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Additive manufacturing machine for cork soles

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The combination of thermoplastics and natural organic fillers are being increasingly explored in recent times where the need of renewable resource products with low environmental impact is in great demand, especially in the consumer market. The use of cork is an example of a sustainable and renewable material, that has been used in the footware industry, but not in a large scale. This project proposes the development of an additive manufacturing (AM) machine to process a compound material with 78% of grounded cork, with its grains individually encapsulated in a thermoplastic matrix. The intended application of these products is the manufacturing of sole preforms for the footware industry, that will be processed afterwords by compression molding. Motivated by the necessity of increasing the consistency of the molded components and the need to control the hardness of the final products, additive manufacture is a possible tool to be used. The solution found was to develop a CNC device to move an infra-red light source that provides thermal energy, bonding the thermoplastic in the compound, creating the layer shape. Specific post processors were developed to adequately modify the machine code to the specific control needed of this process. Success was achieved in the production of an AM manufactured midsole, but further development is needed to improve the quality, especially in the areas of heat control and dimensional accuracy.

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Additive manufacture Cork Natural fillers Thermoplastics Foot-ware Environmental impact

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