Recycling Polymer Blend made from Post-used Styrofoam and Polyethylene for Fuse Deposition Modelling

The present project focus on Recycling Polymer Blend made from Post-used Styrofoam and Polyethylene for Fuse Deposition Modelling. The filament made from this recycled material will be able use for most commercial FDM 3D printer

Styrofoam is widely used as packaging material for many industrials, such as home furniture and electrical appliance. Styrofoam is a non-biodegradable and the disposal Styrofoam causes serious environment issues. This research is intended to recycle post-used Styrofoam into recycled polystyrene (rPS) resin and use to produce filament for Fused Deposition Modelling (FDM). This research also investigates on the effects of blend ratio and compatibilizer on the mechanical, thermal and morphological properties of the rPS/PE FDM filament and 3D printed specimen. Post-used Styrofoam will be collected from electronic appliance stores and processed into rPS resin. Then, the materials included rPS, PE and compatibilizer PE-g-MA will be formulated to different polymer blends prior to the extrusion of rPS/PE FDM filament in order to determine the effects of different blend ratio and existence of compatibilizer. After that, the 3D will be drawn specimen according to ASTM D638 Standard Type IV using SolidWorks and fabricated using 3D printer. The printed specimen and filament will be analysed by conducting mechanical, thermal, morphological and melt flow properties evaluation tests. For mechanical properties, tensile, flexural and impact tests will be carried out. For thermal properties, thermogravimetric analysis (TGA) and differential Scanning Calorimetry (DSC) analysis will be carried out. For the morphological properties, the fracture surface and adhesiveness between layers of printed specimen will be studied through scanning electron microscope (SEM). Melt flow properties will be evaluated as well to determine its flowability. The project is expected to successfully produce the rPS/PE filament suitable for most of the commercial FDM 3D printer.

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