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Material development of non-reinforced and fiber-reinforced polymers for extrusion deposition 3D printing

The aim of this project is to investigate the requirements for materials and semi-finished products which are processed in extrusion deposition 3D printing processes. By gainig a better understanding of the process, a knowledge base should be created, to increase the variety of materials that are available for the extrusion deposition 3D printing processes. This project is conducted in cooperation with the company ALBIS PLASTIC GmbH and under the NRW Fortschrittskolleg “Lightweight – Efficient – Mobile” (FK LEM). As one of the six Forschrittkollegs established in 2014, the FK LEM is sponsored by the Ministry of Innovation, Science and Research of the State of North Rhine-Westphalia.

The to be examined extrusion deposition 3D printing processes are among the most commonly used additive manufacturing processes. For example, they are known by the terms Fused Deposition Modeling (FDM), Fused Layer Modeling (FLM) or Fused Filament Fabrication (FFF). In this methods, the semi-finished product, commonly a wire of a thermoplastic polymer, is melted and forced through a nozzle. The continuous positioning of this nozzle allows the polymer to weld together strand by strand and layer by layer to produce a component. The energy for the welding of the individual strands largely results from the thermal energy of the deposited polymer melt.

It is desirable to be able to use a similarly wide variety of materials with this method as, for example, in the profile extrusion or injection molding technology. Therefore, the processing suitability of any thermoplastic polymer should be estimated based on the material properties or characteristics in advance of the processing. This is currently not possible because, in contrast to conventional methods, only little is known about the required and desirable material properties for the processing of extrusion deposition 3D printing processes.

In this project, the requirements for materials, semi-finished products and processes are investigated by the means of example polymer types. For this purpose, different types of polyamide 6 (PA6) will be systematically extruded into monofilaments and then a supervised processing in an extrusion deposition 3D printing machine will follow. By varying important material properties, such as the viscosity, the material properties should be connected to the processing properties. In addition, the processing of fiber-reinforced materials should be examined. It is assumed that the procedural generation of components by juxtaposing many strands enables the influence of fiber orientation.

Further project information
Project statusIn progress
Project duration 36 months
Funding The Ministry of Innovation, Science and Research of the State of North Rhine-Westphalia
Project managerProf. Dr.-Ing. Volker Schöppner (KTP)
Project coordinatorDr. Dörte Scharnowski (ALBIS PLASTIC GmbH)
Scientific staffChristian Schumacher (DMRC)
Involved chairsKunststofftechnik Paderborn (KTP)
+49 5251 60-3057
+49 5251 60-3821

M.Sc. Christian Schumacher


Fused Deposition Modeling

Christian Schumacher
+49 5251 60-5469
+49 5251 60-5409

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