Dimensional Stability of 3D Printed Objects Made from Plastic Waste Using FDM: Potential Construction Applications

Construction projects are often challenged by tight budgets and limited time and resources. Contractors are, therefore, looking for ways to become competitive by improving efficiency and using cost-effective materials. Using three-dimensional (3D) printing for shaping materials to produce cost-effective construction elements is becoming a feasible option to make contractors more competitive locally and globally. The process capabilities for 3D printers and related devices have been tightened in recent years with the booming of 3D printing industries and applications. Contractors are attempting to improve production skills to satisfy firm specifications and standards, while attempting to have costs within competitive ranges. The aim of this research is to investigate and test the production process capability (Cp) of 3D printers using fused deposition modeling (FDM) to manufacture 3D printed parts made from plastic waste for use in the construction of buildings with different infill structures and internal designs to reduce cost. This was accomplished by calculating the actual requirement capabilities of the 3D printers under consideration. The production capabilities and requirements of FDM printers are first examined to develop instructions and assumptions to assist in deciphering the characteristics of the 3D printers that will be used. Possible applications in construction are then presented. As an essential outcome of this study, it was noticed that the 3D printed parts made from plastic waste using FDM printers are less expensive than using traditional lightweight non-load bearing concrete hollow masonry blocks, hourdi slab hollow bocks, and concrete face bricks.

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