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. 2021 Jul 26;13(15):2455.
doi: 10.3390/polym13152455.

Polymer Composites Based on Polycarbonate (PC) Applied to Additive Manufacturing Using Melted and Extruded Manufacturing (MEM) Technology

Katarzyna Bulanda  1 , Mariusz Oleksy  1 , Rafał Oliwa  1 , Grzegorz Budzik  2 , Łukasz Przeszłowski  2 , Jacek Fal  3 , Teofil Jesionowski  4
Affiliations

Polymer Composites Based on Polycarbonate (PC) Applied to Additive Manufacturing Using Melted and Extruded Manufacturing (MEM) Technology

Katarzyna Bulanda et al. Polymers (Basel). .

Abstract

As part of the present work, polymer composites used in 3D printing technology, especially in Melted and Extruded Manufacturing (MEM) technology, were obtained. The influence of modified fillers such as alumina modified silica, quaternary ammonium bentonite, lignin/silicon dioxide hybrid filler and unmodified multiwalled carbon nanotubes on the properties of polycarbonate (PC) composites was investigated. In the first part of the work, the polymer and its composites containing 0.5-3 wt.% filler were used to obtain a filament using the proprietary technological line. The moldings for testing functional properties were obtained with the use of 3D printing and injection molding techniques. In the next part of the work, the rheological properties-mass flow rate (MFR) and mechanical properties-Rockwell hardness, Charpy impact strength and static tensile strength with Young's modulus were examined. The structure of the obtained composites was also described and determined using scanning electron microscopy (SEM). The porosity, roughness and dimensional stability of samples obtained by 3D printing were also determined. On the other hand, the physicochemical properties were presented on the basis of the research results using thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), wide angle X-ray scattering analysis (WAXS) and Fourier Transform infrared spectroscopy (FT-IR). Additionally, the electrical conductivity of the obtained composites was investigated. On the basis of the obtained results, it was found that both the amount and the type of filler significantly affected the functional properties of the composites tested in the study.

Keywords: 3D printing; MEM; additive manufacturing; polycarbonate; thermoplastic polymer.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
Proprietary technological line for obtaining filaments.
Figure 2
Figure 2
The dimensions of the samples— a bar and a paddle, respectively.
Figure 3
Figure 3
Samples obtained by the method of: (a) 3D printing; (b) injection molding.
Figure 4
Figure 4
Summary of the obtained mass flow rate (MFR) results. PC—polycarbonate, S—modified silica, B—modified bentonite, L—lignin/SiO2 hybrid, CN—multiwalled carbon nanotubes.
Figure 5
Figure 5
Hardness test results (a) samples obtained by 3D printing, (b) samples obtained by injection molding.
Figure 6
Figure 6
SEM test results for the composition: (a) PC, (b) PC/3%S, (c) PC/3%B, (d) PC/3%L, (e) PC/1.5%L/1.5%B, (f) PC/0.5%CN, (g) PC/0.5%CN/1.5%S, (h) PC/0.5%CN/1.5%B, (i) PC/0.5%CN/1.5%L.
Figure 6
Figure 6
SEM test results for the composition: (a) PC, (b) PC/3%S, (c) PC/3%B, (d) PC/3%L, (e) PC/1.5%L/1.5%B, (f) PC/0.5%CN, (g) PC/0.5%CN/1.5%S, (h) PC/0.5%CN/1.5%B, (i) PC/0.5%CN/1.5%L.
Figure 7
Figure 7
Impact test results of (a) samples obtained by 3D printing, (b) samples obtained by injection molding.
Figure 8
Figure 8
Results of static tensile strength tests: stress at break (a) samples obtained by 3D printing, (b) samples obtained by injection molding, Young’s modulus (c) samples obtained by 3D printing, (d) samples obtained by injection molding, strain at break (e) samples obtained by 3D printing, (f) samples obtained by injection molding.
Figure 8
Figure 8
Results of static tensile strength tests: stress at break (a) samples obtained by 3D printing, (b) samples obtained by injection molding, Young’s modulus (c) samples obtained by 3D printing, (d) samples obtained by injection molding, strain at break (e) samples obtained by 3D printing, (f) samples obtained by injection molding.
Figure 9
Figure 9
PC/3%B microstructure: (a) microscope image, (b) image from porosity calculation program.
Figure 10
Figure 10
Thermograms of DTG.
Figure 11
Figure 11
First heating (a) and second heating (b) curves for the composites.
Figure 11
Figure 11
First heating (a) and second heating (b) curves for the composites.
Figure 12
Figure 12
WAXS patterns: (a) fillers; (b) PC and composites with the addition of modified S, B, L and CN fillers; (c) PC and composites with the addition of modified fillers S, B and L.
Figure 12
Figure 12
WAXS patterns: (a) fillers; (b) PC and composites with the addition of modified S, B, L and CN fillers; (c) PC and composites with the addition of modified fillers S, B and L.
Figure 13
Figure 13
Two-dimensional WAXS images: (a) PC; (b) PC/3%S; (c) PC/3%B; (d) PC/3%L; (e) PC/1.5%L/1.5%B; (f) PC/0.5%CN; (g) PC/0.5%CN/1.5%S; (h) PC/0.5%CN/1.5%B; (i) PC/0.5%CN/1.5%L; (j) S; (k) B; (l) L; (m) CN.
Figure 13
Figure 13
Two-dimensional WAXS images: (a) PC; (b) PC/3%S; (c) PC/3%B; (d) PC/3%L; (e) PC/1.5%L/1.5%B; (f) PC/0.5%CN; (g) PC/0.5%CN/1.5%S; (h) PC/0.5%CN/1.5%B; (i) PC/0.5%CN/1.5%L; (j) S; (k) B; (l) L; (m) CN.
Figure 14
Figure 14
FT-IR spectra recorded for the composition.
Figure 15
Figure 15
Electrical conductivity of the obtained composites.
See this image and copyright information in PMC

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