Case Study: Nanocomposite-Based 3D Printing and the Implementation of Quality Management to Enhance the Production of Automotive Parts

Additive manufacturing is one of the pillars of technologies of the industry 4.0 and enables rapid prototyping, testing of new materials, and customized manufacturing of parts with personalized design. Poly(lactic acid) (PLA) is a bio-based and biodegradable polymer that is used in packaging, medical applications, and consumer goods. However, it presents low mechanical strength and thermal stability, which limits its use in automotive parts. The use of reinforcement materials such as cellulose nanofibers (CNF) aim to increase the mechanical strength and thermal stability of PLA without reducing its ecological appeal. However, the addition of nanofibers in the 3D printing process can lead to reproducibility problems and constant clogging of the extruder nozzle due to the material’s lower printability. These difficulties may restrict its application to industrial processes due to reduced productivity. To address the challenges in the production of automotive parts with PLA/CNF composites, this paper explored the implementation of a quality management tool to improve the additive manufacturing process using nanocomposite-based filaments. The Ishikawa diagram was used to understand the difficulties observed during production and based on the potential root causes an action plan was developed using 5W2H (five whys and two hows) technique. Through the implementation of the Ishikawa diagram, it was possible to identify critical areas of improvement. Through the 5W2H, specific actions were defined in the whole process, from the nanocomposite and filament manufacturing process to 3D printing parameters. Additionally, standard operating procedures (SOPs) with special routines for the maintenance of the equipment and also for continuously monitoring all the actions that were implemented along the processing stages. For future work, new quality management tools such as checklists and operation flowcharts will be implemented to guarantee better performance of nanocomposites in 3D printing manufacturing processes.