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ScienceDirect
Procedia CIRP 00 (2018) 000–000
ScienceDirect
Procedia CIRP 00 (2018) 000–000 www.elsevier.com/locate/procedia
Procedia CIRP 00 (2017) 000–000 www.elsevier.com/locate/procedia
Procedia CIRP 79 (2019) 143–146
www.elsevier.com/locate/procedia

12th
12thCIRP
CIRPConference
Conferenceon
onIntelligent
IntelligentComputation
ComputationininManufacturing
ManufacturingEngineering,
Engineering,18-20
CIRPJuly
ICME2018,
'18
Gulf of Naples,
12th CIRP Conference on Intelligent Computation Italy
in Manufacturing Engineering, CIRP ICME '18
A comparison between
28th CIRP mechanical
Design Conference, properties
May 2018, of specimens
Nantes, France
A comparison between
3D printed withmechanical
virgin andproperties
recycled PLA of specimens
A new methodology to analyze
3D printed withthe functional
virgin and physical
and a,recycled PLA aarchitecture of
a
Antonio
existing products forLanzotti , Massimooriented
an assembly Martorelliproduct
*, Saverio Maietta identification
,
Antonio Lanzotti a
, Massimo
b Martorellia,a *, Saveriofamilyc a,
Maietta
Salvatore Gerbino , Francesco Penta , Antonio Gloria
Salvatore Gerbinob, Francesco Pentaa, Antonio Gloriac
a PaulEngineering,
Department of Industrial Stief *,Fraunhofer
Jean-Yves Dantan,
JL IDEAS Alain
– University Etienne,
of Naples Federico II,Ali Siadat
P.le Tecchio 80, 80125 Naples, Italy
a b
Department DiBT Department
of Industrial - Engineering
Engineering, Division,JLUniversity
Fraunhofer IDEAS – of Molise, Via
University De Sanctis
of Naples snc, 86100
Federico II, P.leCampobasso, CB, Italy
Tecchio 80, 80125 Naples, Italy
C
Institute ofÉcole Nationale
Polymers, DiBTSupérieure
b Composites and d’Arts
Department et Métiers,
Biomaterials
- Engineering Arts etResearch
- National
Division, Métiers ParisTech,
Council
University of LCFC
of Molise,Italy, EASanctis
V.le
Via De 4495, 4snc,
Rue86100
J.F. Kennedy Augustin
Pad.Fresnel,
54 - Campobasso, Metz
20, Mostra 57078,
Italy France
CB,d’Oltremare, 80125 Naples,
C Italy
Institute of Polymers, Composites and Biomaterials - National Research Council of Italy, V.le J.F. Kennedy 54 - Pad. 20, Mostra d’Oltremare, 80125 Naples,
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.euItaly
* Corresponding author. Tel.: +39-081-768-2470; fax: +39-081-768-2470. E-mail address: massimo.martorelli@unina.it
* Corresponding author. Tel.: +39-081-768-2470; fax: +39-081-768-2470. E-mail address: massimo.martorelli@unina.it

Abstract
Abstract
Abstract
In today’s business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of
The current research was focused on a further insight into the mechanical properties of 3D parts printed with virgin and recycled polylactic acid
agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production
(PLA). A first
The current set of was
research specimens
focusedwas
on aprinted
furtherwith virgin
insight intoPLA filament and
the mechanical mechanically
properties of 3D tested. Such specimens
parts printed with virginwere then ground
and recycled up andacid
polylactic re-
systems as well as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to
extruded
(PLA). Aintofirstfilament using a homemade
set of specimens was printed extruder. The re-extruded
with virgin PLA filament filament was employed
and mechanically to manufacture
tested. a new were
Such specimens set ofthen
specimens
groundwhich
up and were
re-
analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and
also analysed.
extruded Three recycling
into filament processes were
using a homemade performed
extruder. to assess the
The re-extruded effect was
filament on the mechanical
employed properties. aThe
to manufacture newobtained results suggested
set of specimens that
which were
nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production
3D printing
also analysed.with recycled
Three PLA processes
recycling may be a viable option. to assess the effect on the mechanical properties. The obtained results suggested that
were performed
system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster
© 2018
3D The with
printing Authors. Published
recycled by Elsevier
PLA may B.V.option.
be a viable
these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable
Peer-review
©
© 2018
2019 The
The under
Authors.
Authors.responsibility
Published
Published byof Elsevier
by the scientific
Elsevier B.V.
B.V.thecommittee of the 12th CIRP Conference on Intelligent Computation in Manufacturing
assembly systems. Based on Datum Flow Chain, physical structure of the products is analyzed. Functional subassemblies are identified, and
Engineering.
Peer-review
Peer-review under responsibility
under responsibilityofofthe
thescientific
scientificcommittee
committeeofof
thethe 12th
12th CIRP
CIRP Conference
Conference on Intelligent
on Intelligent Computation
Computation in Manufacturing
a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) isinthe
Manufacturing
output whichEngineering.
depicts the
Engineering.
similarity between product families by providing design support
Keywords: Additive Manufacturing; Mechanical properties; Recycled polymers
to both, production system planners and product designers. An illustrative
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
Keywords: Additive Manufacturing; Mechanical properties; Recycled polymers
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
© 2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 28th CIRP
1. Introduction Design
(FDM) is Conference 2018.
generally considered for small production runs and
1. Introduction (FDM)
prototypesis generally
which areconsidered for small
not “functional” partsproduction
or devices runs and
[21-26].
Keywords: Assembly; Design method; Family identification
Over the past few years additive manufacturing has been prototypes which are not “functional” parts
However, a significant amount of waste is still created byor devices [21-26].
Over the
growing past few
rapidly. Thisyears additive allows
technology manufacturing
for a quick has been
and FDM However,
such asa failed
significant
printsamount
and supportof waste is still created
structures, disposable by
growing
inexpensive production of devices without machining and
rapidly. This technology allows for a quick or FDM such as failed prints and support
prototypes and many iterations. In this context, many structures, disposable
1.inexpensive
tooling. productiontheofimportant
Furthermore,
Introduction devices role without machining or
of computer-aided prototypes
materials
of the product andrange
such asmany and iterations.
polylactic acid In
characteristics (PLA)this andcontext,
manufactured many
acrylonitrile
and/or
tooling. Furthermore,
design (CAD), the reverse important role of computer-aided
engineering and materials such
butadiene styrene
assembled as polylactic
(ABS) In
in this system. arethis acid
employed (PLA)
context, as and
theprinting acrylonitrile
materials.
main challenge in
design (CAD),
theoretical/experimental
Due to the fast development reverse
analyses has been engineering
in frequently
the domain and
stressed
of butadiene styrene
PLA is a biodegradable
modelling and analysis (ABS)is are employed
polymer
now onlyasfrom
coming
not toprinting
copeplant materials.
materials
with single
theoretical/experimental
the literature [1-12]
communication analyses
and asantheongoing has
use of such been frequently
trendmethodologies
of digitization stressed
hasand
led PLA is a abiodegradable
(i.e., corn
products, starch
limitedand polymer
sugar
product cane).coming
range orMoreover,from
existing plantPLA
scrap
product materials
may
families,
thethe
to literature
design[1-12]
digitalization, as the use
of advanced
manufacturing of such
devices
enterprises for methodologies
different has led
are facingapplications
important (i.e.,
be also
but corn
managed starch
to be able and
using sugar
different
to analyze cane). Moreover,
andmethods,
to compare such scrap PLA
as recycling,
products may
to define
to the design
[13-20]. Due
challenges of advanced
in totoday’s
an improvement devices for different applications
in the additive manufacturing
market environments: a continuing be managed
combustion,
new using
composting,
product families. different
It can and methods, such as
dumpingthatinclassical
be observed recycling,
landfills [26].
existing
[13-20]. Due
technologies
tendency to anreduction
and
towards improvement
production in theitdevelopment
ofspeeds,
product additive
seems that manufacturing
the amount
times and combustion,
Concerning
product the
families composting,
environmental
are regrouped andinimpact,
dumping
function of in
recycling landfills
clients far[26].
isorbyfeatures.
the
technologies
of 3D printed
shortened and
product production
polymers will In
lifecycles. speeds,
continue
addition, ittoseems
increase.
there is that the amount
anConsidering
increasing Concerning
best method
However, the environmental
to manage
assembly impact,
scrapproduct
oriented PLA, recycling
whereas
families is by to
composting
are hardly far the
isfind.
not
of
the3D
demandmassprinted polymers
ofproduction will
abilities,
customization, continue thetoknown
it isatwell
being increase.
same that Considering
time 3D
in aprinting
global best method
considered to manage
a realistic
On the product family scrap
solution PLA,
level, as whereas composting
a consequence
products of the
differ mainly is
in twonot
full
the mass
competition production
is characterised abilities,
withbycompetitors it
a volume which is well
all over known
willthe never
world.that 3D
Thisprinting
approach that of
trend, considered
degradation
main atime
realistic
characteristics: and(i)solution
particular
the number asprocess
aofconsequence
conditions.
components of the
and (ii) full
On the
the
is
ancharacterised
which injection
is inducing by athe
molding volume which will
process.
development Anyway, nevermacro
from approach that
today toadditive
microof degradation
otherof hand,
type time
components in and (e.g.particular
terms process
of environmental
mechanical, conditions.
electrical, efficiency, On the
electronical).
an injection
manufacturing
markets, molding
results(i.e.,3D process.
printing) lot
in diminished allowsAnyway,
sizesfordue today
the production additive
to augmenting of a other hand,of
production
Classical in termsdioxide
carbon
methodologies ofconsidering
environmental
clearly mainly
limits theefficiency,
combustion
single products the
manufacturing
great number
product varieties (i.e.,3D
of printing)
parts with
(high-volume toallows
specific for the
shapes
low-volume production
(i.e., up to 5000)
production) of
[1].a production
method.
or of
As reported
solitary, carbon
already in dioxide clearly
preliminary
existing product limits
studies, the combustion
with regard
families analyzeto the the
great
alsocope
To number of
at competitive parts with specific
costs, evenvariety
with this augmenting if fused shapes (i.e.,
as deposition
well as to beup to 5000)
modelling
able to method.structure
product As reported on ain preliminary
physical studies, with regard
level (components to the
level) which
also at competitive
identify costs, even ifpotentials
possible optimization fused deposition in the modelling
existing causes difficulties regarding an efficient definition and
production
2212-8271 © system,
2017 The it is important
Authors. Publishedtobyhave a precise
Elsevier B.V. knowledge comparison of different product families. Addressing this
Peer-review
2212-8271 ©under
2017responsibility
The Authors. of the scientific
Published committee
by Elsevier B.V.of the 11th CIRP Conference on Intelligent Computation in Manufacturing Engineering.
Peer-review under responsibility of the scientific committee of the 11th CIRP Conference on Intelligent Computation in Manufacturing Engineering.
2212-8271©©2017
2212-8271 2019The
The Authors.
Authors. Published
Published by Elsevier
by Elsevier B.V. B.V.
Peer-reviewunder
Peer-review underresponsibility
responsibility
of of
thethe scientific
scientific committee
committee of the
of the 28th12th
CIRPCIRP Conference
Design on 2018.
Conference Intelligent Computation in Manufacturing Engineering.
10.1016/j.procir.2019.02.030
144 Antonio Lanzotti et al. / Procedia CIRP 79 (2019) 143–146
A. Lanzotti et al. / Procedia CIRP 00 (2018) 000–000

environmental impact, PLA recycling results 16 and 50 times

better than combustion and composting, respectively [26-28].
If compared to petroleum-based plastics, PLA has a less
environmental impact [26,29]. For this reason, many kinds of
recycled filaments, which are obtained processing waste using
filament extrusion systems, are currently available in the
market. To potentially save over thousand million MJ of
energy per year and to reduce greenhouse gases, “distributive
recycling” has been conceptually considered instead of
Fig. 1. An image of the filament extrusion.
“centralised recycling” [26,30].
Even though many advances and interesting technical
The re-extruded filament was employed to manufacture a new
features have been reported in this field, little is known about set of specimens which were also analysed. Specifically, three
the mechanical properties of virgin and recycled 3D printed recycling processes were performed to assess the effect on the
polymers [26,31,32]. Specifically, it has been proved that the mechanical properties.
use of a filament recycled twenty times through an extrusion- Mechanical tests for short-beam strength (ASTM D2344)
based process minimally affected the tensile strength and were performed on specimens 3D printed with virgin and
modulus of PLA [26,33]. In addition, a study on recycled recycled PLA. A span length-to-specimen thickness ratio of
polypropylene blends in injection moulding procedure was 4.0 was used.
performed and an appropriate blending ratio of virgin and Test specimens were loaded in three-point bending. They
recycled polymer was assessed, showing that the decrease in were centre-loaded and the ends rested on two supports which
the mechanical properties of devices fabricated from recycled allowed lateral motion. The loading nose was directly
polymers may be improved optimizing the process parameters centered on the midpoint of the specimen (Fig. 2).
during the injection moulding [26,34,35].The influence of The short-beam strength (Fsbs), which is generally defined as
regrind on the properties of polymer processing by injection the shear stress developed at the specimen mid-plane at the
moulding was properly evaluated [26,35]. A study focused on failure event, was calculated according to the following
optimization methods and strategies related to additive equation:
manufacturing and a filament, which was recycled five times
and then employed for the fabrication of a 3D printed
component, demonstrated no decrease of mechanical (1)
properties other than a reduction of 10% in the tensile strain at
break [26,36]. A previous research was already focused on the
mechanical performances (i.e., tensile, shear, and hardness where Pm represents the maximum load measured during
properties) of 3D specimens printed using both virgin and the test, whereas b and h are the specimen width and
recycled PLA [26]. Briefly, PLA specimens were printed and thickness, respectively.
re-extruded into filaments. Further specimens were printed
with recycled PLA filament and then mechanically tested [26]. 3. Results and discussion
The obtained results showed that 3D printing and recycled
The short-beam strength was evaluated from mechanical tests
PLA may be considered a valuable option as the recycling
performed on 3D specimens printed with virgin and recycled
process did not dramatically alter the mechanical properties
PLA, and reported as mean value ± standard deviation (Table
and the tensile elastic modulus was not significantly changed
1).
[26].
Accordingly, the current research was focused on a further
insight into the mechanical properties and a comparison of
specimens 3D printed with virgin and recycled PLA through
the evaluation of the interlaminar properties and short-beam
strength.

2. Materials and methods

Short-beam strength specimens were fabricated according to

the ASTM D2344 in order to analyse the interlaminar
properties and short-beam strength.
The PLA specimens were manufactured at 200°C using a 3D
printer (Prusa I3) and 0.4 mm nozzle. Fig. 2. Schematic representation of the experimental setup – horizontal shear
A first set of specimens was printed with virgin PLA filament load diagram (adapted from ASTM D2344).
and mechanically tested. Such specimens were then ground up
and re-extruded into (1.75 mm) filament using a homemade
extruder (Fig. 1).
 Antonio Lanzotti et al. / Procedia CIRP 79 (2019) 143–146
A. Lanzotti et al. / Procedia CIRP 00 (2018) 000–000
Table 1. Results from mechanical tests: short-beam strength reported as mean
value ± standard deviation.
PLA filament Short-beam strength (MPa)
Virgin 119.1 ± 6.6
One time-recycled 106.8 ± 9.0
Twice recycled 108.5 ± 9.9
Three times recycled 75.0 ± 16.2
Typical images obtained from mechanical tests are reported in
Fig. 3.
As frequently reported, the ASTM D2344 three-point bending
test method is generally employed to determine the short-
beam strength of high-modulus fiber-reinforced composite
materials. It is limited to discontinuous or continuous-fiber-
reinforced polymer matrix composites with balanced and
symmetric elastic properties with respect to the longitudinal
axis of the specimen. Even though a variety of failure modes
may occur as internal stresses are complex, shear is
considered to be the dominant applied loading using such test
method. In addition, taking into account the stress state local
to the loading nose, it is also worth remembering that failure
may initiate as a consequence of a combination of a severe
shear stress concentration with in-plane and transverse and
compressive stresses. Anyway, in the case of more ductile
matrices, the situation under the loading nose may be
alleviated by the plastic yielding, and other failure modes may
occur (i.e., bottom surface fibre tension). Consequently,
unless mid-plane interlaminar failure can be clearly noticed,
the short-beam strength assessed through this test method
cannot be ascribed to a shear property, and the reported
Equation 1 will be unable to yield accurate values for the
shear strength.
However, as FDM process is based on a layer by layer
material deposition method, the employed test method was
used to assess the interlaminar properties and short-beam
strength.
A previous work [26] already demonstrated the possibility to
produce filaments with usable properties even if some
difficulties generally arise from working with recycled
filaments. In particular, Anderson (2017) [26] compared
virgin and recycled formats in terms of hardness, tensile and
shear properties, and demonstrated that devices with
appropriate mechanical properties may be manufactured with
filament recycled from previously 3D printed parts.
For this reason, the current research may be considered a
further insight into the mechanical properties of 3D specimens
printed with recycled PLA and should provide interesting
information in terms of recycling process in the field of 3D
printing.
Fig. 3. Results from mechanical tests: typical failure modes.
145
Taking into consideration the obtained results, it is worth
noting that the use of one-time and twice recycled filaments
did not significantly affect the short-beam strength, which
dramatically decreased after a further recycling process (Table
1). The results obtained from the three times recycled filament
showed an increased standard deviation and, hence, a great
variability (Table 1). Specifically, the decrease in the values
of the short-beam strength as well as the great variability
could be ascribed to different factors (i.e., potential
degradation phenomena of the filament, flow behaviour and
rheological properties) and could be properly avoided through
the optimization of the printing and recycling process.
4. Conclusion
A previous research already evidenced the possibility to
save great amounts of raw materials, energy cost, and CO 2
emissions in the fabrication of 3D printed devices.
The current research represents a further insight into the
mechanical properties of specimens printed with recycled
PLA, especially focusing on interlaminar properties and short-
beam strength. The recycled PLA filament was employed to
manufacture 3D printed specimens and mechanical tests for
short-beam strength were performed. The one-time and twice
recycled specimens showed a short-beam strength (106.8 ±
9.0 MPa and 108.5 ± 9.9 MPa, respectively) which was
similar to that of the virgin specimens (119.1 ± 6.6 MPa).
However, a third recycling process negatively affected the
values of the short-beam strength also producing a great
variability in the results (75.0 ± 16.2 MPa).
Acknowledgements
This study was supported by the project INCLUDE all
(INnovative methods for design and manufaCturing of
personaLized interfaces for all stUDEnts) financed by the
University of Naples Federico II.
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