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<p>In recent years, 3D foam printing has attracted widespread attention due to its processing flexibility, although numerous filament-based foam printing methods still exhibit Limitations. This study investigates the feasibility of material foaming via pellet-based 3D printing technology using polyethylene terephthalate glycol (PETG) pellets and chemical foaming agents (CFAs) as raw materials, with comprehensive characterization of the products. Experimental results demonstrated the viability of pellet-based 3D foam printing. The characterization included scanning electron microscopy (SEM), density measurement, hardness testing, mechanical property evaluation (tensile, compressive, flexural, and impact strengths), and contact angle measurement. Through optimized analysis of these experimental data, the relationship between Different CFA contents and the expansion ratio of PETG materials was determined. Furthermore, the influence of CFA content on various mechanical properties and their retention in the foamed materials was thoroughly investigated. The printing process demonstrated that the pellet-based 3D foam printing method exhibited remarkable flexibility, effectively overcoming the Limitations in foaming agent selection associated with traditional filament-based foam printing, while allowing for flexible adjustment of CFA content. Experimental results revealed that the density of foamed PETG decreased from 1.26&#xa0;g/cm<sup>3</sup> (0 wt%) to 1.09&#xa0;g/cm<sup>3</sup> (3 wt%), while the Young’s modulus was reduced from 888.21&#xa0;MPa (0 wt%) to 747.74&#xa0;MPa (3 wt%). In contrast, no significant variation was observed in the glass transition temperature (<i>Tg</i>). This research provides new perspectives for 3D foam printing technology, offering enhanced processing flexibility and cost efficiency while expanding material selection possibilities for functional foam applications.</p>

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Pellet-based 3D printing foamof PETG: Process feasibility and material characterization

  • 期刊论文

  • 发表日期：

    2025年9月30日

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  • Yinshi Lu,
  • Handai Liu,
  • Ke Gong,
  • Alexandre Portela,
  • Alan Murphy,
  • Zhi Cao

摘要

In recent years, 3D foam printing has attracted widespread attention due to its processing flexibility, although numerous filament-based foam printing methods still exhibit Limitations. This study investigates the feasibility of material foaming via pellet-based 3D printing technology using polyethylene terephthalate glycol (PETG) pellets and chemical foaming agents (CFAs) as raw materials, with comprehensive characterization of the products. Experimental results demonstrated the viability of pellet-based 3D foam printing. The characterization included scanning electron microscopy (SEM), density measurement, hardness testing, mechanical property evaluation (tensile, compressive, flexural, and impact strengths), and contact angle measurement. Through optimized analysis of these experimental data, the relationship between Different CFA contents and the expansion ratio of PETG materials was determined. Furthermore, the influence of CFA content on various mechanical properties and their retention in the foamed materials was thoroughly investigated. The printing process demonstrated that the pellet-based 3D foam printing method exhibited remarkable flexibility, effectively overcoming the Limitations in foaming agent selection associated with traditional filament-based foam printing, while allowing for flexible adjustment of CFA content. Experimental results revealed that the density of foamed PETG decreased from 1.26 g/cm3 (0 wt%) to 1.09 g/cm3 (3 wt%), while the Young’s modulus was reduced from 888.21 MPa (0 wt%) to 747.74 MPa (3 wt%). In contrast, no significant variation was observed in the glass transition temperature (Tg). This research provides new perspectives for 3D foam printing technology, offering enhanced processing flexibility and cost efficiency while expanding material selection possibilities for functional foam applications.