, Volume 70, Issue 3, pp 310–314 | Cite as

Additive Manufacturing of Syntactic Foams: Part 2: Specimen Printing and Mechanical Property Characterization

  • Ashish Kumar Singh
  • Brooks Saltonstall
  • Balu Patil
  • Niklas Hoffmann
  • Mrityunjay Doddamani
  • Nikhil Gupta
Additive Manufacturing of Composites and Complex Materials


High-density polyethylene (HDPE) and its fly ash cenosphere-filled syntactic foam filaments have been recently developed. These filaments are used for three-dimensional (3D) printing using a commercial printer. The developed syntactic foam filament (HDPE40) contains 40 wt.% cenospheres in the HDPE matrix. Printing parameters for HDPE and HDPE40 were optimized for use in widely available commercial printers, and specimens were three-dimensionally (3D) printed for tensile testing at strain rate of 10−3 s−1. Process optimization resulted in smooth operation of the 3D printer without nozzle clogging or cenosphere fracture during the printing process. Characterization results revealed that the tensile modulus values of 3D-printed HDPE and HDPE40 specimens were higher than those of injection-molded specimens, while the tensile strength was comparable, but the fracture strain and density were lower.



Mrityunjay Doddamani acknowledges Department of Science and Technology, India, Grant DST/TSG/AMT/2015/394/G and Visiting Scientist Fellowship Grant VSP 17-7-001 by the U.S. Office of Naval Research—Global (program manager Dr. Ramesh Kolar) to visit NYU for this work. Nikhil Gupta acknowledges Office of Naval Research Grant N00014-10-1-0988. The views expressed in this article are those of the authors, not of funding agencies.

Supplementary material

11837_2017_2731_MOESM1_ESM.pdf (20 kb)
Supplementary material 1 (PDF 19 kb)


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Copyright information

© The Minerals, Metals & Materials Society 2018

Authors and Affiliations

  1. 1.Composite Materials and Mechanics Laboratory, Mechanical and Aerospace Engineering DepartmentNew York University, Tandon School of EngineeringBrooklynUSA
  2. 2.Advanced Manufacturing Laboratory, Department of Mechanical EngineeringNational Institute of Technology KarnatakaSurathkalIndia
  3. 3.Institut für MaschinenwesenTechnische Universität ClausthalZellerfeldGermany

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