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    <copyright>Copyright © 2026. National Academy of Sciences. All rights reserved.</copyright>
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    <managingEditor>tris-trb@nas.edu (Bill McLeod)</managingEditor>
    <webMaster>tris-trb@nas.edu (Bill McLeod)</webMaster>
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      <title>Recycling Large-Scale 3 D-Printed Polymer Composite Precast Concrete Forms (2.18)</title>
      <link>https://rip.trb.org/View/1994577</link>
      <description><![CDATA[Large-scale thermoplastic composite extrusion-based 3D printing has been used in research labs and is moving into industry. One significant use of large-scale 3D printing has been to make forms for manufacturing precast concrete parts. Once the forms have been used for casting concrete parts, there is an opportunity to reuse the material and recycle the thermoplastic composite. Ideally, the 3D printed thermoplastic composite can be recycled into feedstock pellets that can be used again for 3D printing newer parts. However, the process of recycling 3D printed concrete forms is not well-established. Efficient ways of removing debris, cutting the 3D printed parts into smaller pieces, and pelletizing need to be figured out. The degradation in material properties with each recycling needs to be characterized and if necessary, a suitable ratio of a mix between virgin and recycled polymer needs to be determined. The cost of recycling needs to be evaluated and compared to the cost of the 3D-printed material.]]></description>
      <pubDate>Fri, 15 Jul 2022 15:08:52 GMT</pubDate>
      <guid>https://rip.trb.org/View/1994577</guid>
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      <title>Thermoplastic Composites by 3D Printing and Automated Manufacturing 
to Extend the Life of Transportation Facilities (2.4)</title>
      <link>https://rip.trb.org/View/1590583</link>
      <description><![CDATA[Recent advances in large-scale 3D printing and thermoplastic composite materials with bio-based fillers and reinforcements have great potential for expanding the possibilities of making forms for precast concrete structures. The 3D printing technology for making molds, forms, and tooling for precast concrete is expected to reduce labor cost. 3D printed molds allow design optimization of precast concrete parts since the additive manufacturing cost is only a function of thermoplastic material weight and is independent of part complexity. Additionally, 3D printed molds become an asset, since thermoplastic composite materials can be reprocessed. However, the performance and durability of such molds needs to be evaluated to ensure optimal performance with repeated casting and demolding operations. The work of this research project will evaluate the mechanical performance of 3D printed molds after repeated use during casting of concrete and removal of the cured concrete part. Additionally, the work conducted by the research team will evaluate the durability and dimensional tolerance of bio-based 3D printed forms.

The objectives of the project are to:
a. Identify potential applications for large-scale 3D printing of forms and tooling for precast concrete parts in transportation using bio-based fillers and reinforcements and cost-effective thermoplastic materials.
b. Determine the feasibility of making 3D printed forms for optimized precast concrete parts and elements to extend durability and reduce cost.
c. Document the demonstration of large-scale 3D printing of precast concrete forms and assess the quality of the parts. Establish material and manufacturing specifications to assist the DOTs implementation of this technology in transportation applications.
d. Investigate the potential for recycling the 3D printed forms and tooling and reusing/reprinting the wood-filled thermoplastic material to make it a capital asset for precasters.
]]></description>
      <pubDate>Tue, 05 Mar 2019 09:58:36 GMT</pubDate>
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