| Abstract Scope |
This study delves into the development of sustainable natural carbon-enhanced polymer composites (NCPC) for utilization in high-volume additive manufacturing (AM) applications including additive housing and composite tooling. Readily available and inexpensive high-density polyethylene (HDPE) was compounded with natural carbons including freshly mined coal, reclaimed coal waste, and coal-derived carbon at various loadings (15-70 wt. %) to create 3D printable material that is compatible with fused deposition modeling (FDM) and fused granulate fabrication (FGF) printers. The effect of the type and content of natural carbon on the tensile, compressive, flexural, and impact properties of the resulting composites was investigated. The incorporation of natural carbons into the HDPE matrix showed to improve printability, mitigate warpage/shrinkage, and enhance mechanical performance. Compared to state-of-the-art technologies, additive manufacturing using NCPC materials is projected to substantially reduce manufacturing and material costs, and lower embodied energy and CO2 emissions, while meeting the ASTM and building code requirements. |