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Česnik M, Slavič J. Frequency-Dependent Fatigue Properties of Additively Manufactured PLA. Polymers (Basel) 2024; 16:2147. [PMID: 39125173 PMCID: PMC11313685 DOI: 10.3390/polym16152147] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/12/2024] [Revised: 07/23/2024] [Accepted: 07/26/2024] [Indexed: 08/12/2024] Open
Abstract
Vibration-fatigue failure occurs when a structure is dynamically excited within its natural frequency range. Unlike metals, which have constant fatigue parameters, polymers can exhibit frequency-dependent fatigue parameters, significantly affecting the vibration resilience of 3D-printed polymer structures. This manuscript presents a study utilizing a novel vibration-fatigue testing methodology to characterize the frequency dependence of polymer material fatigue parameters under constant temperature conditions. In this investigation, 3D-printed PLA samples with frequency-tunable geometry were experimentally tested on an electro-dynamical shaker with a random vibration profile. Using the validated numerical models, the estimation of vibration-fatigue life was obtained and compared to the experimental results. Performing the numerical minimization of estimated and actual fatigue lives, the frequency-dependent fatigue parameters were assessed. In particular, the results indicate that the tested samples exhibit varying fatigue parameters within the loading frequency range of 250-750 Hz. Specifically, as the loading frequency increases, the fatigue exponent increases and fatigue strength decreases. These findings confirm the frequency dependence of fatigue parameters for 3D-printed polymer structures, underscoring the necessity of experimental characterization to reliably estimate the vibration-fatigue life of 3D-printed polymer structures. The utilization of the introduced approach therefore enhances the vibration resilience of the 3D-printed polymer mechanical component.
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Affiliation(s)
| | - Janko Slavič
- Faculty of Mechanical Engineering, University of Ljubljana, Aškerčeva 6, 1000 Ljubljana, Slovenia;
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2
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Gupta A, Alifui-Segbaya F, Hasanov S, White AR, Ahmed KE, Love RM, Fidan I. Material extrusion of thermoplastic acrylic for intraoral devices: Technical feasibility and evaluation. J Mech Behav Biomed Mater 2023; 143:105950. [PMID: 37285773 DOI: 10.1016/j.jmbbm.2023.105950] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/08/2023] [Revised: 05/29/2023] [Accepted: 05/30/2023] [Indexed: 06/09/2023]
Abstract
With global demand for 3D printed medical devices on the rise, the search for safer, inexpensive, and sustainable methods is timely. Herein, we assessed the practicality of the material extrusion process for acrylic denture bases of which successful outcomes can be extended to implant surgical guides, orthodontic splints, impression trays, record bases and obturators for cleft palates or other maxillary defects. Representative materials comprising denture prototypes and test samples were designed and built with in-house polymethylmethacrylate filaments using varying print directions (PDs), layer heights (LHs) and reinforcements (RFs) with short glass fiber. The study undertook a comprehensive evaluation of the materials to determine their flexural, fracture, and thermal properties. Additional analyses for tensile and compressive properties, chemical composition, residual monomer, and surface roughness (Ra) were completed for parts with optimum parameters. Micrographic analysis of the acrylic composites revealed adequate fiber-matrix compatibility and predictably, their mechanical properties improved simultaneously with RFs and decreased LHs. Fiber reinforcement also improved the overall thermal conductivity of the materials. Ra, on the other hand, improved visibly with decreased RFs and LHs and the prototypes were effortlessly polished and characterized with veneering composites to mimic gingival tissues. In terms of chemical stability, the residual methyl methacrylate monomer contents are well below standards threshold for biological reactions. Notably, 5 vol% acrylic composites built with 0.05 mm LH in 0° on z-axis produced optimum properties that are superior to those of conventional acrylic, milled acrylic and 3D printed photopolymers. Finite element modeling successfully replicated the tensile properties of the prototypes. It may well be argued that the material extrusion process is cost-effective; however, the speed of manufacturing could be longer than that of established methods. Although the mean Ra is within an acceptable range, mandatory manual finishing and aesthetic pigmentation are required for long-term intraoral use. At a proof-of-concept level, it is evident that the material extrusion process can be applied to build inexpensive, safe, and robust thermoplastic acrylic devices. The broad outcomes of this novel study are equally worthy of academic reflection, and further translation to the clinic.
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Affiliation(s)
- Ankit Gupta
- College of Engineering, Computer Science, and Technology, Department of Engineering and Technology, California State University, Los Angeles, USA.
| | - Frank Alifui-Segbaya
- School of Medicine and Dentistry, Ian O'Connor Building, Griffith Health, Gold Coast Campus, Griffith University, QLD, 4222, Australia.
| | - Seymur Hasanov
- Harvard John A. Paulson School of Engineering and Applied Sciences, Harvard University, Cambridge, MA, 02138, USA.
| | - Alan R White
- School of Environment and Science, Griffith Sciences, Nathan Campus, Griffith University, QLD, 4111, Australia.
| | - Khaled E Ahmed
- School of Medicine and Dentistry, Ian O'Connor Building, Griffith Health, Gold Coast Campus, Griffith University, QLD, 4222, Australia.
| | - Robert M Love
- School of Medicine and Dentistry, Ian O'Connor Building, Griffith Health, Gold Coast Campus, Griffith University, QLD, 4222, Australia.
| | - Ismail Fidan
- Tennessee Tech University, 920 N. Peachtree Avenue, MET Department, LEWS 103, Cookeville, TN, 38505-5003, USA.
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Yankin A, Serik G, Danenova S, Alipov Y, Temirgali A, Talamona D, Perveen A. Optimization of Fatigue Performance of FDM ABS and Nylon Printed Parts. MICROMACHINES 2023; 14:304. [PMID: 36838004 PMCID: PMC9960376 DOI: 10.3390/mi14020304] [Citation(s) in RCA: 4] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/24/2022] [Revised: 01/15/2023] [Accepted: 01/17/2023] [Indexed: 06/18/2023]
Abstract
This research work aims to proceed with the optimization of Fused Deposition Modeling (FDM) printing parameters for acrylonitrile butadiene styrene (ABS) and polyamide (Nylon) to improve fatigue resistance. For that purpose, the methodology of the paper involves two main approaches: experimental study and finite element analysis. The experimental part of the paper used the Taguchi method to find the effects of printing internal geometry, printing speed, and nozzle diameter on the fatigue life of ABS and Nylon plastic materials. ANCOVA multiple linear regression and sensitivity analysis was used to investigate the effects of printing parameters on the fatigue life of materials. The analysis of the results revealed: Nylon performed better than ABS, but had a higher slope; the 'tri-hexagon' structure resulted in the highest fatigue life, but the effect was statistically significant only for ABS material; the fatigue life of both materials increased with decreasing the nozzle diameter; the printing speed had no statistically significant influence neither on ABS nor Nylon. The experimental results then were validated by numerical simulations and the difference between the values was within ±14% depending on the experiment. Such differences might occur due to numerical and experimental errors.
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Mitchell K, Raymond L, Wood J, Su J, Zhang J, Jin Y. Material Extrusion of Helical Shape Memory Polymer Artificial Muscles for Human Space Exploration Apparatus. Polymers (Basel) 2022; 14:polym14235325. [PMID: 36501720 PMCID: PMC9738167 DOI: 10.3390/polym14235325] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/27/2022] [Revised: 12/01/2022] [Accepted: 12/02/2022] [Indexed: 12/12/2022] Open
Abstract
Astronauts suffer skeletal muscle atrophy in microgravity and/or zero-gravity environments. Artificial muscle-actuated exoskeletons can aid astronauts in physically strenuous situations to mitigate risk during spaceflight missions. Current artificial muscle fabrication methods are technically challenging to be performed during spaceflight. The objective of this research is to unveil the effects of critical operating conditions on artificial muscle formation and geometry in a newly developed helical fiber extrusion method. It is found that the fiber outer diameter decreases and pitch increases when the printhead temperature increases, inlet pressure increases, or cooling fan speed decreases. Similarly, fiber thickness increases when the cooling fan speed decreases or printhead temperature increases. Extrusion conditions also affect surface morphology and mechanical properties. Particularly, extrusion conditions leading to an increased polymer temperature during extrusion can result in lower surface roughness and increased tensile strength and elastic modulus. The shape memory properties of an extruded fiber are demonstrated in this study to validate the ability of the fiber from shape memory polymer to act as an artificial muscle. The effects of the operating conditions are summarized into a phase diagram for selecting suitable parameters for fabricating helical artificial muscles with controllable geometries and excellent performance in the future.
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Affiliation(s)
- Kellen Mitchell
- Department of Mechanical Engineering, University of Nevada Reno, Reno, NV 89557, USA
| | - Lily Raymond
- Department of Mechanical Engineering, University of Nevada Reno, Reno, NV 89557, USA
| | - Joshua Wood
- Department of Mechanical Engineering, University of Nevada Reno, Reno, NV 89557, USA
| | - Ji Su
- Advanced Materials and Processing Branch, NASA Langley Research Center, Hampton, VA 23681, USA
| | - Jun Zhang
- Department of Mechanical Engineering, University of Nevada Reno, Reno, NV 89557, USA
| | - Yifei Jin
- Department of Mechanical Engineering, University of Nevada Reno, Reno, NV 89557, USA
- Correspondence: ; Tel.: +001-(775)-784-1412
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Wang K, Xiang J, Wang J, Xie G, Liu Y, Peng Y, Rao Y, Matadi Boumbimba R. Effects of printing direction on quasi‐static and dynamic compressive behavior of
3D
printed short fiber reinforced polyamide‐based composites. POLYM ADVAN TECHNOL 2022. [DOI: 10.1002/pat.5696] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Affiliation(s)
- Kui Wang
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic and Transportation Engineering Central South University Changsha China
| | - Jiangyang Xiang
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic and Transportation Engineering Central South University Changsha China
| | - Jin Wang
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic and Transportation Engineering Central South University Changsha China
| | - Guoquan Xie
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic and Transportation Engineering Central South University Changsha China
| | - Yisen Liu
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic and Transportation Engineering Central South University Changsha China
| | - Yong Peng
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic and Transportation Engineering Central South University Changsha China
| | - Yanni Rao
- Key Laboratory of Traffic Safety on Track of Ministry of Education, School of Traffic and Transportation Engineering Central South University Changsha China
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Thermal Deformations of Thermoplast during 3D Printing: Warping in the Case of ABS. MATERIALS 2021; 14:ma14227070. [PMID: 34832469 PMCID: PMC8620654 DOI: 10.3390/ma14227070] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 09/28/2021] [Revised: 11/08/2021] [Accepted: 11/18/2021] [Indexed: 11/26/2022]
Abstract
This research focuses on thermal deformations of thermoplast during three-dimensional printing. A filament acrylonitrile butadiene styrene was used, and the main focus was put on warping. Twenty-seven cuboids divided in six categories by their length, height, surface area, color, nozzle temperature and bed temperature were printed by Fused Filament Fabrication 3D printer. The whole process was captured by a thermal camera and the movies were used to analyze the temperature distribution during printing. All printouts were measured and scanned with a 3D scanner in order to highlight any abbreviations from the original digital models. The obtained results were used to formulate some general conclusions on the influence of selected parameters on the warping process. Based on the outcomes of the study, a set of guidelines on how to minimalize warping was proposed.
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EL MAGRI A, VANAEI S, SHIRINBAYAN M, Vaudreuil S, TCHARKHTCHI A. An Investigation to Study the Effect of Process Parameters on the Strength and Fatigue Behavior of 3D-Printed PLA-Graphene. Polymers (Basel) 2021; 13:3218. [PMID: 34641034 PMCID: PMC8512064 DOI: 10.3390/polym13193218] [Citation(s) in RCA: 18] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/17/2021] [Revised: 09/02/2021] [Accepted: 09/17/2021] [Indexed: 01/13/2023] Open
Abstract
3D printing, an additive manufacturing process, draws particular attention due to its ability to produce components directly from a 3D model; however, the mechanical properties of the produced pieces are limited. In this paper, we present, from the experimental aspect, the fatigue behavior and damage analysis of polylactic acid (PLA)-Graphene manufactured using 3D printing. The main purpose of this paper is to analyze the combined effect of process parameters, loading amplitude, and frequency on fatigue behavior of the 3D-printed PLA-Graphene specimens. Firstly, a specific case study (single printed filament) was analyzed and compared with spool material for understanding the nature of 3D printing of the material. Specific experiments of quasi-static tensile tests are performed. A strong variation of fatigue strength as a function of the loading amplitude, frequency, and process parameters is also presented. The obtained experimental results highlight that fatigue lifetime clearly depends on the process parameters as well as the loading amplitude and frequency. Moreover, when the frequency is 80 Hz, the coupling effect of thermal and mechanical fatigue causes self-heating, which decreases the fatigue lifetime. This paper comprises useful data regarding the mechanical behavior and fatigue lifetime of 3D-printed PLA-Graphene specimens. In fact, it evaluates the effect of process parameters based on the nature of this process, which is classified as a thermally-driven process.
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Affiliation(s)
- Anouar EL MAGRI
- Euromed Polytechnic School, Euromed Research Center, Euromed University of Fes, Route de Meknès (Rond point Bensouda), Fès 30 000, Morocco;
| | | | - Mohammadali SHIRINBAYAN
- Arts et Metiers Institute of Technology, CNRS, CNAM, PIMM, HESAM University, 75013 Paris, France; (M.S.); (A.T.)
| | - Sébastien Vaudreuil
- Euromed Polytechnic School, Euromed Research Center, Euromed University of Fes, Route de Meknès (Rond point Bensouda), Fès 30 000, Morocco;
| | - Abbas TCHARKHTCHI
- Arts et Metiers Institute of Technology, CNRS, CNAM, PIMM, HESAM University, 75013 Paris, France; (M.S.); (A.T.)
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Bi X, Luo Z, Liu B, Xu M, Wang Z. Enhancing Interfacial Reliability of Metal-Thermoplastic Hybrid Joints via Adding Carbon Fiber and Adjusting Welding Heat Input. ACS APPLIED MATERIALS & INTERFACES 2021; 13:33722-33733. [PMID: 34240607 DOI: 10.1021/acsami.1c08977] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/13/2023]
Abstract
Interfacial structures govern the reliability of metal-thermoplastic hybrid joints used in the aerospace industry. The current work demonstrated by experimental methods and density functional theory (DFT) calculations that introduction of carbon fibers (CFs) enhanced the mechanical properties and weakened the corrosion resistance of polyamide 6 (PA6)/A6061-T6 (6061) joints. The bonding strength of typical PA6/6061 joints was increased by 33.70% with the introduction of CF. However, the differences in intrinsic work functions of the CF and various phases within 6061 led to the formation of serious cracks at CFRPA6/6061 interfaces and heavy corrosion on 6061 surfaces, corresponding to the decreased corrosion resistance of PA6/6061 joints. Herein, we present a potential solution to adjust the welding heat input to enhance metal/thermoplastic interfacial reliability. With a rotation speed of 400 mm/min during friction lap joining (FLJ), the fabricated CFRPA6/6061 joint could achieve a strong interface with high strength (bonding strength = 1.730 kN) and relative corrosion resistance (corrosion rate < 0.1 mm/a). The results provide a reliable explanation for the effect of CF on mechanical properties and corrosion resistance of CFRPA6/6061 joints. Furthermore, the knowledge gained in this work will benefit future research in the optimization of processes to improve the reliability of metal-thermoplastic hybrid structures.
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Affiliation(s)
- Xiaoyang Bi
- School of Mechanical & Automotive Engineering, South China University of Technology, Guangzhou 510641, P. R. China
| | - Zhengtang Luo
- Department of Chemical and Biological Engineering, William Mong Institute of Nano Science and Technology, Guangdong-Hong Kong-Macao Joint Laboratory for Intelligent Micro-Nano Optoelectronic Technology and Hong Kong Branch of Chinese National Engineering Study Center for Tissue Restoration and Reconstruction, The Hong Kong University of Science and Technology, Clear Water Bay, Kowloon 999077, Hong Kong, P. R. China
| | - Bosheng Liu
- School of Mechanical & Automotive Engineering, South China University of Technology, Guangzhou 510641, P. R. China
| | - Mengjia Xu
- School of Mechanical & Automotive Engineering, South China University of Technology, Guangzhou 510641, P. R. China
| | - Zhenmin Wang
- School of Mechanical & Automotive Engineering, South China University of Technology, Guangzhou 510641, P. R. China
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Striemann P, Gerdes L, Huelsbusch D, Niedermeier M, Walther F. Interlayer Bonding Capability of Additively Manufactured Polymer Structures under High Strain Rate Tensile and Shear Loading. Polymers (Basel) 2021; 13:polym13081301. [PMID: 33921139 PMCID: PMC8071558 DOI: 10.3390/polym13081301] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/12/2021] [Revised: 04/06/2021] [Accepted: 04/14/2021] [Indexed: 11/16/2022] Open
Abstract
Additive manufacturing of polymers via material extrusion and its future applications are gaining interest. Supporting the evolution from prototype to serial applications, additional testing conditions are needed. The additively manufactured and anisotropic polymers often show a weak point in the interlayer contact area in the manufacturing direction. Different process parameters, such as layer height, play a key role for generating the interlayer contact area. Since the manufacturing productivity depends on the layer height as well, a special focus is placed on this process parameter. A small layer height has the objective of achieving better material performance, whereas a larger layer height is characterized by better economy. Therefore, the capability- and economy-oriented variation was investigated for strain rates between 2.5 and 250 s−1 under tensile and shear load conditions. The test series with dynamic loadings were designed monitoring future applications. The interlayer tensile tests were performed with a special specimen geometry, which enables a correction of the force measurement. By using a small specimen geometry with a force measurement directly on the specimen, the influence of travelling stress waves, which occur due to the impact at high strain rates, is reduced. The interlayer tensile tests indicate a strain rate dependency of additively manufactured polymers. The capability-oriented variation achieves a higher ultimate tensile and shear strength compared to the economy-oriented variation. The external and internal quality assessment indicates an increasing primary surface profile and void volume content for increasing the layer height.
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Affiliation(s)
- Patrick Striemann
- Laboratory of Material Testing, University of Applied Sciences Ravensburg-Weingarten, Doggenriedstraße 42, D-88250 Weingarten, Germany;
- Correspondence: ; Tel.: +49-751-501-9695
| | - Lars Gerdes
- Department of Materials Test Engineering (WPT), TU Dortmund University, Baroper Str. 303, D-44227 Dortmund, Germany; (L.G.); (D.H.); (F.W.)
| | - Daniel Huelsbusch
- Department of Materials Test Engineering (WPT), TU Dortmund University, Baroper Str. 303, D-44227 Dortmund, Germany; (L.G.); (D.H.); (F.W.)
| | - Michael Niedermeier
- Laboratory of Material Testing, University of Applied Sciences Ravensburg-Weingarten, Doggenriedstraße 42, D-88250 Weingarten, Germany;
| | - Frank Walther
- Department of Materials Test Engineering (WPT), TU Dortmund University, Baroper Str. 303, D-44227 Dortmund, Germany; (L.G.); (D.H.); (F.W.)
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Vidakis N, Petousis M, Tzounis L, Maniadi A, Velidakis E, Mountakis N, Kechagias JD. Sustainable Additive Manufacturing: Mechanical Response of Polyamide 12 over Multiple Recycling Processes. MATERIALS (BASEL, SWITZERLAND) 2021; 14:466. [PMID: 33478083 PMCID: PMC7835918 DOI: 10.3390/ma14020466] [Citation(s) in RCA: 34] [Impact Index Per Article: 11.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/27/2020] [Revised: 01/12/2021] [Accepted: 01/15/2021] [Indexed: 01/10/2023]
Abstract
Plastic waste reduction and recycling through circular use has been critical nowadays, since there is an increasing demand for the production of plastic components based on different polymeric matrices in various applications. The most commonly used recycling procedure, especially for thermoplastic materials, is based on thermomechanical process protocols that could significantly alter the polymers' macromolecular structure and physicochemical properties. The study at hand focuses on recycling of polyamide 12 (PA12) filament, through extrusion melting over multiple recycling courses, giving insight for its effect on the mechanical and thermal properties of Fused Filament Fabrication (FFF) manufactured specimens throughout the recycling courses. Three-dimensional (3D) FFF printed specimens were produced from virgin as well as recycled PA12 filament, while they have been experimentally tested further for their tensile, flexural, impact and micro-hardness mechanical properties. A thorough thermal and morphological analysis was also performed on all the 3D printed samples. The results of this study demonstrate that PA12 can be successfully recycled for a certain number of courses and could be utilized in 3D printing, while exhibiting improved mechanical properties when compared to virgin material for a certain number of recycling repetitions. From this work, it can be deduced that PA12 can be a viable option for circular use and 3D printing, offering an overall positive impact on recycling, while realizing 3D printed components using recycled filaments with enhanced mechanical and thermal stability.
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Affiliation(s)
- Nectarios Vidakis
- Mechanical Engineering Department, Hellenic Mediterranean University, 71410 Heraklion, Crete, Greece; (N.V.); (E.V.); (N.M.)
| | - Markos Petousis
- Mechanical Engineering Department, Hellenic Mediterranean University, 71410 Heraklion, Crete, Greece; (N.V.); (E.V.); (N.M.)
| | - Lazaros Tzounis
- Department of Materials Science and Engineering, University of Ioannina, 45110 Ioannina, Greece;
| | - Athena Maniadi
- Department of Materials Science and Technology, University of Crete, 70013 Heraklion, Crete, Greece;
| | - Emmanouil Velidakis
- Mechanical Engineering Department, Hellenic Mediterranean University, 71410 Heraklion, Crete, Greece; (N.V.); (E.V.); (N.M.)
| | - Nikolaos Mountakis
- Mechanical Engineering Department, Hellenic Mediterranean University, 71410 Heraklion, Crete, Greece; (N.V.); (E.V.); (N.M.)
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