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pps proceeding
Symposium: S18 - Special Symposium: Additive Manufacturing for Plastic Components
Oral Presentation
 
 

Relationships between ABS Copolymer Composition, Filament Quality and 3D Printing Performance in FDM Process

Baumann Stéphanie (1)*, Eisenträger Frank (2), Niessner Norbert (3), Meiners Josef (2), Schmidt Hans-Werner (4), Bastian Martin (1)

(1) SKZ - German Plastics Center - Würzburg - Germany, (2) Styrolution Europe GmbH - Cologne - Germany, (3) Styrolution Group GmbH - Frankfurt - Germany, (4) University of Bayreuth, Macromolecular Chemistry I - Bayreuth - Germany

Fused Deposition Modeling (FDM) is a well-known additive manufacturing process used for producing household objects as well as industrial prototypes and end-use parts directly from three dimensional computer aided design (CAD) models. The FDM technology generates 3D printed products by feeding a filament of thermoplastic material through a heated extrusion nozzle which deposits material strands onto a platform from the bottom up, layer-by-layer. The most widely used FDM material offering a good heat, moisture and chemical resistance is acrylonitrile butadiene styrene (ABS). Besides process parameters, such as extrusion and building chamber temperatures, building orientation, filling raster angle and air gap, the material characteristics also play a significant role in the performance of the 3D printed parts, but they have still not been sufficiently investigated. Over the course of our research, we studied the relationships between the ABS copolymer composition, the filament quality and the 3D printing performance in the FDM process. A series of ABS materials made up of diverse styrene acrylonitrile (SAN) copolymers and different butadiene (BR) amounts were prepared using compounding process by blending diverse SAN matrices with different amounts of SAN-grafted butadiene rubber (BR-g-SAN). Filaments from the ABS materials were fabricated using extrusion process, analyzed with regard to their diameter consistency and roundness and tested on a FDM 3D printing machine. For the assessment of the 3D printing performance, appropriate test specimens were printed and characterized. The evaluated properties included dimensional accuracy, overhang and bridge building ability as well as tensile characteristics like tensile modulus, tensile strength and elongation at break. The results show a correlation between the butadiene amount and the evaluated properties. The findings form the basis for further FDM material qualification and development.