Going against the grain: Porous defects in polymer-zeolite composite extrusion to enhance contaminant adsorption

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing Pub Date : 2025-04-05 DOI:10.1016/j.addma.2025.104762

Alan J. Kennedy , Christopher B. Williams , Stephen M. Martin , Chris S. Griggs , Travis L. Thornell , Lauren R. May , Michael J. Bortner

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引用次数: 0

Abstract

While engineers seek to reduce voids and mechanical anisotropies to match injection molding properties, this investigation embraces voids inherent to polymer melt Additive Manufacturing (AM) to enable innovative water treatment solutions. Extrusion of polymer-zeolite micro-composite filaments was exploited to increase structural porosity to enhance contaminant adsorption through print parameter selection, correlating process physics and material physical properties to printed structure performance. Zeolite (32 % w/w) was immobilized in polylactic acid (PLA) filament by twin screw extrusion. Since increasing zeolite loading in dense printed structures did not improve adsorption, we hypothesized that applying print parameters to enhance voids would. While high surface area geometries are an obvious choice for water treatment, this research isolated how print parameters alone affect porous deposition and adsorptive performance at smaller dimensional scales than intentionally printed infill. Experiments determined printing PLA-zeolite faster (80 mm/s) at lower temperature (190 °C) through larger nozzles (0.8 mm) and layer heights (0.3 mm) improved porous structure-adsorptive property relationships, promoting faster ammonia adsorption. Impactful findings include: (1) dense PLA-zeolite injection molds performed poorly, emphasizing layered structure is imperative to allow voids; (2) evidence that controlling physical (roadway spacing) and rheological (extrusion/deposition/solidification) considerations are critical for functional porous structures; and (3) zeolite presence alters rheological controls to achieve printed porosity relative to neat PLA. This work catalyzes new thinking in application-specific success metrics in printed hierarchical structures for both designed and actual deposited structures and an expansion of research avenues in novel environmental applications to optimize printing away from fully dense structures.

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与颗粒相反：聚合物-沸石复合挤出多孔缺陷，增强污染物吸附

虽然工程师们试图减少空隙和机械各向异性以匹配注塑性能，但本研究包含了聚合物熔体增材制造（AM）固有的空隙，以实现创新的水处理解决方案。通过打印参数的选择，将工艺物理和材料物理性能与打印结构性能相关联，利用聚合物-沸石微复合长丝的挤压来增加结构孔隙度，从而提高污染物的吸附能力。采用双螺杆挤出法将沸石（32 % w/w）固定在聚乳酸（PLA）长丝中。由于增加密集印刷结构中沸石的负载并不能改善吸附，我们假设应用印刷参数来增强空隙会改善吸附。虽然高表面积几何形状是水处理的明显选择，但该研究分离了打印参数如何在较小尺寸尺度上影响多孔沉积和吸附性能。实验确定在较低温度（190℃）下，通过较大喷嘴（0.8 mm）和层高（0.3 mm），打印pla -沸石速度更快（80 mm/s），改善了多孔结构-吸附性能关系，促进了更快的氨吸附。有影响的发现包括：(1)致密pla -沸石注塑模具性能不佳，强调分层结构是允许空隙的必要条件；(2)有证据表明，控制物理（巷道间距）和流变（挤压/沉积/凝固）因素对功能性多孔结构至关重要；(3)沸石的存在改变了流变控制，以实现相对于纯PLA的印刷孔隙率。这项工作催化了在设计和实际沉积结构的印刷分层结构中特定应用成功指标的新思维，并扩展了在新环境应用中的研究途径，以优化远离全致密结构的印刷。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Additive manufacturing Materials Science-General Materials Science

CiteScore

19.80

自引率

12.70%

发文量

648

审稿时长

35 days

期刊介绍： Additive Manufacturing stands as a peer-reviewed journal dedicated to delivering high-quality research papers and reviews in the field of additive manufacturing, serving both academia and industry leaders. The journal's objective is to recognize the innovative essence of additive manufacturing and its diverse applications, providing a comprehensive overview of current developments and future prospects. The transformative potential of additive manufacturing technologies in product design and manufacturing is poised to disrupt traditional approaches. In response to this paradigm shift, a distinctive and comprehensive publication outlet was essential. Additive Manufacturing fulfills this need, offering a platform for engineers, materials scientists, and practitioners across academia and various industries to document and share innovations in these evolving technologies.