Evaluation of recycled carbon fibers as PLA reinforcement for additive manufacturing applications

The increased exploitation of carbon fiber reinforced polymers (CFRP) is inevitably bringing about an increase in production scraps and end-of-life components, resulting in a sharp increase in CFRP waste. Therefore, it is of paramount importance to find efficient ways to reintroduce waste into the manufacturing cycle. At present, several recycling methods for treating CFRPs are available, even if all of them still have to be optimized. The step after CFRP recycling, and also the key to build a solid and sustainable CFRP recycling market, is represented by the utilization of Re-CFs. The smartest way to utilize recovered carbon fibers is through the manufacturing of recycled CFRPs, that can be done by re-impregnating the recovered fibers with a new polymeric matrix. Fused Filament Fabrication (FFF) is one of the most widely used additive manufacturing (3D printing) techniques that fabricates parts with a polymeric filament deposition process that allows to produce parts adding material layer-by-layer, only where it is needed, saving energy, raw material cost, and waste. The filament can also contain fillers or reinforcements such as recycled short carbon fibers and this makes it perfectly compliant with the re-application of the shortened recycled CF. Therefore, in this thesis work recycled and virgin carbon fiber reinforced PLA filaments have been initially produced using 5% and 10% of CFs load. Properties and characteristics of the filaments have been determined conducting different analysis (TGA, DMA, DSC). Subsequently the 5%wt. Re-CFs filament has been used to 3D print specimens for mechanical characterization (DMA, tensile test and CTE), in order to evaluate properties of printed PLA composites containing Re-CFs and evaluate the feasibility of Re-CFs in 3D printing application.

Biopolyester fibers for sustainable and biocompatible applications

The rising of concerns around the scarcity of non-renewable resources has raised curiosity around new frontiers in the polymer science field. Biopolymers is a general term describing different kind of polymers that are linked with the biological world because of either monomer derivation, end of life degradation or both. The current work is aimed at studying one example of both biopolymers types. Polyhydroxibutyrate (P3HB) is a biodegradable microbial-produced polymer which holds massive potentiality as a substitute of polyolefins such as polypropylene. Though, its highly crystalline nature and stereoregularity of structure make it difficult to work with. The project P3HB-Mono take advantage of polarized Raman spectroscopy to see how annealing of chains with different weights influence the crystallinity and molecular structure of the polymer, eventually reflecting on its mechanical properties. The technique employed is also optimal in order to see how mesophase, a particular conformation of chains different from crystalline and amorphous phase, develops in the polymer structure and changes depending on temperature and mechanical stress applied to the fiber. Polycaprolactone (PCL) on the other hand is a biodegradable fossil-fuel polymer which has biocompatibility and bio-resorbability features. As a consequence this material is very appealing for medical industry and can be used for different applications in this field. One interesting option is to produce narrow and long liquid filled fibers for drug delivery inside human body, using a traditional technique in an innovative way. The project BioLiCoF investigates the feasability of producing liquid filled fibers using melt-spinning techniques and will examine the role that melt-spinning parameters and liquids employed as a core solution have on the final fiber. The physical analysis of the fibers is also interpreted and idea on future developments of the trials are suggested.