Project 2.4: Thermoplastic Composites by 3D Printing and Automated Manufacturing to Extend the Life of Transportation Facilities

Project Abstract:

Recent advances in large-scale 3D printing and thermoplastic composite materials with bio-based fillers and reinforcements have great potential for expanding the possibilities of making forms for precast concrete structures. The 3D printing technology for making molds, forms, and tooling for precast concrete is expected to reduce labor cost. 3D printed molds allow design optimization of precast concrete parts since the additive manufacturing cost is only a function of thermoplastic material weight and is independent of part complexity. Additionally, 3D printed molds become an asset, since thermoplastic composite materials can be reprocessed. However, the performance and durability of such molds needs to be evaluated to ensure optimal performance with repeated casting and demolding operations. The work of this research project will evaluate the mechanical performance of 3D printed molds after repeated use during casting of concrete and removal of the cured concrete part. Additionally, the work conducted by the research team will evaluate the durability and dimensional tolerance of bio-based 3D printed forms.

The objectives of the project are to:
a. Identify potential applications for large-scale 3D printing of forms and tooling for precast concrete parts in transportation using bio-based fillers and reinforcements and cost-effective thermoplastic materials.
b. Determine the feasibility of making 3D printed forms for optimized precast concrete parts and elements to extend durability and reduce cost.
c. Document the demonstration of large-scale 3D printing of precast concrete forms and assess the quality of the parts. Establish material and manufacturing specifications to assist the DOTs implementation of this technology in transportation applications.
d. Investigate the potential for recycling the 3D printed forms and tooling and reusing/reprinting the wood-filled thermoplastic material to make it a capital asset for precasters.

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Sponsors:
University Transportation Centers Program, Department of Transportation
University of Maine

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Implementation of Research Outcomes:
This project is in its initial research phase. Implementation of Research outcomes will be reported upon completion of initial research.

Impacts and Benefits of Implementation:
This project is in its initial research phase. Impacts and benefits of the research will be reported after the implementation phase.

Related Links:
Bhandari S., Lopez-Anido R.A. and Gardner, D.J. “Enhancing the interlayer tensile strength
of 3D printed short carbon fiber reinforced PETG and PLA composites via annealing,”
Additive Manufacturing 30, 1000922 (2019). https://doi.org/10.1016/j.addma.2019.100922

Bhandari S., Lopez-Anido R.A., Wang, L. and Gardner, D.J. “Elasto-Plastic Finite Element
Modeling of Short Carbon Fiber Reinforced 3D Printed Acrylonitrile Butadiene Styrene
Composites,” The Journal of The Minerals, Metals & Materials Society, JOM 72, 475–484
(2020). https://doi.org/10.1007/s11837-019-03895-w

Bhandari, S., Lopez-Anido, R.A., and Anderson, J., “Large scale 3D printed thermoplastic
composite forms for precast concrete structures,” ITHEC 2020, 5th International Conference
on Thermoplastic Composites, Virtual, Emerging Technologies III: 3D Printing – 5, pp. 182-
187, October 13-15, 2020.

Bhandari, S., and Lopez-Anido, R., “Discrete event simulation thermal model for extrusion-based additive manufacturing of PLA and ABS, ”Materials, SI: Additive Manufacturing
Methods and Modeling Approaches (under review), 2020.
https://www.mdpi.com/journal/materials

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Downloadable Documents