applications feature | 3D printing PLA developments
PLA polymer major NatureWorks says that this year it is making an aggressive move to support the 3D printing market, with the launch of a new series of Ingeo 3D grades. Since late 2013, it has been engaging with 3D fi lament suppliers, printer manufacturers and operators to understand the needs of the various players along the supply chain through to the fi nal consumer.
Dan Sawyer, global leader, new business segment, at NatureWorks, says that there are numerous reasons why the 3D printing world, particularly the desktop user market, has evolved around the use of PLA. “Low polymer thermal shrinkage means high resolution printing – and such high accuracy is critical for complex parts,” he says. “Strong polymer fusing performance means it’s easy to use and performs well on most prints. Relatively low melt point means safe lower temperature printing and very low emissions mean no unpleasant odours when printing.”
NatureWorks test results show its second-generation Ingeo 3D formulation gives heat resistance (HDT) and impact (notched izod) values on par with published values typical of injection moulded ABS
on the materials side. For example, the Czech profi le extrusion company Parzlich, which produces various 3D printing fi laments under the Fillamentum brand, has been working with Tomas Bata University in Zlin on conductive materials incorporating multiwall carbon nanotubes (MWCNT). Of the various types of additive that can be used to
impart conductivity (carbon black, graphene, nanotubes, metal powder, etc.), each has its own advantages and disadvantages, says Parzlich managing director Josef Dolecek. The most effective is MWCNT, although this does come at a price, which he puts at US$400-500/kg. “In order to get a conductive compound, you need to add at least 15% wt of CNT, so just the price of CNT for 1 kg of extra-conductive polymer is about $75,” he says. On top of this, there are also extra costs involved in prepar- ing the CNTs for blending with the polymer matrix for masterbatch preparation. So the application does need to be very special to merit the use of such compounds. Dolecek says the partners have tested several
materials in order to compare processability, conductiv- ity, mechanical properties and printability on 3D printer. They are currently fi nalizing formulation of pre-produc- tion compounds, which will then undergo further testing at potential customers.
46 COMPOUNDING WORLD | May 2015
Sawyer says there are now hundreds of producers rushing to supply this growing market with PLA fi lament. “An upside is a range of competitive suppliers and supply options around the world. An inevitable downside to this “gold rush,” however, is a tremendous range in the quality and properties of the 3D fi lament that’s being produced,” he says.
“We believe this may be in part because some less experienced converters are choosing PLA chemistries and properties not well suited to the needs of the 3D printing market. That’s not helpful to the downstream market. But what we also see happening is that compounders large and small are formulating to provide further fi lament properties and options. And that’s the sort of innovation NatureWorks wants to support and amplify.”
NatureWorks is now launching an Ingeo 3D printing
platform that will include an entirely new series of grades designed specifi cally for the 3D printing market. It is also offering technical support for targeted 3D partners, including fi lament processing guides, technical data sheets, and technical service resources. In addition, it is establishing an in-house print lab that will enable it to rapidly prototype new 3D formulations. “NatureWorks now has multiple 3D machines set up in-house to assess fi rst-hand the performance of fi lament made from its developmental formulations, both in the printer, and in the fi nal fi nished part,” says Sawyer. “This capability will help cut the time-to-mar- ket for new grades.” The company is already offering a new base grade designed to provide a good overall balance of process- ability in fi lament production, fi lament consistency, and print quality. “It is designed to provide optimum
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