Fused deposition modeling with polypropylene

• Extrusion optimization of PP and GRPP filaments for 3D printing.
• 3D printing vs. compression molding benchmark with the same raw material.
• Optimal 3D printing conditions for PP and GRPP.
• 3D printing deposition orientation with minimum mechanical performance impact.
• Reinforcing role of glass fibers is maintained with 3D printing.

This paper addresses the potential of polypropylene (PP) as a candidate for fused deposition modeling (FDM)-based 3D printing technique. The entire filament production chain is evaluated, starting with the PP pellets, filament production by extrusion and test samples printing. This strategy enables a true comparison between parts printed with parts manufactured by compression molding, using the same grade of raw material. Printed samples were mechanically characterized and the influence of filament orientation, layer thickness, infill degree and material was assessed. Regarding the latter, two grades of PP were evaluated: a glass-fiber reinforced and a neat, non-reinforced, one. The results showed the potential of the FDM to compete with conventional techniques, especially for the production of small series of parts/components; also, it was showed that this technique allows the production of parts with adequate mechanical performance and, therefore, does not need to be restricted to the production of mockups and prototypes.

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