolithography (SLA) …………………………………… 11

2.2.1.5 Selective laser melting (SLM) ……………………… 18

2.3 Studies Done So Far ………………………………………. 23

3.1 Materials ……………………………………………………… 24

3.2 Design And Simulation Of The Electrical Component ………24

3.3 Procedures For The Characterization Of The 3d Printed Components ………26

3.3.2 Determination of differential scanning calorimetry…………28

3.3.5 Determination of Density …………………………………………31

3.3.6     Determination of Thermal Gravimetric Analysis …………31

3.3.7   Determination of Fourier Transform Infrared Spectroscopy (FTIR) ………32

4.1 Hardness Test ………………………………….………… 34

4.2 Differential Scanning Calorimetry Test Result …….………… 35

4.3 Test For Tensile …………………………………………… 36 

4.4 Flexural Test Result ………………………………………… 37

4.5 Density Test Result ………………………………………38

4.6 Thermal Gravimetric Analysis (TGA) Result ……………………. 39

4.7 Fourier Transform Infrared Spectroscopy (Ftir) Result …… 40

4.8 Comparative Evaluation Result …………………….41

REFERENCES………………………………………………………. 44

 

 

Making three-dimensional solid objects from a digital file is a process known as 3D printing or additive manufacturing (AM). To build items of nearly any shape or geometry, successive layers of material are generated under computer control during methods used to synthesis three-dimensional objects (Cummins, 2010).Economy of scale is undermined by three-dimensional printing since it makes producing a single item as affordable as producing thousands of them.

There are now numerous 3D printing techniques accessible. The key variations between techniques are in the materials employed and how layers are deposited to make pieces. Selective laser melting (SLM), selective laser sintering (SLS), selective heat sintering (SHS), fused deposition modeling (FDM), and fused filament fabrication (FFF) are a few techniques that melt or soften the material to create the layers, while stereolithography is another that cures liquid materials (SLA).Each technique has benefits and cons of its own (The Economist, 2007). The most advanced 3D printers employ materials that are powdered. Then, using heat, typically from a laser, these powders are fused selectively. The strength of this technique is that practically any substance can be printed using it; in other words, if it can be reduced to powder, it can usually be printed.

Plastics are synthetic, non-biodegradable polymers that may be molded into completed goods. They are formed of long chain hydrocarbons and additives, and are predominantly sourced from fossil fuels (Rosato, 2001). These polymers are broken down into monomers like ethylene, propylene, vinyl, styrene, and benzene in the presence of an appropriate catalyst. Following chemical polymerization, these monomers are transformed into various types of plastics. Thermoplastics and Thermoset Plastics are two general categories for plastics. When thermoplastics are heated to produce items, the plastic will soften and melt once more when the finished objects are heated again. Among them are PET, HDPE, LDPE, PP, PVC, PS, and so forth. Thermoset plastics can be melted and moulded, but once they have hardened and taken on their desired shape, they remain that way and cannot be remelted like thermoplastics can. These materials include laminated and multilayer plastics, nylon, polycarbonate, melamine, bakelite, and others (Luo et al., 2009).Consequently, all thermoplastics are recyclable. Apart from their extensive use in household wares and food processing, plastics are also used for various engine parts and other machine components. The IC engine for instance has numerous plastic components, depending on its size and capacity. Some of these plastic components include armature fan, carburetor floater, engine block cooler, starter catcher, oil gauge, etc. 

Prior to the invention of 3D printing, injection molding was the most used manufacturing process for the production of plastic parts. However, issues such as the high cost of developing new molds, the presence of flaws (such as bubbles, unfilled sections, sink marks, etc.), the challenge of producing complex parts in one piece, and the inconsistent color of moulded parts led to its innovation.

PLA (Polylactic Acid) is a thermoplastic polymer made from renewable resources, more precisely from maize starch or sugar cane. This distinguishes the substance from other types of widely used plastics, which are produced by distilling and polymerizing non-renewable petroleum reserves. PLA is significantly more ecologically friendly than other thermoplastic polymers since it decomposes in three to six months as opposed to up to a thousand years for other thermoplastics.

The popularity of FDM 3D printing has brought PLA material into the public eye. Numerous colors and combinations of PLA filament are available, and new PLA-based products appear to be continually being introduced to the market. In addition to being used for 3D printing, PLA is also utilized to make disposable dinnerware, food packaging, and medical implants. The printing of plastic components for home appliances and other electrical appliances is one of the many uses for PLA filament.

Household electrical components like switches, wall sockets, multiple sockets, junction boxes, fan canopies, fan regulators, resistors, and capacitors can be 3D printed into different colours, shapes, or styles with an FDM 3D printer that uses PLA filament.

These days, daily production of plastics has led to an increase in the amount of plastics consumed globally, from 5 million tons in the 1950s to approximately 100 million tons now (PlasticsEurope, 2008; Andrady, 2003). In Nigeria, the weight of plastic garbage in municipal solid waste is 78%. (Abah, 2013). Plastic products are emerging for various use and then most if not all the containers are disposed after use causing environmental hazard especially as plastics are non-biodegradable.

Evaluation of an electrical component produced using PLA filament in 3D printing is the major goals of this work.The specific objective are:

The development of the 3D printed parts will encourage local manufacturing of components. This will reduce reliance on imported goods and promote development of indigenous technology. It will also encourage spare part production as spoilt or worn-out component can be easily reprinted. Also, parts can be easily modified to suit users’ personal needs.