This study employs recycled polycarbonate-based SORPLAS Impact as the material for Fused Filament Fabrication (FFF) in order to systematically investigate the effect of multiple printing parameters on flame-retardant performance. Four key parameters—infill pattern, infill density, primary layer height, and external solid layer thickness—were varied to fabricate test specimens, which were then subjected to combustion tests, thermal imaging, and grayscale analyses for quantitative evaluation. Temperature distribution and char formation behaviors were recorded during burning, and analysis of variance (ANOVA) along with Tukey’s HSD comparisons was used to identify the critical factors influencing flame retardancy. The results show that infill density and external solid layer thickness significantly affect ignition time, flame propagation, and post-combustion structural integrity. While moderate increases in material content promote stable char formation and effective thermal insulation, excessive accumulation can lead to expansion and deformation. Grayscale variations in thermal images further verify how each parameter set influences heat conduction and char formation. Overall, the findings demonstrate that carefully balancing these printing parameters and material usage can enhance flame retardancy and mechanical properties of 3D-printed parts, while also aligning with sustainability objectives. This work provides practical guidelines for advancing recycled flame-retardant materials and their applications in additive manufacturing.
Relation:
The International Journal of Advanced Manufacturing Technology 140, p.989-1014
