Optimization of Extrusion Process Parameters of Recycled High-Density Polyethylene-Thermoplastic Starch Composite for Fused Filament Fabrication

High-density poly-ethylene (HDPE) is a nonbiodegradable recyclable plastic which is widely utilized in single use packaging applications. Consequently, it constitutes a significant amount of plastic waste found in landfills. From literature, it has been shown that parts produced using composites of HDPE with carbohydrate-based polymers, such as thermoplastic starch (TPS), experience mechanical degradation through hydrolytic degradation process. The possible utilization of recycled-HDPE (rHDPE) and TPS composite in nonconventional manufacturing processes such as Fused filament fabrication (FFF) has however not been explored. This study explores the potential application of rHDPE and TPS composites in FFF and optimizes the extrusion process parameters used in rHDPE-TPS filament production process. Taguchi method was utilized to analyze the extrusion process. The extrusion process parameters studied were the spooling speed, extrusion speed and the extrusion temperatures. The response variable studied was the filament diameter. In this research, the maximum TPS content achieved during filament production was 40 wt%. This filament was however challenging to use in FFF printers due to frequent nozzle clogging. Printing was therefore done with filaments that contained 0 - 30 wt% TPS. The experimental results showed that the most significant parameter in extrusion process was the spooling speed, followed by extrusion speed. Extrusion temperature had the least significant influence on the filament diameter. It was observed that increase in TPS content resulted in reduced warping and increased rate of hydrolytic degradation. Mechanical properties of printed parts were investigated and the results showed that increasing TPS content resulted in reduction in tensile strength, reduction in compression strength and increase in stiffness. The findings of this research provide valuable insights to plastic recycling industries and researchers regarding the utilization of recycled HDPE and TPS composites as substitute materials in FFF.