STEPUP

STEP UP IN POLYMER BASED RM PROCESSES

 Partecipanti

Mappa

 Word cloud

Esplora la "nuvola delle parole (Word Cloud) per avere un'idea di massima del progetto.

 Obiettivo del progetto (Objective)

'An innovative mechano-chemical approach (based on the high energy ball milling) will be used for the development of innovative nanopolymers to be used in Rapid Manufacturing (RM) based on Selective Laser Sintering (SLS),by: 1.Structural modification (up nanopolymers stage) using a currently widely used polymer like Polyammide PA (a “nanoPA” will be produced); 2.Alloying (at nanoscale) with different polymers to tune mechanical properties; 3.Nanocharging of polymers (development of nanocomposites). Moving from this background, the project will make a real, LARGE, step up in polymers and composites properties by including nano features into the base materials and the final products. The final products will benefit from radically extended performances (i.e. operating temperatures, increased strength). In this way it will be possible, using existing prototyping machines, to realize freeform manufacturing technologies for the direct automated and customised production of parts and products from small to medium size batches for a wide range of possible applications (from vehicle applications to biomedical devices). The following are the project S/T objectives of SLS materials and parts produced using the modified PA -New nanostructured materials based on Poliammides (PA) -Agglomerated (scale of 20-50 micron) nanophased (scale of 10-20 nm) particles suited for RM via SLS -Properties improvements in materials and RM/SLS parts properties (referred to conventional PA) of more than 200%. -Parts having improved properties and wider application window for automotive sector, consumer goods and medical instrumentation. For these reasons STEPUP responds quite well to the call topics by: introducing new concepts for the micro/nano fabrication (usage of nanoplymers); enabling transition of RM to customised solutions integrating materials design and simulations.'

Introduzione (Teaser)

While mass manufacturing will always be an important part of most economies, demand for customised components is growing. Scientists developed novel polymers suited to cost-effective and rapid manufacturing (RM) of tailor-made parts.

Descrizione progetto (Article)

RM, also called additive manufacturing, enables faster production through a bottom-up layering approach (additive) rather than cutting components from a large piece or requiring moulds for shaping. In addition, there is less materials waste and programmes can automatically generate machine process parameters via computer-aided design, all of which increase speed, decrease costs and enhance flexibility.

A current drawback in the production of polymeric components is the lack of polymers suited to conventional processing techniques. The EU-funded project 'Step up in polymer based RM processes' (STEPUP) sought to bring RM technology to its maturity for selective laser sintering (SLS) of polymers through the development of novel polymeric materials.

SLS is a RM technique that uses a laser beam to selectively fuse powders to be processed. STEPUP developed cost-effective synthesis routes to produce nanostructural modifications to conventional polymer powders. The modifications enhanced the final mechanical and thermal properties of products while being compatible with existing SLS production equipment. In addition, decision support software and modelling tools enabled design engineers to identify the best new candidate to replace conventional materials based on predicted performance of the SLS-compatible materials.

The most promising materials developed exhibited enhanced mechanical properties at elevated temperatures and facilitated good accuracy and surface quality of components. Process costs were comparable to currently available SLS powders and promising reductions in material cost due to recycling are also expected.

The STEPUP project developed novel nanopolymers including synthesis methods to enable RM using existing SLS equipment. Design tools and models will help engineers choose the appropriate alternative to currently available polymers based on desired mechanical and thermal properties. Optimisation and commercialisation of concepts has the potential to significantly enhance the quality and types of customised polymeric products that can be inexpensively manufactured.