3DsusCOMP

Pure and self-reinforcing hydrocarbon composites (all-hydrocarbon composites, ‘all-HC’) are particularly attractive for sustainable lightweight construction and the circular economy. As both the matrix and the reinforcing phase consist of highly oriented polymer fibres made from the same high-molecular hydrocarbon (polyethylene), these materials can be recycled largely residue-free in terms of materials, raw materials and energy. The outstanding mechanical properties of all-HC composites are caused by the microstructure of the components, which is created under suitable processing conditions, for example during injection moulding.

Only recently has it become possible to process pure hydrocarbon composites in an additive manufacturing process known as fused filament fabrication. This represents a breakthrough for the application of all-HC composites, as the orientation of the reinforcing structure can be specifically controlled by the choice of 3D printing paths when depositing the composite strands.

Building on the work of the LZN pilot project susCOMP, the 3DsusCOMP project investigated extended application possibilities for ‘all-HC’ resulting from additive manufacturing (specifically: the fused filament fabrication process (FFF) and the Arburg freeformer process).

The 3DsusCOMP consortium produced three demonstrators to illustrate all-HC material innovations:

1. All-HC gear wheels for plastic gears with water-based lubrication
2. Customised All-HC lightweight components with adjustable mechanical properties for orthoses and protectors in sports and medicine and grippers in automation technology
3. All-HC plug connections (‘All-HC Interlocking’)

Potential areas of application for All-HC components include actuators. During recycling, components may have to be separated from each other again, which is where plug connections can prove useful.  

Overall, 3DsusCOMP was able to demonstrate the potential of ‘all-HC’ for industrial applications. In the development of sustainable drive systems, for example, ‘all-HCs’ offer opportunities in terms of recyclability and lightweight construction that are recognised by industry - which is reflected in the ongoing cooperation with industrial partners even after the end of the project.

The potential of ‘all-HC’ for sustainable lightweight construction was demonstrated using the (injection-moulded) demonstrator ‘gearwheel’, the functionality of the plug-in connection was examined using a model, the mechanical properties of the sample bodies produced additively using the FFF process exhibit the desired mechanical properties, and filigree components can be printed using the Arburg freeformer - even if the parameters for this process have to be adjusted again in order to achieve the desired mechanical component properties.