MATERIALS | 3D PRINTING IMAGE: INSIGHT POLYMERS


Low gloss Insight Polymers & Compounding has launched two new low gloss masterbatches for PLA and PETG fused deposition modelling (FDM) systems. Insight LAA112 PLA and TCA112 PETG master-


batches reduce gloss and improve the aesthetic profiles of 3D printed objects with minimal impact on mechanical properties. “Low gloss materials reduce or eliminate the


Above: Two low-gloss masterbatches for FDM systems improve the aesthetic appearance of 3D printed products


It will allow end-of-life products to be recycled within an almost fully closed-loop system, they said. Photopolymer resins, which cure on exposure to


light, are typically used to make 3D printed parts. However, these materials – usually epoxies or acrylics – come mainly from petrochemicals. More sustainable resins are still difficult to recycle because they rely on irreversible bonds being created when the resin hardens. To break the bonds, extra chemicals have to be added at each stage, say the researchers. The Birmingham-led team has managed to


produce a photopolymer resin that can be printed at high resolution – then broken back down to its constituent parts, recycled and reprinted – with a small amount of photo initiator to maintain its curable properties. “Our approach is an important step away from


relying on 3D-printable resins made from petro- chemicals, which cannot be efficiently recycled,” said Andrew Dove, professor of chemistry at the university, who led the research. “While we still have improvements to make to the properties of the new resin, this research opens up exciting new avenues for development.” The feedstock for the process is lipoic acid, a


naturally occurring fatty acid molecule that is commonly sold as a dietary supplement. The team combined two monomers from the lipoic acid, to make a resin that could be recycled either back into the monomers, or right back to the original molecule.


In the study, the researchers completed two


‘recycles’, but anticipate that more would be possible.


While the material is currently more flexible than might be commonly used in industry, future applications could include automotive parts and medical and dental components. The university has filed a patent application covering the resin and its use in 3D printing.


38 INJECTION WORLD | July/August 2024


glossy, layered look of parts, improving aesthetics,” said AJ Pasquale, director of operations at Insight Polymers. “Conventional 3D printed parts with high gloss accentuate layer-lines and other defects – suggesting lack of durability, or prototype and single-use only applications.” The masterbatch is typically used at a level of


10-30%. “Additive manufacturing is now used to produce finished goods rather than prototypes for injection moulds,” said Pasquale. “We facilitate that trend by producing masterbatches that make end-products more aesthetically acceptable to the customer.” Insight developed the PLA and PETG master-


batches because these are the resins of most interest – though other resins, including nylons, can be made available upon request. And, while these low gloss masterbatches are designed for FDM, Insight can design materials for SLS (selective laser sintering) and BAAM (Big Area Additive Manufac- turing), according to customer interest.


Shot weight A biodegradable PHA filament has been used with rapid prototyping in the design of commercial shotgun wads. In sports such as clay pigeon shooting, the wad is a critical component of a shotgun shell – which separates the shot from the powder charge. It is expelled when fired and is often not collected. The partnership between Beyond Plastic and US- based Eco Shot will help to address growing concerns of plastic waste affecting wildlife. Traditional wads are made from polyethylene or


polypropylene. These contribute to plastic pollu- tion – and can be ingested by wildlife. The biode- gradable PHA version offers a solution to these concerns. PHA, which is derived from renewable resources such as plant oils, decomposes naturally, minimising environmental harm and reducing the accumulation of plastic waste. “When the wads are discharged, they won’t harm the environment, naturally biodegrading into the soil in months – as opposed to traditional plastic that lasts for hundreds of years,” says Fred Pinczuk, chief technology officer of Beyond Plastic.


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