, Volume 70, Issue 3, pp 303–309 | Cite as

Additive Manufacturing of Syntactic Foams: Part 1: Development, Properties, and Recycling Potential of Filaments

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


This work focuses on developing filaments of high-density polyethylene (HDPE) and their hollow particle-filled syntactic foams for commercial three-dimensional (3D) printers based on fused filament fabrication technology. Hollow fly-ash cenospheres were blended by 40 wt.% in a HDPE matrix to produce syntactic foam (HDPE40) filaments. Further, the recycling potential was studied by pelletizing the filaments again to extrude twice (2×) and three times (3×). The filaments were tensile tested at 10−4 s−1, 10−3 s−1, and 10−2 s−1 strain rates. HDPE40 filaments show an increasing trend in modulus and strength with the strain rate. Higher density and modulus were noticed for 2× filaments compared to 1× filaments because of the crushing of some cenospheres in the extrusion cycle. However, 2× and 3× filament densities are nearly the same, showing potential for recycling them. The filaments show better properties than the same materials processed by conventional injection molding. Micro-CT scans show a uniform dispersion of cenospheres in all filaments.



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


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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 Department, Tandon School of EngineeringNew York UniversityBrooklynUSA
  2. 2.Advanced Manufacturing Laboratory, Department of Mechanical EngineeringNational Institute of Technology KarnatakaSurathkalIndia
  3. 3.Institut für MaschinenwesenTechnische Universität ClausthalClausthal-ZellerfeldGermany

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