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Applications of 3D FDMPrinting Material

SHENZHEN ESUN INDUSTRIAL CO.,LTD.


2

Content

1 1.FDM

2.PLA applications in 3D printing2

3.PLA modifications3

4.PVA applications in 3D printing4

5.PVA modifications5

6.ESUN 3D filament6


1.FDM

1.1 　 FDM technology

Esun

Filament spool

Extruder feeds and retracts the thermoplastic filament in precise amounts

Nozzle head heats the filament and turns the flow of the extruded material on and off

Stepper motors or servo motors, controlled by computer-aided manufacturing (CAM) software package, move the extruder and nozzle head in XYZ directions

Extruded material is laid down in a specific diameter on the bed


1.2 Why is the FDM3D sector growing so fast?

a. Open-source software reduces the technology threshold, manufacturers focus

on software optimization and merchants focus on structural design, thus

resulting in the involvement of more companies.

b. Market competition leads to decrease in 3D printer price.

Open-source

Pricing decreasedVariety in

printing materials

Cost effectiveness

Government funding

c. Increased variety in printing materials and

reasonable price attracts more attention.

d. Improvements in cost effectiveness allow

entry into individual consumer market.

e. Government funding supports 3D

printing in different countries.

1.FDM


1 Stability of filaments.

Easily crack Bubble

Block the extruder Inaccurate

diameter

Easily warp

　 1.3 Main problems of FDM3D material

1.FDM


　 1.3 Main problems of FDM3D material

1.FDM

Solution ~ Esun Filament

2 Limited functional materials for unlimited applications.

3 Material fluency compared with prototype speed.

4 Protection of environment and harm to the human body.

Economical pricing.5


GoodQuality

MaterialsVariety

Economical

EnvironmentallyFriendly

1.4 Standards for good FDM3D material

1.FDM


2.1 　 What's PLA ？

2.PLA applications in 3D printing

Poly(lactic acid) or polylactide (PLA) is a thermoplastic aliphatic polyester derived

from renewable resources. Due to its wide applications and environmentally friendly

nature, PLA is regarded as “one new industrial revolution in Polymers”.

PLA: Poly(lactic acid) or Polylactide

From renewable resources, such

as:• Corn starch (in the United States)• Tapioca roots, chips or starch

(mostly in Asia)• Sugarcane (in the rest of the

world)


2.2 Advantages of PLA

Bio-based Low shrink rateEnvironmentally

FriendlyBiocompatibility Transparent



http://news.typeamachines.com/

Name: Turbofan

Material: Esun PLA

Company: Type A Machi

nes

(USA)

Place: BAY MAKER FAIRE,

USA

Date: May, 2013.



Although PLA has good performance, it

still requires some modifications

before it can be effectively used for

3D printing.

1. Control Melt Flow Index.

2. Match crystallization and rapid

prototype technology.

3. Improve Impact Strength.

4. Improve temperature resistance.

5. Lifetime study on PLA.

6. Functional optimization.

2.3 Improvements of PLA for FDM3D printing



3.1 2D nucleation system — control PLA cooling speed 　

Item Unit PLA1001 1D structure

2D structure ABS

Solidification Time S 15 10 6 10

Tensile Yield Strength MPa 63 60 58 45

Table 1 Influence of crystallization on PLA solidification time

3.PLA modifications

PLA with poorcooling speed

PLA with goodcooling speed


Item Unit PLA

PLA: Ingredient (95:5)PLA: Ingredient

(90:10)

Ingredient1#

Ingredient2#

Ingredient3#

Ingredient4#

Ingredient 2#

Tensile Yield Strength

MPa 69.1 48.0 44.2 60.4 46.7 40.4

Elongation at Break

% 5.5 5.5 9.8 3.4 9.6 13.1

Flexural Strength MPa 61.1 65.0 53.9 53.7 53.3 49.4

Flexural Modulus MPa 2732 2768 1959 2830 2090 1678

Impact Strength KJ/m2 3.5 5.2 4.72 4.63 4.27 5.55

Table 2 Influence of STIS on PLA performance

3.2 Improvement of PLA Impact Strength

3.2.1 Single toughness improvement system(STIS) is limited to increase PLA toughness

3.PLA modifications


3.2.2 Influence of added ingredient on PLA performance

Figure 1 Influence of ingredienton PLA toughness

Figure 2 Influence of ingredient on PLA Tensile Yield Strength and Flexural Strength

0 5 10 154

5

6

7

8

Not

ched

Izod

Impa

ct (

kJ/m

2)

Toughening Agent Content %（）0 5 10 15

34

36

38

40

42

44

46

48

50

52

54

Ten

sile

Str

engt

h (M

Pa)

Toughening Agent Content %（）

18

20

22

24

26

28

30

32

34

Elo

ngat

ion

at B

reak

(%

)

3.PLA modifications


0 5 10 156

7

8

9

10

11

12

13

14

15

16

Not

ched

Izod

Impa

ct (

kJ/m

2)

Content (%)

0 5 10 1522

24

26

28

30

32

34

Content (%)

34

36

38

40

42

44

46

48

Ten

sile

Str

engt

h (M

Pa)

Fle

xura

l Str

engt

h (M

Pa)

3.PLA modifications

3.2.3 Influence of added ingredient on PLA Impact Strength

Figure 3 Influence of ingredienton PLA toughness

Figure 4 Influence of ingredient on PLA Tensile Yield Strength and Flexural Strength


Toughened PLA1# 2# 3# 4#0

1

2

3

4

5

6

7

4.72

6.35

4.32

5.71 5.54

Rigid Particle Types

Not

ched

Izod

Impa

ct (

kJ/m

2)

44.2 43.6

55.6

49.2 48.8

Toughened PLA 1# 2# 3# 4#0

10

20

30

40

50

60

70

Ten

sile

Str

engt

h (M

Pa)

Rigid Particle Types

AIM : Increase friction between clamping tooth, reduce relative shift and ensure stable material feeding

RESULT : Improve printing precision, size stability and warp resistance.

Figure 5 Influence of different rigid particle on PLA toughness

Figure 6 Influence of different rigid particle on Tensile Yield Strength

3.3 Presence of rigid particles help reduce the shift between material clamping tooth

3.PLA modifications

Presence of certain rigid particles


3.4 Improvement of PLA printing fluency

Just like writing needs smooth ink flow, 3D printing with FDM technology needs materials with good fluency. Material fluency cannot be too fast or too slow, it must match the printing speed. This ensures that printing precision is maintained and not degraded.

Material fluency is closely related to PLA melting speed, where Esun employs the following factors to ensure optimal PLA melting speed:

1. Adjust PLA molecular weight and distribution when synthesizing PLA.2. Further addition of molecular weight ingredient to control PLA melting

speed.3. Adopt composite lubrication system to control PLA melting speed.4. Adopt sheet structure and fiber material to adjust PLA melting speed.

3.PLA modifications


3.5 　 PLA Lifetime adjustment

1. Method adopted: Generation of various compounds to adjust PLA lifetime

2. Current compounds tested: PLA/PHA, PLA/PCL, PLA/PBS, PLA/PPC,

PLA/PBC, PLA/PEG by melting mix, and printing body organs via FDM

technology for medical application.

3.PLA modifications


4.1 　 What's PVA ？

　　 PVA (polyvinyl alcohol) is a water-soluble synthetic polymer. Two

methods are usually used to obtain PVA.

1. Oil Method:

Ethene Vinyl acetate Polyvinyl alcohol

2. Carbide method:

Ethyne Vinyl acetate Polyvinyl alcohol

4.PVA applications in 3D printing


4.2 Advantages of PVA

Low shrink rateEnvironmentally

FriendlyGood adhesion

Soluble in water under normal temp.



4.3 Applications of PVA

Remove supporting structures due to

PVA’s water soluble property.

Co-printing with many materials possible

due to PVA’s good adhesive property.

Safe, environmentally friendly and low-

carbon characteristic.

PVA's dissolving process



4.4 Defects of pure PVA in FDM 3D printing

Low fluency for printing

2High melting temperature,

hard to plasticize

1Cannot print continuously

3



5.1 Improvement on plasticity and printing temperature

Figure 7 Influence of plasticizer on PVA plasticity and printing

5.PVA modifications

Mel

t T

empe

ratu

re (

°C)

Plasticizer Content (phr)


Figure 8 Influence of ingredient on adjustment of PVA melting speed

5.2 Improvement on printing fluency

5.PVA modifications


1. Increasing friction between clamping

teeth and pressure bearing capacity

— to ensure stable material feeding.

2. Reducing the expansion coefficient and

shrink ratio of filament

— to improve dimensional stability and

anti-warp capacity, which improves

printing precision.

5.3 Improvement on continuous printing of PVA

5.PVA modifications

Esun

More friction

Less shrinkage


6.ESUN 3D Filament

6.1 　 About ESUNEstablished in 2002 and located in Shenzhen Special Economic Zone, Shenzhen Esun Industrial Co., Ltd. is a high-tech enterprise specializing in researching, developing, producing and operating degradable polymer materials, such as PLA and Polymorph. ESUN owns three different R&D centers, which specialize in material syntheses, modification and application.

Since 2007, ESUN has began to research 3D printing materials. So far, ESUN has successfully developed PLA, ABS, PVA (water soluble support), conductive, HIPS, PA, Polymorph, and PC filaments etc. With the exclusive professional formulas and professional production lines, ESUN 3D filament is characterized by absolutely round shape, accurate diameter, high tenacity, uniform color shade and stable melting point.


6.ESUN 3D Filament


Products: PLA, ABS, PVA, PC, HIPS, conductive and nylon etc.

Diameter: 3.0mm, 1.75mm

Spool N.W: 0.5kg, 1kg

Color: 19 colors

6.ESUN 3D Filament


6.ESUN 3D Filament


6.ESUN 3D Filament

Wood filament


Makerbot Up

Cubify RepRap

Suitable for Makerbot,Up,RepRap,Cubify and any other FDM 3D printers !

6.ESUN 3D Filament

Esun 3D filaments are compatible with major 3D printer brands, such as:


R&D on PLA

1. PLA filament2. ABS filament

R&D on 12 colors of ABS and PLA filament

1. Soft PLA filament2. Nylon filament3. Conductive filament4. PC filament

1. FDM special filament2. SLA material3. SLS material

Powder and other material for various 3D printers

1. PVA filament2. HIPS filament3. Fluorescence filament

2002

2007

2011

2012 2014

After 20142013

6.ESUN 3D Filament


SGSFDA DIN

6.ESUN 3D Filament


eSun’s expo & speech in 2014


THANKS ！Welcome to our booth 101

SHENZHEN ESUN INDUSTRIAL CO.,LTD.

[email protected]+86 755 26031978

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