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Research article Special Issues

Design of a hybrid high-throughput fused deposition modeling system for circular economy applications

  • Received: 06 August 2022 Accepted: 30 September 2022 Published: 13 October 2022
  • In recent years, recycling of plastics has opened several doors of advancements in the field of additive manufacturing (AM). The process of fused deposition modelling (FDM) has already been utilized for reprocessing waste plastics into filaments and finally printing them into useful products. Yet another concept of extrusion additive manufacturing (EAM) is gaining lots of attention. In this work, a screw assisted system based on EAM is designed and installed alongside a pre-existing FDM system. This system is referred to as the direct FDM (DFDM) system throughout this work. The DFDM system used operates with a 1.75 mm nozzle and has the ability of giving a high throughput. The focus of this work is to use this hybrid system (combination of FDM and DFDM systems) to print both virgin as well as recycled plastics. The scope of this work is to use one technology (either FDM or DFDM) at a time and to use both simultaneously for multi-material printing in future. After several trials of printing and setting up some printing parameters, the proposed system has been able to print with virgin as well as recycled PLA.

    Citation: Tanay Kuclourya, Roberto Monroy, Miguel Castillo, David Baca, Rafiq Ahmad. Design of a hybrid high-throughput fused deposition modeling system for circular economy applications[J]. Clean Technologies and Recycling, 2022, 2(4): 170-198. doi: 10.3934/ctr.2022010

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  • In recent years, recycling of plastics has opened several doors of advancements in the field of additive manufacturing (AM). The process of fused deposition modelling (FDM) has already been utilized for reprocessing waste plastics into filaments and finally printing them into useful products. Yet another concept of extrusion additive manufacturing (EAM) is gaining lots of attention. In this work, a screw assisted system based on EAM is designed and installed alongside a pre-existing FDM system. This system is referred to as the direct FDM (DFDM) system throughout this work. The DFDM system used operates with a 1.75 mm nozzle and has the ability of giving a high throughput. The focus of this work is to use this hybrid system (combination of FDM and DFDM systems) to print both virgin as well as recycled plastics. The scope of this work is to use one technology (either FDM or DFDM) at a time and to use both simultaneously for multi-material printing in future. After several trials of printing and setting up some printing parameters, the proposed system has been able to print with virgin as well as recycled PLA.



    In this paper, we are concerned on the Cauchy problem to a nonlinear Fokker-Planck equation as follows

    {tF+vxF=ρv(vF+vF),F(0,x,v)=F0(x,v), (1.1)

    where the nonnegative unknown functions F(t,x,v) is the distribution function of particles with position x=(x1,x2,x3)R3 and velocity v=(v1,v2,v3)R3 at time t0, and the density ρ(t,x) is defined as ρ=R3Fdv.

    In statistical mechanics, nonlinear Fokker-Planck equation is a partial differential equation which describes the Brownian motion of particles. This equation illustrates the evolution of particle probability density function with velocity, time and space position under the influence of resistance or random force. This equation is also widely used in various fields such as plasma physics, astrophysics, nonlinear hydrodynamics, theory of electronic circuitry and laser arrays, population dynamics, human movement sciences and marketing.

    The global equilibrium for the nonlinear Fokker-Planck Eq (1.1) is the normalized global Maxwellian

    μ=μ(v)=(2π)32e|v|22.

    Therefore, we can define the perturbation f=f(t,x,v) by

    F(t,x,v)=μ+μ12f(t,x,v),

    then the Cauchy problem (1.1) of the nonlinear Fokker-Planck equation is reformulated as

    {tf+vxf=ρLf,ρ=1+R3μ12fdv,f(0,x,v)=f0(x,v)=μ12(F0(x,v)μ), (1.2)

    where the linear Fokker-Planck operator L is given by

    Lf=μ12v(μv(μ12f))=Δvf+14(6|v|2)f. (1.3)

    Let us define the velocity orthogonal projection

    P:L2(R3v)Span{μ12, viμ12(1i3)}.

    For any given function f(t,x,v)L2(R3v), one has

    Pf=a(t,x)μ12+b(t,x)vμ12, (1.4)

    with

    a=R3μ12fdv,b=R3vμ12fdv. (1.5)

    Then by the macro-micro decomposition introduced in [9], we get the decomposition of solutions f(t,x,v) of the nonlinear Fokker-Planck Eq (1.1) as follows

    f(t,x,v)=Pf(t,x,v)+{IP}f(t,x,v), (1.6)

    where I denotes the identity operator, Pf and {IP}f are called the macroscopic and the microscopic component of f(t,x,v), respectively.

    Before the statement of main result, we need list some notations used in this paper.

    AB means that there is a constant C>0 such that ACB. AB means AB and BA.

    ● For a multi-index α=(α1,α2,α3), the length of α is |α|=α1+α2+α3. We denote α=αx=α1x1α2x2α3x3 and use i to denote xi for each i=1,2,3.

    ● For any function f and g, denote the inner product and norm as follows

    f,g:=R3fgdv,|f|2L2v=R3f2dv,|f|2ν:=|f|2L2ν=R3(|vf|2+ν(v)|f|2)dv where ν(v):=1+|v|2,f2ν:=R3|f|2νdx=R3R3(|vf|2+ν(v)|f|2)dvdx,f2:=f2L2(R3x×R3v) or a2:=a2L2(R3x).

    ● Denoting the function spaces HNxL2v and HNxL2ν with the norm as

    f2HNxL2v=|α|Nαxf2,f2HNxL2ν=|α|Nαxf2ν.

    The basic properties of the linearized Fokker-Planck operator L in (1.3) can be referred in [3,6,7,10,15] as follows

    f,Lg=Lf,g,KerL=Span{μ12},L(vμ12)=vμ12, (1.7)

    and the Fokker-Planck operator L is coercive in the sense that there is a positive constant λ0 such that

    f,Lf=R3|vf+v2f|2dvλ0|{IP}f|2ν+|b|2. (1.8)

    There are a lot of results about the global existence and large time behavior of solutions to the Fokker-Planck type equation. Such as for the Fokker-Planck-Boltzmann equation, DiPerna and Lions [4] first obtained the renormalized solution and established global existence for the Cauchy problem with large data. Li and Matsumura [12] proved that the strong solution for initial data near an absolute Maxwellian exist globally in time and tends asymptotically in the Ly(L1ξ)-norm to another time dependent self-similar Maxwellian in large time. The global existence and temporal decay estimates of classical solutions are established based on the nonlinear energy method developed in [9] under Grad's angular cut-off in [17] and without cut-off in [16], respectively.

    As for the Vlasov-Poisson-Fokker-Planck equation, Duan and liu [6] obtained the time-periodic small-amplitude solution in the three dimensional whole space by Serrin's method. Hwang and Jang [10], Wang [18] obtained the global existence and the time decay of the solution. For the problem (1.1), the global existence is proved by combining uniform-in-time energy estimates and the decay rates of the solution is obtained by using the precise spectral analysis of the linearized Fokker-Planck operator as well as the energy method in [13]. Interested readers can refer to the references [2,7,8,12,14,19] for more related details.

    For the nonlinear Fokker-Planck equation, Imbert and Mouhot [11] obtained the Hölder continuity by De Giorgi and Moser argument together with the averaging lemma. Liao et al.[13] deduced the global existence of the Cauchy problem to the equation based on the energy estimates and the decay rates of the solutions by using the precise spectral analysis of the linearized Fokker-Planck operator in Sobolev space HNx,N4. Also the new difficulty caused by the nonlinear term was resolved by additional tailored weighted-in-v energy estimates suitable for Fokker-Planck operators. However, in this paper, we find that we can deal with the difficult by using the definition of the linearized Fokker-Planck operator L in (1.3) which is not necessary to estimate the dissipation Lg2HNxL2v.

    The rest of this paper is organized as follows. In Section 2, we give the main result of this paper. In Section 3, we deduce the microscopic and macroscopic dissipation by a refined energy method, respectively. Section 4 is devoted to close the a priori estimate, then the proof of main theorem is completed based on the continuation argument.

    Now we define the energy norm and the corresponding dissipation rate norm, respectively, by

    E(t)|α|2αxf2, (2.1)
    D(t)|α|2(αx{IP}f2ν+αxb2)+|α|1αxxa2. (2.2)

    With the above preparation in hand, our main result can be stated as follows.

    Theorem 2.1. Assume there exist a sufficiently small positive constant ϵ0 such that F0(x,v)=μ+μ12f0(x,v)0 satisfies E(0)ϵ0, then the Cauchy problem (1.2) admits a unique global solution f(t,x,v) satisfying F(t,x,v)=μ+μ12f(t,x,v)0, and it holds that

    E(t)+t0D(s)dsE(0), (2.3)

    for any t>0. In particular, we have the global energy estimate

    supt0f(t)H2xL2vf0H2xL2v.

    Remark 2.1.Compared with the integer Sobolev space H4x used in [13], the regularity assumption on the initial data in H2x is weaker by virtue of the Sobolev embedding in Lemma 3.1, especially the estimate of L6(R3).

    In order to overcome the difficulty from the nonlinear term, the authors in [13] need to estimate the dissipation Lg2HNxL2v. However, it seems to be not necessary for our estimates.

    In this section, we will derive the energy estimates for the nonlinear Fokker-Planck equation. The first part is concerned on the estimates of the microscopic dissipation and the second part is about the estimates of macroscopic dissipation by the macroscopic equations similar as [13]. We need list the following lemma about Sobolev inequalities which are very important to obtain the corresponding energy estimates.

    Lemma 3.1. (See [1,5].) Let uH2(R3), then there is a constant C>0 such that

    uLCu122u12CuH1,

    uL6Cu,

    uLqCuH1, 2q6.

    Firstly, we need the estimates of the microscopic dissipation for the solution f in (1.2).

    Lemma 3.2. It holds that

    12ddt|α|2αxf2+λ0|α|2αx{IP}f2ν+|α|2αxb2E12(t)D(t), (3.1)

    for any t>0.

    Proof. Step 1. α=0. Multiply (1.2)1 by f and integrate over R3v×R3x to obtain

    12ddtR3R3f2dvdxR3R3fLfdvdx=R3R3afLfdvdx. (3.2)

    By using (1.5) and (1.7), we have

    LPf,f=L(aμ12),f+L(bvμ12),f=aL(μ12),f+bL(vμ12),f=bvμ12,f=|b|2. (3.3)

    Similarly, we can get

    L{IP}f,f=L{IP}f,{IP}f+L{IP}f,Pf=L{IP}f,{IP}f+LPf,{IP}f=L{IP}f,{IP}f. (3.4)

    Therefore, by (3.3) and (3.4) and the definition of L (1.3), we can obtain

    Lf,f=LPf,f+L{IP}f,f=L{IP}f,{IP}f|b|2=Δv{IP}f,{IP}f+32{IP}f,{IP}f|v|2{IP}f,{IP}f|b|2=|v{IP}f|2L2v+32|{IP}f|2L2v|v{IP}f|2L2v|b|2,

    where we have used the integration by parts of v, i.e.,

    Δv{IP}f,{IP}f=v{IP}f,v{IP}f=|v{IP}f|2L2v.

    Consequently,

    |Lf,f|=|v{IP}f|2L2v+32|{IP}f|2L2v+|v{IP}f|2L2v+|b|2C(|{IP}f|2ν+|b|2).

    Furthermore, Sobolev embedding in Lemma 3.1 yields

    |R3R3afLfdvdx|R3|a||f,Lf|dxR3|a|(|{IP}f|2ν+|b|2)dxa2Lx({IP}f2ν+b2)xaH1xD(t)E12(t)D(t).

    Therefore, from (3.2) we have

    12ddtf2+λ0{IP}f2ν+b2E12(t)D(t).

    Step 2. 1|α|2. Taking αx of (1.2)1 yields

    tαxf+vxαxf=Lαxf+αx(aLf), (3.5)

    Multiply above equation by αxf and integrate over R3v×R3x to get

    12ddtR3R3|αxf|2dvdxR3R3αxfL(αxf)dvdx=R3R3|β||α|CβααβxaL(βxf)(αxf)dvdx. (3.6)

    Case 1. β=0. The estimates of the last term in above equation is as follows by the definition of L (1.3):

    R3R3αxaLfαxfdvdx=R3R3αxa(Δvf+14(6|v|2)f)αxfdvdx=R3R3αxaΔvfαxfdvdxJ1+32R3R3αxafαxfdvdxJ2R3R3αxa|v|2fαxfdvdxJ3. (3.7)

    Using the integration by parts of v, Hölder inequality and Sobolev embedding in Lemma 3.1 to get

    |J1|=|R3R3αxavfαxvfdvdx|R3|αxa||vf|L2v|αxvf|L2vdxαxaL2xvfLxL2vαxvfL2xL2vαxaL2xxvfH1xL2vαxvfL2xL2vE12(t)D(t), (3.8)

    where we have used

    xvfH1xL2vxvPfH1xL2v+xv{IP}fH1xL2vxaH1x+xbH1x+x{IP}fH1xL2νD12(t),
    αxvfL2xL2vαxvPfL2xL2v+αxv{IP}fL2xL2vαxaL2x+αxbL2x+αx{IP}fL2xL2νD12(t).

    Similarly, we can easily get

    |J2|E12(t)D(t),|J3|E12(t)D(t).

    Case 2. β=1. The estimates of the last term in (3.6):

    R3R3αβxaL(βxf)(αxf)dvdx=R3R3αβxaΔvβxfαxfdvdxJ4+32R3R3αβxaβxfαxfdvdxJ5R3R3αβxa|v|2βxfαxfdvdxJ6. (3.9)

    Using the similar techniques to estimate J1, we have

    |J4|=|R3R3αβxaβxvfαxvfdvdx|R3|αβxa||βxvf|L2v|αxvf|L2vdxαβxaL3xβxvfL6xL2vαxvfL2xL2vαβxaH1xxβxvfL2xL2vαxvfL2xL2vE12(t)D(t). (3.10)

    Similarly, we can easily get

    |J5|E12(t)D(t),|J6|E12(t)D(t).

    Case 3. β=α. It holds that

    R3R3aL(αxf)(αxf)dvdx=R3R3aΔvαxfαxfdvdxJ7+32R3R3aαxfαxfdvdxJ8R3R3a|v|2αxfαxfdvdxJ9 (3.11)

    Using the similar techniques to estimate J1, we have

    |J7|=|R3R3aαxvfαxvfdvdx|R3|a||αxvf|L2v|αxvf|L2vdxaLxαxvfL2xL2vαxvfL2xL2vxaH1xαxvf2L2xL2vE12(t)D(t). (3.12)

    Similarly, we can easily get

    |J8|E12(t)D(t),|J9|E12(t)D(t).

    Take the summation over 1|α|2 to get

    12ddt|α|2αxf2+λ0|α|2αx{IP}f2ν+|α|2αxb2E12(t)D(t).

    Thus we complete the proof of Lemma 3.2.

    Now we give the estimate of the macroscopic component a by the macroscopic equations.

    Lemma 3.3. It holds that

    ddt|α|1R3αxbxαxadx+|α|1xαxa2|α|1xαxb2+|α|1xαx{IP}f2+|α|1αxb2+E12(t)D(t). (3.13)

    Proof. Firstly, multiplying (1.2)1 by μ12 and vμ12 respectively, then integrating with respect to v over R3 to obtain

    ta+xb=0, (3.14)

    and

    tb+xa+xvvμ12,{IP}f+(a+1)b=0. (3.15)

    Secondly, taking αx of (3.15) for |α|1 to get

    αxtb+xαxa+xvvμ12,αx{IP}f+αx(ab)+αxb=0.

    Multiply the above equation by xαxa and integrate with respect to x to obtain

    xαxa2=R3αxtbxαxadxR3xvvμ12,αx{IP}fxαxadxR3αx(ab)xαxadxR3αxbxαxadx. (3.16)

    Using (3.14) to get

    R3αxtbxαxadx=ddtR3αxbxαxadxR3αxbxαxtadx=ddtR3αxbxαxadxxαxb2. (3.17)

    By Young's inequality, we have

    |R3xvvμ12,αx{IP}fxαxadx|R3|xαx{IP}f|L2v|xαxa|dxηxαxa2+Cηxαx{IP}f2, (3.18)

    and

    |R3αxbxαxadx|ηxαxa2+Cηαxb2, (3.19)

    where η>0 is a sufficiently small universal constant and Cη>0. Using Sobolev embedding in Lemma 3.1 to derive

    |R3αxabxαxadx|αxaL2xbLxxαxaL2xαxaL2xxbH1xxαxaL2xE12(t)D(t),

    and

    |R3aαxbxαxadx|aLxαxbL2xxαxaL2xxaH1xαxbL2xxαxaL2xE12(t)D(t).

    Thus we can obtain

    |R3αx(ab)xαxadx|=|R3(αxab+aαxb)xαxadx|R3|αxa||b||xαxa|dx+R3|a||αxb||xαxa|dxE12(t)D(t). (3.20)

    Combining (3.17)–(3.20) with (3.16) to derive, for |α|1

    ddt|α|1R3αxbxαxadx+|α|1xαxa2|α|1xαxb2+|α|1xαx{IP}f2+|α|1αxb2+E12(t)D(t),

    where we take η>0 sufficiently small enough. Thus the proof of Lemma 3.3 is completed.

    This section is devoted to proving our main result based on the continuation argument. First, we need to close the a priori estimate.

    Proposition 4.1. There is a small positive constant M>0 such that if

    sup0tTE(f(t))M

    for any 0<T<, then it holds that

    ddtE(t)+D(t)0. (4.1)

    Proof. Taking the linear combination (3.1)+κ×(3.13) with κ>0 sufficiently small to get

    ddt(|α|2αxf2+κ|α|1R3αxbxαxadx)+κ|α|1xαxa2+λ0|α|2αx{IP}f2ν+|α|2αxb2E12(t)D(t). (4.2)

    Noticing that

    |α|1|R3αxbxαxadx|12|α|1[αxb2+xαxa2]|α|2αxf2,

    then we have

    κ|α|2αxf2κ|α|1R3αxbxαxadxκ|α|2αxf2,

    i.e.,

    (1κ)|α|2αxf2|α|2αxf2+κ|α|1R3αxbxαxadx(1+κ)|α|2αxf2.

    Consequently, let κ>0 be small enough, it holds

    |α|2αxf2+κ|α|1R3αxbxαxadx|α|2αxf2E(t).

    By (4.2) and the definition of D(t) (2.2), it derives to

    ddtE(t)+D(t)E12(t)D(t).

    Finally, choosing M>0 to be small enough, then the desired estimate (4.1) is obtained.

    Proof of Theorem 2.1. Firstly, the local-in-time existence and uniqueness of the solutions to the Cauchy problem (1.2) can be established by performing the standard arguments as in [13]. To extend the local solution into the global one, we can deduce that

    E(t)+t0D(s)dsE(0),

    from (4.1) in Proposition 4.1 by virtue of the smallness assumption on E(0). Combining this with the local existence, the global existence of solution and uniqueness follows immediately from the standard continuity argument. This completes the proof of the global existence and the uniform estimate of Theorem 2.1.

    This paper proves the global existence to the Cauchy problem on a nonlinear Fokker- Planck equation near Maxwellian with small-amplitude initial data by a refined nonlinear energy method. And the regularity assumption on the initial data is much weaker by virtue of the Sobolev embedding inequalities.

    The authors would like to thank the anonymous reviewers for providing useful comments and suggestions which help to strengthen the manuscript.

    The research of Xingang Zhang is supported by the Key Scientific Research Projects of Colleges and Universities in Henan Province of China under contracts 23A520027, 23A520038 and Key Scientific and Technological Research Projects in Henan Province under contracts 222102320369. The corresponding author is supported by the National Natural Science Foundation of China under contracts 12026263, Research ability cultivation fund of Hubei University of Arts and Science (2020kypytd006), the Project of Hubei University of Arts and Science (XK2021022), the Humanities and Social Science Youth Foundation of Ministry of Education of China (17YJC630084), the Hubei Provincial Department of Education (B2021211).

    The authors declare that they have no competing interests.



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