Polystyrene in Granular Form for Fused Deposition Modeling

Fused deposition modeling has become one of the most successful rapid prototyping technologies, and is probably the candidate for the future rapid manufacturing, challenging its traditional counterpart, injection moulding in small to medium scale production. While ABS polymer is the predominant material currently used, the filament form being a precursor, adds up to initial costs, resulting in poor economics. Alternative materials were attempted earlier, but all of them invariably undertook the filament path, necessitating the production of the filament as the first step. The current paper addresses the question if thermoplastic polymers in the granule form could directly be used for fused deposition modeling. Initial experimental results involving the extrusion of polystyrene through a portable polymer extrusion head are promising, and open up further avenues for research.