Hamzah, Aslam Hadi (2025) Investigating the effect of wall line numbers on the mechanical performance of developed RPET-HDPE composite filament in FDM 3D printing. Masters thesis, Universiti Teknikal Malaysia Melaka.
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Abstract
Fused Deposition Modelling (FDM) is considered as the most common 3D printing technique for manufacturing 3D models. The mechanical properties of 3D-printed parts using FDM process can be affected with different printing parameters. However, the investigation on printing parameters of wall line count influencing mechanical properties is limited. In addition, waste plastic bottles contribute to plastic pollution, affecting humans and the environment, and by upcycling into 3D printing material, it can create a sustainable environment, which protect natural resources. For that reason, plastic bottles are recycled and developed as a potential bioplastic for 3D printing applications, known as recycled Polyethylene Terephthalate (rPET). Therefore, this study aims to fabricate 3D filament using blended rPET + High Density Polyethylene (HDPE) with two composition ratios of 1:99 and 5:99, respectively. The 3D filaments were produced with different ratios of rPET:HDPE through single screw extrusion process. Then, the thermal properties for 3D filament were characterised using differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) to determine the thermal temperature of rPET and observe any shifts due to blending with HDPE. Meanwhile, the mechanical properties were analyzed using tensile, flexural, and impact strength to evaluate how the addition of rPET affects strength and overall performance of material, especially in the context of FDM 3D printing. The thermal properties of 3D filaments were analyzed to understand the melting temperature of blended materials for 3D printing process. After thermal analysis, surface morphology was conducted to observe surface quality on the 3D filaments. Next, the 3D filaments were used to manufacture 3D-printed samples using FDM process with varying wall counts of 5, 10, and 15 layers for evaluating the mechanical properties. Based on the result, it is found that the addition of 5 % rPET produced higher melting temperature at 132.1 ℃ compared to 131.1 ℃, exhibited by the 1 % rPET. It can be observed with the increase of rPET from 1 % to 5 % exhibits 0.76 % increment in melting temperature. However, the degradation temperature shows a 0.42 % reduction with increasing in rPET. From the surface morphology observation, the addition of 1 % and 5 % rPET of 3D filaments exhibits a smooth and uniform surface. The mechanical properties demonstrate that the 5 % rPET with 10 wall line counts exhibits the best mechanical properties. It was found that 5 % rPET with 10 wall line counts exhibits two times higher tensile strength at 28.34 MPa compared to the 1 % rPET with 5 wall line counts, which resulted at 14.32 MPa. From the fracture surface image under microscopy observation, it shows ductile characteristic with the 10 wall line counts sample, revealing fibrous strand of the fracture after tensile test, which supported by the tensile strength. Overall, the result shows that the addition of 5 % rPET into HDPE was comparable with PLA, indicating the 3D filament using rPET and HDPE with 10 wall line counts produce the best result and feasible for FDM process, with significantly contributing for the sustainability of the environment.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | FDM, rPET, HDPE, Wall line count, Mechanical properties |
| Subjects: | T Technology T Technology > TS Manufactures |
| Divisions: | Faculty Of Industrial And Manufacturing Technology And Engineering |
| Depositing User: | Norhairol Khalid |
| Date Deposited: | 26 Dec 2025 08:21 |
| Last Modified: | 26 Dec 2025 08:21 |
| URI: | http://eprints.utem.edu.my/id/eprint/29372 |
| Statistic Details: | View Download Statistic |
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