Application of low cost bio filled thermoplastics to 3D printed marine tooling

Principal Investigator: Douglas Gardner (UMaine, Advanced Structure and Composite Center)

Partners: Mindy Crandall (UMaine, School of Forest Resources), James Anderson (UMaine, Advanced Structure and Composite Center, Lyman Morse, Hinckley Yachts, Hodgdon Yachts, Sabre, & Thermwood Corporation

Abstract: For small to medium boat builders, the biggest cost and longest lead time item in developing a new boat model is tooling. Tooling can represent 50% of the non-recurring development costs and has a 6-12 month lead time for a full set of molds. The Advanced Structure and Composite Center (ASCC) is seeking to acquire a Large-Scale Additive Manufacturing Machine (LSAM) to investigate the use of a wide area, high-feed-rate 3D printing using low cost, bio-filled thermoplastics for applications such as marine tooling. The overall goal of the proposed research is to test candidate materials, engage local boat builders, and print a small demonstration tool. Work by Oak Ridge National Laboratories has shown that large-scale 3D printed carbon-filled ABS ($5/lb) parts offer huge benefits in cost and lead time for aerospace tooling. ASCC has expertise in the extrusion of low-cost bio-filled thermoplastics ($0.5- 2/lb) and has successfully applied this technology to polypropylene wood plastic composite (WPC) decking, sheet piling, and box beams and is investigating the application of styrene maleic anhydride WPC lumber to aquaculture structures. Large scale 3D printing is an extrusion process to which this knowledge and expertise can be directly applied. Maine boat building has a history of quality and innovation but constantly needs to evolve to remain cost competitive. This effort is supported by four of Maine’s largest boat builders: Lyman Morse, Hinckley Yachts, Hodgdon Yachts, and Sabre, as well as by Thermwood Corporation, the manufacturer of the LSAM printer.