Reactor-Made Polypropylene for 3D Printing: A Low-Crystallinity Approach

Volume: 11 | Issue: 2 | Year 2025 | Subscription
International Journal of Polymer Science and Engineering
Received Date: 03/25/2025
Acceptance Date: 06/13/2025
Published On: 2025-08-04
First Page: 1
Last Page: 17

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By: Hiren M. Bhajiwala and Virendra Kumar Gupta.

1. Hiren M. Bhajiwala, Research Scientist, Polymer Synthesis & Catalysis, Reliance Research and Development Centre, Reliance Industries Limited, Navi Mumbai, Maharashtra, India.
2. Virendra Kumar Gupta, Senior Vice President, Polymer Synthesis & Catalysis, Reliance Research and Development Centre, Reliance Industries Limited, Navi Mumbai, Maharashtra, India.

Abstract

3D printing is technology that enables the complex structure, which is difficult in conventional technique. However, relatively slow manufacturing process and using of limited polymeric material leads to attention of scientist towards newer cost-effective material and technology. In this study, we overcome this issue by synthesizing reactor-made polypropylene (mPP) using Dimethylsilylene-(cyclopentadienyl) (fluorenyl)-zirconium-dichloride metallocene catalyst. The polymerization process was systematically optimized by varying Al/Zr molar ratios, catalyst concentrations, and temperatures to achieve tailored properties suitable for 3D-printing. The synthesized polymer was characterized through different analytical tools including NMR, DSC, WAXD, GPC, and TREF, revealed the influence of polymerization conditions on molecular weight distribution, microstructure, and crystallization behavior. The resulting PP exhibited a balanced composition of syndiotactic, isotactic, and atactic structures including dual melting temperatures and lower crystalline. The synthesized PP is used for the preparation of 1.7 mm filament for FDM. The filament exhibited highly transparent and flexible in nature attributed to balanced crystallinity and smaller spherulite structure. Furthermore, the drawn filament was printed on FDM, which exhibited good printability, excellent adhesion to the printer bed with minimal warping, this is due to reduced shrinkage and internal stresses, more uniform cooling due to amorphous nature, improved layer adhesion due to interlayer diffusion and bonding and smaller spherulites leads to improving mechanical homogeneity. This research demonstrates reactor-made polypropylene, with tailored properties, presents a viable solution for overcoming the challenges associated with 3D-printing semi-crystalline polymers, paving the way for broader applications in additive manufacturing.

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How to cite this article: Hiren M. Bhajiwala and Virendra Kumar Gupta Reactor-Made Polypropylene for 3D Printing: A Low-Crystallinity Approach. International Journal of Polymer Science and Engineering. 2025; 11(2): 1-17p.

How to cite this URL: Hiren M. Bhajiwala and Virendra Kumar Gupta, Reactor-Made Polypropylene for 3D Printing: A Low-Crystallinity Approach. International Journal of Polymer Science and Engineering. 2025; 11(2): 1-17p. Available from:https://journalspub.com/publication/ijpse/article=20186

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