Composite Filament Made from Post-used Styrofoam and Corn Husk Fiber for Fuse Deposition Modeling

Abstract

This research aimed at developing composite filament for fuse deposition modeling (FDM) application was carried out by recycling post-used expanded polystyrene foam (EPS) as a binding matrix for natural fibers derived from corn husk (CH) waste. The recycled polystyrene (rPS) resin, CH fibers, and predefined amount of processing aid were primarily compounded using a Brabender® internal mixer to produce composite masterbatch feedstock. The composite masterbatch was further blended with measured amount of rPS resin, and the mixtures were extruded into composite filament containing different weight percentage (wt%) of CH fiber loading, ranging from 2.5 to 10 wt%. The 3D printability of the composite filament was assessed through observation on melt flow behavior and viscosity of the molten composite material subjected to typical FDM process conditions, where tensile dumbbell specimen was produced. Through repeated attempts carried out to FDM 3D-print the rPS/CH fiber filled composite filament, the result suggested that higher FDM extrusion percentage was required to produce quality part from composite filament with increase fiber content from 2.5 to 7.5 wt%. Composite filament with 10 wt% fiber loading failed to be printed due to premature thermal degradation and the slightly higher melt viscosity that tend to clog the printer nozzle.

Keywords

• composite filament
• post-used expanded polystyrene foam
• corn husk fiber
• fuse deposition modeling