Big Area Added Manufacturing with discarded material and bioplastics

Big Area Added Manufacturing (BAAM) is a 3DXL printing technique in which a large-volume product is printed layer by layer. A large robot equipped with a pellet extruder with nozzle ensure the right supply in the right place. The technology has been developing rapidly in recent years and faces a number of challenges. The optimisation of systems and control ensure a more stable process. Methodologies are being developed to measure performance, both during printing and of the products. By applying newly developed fibre-reinforced (bio-) composites, mechanical, dimensional and structural properties can be improved. 

Reason 

The technique also provides opportunities for sustainability. Less material is needed compared to traditional production techniques where material is removed. Producing moulds with fibre-reinforced thermoplastics results in a strong reduction in CO2 emissions compared to epoxy. Circular production is possible because thermoplastics can be mechanically recycled and used as a fraction for subsequent production. Also interesting is the application of degradable and bio-based composites.  

The suitability of a fibre-reinforced thermoplastic for circular production depends on the degree of property degradation. A common method is to mix recyclate in blends with virgin material. It is still unclear how to determine the degradation of a given blend in a given recycling step. This raises questions about the lifespan and reliability of recycled products.   

What problem does the project solve?  

Research into the performance of circular products produced with the 3DXL technique is of great importance for the acceptance of the technique. This research develops a method for microscopic analysis of the printed products. The orientation of the fibres strengthens the material and limits shrinkage behaviour. Inherent to layer-on-layer printing is the trapping of air or moisture. Based on this research, efforts are being made to understand the orientation and length of the fibres and the presence of contamination. In addition, research is carried out to determine mechanical and dimensional properties.