Improving the Impact Strength and Heat Resistance of 3D Printed Models: Structure, Property, and Processing Correlationships during Fused Deposition Modeling (FDM) of Poly(Lactic Acid)

The Development of Sustainable Polyethylene Terephthalate Glycol-Based (PETG) Blends for Additive Manufacturing Processing-The Use of Multilayered Foil Waste as the Blend Component

The polymer foil industry is one of the leading producers of plastic waste. The development of new recycling methods for packaging products is one of the biggest demands in today's engineering. The subject of this research was the melt processing of multilayered PET-based foil waste with PETG copolymer. The resulting blends were intended for additive manufacturing processing using the fused deposition modeling (FDM) method. In order to improve the properties of the developed materials, the blends compounding procedure was conducted with the addition of a reactive chain extender (CE) and elastomeric copolymer used as an impact modifier (IM). The samples were manufactured using the 3D printing technique and, for comparison, using the traditional injection molding method. The obtained samples were subjected to a detailed characterization procedure, including mechanical performance evaluation, thermal analysis, and rheological measurements. This research confirms that PET-based film waste can be successfully used for the production of filament, and for most samples, the FDM printing process can be conducted without any difficulties. Unfortunately, the unmodified blends are characterized by brittleness, which makes it necessary to use an elastomer additive (IM). The presence of a semicrystalline PET phase improves the thermal resistance of the prepared blends; however, an annealing procedure is required for this purpose.

Mathematical Model of the Layer-by-Layer FFF/FGF Polymer Extrusion Process for Use in the Algorithm of Numerical Implementation of Real-Time Thermal Cycle Control

An approach for improving and maintaining a consistent weld quality of the deposited material during the FFF printing process is proposed. The approach is based on the analysis of the printing process thermal cycle and the real-time nozzle temperature control. The mathematical model of the FFF printing process has been developed with the use of real-time control in the algorithm of numerical implementation. The successful solution of the thermal conductivity problem made it possible to determine segment-wise heating settings for use during the printing process, resulting in a high and stable quality of welding. Comparison of the results of modeling with other well-known mathematical models of the FFF printing process and experimental results showed the adequacy of the proposed model. A maximum deviation of 17.7% between the simulation results and the thermography data was observed. The proposed model was verified using rectangular 3D polylactide shapes printed with and without regulation of the power of the heat source according to the previously estimated settings. The overall quality of regulation, stability of the system, and the PI coefficients of the controller were evaluated using a simulated model of the control system. The results of the experiment fully correspond with the modeling results.

Establishing a Framework for Fused Filament Fabrication Process Optimization: A Case Study with PLA Filaments

Developments in polymer 3D printing (3DP) technologies have expanded their scope beyond the rapid prototyping space into other high-value markets, including the consumer sector. Processes such as fused filament fabrication (FFF) are capable of quickly producing complex, low-cost components using a wide variety of material types, such as polylactic acid (PLA). However, FFF has seen limited scalability in functional part production partly due to the difficulty of process optimization with its complex parameter space, including material type, filament characteristics, printer conditions, and "slicer" software settings. Therefore, the aim of this study is to establish a multi-step process optimization methodology-from printer calibration to "slicer" setting adjustments to post-processing-to make FFF more accessible across material types, using PLA as a case study. The results showed filament-specific deviations in optimal print conditions, where part dimensions and tensile properties varied depending on the combination of nozzle temperature, print bed conditions, infill settings, and annealing condition. By implementing the filament-specific optimization framework established in this study beyond the scope of PLA, more efficient processing of new materials will be possible for enhanced applicability of FFF in the 3DP field.

Influence of FFF Process Conditions on the Thermal, Mechanical, and Rheological Properties of Poly(hydroxybutyrate-co-hydroxy Hexanoate)

Polyhydroxyalkanoates are natural polyesters synthesized by microorganisms and bacteria. Due to their properties, they have been proposed as substitutes for petroleum derivatives. This work studies how the printing conditions employed in fuse filament fabrication (FFF) affect the properties of poly(hydroxybutyrate-co-hydroxy hexanoate) or PHBH. Firstly, rheological results predicted the printability of PHBH, which was successfully realized. Unlike what usually happens in FFF manufacturing or several semi-crystalline polymers, it was observed that the crystallization of PHBH occurs isothermally after deposition on the bed and not during the non-isothermal cooling stage, according to calorimetric measurements. A computational simulation of the temperature profile during the printing process was conducted to confirm this behavior, and the results support this hypothesis. Through the analysis of mechanical properties, it was shown that the nozzle and bed temperature increase improved the mechanical properties, reducing the void formation and improving interlayer adhesion, as shown by SEM. Intermediate printing velocities produced the best mechanical properties.

Mechanical properties of CAD/CAM polylactic acid as a material for interim restoration

Statement of problem

Biomaterials, including polymethyl methacrylate (PMMA) and bisacrylate, have been widely used as conventional interim materials and may exhibit cytotoxicity or systemic toxicity.

Purpose

This study was designed to compare the mechanical properties of polylactic acid (PLA) as an alternative to conventional dental polymers for computer-aided design and manufacturing (CAD/CAM).

Material and methods

Four groups (n = 20 per group) of CAD/CAM polymers were assessed. Specimens of PLA (PLA Mill) and PMMA (PMMA Mill) for subtractive manufacturing, PLA for fused deposition modeling (PLA FDM), and bisphenol for additive manufacturing by stereolithography (Bisphenol SLA) were fabricated into 2-mm-wide, 2-mm-thick and 25-mm-long specimens using a milling machine, an FDM printer, and an SLA printer, respectively.The flexural strength (FS) and elastic modulus (EM) were calculated. The surface roughness and Shore D hardness were analyzed with a 3D optical surface roughness analyzer and a Shore durometer, respectively.

Results

PLA Mill showed the lowest FS (64.9 ± 8.28), followed by PLA FDM (104.27 ± 4.42 MPa), PMMA Mill (139.2 ± 20.95 MPa), and Bisphenol SLA (171.56 ± 15.38 MPa), with statistically significant differences. PLA FDM showed the highest EM, followed by PLA Mill, Bisphenol SLA, and PMMA Mill. Significant differences were observed not only between PMMA Mill and Bisphenol SLA but also between PLA FDM and PLA Mill. The lowest Shore D hardness was observed for PLA FDM, followed by PLA Mill, PMMA Mill, and Bisphenol SLA, which showed the highest value among the 4 groups, with significance. The highest values for the surface roughness parameters were observed for PLA Mill, and the lowest were observed for Bisphenol SLA.

Conclusions

Among the tested CAD/CAM polymers, Bisphenol SLA was the most durable material, and the mechanical properties of PLA FDM were within the clinically acceptable range.

Strategies To Modify the Surface and Bulk Properties of 3D-Printed Solid Scaffolds for Tissue Engineering Applications

3D printing is one of the effective scaffold fabrication techniques that emerged in the 21st century that has the potential to revolutionize the field of tissue engineering. The solid scaffolds developed by 3D printing are still one of the most sought-after approaches for developing hard-tissue regeneration and repair. However, applications of these solid scaffolds get limited due to their poor surface and bulk properties, which play a significant role in tissue integration, loadbearing, antimicrobial/antifouling properties, and others. As a result, several efforts have been directed to modify the surface and bulk of these solid scaffolds. These modifications have significantly improved the adoption of 3D-printed solid scaffolds and devices in the healthcare industry. Nevertheless, the in vivo implant applications of these 3D-printed solid scaffolds/devices are still under development. They require attention in terms of their surface/bulk properties, which dictate their functionality. Therefore, in the current review, we have discussed different 3D-printing parameters that facilitate the fabrication of solid scaffolds/devices with different properties. Further, changes in the bulk properties through material and microstructure modification are also being discussed. After that, we deliberated on the techniques that modify the surfaces through chemical and material modifications. The computational approaches for the bulk modification of these 3D-printed materials are also mentioned, focusing on tissue engineering. We have also briefly discussed the application of these solid scaffolds/devices in tissue engineering. Eventually, the review is concluded with an analysis of the choice of surface/bulk modification based on the intended application in tissue engineering.

Bioresorbable PPDO sliding-lock stents with optimized FDM parameters for congenital heart disease treatment

Stent implantation has been a promising therapy for congenital heart disease (CHD) due to better efficacy. Compared to permanent metal stents, bioresorbable polymer stents have shown a great advantage in accommodating the vascular growth of pediatric patients, but the application is still limited due to inferior radial strength. Here, bioresorbable poly(p-dioxanone) (PPDO) sliding-lock stents for CHD treatment were fabricated by fused deposition modeling (FDM). The effects of FDM processing parameters, including nozzle temperature, bed temperature, layer thickness, and printing speed, on the mechanical properties of PPDO parts were investigated to optimize the processing condition to enhance the radial strength of stents. Finite element analysis (FEA) was also used to evaluate the mechanical properties of stents. PPDO sliding-lock stents fabricated under optimized FDM parameters showed radial strength of 3.315 ± 0.590 N/mm, superior to benchmark commercial metal stents. Radial strength curve and compression behavior of PPDO sliding-lock stents were investigated. Results of FEA exhibited that strut width, shape of the mesh cell and surface coverage ratio had an impact on the compression force of PPDO sliding-lock stents. PPDO sliding-lock stents fabricated with optimized FDM parameters show favorable mechanical performance and meet the requirement of CHD treatment.

A Comparative Analysis of Chemical, Plasma and In Situ Modification of Graphene Nanoplateletes for Improved Performance of Fused Filament Fabricated Thermoplastic Polyurethane Composites Parts

The limited number of materials and mechanical weakness of fused deposition modeling (FDM) parts are deficiencies of FDM technology. The preparation of polymer composites parts with suitable filler is a promising method to improve the properties of the 3D printed parts. However, the agglomerate of filler makes its difficult disperse in the matrix. In this work, graphene nanoplatelets (GnPs) were surface modified with chemical, low-temperature plasma and in situ methods, in order to apply them as fillers for thermoplastic polyurethane (TPU). Following its modification, the surface chemical composition of GnPs was analyzed. Three wt% of surface-modified GnPs were incorporated into TPU to produce FDM filaments using a melting compounding process. Their effects on rheology properties and electrical conductivity on TPU/GnPs composites, as well as the dimensional accuracy and mechanical properties of FDM parts, are compared. The images of sample facture surfaces were examined by scanning electron microscope (SEM) to determine the dispersion of GnPs. Results indicate that chemical treatment of GnPs with zwitterionic surfactant is a good candidate to significantly enhance TPU filaments, when considering the FDM parts demonstrated the highest mechanical properties and lowest dimensional accuracy.

A comprehensive review on fused deposition modelling of polylactic acid

Fused Deposition Modelling (FDM) is one of the additive manufacturing (AM) techniques that have emerged as the most feasible and prevalent approach for generating functional parts due to its ability to produce neat and intricate parts. FDM mainly utilises one of the widely used polymers, polylactic acid, also known as polylactide (PLA). It is an aliphatic polyester material and biocompatible thermoplastic, with the best design prospects due to its eco-friendly properties; when PLA degrades, it breaks down into water and carbon dioxide, neither of which are hazardous to the environment. However, PLA has its limitations of poor mechanical properties. Therefore, a filler reinforcement may enhance the characteristics of PLA and produce higher-quality FDM-printed parts. The processing parameters also play a significant role in the final result of the printed parts. This review aims to study and discover the properties of PLA and the optimum processing parameters. This review covers PLA in FDM, encompassing its mechanical properties, processing parameters, characterisation, and applications. A comprehensive description of FDM processing parameters is outlined as it plays a vital role in determining the quality of a printed product. In addition, PLA polymer is highly desirable for various field industrial applications such as in a medical, automobile, and electronic, given its excellent thermoplastic and biodegradability properties.

AI-Based Support System for Monitoring the Quality of a Product within Industry 4.0 Paradigm

Three-dimensional (3D) printing, also known as additive manufacturing (AM), has already shown its potential in the fourth technological revolution (Industry 4.0), demonstrating remarkable applications in manufacturing, including of medical devices. The aim of this publication is to present the novel concept of support by artificial intelligence (AI) for quality control of AM of medical devices made of polymeric materials, based on the example of our own elbow exoskeleton. The methodology of the above-mentioned inspection process differs depending on the intended application of 3D printing as well as 3D scanning or reverse engineering. The use of artificial intelligence increases the versatility of this process, allowing it to be adapted to specific needs. This brings not only innovative scientific and technological solutions, but also a significant economic and social impact through faster operation, greater efficiency, and cost savings. The article also indicates the limitations and directions for the further development of the proposed solution.

An experimental investigation on the tensile properties of PEEK-PEI sandwich structures prepared via fused filament fabrication

High-temperature-resistant thermoplastics, e.g., Polyetheretherketone (PEEK) and Polyetherimide (PEI), exhibit much more superior material properties than conventional plastics. They are recently becoming favorable feedstock materials in Fused Filament Fabrication (FFF) 3D printing applications, which yields a low-cost and high-efficient approach providing complex parts and tooling. This paper fabricates the PEEK-PEI combined sandwich structures by properly alternating the fed material during FFF processes, aiming to combine the benefits of both materials. This is considered one of the first few attempts to prepare high-performance thermoplastics-based sandwich samples via the FFF method. The specimens are designed as three-layer and five-layer sandwiches (i.e., each “layer” contain a unique material). In addition, the printed samples are post-processed via a thermal annealing treatment. Experimental results show that the sandwich specimens exhibit higher surface quality than independently printed PEEK materials. The PEI material can be printed in 100% infill density in sandwich structures, while it can be rarely printed independently with infill densities exceeding 40%. Annealing may not enhance the mechanical properties of sandwich specimens while stabilizing their mechanical performances. Under the same PEEK/PEI volumetric ratio (i.e., 1:1), increasing the number of alternating stack layers improves the tensile strength of the sandwich specimens by up to 17%. The sandwich printing method is also cost-effective, such that the five-layer sandwich specimen provides competitive tensile performance as compared to the virgin PEEK material. At the same time, its cost is only ∼60% of all-PEEK specimens.

Parametric Investigation and Optimization to Study the Effect of Process Parameters on the Dimensional Deviation of Fused Deposition Modeling of 3D Printed Parts

Fused deposition modeling (FDM) is the most economical additive manufacturing (AM) technology available for fabricating complex part geometries. However, the involvement of numerous control process parameters and dimensional instabilities are challenges of FDM. Therefore, this study investigated the effect of 3D printing parameters on dimensional deviations, including the length, width, height, and angle of polylactic acid (PLA) printed parts. The selected printing parameters include layer height, number of perimeters, infill density, infill angle, print speed, nozzle temperature, bed temperature, and print orientation. Three-level definitive screening design (DSD) was used to plan experimental runs. The results revealed that infill density is the most consequential parameter for length and width deviation, while layer height is significant for angle and height deviation. The regression models developed for the four responses are non-linear quadratic. The optimal results are obtained considering the integrated approach of desirability and weighted aggregated sum product assessment (WASPAS). The optimal results include a layer height of 0.1 mm, a total of six perimeters, an infill density of 20%, a fill angle of 90°, a print speed of 70 mm/s, a nozzle temperature of 220 °C, a bed temperature of 70 °C, and a print orientation of 90°. The current study provides a guideline to fabricate assistive devices, such as hand and foot orthoses, that require high dimensional accuracies.

A Novel Manufacturing Concept of LCP Fiber-Reinforced GPET-Based Sandwich Structures with an FDM 3D-Printed Core

The presented research was focused on the development of a new method of sandwich structure manufacturing involving FDM-printing (fused deposition modeling) techniques and compression molding. The presented concept allows for the preparation of thermoplastic-based composites with enhanced mechanical properties. The sample preparation process consists of 3D printing the sandwich's core structure using the FDM method. For comparison purposes, we used two types of GPET (copolymer of polyethylene terephthalate)-based filaments, pure resin, and carbon fiber (CF)-reinforced filaments. The outer reinforcing layer "skins" of the sandwich structure were prepared from the compression molded prepregs made from the LCP (liquid-crystal polymer)-fiber fabric with the GPET-based matrix. The final product consisting of an FDM-printed core and LCP-based prepreg was prepared using the compression molding method. The prepared samples were subjected to detailed materials analyses, including thermal analyses (thermogravimetry-TGA, differencial scanning calorimetry-DSC, and dynamic thermal-mechanical analysis-DMTA) and mechanical tests (tensile, flexural, and impact). As indicated by the static test results, the modulus and strength of the prepared composites were slightly improved; however, the stiffness of the prepared materials was more related to the presence of the CF-reinforced filament than the presence of the composite prepreg. The main advantage of using the developed method is revealed during impact tests. Due to the presence of long LCP fibers, the prepared sandwich samples are characterized by very high impact resistance. The impact strength increased from 1.7 kJ/m² for pure GPET samples to 50.4 kJ/m² for sandwich composites. For GPET/CF samples, the increase is even greater. The advantages of the developed solution were illustrated during puncture tests in which none of the sandwich samples were pierced.

The Use of Nanoscale Montmorillonite (MMT) as Reinforcement for Polylactide Acid (PLA) Prepared by Fused Deposition Modeling (FDM)—Comparative Study with Biocarbon and Talc Fillers

The subject of the presented research focuses on a comparative assessment of three types of polymer fillers used to modify highly crystalline poly(lactic acid) PLA intended for the FDM technique. The aim of the presented work was to determine the performance of the developed materials. The key aspect of the work was the use of polymer fillers of three different types. Nano-sized montmorillonite (MMT), biobased biocarbon (BC) and mineral talc. The several types of composites were prepared using extrusion technique. The maximum content for BC and talc filler was limited to 20 wt%, while for MMT it was 5 wt%. Prepared samples were subjected to detailed material analysis including mechanical tests (tensile, flexural, Charpy), thermal analysis (DSC, DMTA), HDT/Vicat tests and structure analysis. The results of the test confirmed that even relatively small amount of nano-type filler can be more efficient than micrometric particles. The used type of matrix was highly crystalline PLA, which resulted in a significant nucleation effect of the crystalline structure. However, thermomechanical tests revealed no improvement in thermal resistance. Microscopic survey confirmed that for MMT and talc filler the structure anisotropy was leading to more favorable properties, especially when compared to structures based on spherical BC particles.

Rheological Behavior and Dynamic Mechanical Properties for Interpretation of Layer Adhesion in FDM 3D Printing

Commercial filaments of poly(lactic acid) (PLA) composites with particulate filler, carbon fiber, and copper powder with different contents were fabricated by FDM 3D printing in XZ-direction at bed temperatures of 45 °C and 60 °C. The effects of additives and bed temperatures on layer adhesion, fracture behavior, and mechanical performance of the PLA composites 3D printing were evaluated. Rheological properties informed viscous nature of all filaments and interface bonding in the PLA composites, which improved printability and dimensional stability of the 3D printing. Crystallinity of the PLA composites 3D printing increased with increasing bed temperature resulting in an improvement of storage modulus, tensile, and flexural properties. On the contrary, the ductility of the 3D printing was raised when printed at low bed temperature. Dynamic mechanical properties, the degree of entanglement, the adhesion factor, the effectiveness coefficient, the reinforcing efficiency factor, and the Cole–Cole analysis were used to understand the layer adhesion, and the interfacial interaction of the composites as compared to the compression molded sheets. SEM images revealed good adhesion between the additives and the PLA matrix. However, the additives induced faster solidification and showed larger voids in the 3D printing, which indicated lower layer adhesion as compared to neat PLA. It can be noted that the combination of the additives and the optimized 3D printing conditions would be obtain superior mechanical performance even layer adhesion has been restricted.

The Influence of the Printing Temperature and the Filament Color on the Dimensional Accuracy, Tensile Strength, and Friction Performance of FFF-Printed PLA Specimens

The printing variable least addressed in previous research aiming to reveal the effect of the FFF process parameters on the printed PLA part’s quality and properties is the filament color. Moreover, the color of the PLA, as well as its manufacturer, are rarely mentioned when the experimental conditions for the printing of the samples are described, although current existing data reveal that their influence on the final characteristics of the print should not be neglected. In order to point out the importance of this influential parameter, a natural and a black-colored PLA filament, produced by the same manufacturer, were selected. The dimensional accuracy, tensile strength, and friction properties of the samples were analyzed and compared for printing temperatures ranging from 200 °C up to 240 °C. The experimental results clearly showed different characteristics depending on the polymer color of samples printed under the same conditions. Therefore, the optimization of the FFF process parameters for the 3D-printing of PLA should always start with the proper selection of the type of the PLA material, regarding both its color and the fabricant.

Large-Scale Robot-Based Polymer and Composite Additive Manufacturing: Failure Modes and Thermal Simulation

Additive manufacturing (AM) of large-scale polymer and composite parts using robotic arms integrated with extruders has received significant attention in recent years. Despite the contributions of great technical progress and material development towards optimizing this manufacturing method, different failure modes observed in the final printed products have hindered its application in producing large engineering structures used in aerospace and automotive industries. We report failure modes in a variety of printed polymer and composite parts, including fuel tanks and car bumpers. Delamination and warpage observed in these parts originate mostly from thermal gradients and residual stresses accumulated during material deposition and cooling. Because printing large structures requires expensive resources, process simulation to recognize the possible failure modes can significantly lower the manufacturing cost. In this regard, accurate prediction of temperature distribution using thermal simulations is the first step. Finite element analysis (FEA) was used for process simulation of large-scale robotic AM. The important steps of the simulation are presented, and the challenges related to the modeling are recognized and discussed in detail. The numerical results showed reasonable agreement with the temperature data measured by an infrared camera. While in small-scale extrusion AM, the cooling time to the glassy state is less than 1 s, in large-scale AM, the cooling time is around two orders of magnitudes longer.

Fused-Filament Fabrication of Short Carbon Fiber-Reinforced Polyamide: Parameter Optimization for Improved Performance under Uniaxial Tensile Loading

This study intends to contribute to the state of the art of Fused-Filament Fabrication (FFF) of short-fiber-reinforced polyamides by optimizing process parameters to improve the performance of printed parts under uniaxial tensile loading. This was performed using two different approaches: a more traditional 2k full factorial design of experiments (DoE) and multiple polynomial regression using an algorithm implementing machine learning (ML) principles such as train-test split and cross-validation. Evaluated parameters included extrusion and printing bed temperatures, layer height and printing speed. It was concluded that when exposed to new observations, the ML-based model predicted the response with higher accuracy. However, the DoE fared slightly better at predicting observations where higher response values were expected, including the optimal solution, which reached an UTS of 117.1 ± 5.7 MPa. Moreover, there was an important correlation between process parameters and the response. Layer height and printing bed temperatures were considered the most influential parameters, while extrusion temperature and printing speed had a lower influence on the outcome. The general influence of parameters on the response was correlated with the degree of interlayer cohesion, which in turn affected the mechanical performance of the 3D-printed specimens.

The Influence of the Process Parameters on the Mechanical Properties of PLA Specimens Produced by Fused Filament Fabrication-A Review

Polylactic acid (PLA) is produced from renewable materials, has a low melting temperature and has a low carbon footprint. These advantages have led to the extensive use of polylactic acid in additive manufacturing, particularly by fused filament fabrication (FFF). PLA parts that are 3D printed for industrial applications require stable mechanical properties and predictability regarding their dependence on the process parameters. Therefore, the development of the FFF process has been continuously accompanied by the development of software packages that generate CNC codes for the printers. A large number of user-controllable process parameters have been introduced in these software packages. In this respect, a lot of articles in the specialized literature address the issue of the influence of the process parameters on the mechanical properties of 3D-printed specimens. A systematic review of the research targeting the influence of process parameters on the mechanical properties of PLA specimens additively manufactured by fused filament fabrication was carried out by the authors of this paper. Six process parameters (layer thickness, printing speed, printing temperature, build plate temperature, build orientation and raster angle) were followed. The mechanical behavior was evaluated by tensile, compressive and bending properties.

Anisotropic solid-state PLA foaming templated by crystal phase pre-oriented with 3D printing: Cell supporting structures with directional capillary transfer function

Bones represent a superb biomaterial that combines high mechanical stiffness with nutrition delivery to its osteocyte cells through the microscopical Haversian canals and bone canaliculi. Such structure is hard to...

Hierarchical crystallization strategy adaptive to 3-dimentional printing of polylactide matrix for complete stereo-complexation

A novel strategy adaptive to 3D printing of PLA matrix for complete stereo-complexation was designed. Stereo-complexation has been demonstrated for its effectiveness in simultaneously improving aqueous stability and heat resistance of PLA. However, current techniques could not be directly incorporated into 3D printing of stereo-complexed PLA since stereo-complexed crystallites are easily formed before printing. High printing temperatures are thus required but decompose PLA materials at the same time. The hypothesis for this research is that controllable hierarchical crystallization in three thermal processes, the filament preparation, 3D printing and post annealing, could ensure feasibility of the strategy and a 100% stereo-complexation level in PLA matrices. Effects of extrusion, ambient and annealing temperatures on material structures were analyzed via WAXD, DSC and DMA. Resistance to hydrolysis and heat of the 3D printed PLA matrix was evaluated under practical conditions. It was showed that homo-crystallites anchored molecular chains of PLA during the post-annealing process for a high retention of tensile properties, while stereo-complexed crystallites provided stronger intermolecular interactions for improved hydrolytic and thermal resistance. This novel strategy via incorporating controlled hierarchical crystallization into 3D printing would enrich the fabrication and exploration of high-performance 3D printed PLA materials.

Additive manufacturing technology of polymeric materials for customized products: recent developments and future prospective

The worldwide demand for additive manufacturing (AM) is increasing due to its ability to produce more challenging customized objects based on the process parameters for engineering applications. The processing of conventional materials by AM processes is a critically demanded research stream, which has generated a path-breaking scenario in the rapid manufacturing and upcycling of plastics. The exponential growth of AM in the worldwide polymer market is expected to exceed 20 billion US dollars by 2021 in areas of automotive, medical, aerospace, energy and customized consumer products. The development of functional polymers and composites by 3D printing-based technologies has been explored significantly due to its cost-effective, easier integration into customized geometries, higher efficacy, higher precision, freedom of material utilization as compared to traditional injection molding, and thermoforming techniques. Since polymers are the most explored class of materials in AM to overcome the limitations, this review describes the latest research conducted on petroleum-based polymers and their composites using various AM techniques such as fused filament fabrication (FFF), selective laser sintering (SLS), and stereolithography (SLA) related to 3D printing in engineering applications such as biomedical, automotive, aerospace and electronics.

Improvements of Arboblend V2 Nature Characteristics through Depositing Thin Ceramic Layers

The paper aims to investigate the behavior of Arboblend V2 Nature biopolymer samples covered with three ceramic powders, Amdry 6420 (Cr₂O₃), Metco 143 (ZrO₂ 18TiO₂ 10Y₂O₃) and Metco 136F (Cr₂O₃-xSiO₂-yTiO₂). The coated samples were obtained by injection molding, and the micropowder deposition was achieved by using the Atmospheric Plasma Spray (APS) method, with varied thickness layers. The present study will only describe the results for nine-layer deposition because, as the number of layers’ increases, the surface quality and mechanical/thermal characteristics such as wear, hardness and thermal resistance are also increased. The followed determinations were conducted: the adhesion strength, hardness on a microscopic scale by micro-indentation, thermal analysis and structural and morphological analysis. The structural analysis has highlighted a uniform deposition for the ZrO₂ 18TiO₂ 10Y₂O₃ layer, but for the layers that contained Cr₂O₃ ceramic microparticles, the deposition was not completely uniform. The thermal analysis revealed structural stability up to a temperature of 230 °C, the major degradation of the biopolymer matrix taking place at a temperature around 344 °C. The samples’ crystalline structure as well as the presence of the Cr₂O₃ compound significantly influenced the micro-indentation and scratch analysis responses. The novelty of this study is given by itself the coating of the Arboblend V2 Nature biopolymer (as base material), with ceramic microparticles as the micropowder coating material. Following the undertaken study, the increase in the mechanical, tribological and thermal characteristics of the samples recommend all three coated biopolymer samples as suitable for operating in harsh conditions, such as the automotive industry, in order to replace plastic materials.

Modified Polylactic Acid with Improved Impact Resistance in the Presence of a Thermoplastic Elastomer and the Influence of Fused Filament Fabrication on Its Physical Properties

The standard polylactic acid (PLA), as a biodegradable thermoplastic polymer, is commonly used in various industrial sectors, food, and medical fields. Unfortunately, it is characterized by a low elongation at break and low impact energy. In this study, a thermoplastic copolyester elastomer (TPCE) was added at different weight ratios to improve the impact resistance of PLA. DSC analysis revealed that the two polymers were immiscible. A good balance of impact resistance and rigidity was reached using the formulation that was composed of 80% PLA and 20% TPCE, with an elongation at break of 155% compared to 4% for neat PLA. This new formulation was selected to be tested in a fused filament fabrication process. The influence of the nozzle and bed temperatures as printing parameters on the mechanical and thermal properties was explored. Better impact resistance was observed with the increase in the two thermal printing parameters. The crystallinity degree was not influenced by the variation in the nozzle temperature. However, it was increased at higher bed temperatures. Tomographic observations showed an anisotropic distribution of the porosity, where it was mostly present between the adjacent printed filaments and it was reduced with the increase in the nozzle and bed temperatures.

Nanocomposite Biopolymer Arboblend V2 Nature AgNPs

Due to the pressing problems of today’s world, regarding both the finding of new, environmentally friendly materials which have the potential to replace classic ones, and the need to limit the accelerated spread of bacteria in hospitals, offices and other types of spaces, many researchers have chosen to develop their work in this field. Thus, biopolymeric materials have evolved so much that they are gradually becoming able to remove fossil-based plastics from major industries, which are harmful to the environment and implicitly to human health. The biopolymer employed in the present study, Arboblend V2 Nature with silver nanoparticle content (AgNP) meets both aspects mentioned above. The main purpose of the paper is to replace several parts and products in operation which exhibit antibacterial action, preventing the colonization and proliferation of bacteria (Streptococcus pyogenes and Staphylococcus aureus, by using the submerged cultivation method), but also the possibility of degradation in different environments. The biopolymer characterization followed the thermal behavior of the samples, their structure and morphology through specific analyses, such as TGA (thermogravimetric analysis), DSC (differential scanning calorimetry), SEM (scanning electron microscopy) and XRD (X-ray diffraction). The obtained results offer the possibility of use of said biocomposite material in the medical field because of its antibacterial characteristics that have proved to be positive, and, therefore, suitable for such applications. The thermal degradation and the structure of the material highlighted the possibility of employing it in good conditions at temperatures up to 200 °C. Two types of samples were used for thermal analysis: first, in the form of granules coated with silver nanoparticles, and second, test specimen cut from the sample obtained by injection molding from the coated granules with silver nanoparticles.

Post-Processing of 3D-Printed Polymers

Additive manufacturing, commonly known as 3D printing, is an advancement over traditional formative manufacturing methods. It can increase efficiency in manufacturing operations highlighting advantages such as rapid prototyping, reduction of waste, reduction of manufacturing time and cost, and increased flexibility in a production setting. The additive manufacturing (AM) process consists of five steps: (1) preparation of 3D models for printing (designing the part/object), (2) conversion to STL file, (3) slicing and setting of 3D printing parameters, (4) actual printing, and (5) finishing/post-processing methods. Very often, the 3D printed part is sufficient by itself without further post-printing processing. However, many applications still require some forms of post-processing, especially those for industrial applications. This review focuses on the importance of different finishing/post-processing methods for 3D-printed polymers. Different 3D printing technologies and materials are considered in presenting the authors’ perspective. The advantages and disadvantages of using these methods are also discussed together with the cost and time in doing the post-processing activities. Lastly, this review also includes discussions on the enhancement of properties such as electrical, mechanical, and chemical, and other characteristics such as geometrical precision, durability, surface properties, and aesthetic value with post-printing processing. Future perspectives is also provided towards the end of this review.

The Extent of Interlayer Bond Strength during Fused Filament Fabrication of Nylon Copolymers: An Interplay between Thermal History and Crystalline Morphology

One of the main drawbacks of Fused Filament Fabrication is the often-inadequate mechanical performance of printed parts due to a lack of sufficient interlayer bonding between successively deposited layers. The phenomenon of interlayer bonding becomes especially complex for semi-crystalline polymers, as, besides the extremely non-isothermal temperature history experienced by the extruded layers, the ongoing crystallization process will greatly complicate its analysis. This work attempts to elucidate a possible relation between the degree of crystallinity attained during printing by mimicking the experienced thermal history with Fast Scanning Chip Calorimetry, the extent of interlayer bonding by performing trouser tear fracture tests on printed specimens, and the resulting crystalline morphology at the weld interface through visualization with polarized light microscopy. Different printing conditions are defined, which all vary in terms of processing parameters or feedstock molecular weight. The concept of an equivalent isothermal weld time is utilized to validate whether an amorphous healing theory is capable of explaining the observed trends in weld strength. Interlayer bond strength was found to be positively impacted by an increased liquefier temperature and reduced feedstock molecular weight as predicted by the weld time. An increase in liquefier temperature of 40 °C brings about a tear energy value that is three to four times higher. The print speed was found to have a negligible effect. An elevated build plate temperature will lead to an increased degree of crystallinity, generally resulting in about a 1.5 times larger crystalline fraction compared to when printing occurs at a lower build plate temperature, as well as larger spherulites attained during printing, as it allows crystallization to occur at higher temperatures. Due to slower crystal growth, a lower tie chain density in the amorphous interlamellar regions is believed to be created, which will negatively impact interlayer bond strength.

Extrusion Based 3D Printing of Sustainable Biocomposites from Biocarbon and Poly(trimethylene terephthalate)

Three-dimensional (3D) printing manufactures intricate computer aided designs without time and resource spent for mold creation. The rapid growth of this industry has led to its extensive use in the automotive, biomedical, and electrical industries. In this work, biobased poly(trimethylene terephthalate) (PTT) blends were combined with pyrolyzed biomass to create sustainable and novel printing materials. The Miscanthus biocarbon (BC), generated from pyrolysis at 650 °C, was combined with an optimized PTT blend at 5 and 10 wt % to generate filaments for extrusion 3D printing. Samples were printed and analyzed according to their thermal, mechanical, and morphological properties. Although there were no significant differences seen in the mechanical properties between the two BC composites, the optimal quantity of BC was 5 wt % based upon dimensional stability, ease of printing, and surface finish. These printable materials show great promise for implementation into customizable, non-structural components in the electrical and automotive industries.

Optimisation of Strength Properties of FDM Printed Parts-A Critical Review

Additive Manufacturing is currently growing fast, especially fused deposition modeling (FDM), also known as fused filament fabrication (FFF). When manufacturing parts use FDM, there are two key parameters—strength of the part and dimensional accuracy—that need to be considered. Although FDM is a popular technology for fabricating prototypes with complex geometry and other part product with reduced cycle time, it is also limited by several drawbacks including inadequate mechanical properties and reduced dimensional accuracy. It is evident that part qualities are greatly influenced by the various process parameters, therefore an extensive review of the effects of the following process parameters was carried out: infill density, infill patterns, extrusion temperature, layer thickness, nozzle diameter, raster angle and build orientation on the mechanical properties. It was found from the literature that layer thickness is the most important factor among the studied ones. Although manipulation of process parameters makes significant differences in the quality and mechanical properties of the printed part, the ideal combination of parameters is challenging to achieve. Hence, this study also includes the influence of pre-processing of the printed part to improve the part strength and new research trends such as, vacuum-assisted FDM that has shown to improve the quality of the printing due to improved bonding between the layers. Advances in materials and technologies that are currently under development are presented. For example, the pre-deposition heating method, using an IR lamp of other technologies, shows a positive impact on the mechanical properties of the printed parts.

Design and characterization of 3D printed, neomycin-eluting poly-L-lactide mats for wound-healing applications

This study evaluates the suitability of 3D printed biodegradable mats to load and deliver the topical antibiotic, neomycin, for up to 3 weeks in vitro. A 3D printer equipped with a hot melt extruder was used to print bandage-like wound coverings with porous sizes appropriate for cellular attachment and viability. The semicrystalline polyester, poly-l-lactic acid (PLLA) was used as the base polymer, coated (post-printing) with polyethylene glycols (PEGs) of MWs 400 Da, 6 kDa, or 20 kDa to enable manipulation of physicochemical and biological properties to suit intended applications. The mats were further loaded with a topical antibiotic (neomycin sulfate), and cumulative drug-release monitored for 3 weeks in vitro. Microscopic imaging as well as Scanning Electron Microscopy (SEM) studies showed pore dimensions of 100 × 400 µm. These pore dimensions were achieved without compromising mechanical strength; because of the "tough" individual fibers constituting the mat (Young's Moduli of 50 ± 20 MPa and Elastic Elongation of 10 ± 5%). The in vitro dissolution study showed first-order release kinetics for neomycin during the first 20 h, followed by diffusion-controlled (Fickian) release for the remaining duration of the study. The release of neomycin suggested that the ability to load neomycin on to PLLA mats increases threefold, as the MW of the applied PEG coating is lowered from 20 kDa to 400 Da. Overall, this study demonstrates a successful approach to using a 3D printer to prepare porous degradable mats for antibiotic delivery with potential applications to dermal regeneration and tissue engineering. Illustration of the process used to create and characterize 3D printed PLLA mats.

Indirect Temperature Measurement in High Frequency Heating Systems

One of the biggest challenges of fused deposition modeling (FDM)/fused filament fabrication (FFF) 3D-printing is maintaining consistent quality of layer-to-layer adhesion, and on the larger scale, homogeneity of material inside the whole printed object. An approach for mitigating and/or resolving those problems, based on the rapid and reliable control of the extruded material temperature during the printing process, was proposed. High frequency induction heating of the nozzle with a minimum mass (<1 g) was used. To ensure the required dynamic characteristics of heating and cooling processes in a high power (peak power > 300 W) heating system, an indirect (eddy current) temperature measurement method was proposed. It is based on dynamic analysis over various temperature-dependent parameters directly in the process of heating. To ensure better temperature measurement accuracy, a series-parallel resonant circuit containing an induction heating coil, an approach of desired signal detection, algorithms for digital signal processing and a regression model that determines the dependence of the desired signal on temperature and magnetic field strength were proposed. The testbed system designed to confirm the results of the conducted research showed the effectiveness of the proposed indirect measurement method. With an accuracy of ±3 °C, the measurement time is 20 ms in the operating temperature range from 50 to 350 °C. The designed temperature control system based on an indirect measurement method will provide high mechanical properties and consistent quality of printed objects.

Improvement of Interlayer Adhesion and Heat Resistance of Biodegradable Ternary Blend Composite 3D Printing

Poly(lactic acid) (PLA) filaments have been the most used in fused deposition modeling (FDM) 3D printing. The filaments, based on PLA, are continuing to be developed to overcome brittleness, low heat resistance, and obtain superior mechanical performance in 3D printing. From our previous study, the binary blend composites from PLA and poly(butylene adipate-co-terephthalate) (PBAT) with nano talc (PLA/PBAT/nano talc) at 70/30/10 showed an improvement in toughness and printability in FDM 3D printing. Nevertheless, interlayer adhesion, anisotropic characteristics, and heat resistance have been promoted for further application in FDM 3D printing. In this study, binary and ternary blend composites from PLA/PBAT and poly(butylene succinate) (PBS) with nano talc were prepared at a ratio of PLA 70 wt. % and blending with PBAT or PBS at 30 wt. % and nano talc at 10 wt. %. The materials were compounded via a twin-screw extruder and applied to the filament using a capillary rheometer. PLA/PBAT/PBS/nano talc blend composites were printed using FDM 3D printing. Thermal analysis, viscosity, interlayer adhesion, mechanical properties, and dimensional accuracy of binary and ternary blend composite 3D prints were investigated. The incorporation of of PBS-enhanced crystallinity of the blend composite 3D prints resulted in an improvement to mechanical properties, heat resistance, and anisotropic characteristics. Flexibility of the blend composites was obtained by presentation of PBAT. It should be noted that the core-shell morphology of the ternary blend influenced the reduction of volume shrinkage, which obtained good surface roughness and dimensional accuracy in the ternary blend composite 3D printing.

Enhancing Mechanical Properties of Polymer 3D Printed Parts

Parts made from thermoplastic polymers fabricated through 3D printing have reduced mechanical properties compared to those fabricated through injection molding. This paper analyzes a post-processing heat treatment aimed at enhancing mechanical properties of 3D printed parts, in order to reduce the difference mentioned above and thus increase their applicability in functional applications. Polyethylene Terephthalate Glycol (PETG) polymer is used to 3D print test parts with 100% infill. After printing, samples are packed in sodium chloride powder and then heat treated at a temperature of 220 °C for 5 to 15 min. During heat treatment, the powder acts as support, preventing deformation of the parts. Results of destructive testing experiments show a significant increase in tensile and compressive strength following heat treatment. Treated parts 3D printed in vertical orientation, usually the weakest, display 143% higher tensile strength compared to a control group, surpassing the tensile strength of untreated parts printed in horizontal orientation—usually the strongest. Furthermore, compressive strength increases by 50% following heat treatment compared to control group. SEM analysis reveals improved internal structure after heat treatment. These results show that the investigated heat treatment increases mechanical characteristics of 3D printed PETG parts, without the downside of severe part deformation, thus reducing the performance gap between 3D printing and injection molding when using common polymers.

A review on spacers and membranes: Conventional or hybrid additive manufacturing?

Over the past decade, 3D printing or additive manufacturing (AM) technology has seen great advancement in many aspects such as printing resolution, speed and cost. Membranes for water treatment experienced significant breakthroughs owing to the unique benefits of additive manufacturing. In particular, 3D printing's high degree of freedom in various aspects such as material and prototype design has helped to fabricate innovative spacers and membranes. However, there were conflicting reports on the feasibility of 3D printing, especially for membranes. Some research groups stated that technology limitations today made it impossible to 3D print membranes, but others showed that it was possible by successfully fabricating prototypes. This paper will provide a critical and comprehensive discussion on 3D printing specifically for spacers and membranes. Various 3D printing techniques will be introduced, and their suitability for membrane and spacer fabrication will be discussed. It will be followed by a review of past studies associated with 3D-printed spacers and membranes. A new category of additive manufacturing in the membrane water industry will be introduced here, known as hybrid additive manufacturing, to address the controversies of 3D printing for membrane. As AM technology continues to advance, its possibilities in the water treatment is limitless. Some insightful future trends will be provided at the end of the paper.

The Influence of Sub-Zero Conditions on the Mechanical Properties of Polylactide-Based Composites

Polylactide-based composites filled with waste fillers due to their sustainability are a subject of many current papers, in which their structural, mechanical, and thermal properties are evaluated. However, few studies focus on their behavior in low temperatures. In this paper, dynamic and quasi-static mechanical properties of polylactide-based composites filled with 10 wt% of linseed cake (a by-product of mechanical oil extraction from linseed) were evaluated at room temperature and at -40 °C by means of dynamic mechanical analysis (DMA), Charpy's impact strength test and uniaxial tensile test. It was found that the effect of plasticization provided by the oil contained in the filler at room temperature is significantly reduced in sub-zero conditions due to solidification of the oil around -18 °C, as it was shown by differential scanning calorimetry (DSC) and DMA, but the overall mechanical performance of the polylactide-based composites was sufficient to enable their use in low-temperature applications.

Crystallization of polylactide-based green composites filled with oil-rich waste fillers

Polylactide is a highly demanded biopolymer, whose industrial application constantly increases. Its disadvantages such as brittleness and slow crystallization rate can be overcome by application of different additives. Because of environmental issues, using natural waste fillers as modifying agents for polylactide is especially interesting. In this study linseed cake, a byproduct of oil extraction from linseed, characterized by oil content of 0.9–39.8 wt.%, was added to polylactide to influence its crystallization behavior. The formation of the crystalline phase was studied by differential scanning calorimetry in isothermal and non-isothermal conditions and analyzed according to methods by Jeziorny, Ozawa, Mo and Avrami. The samples’ microstructures were observed using polarized light microscopy. The crystallization rate and Avrami exponent of samples crystallized in different conditions were evaluated. It was found that addition of 10 wt.% of linseed cake containing at least 17.7 wt.% oil notably changes the crystallization of polylactide, increasing its crystallinity and promoting the growth of crystallites.

Review of Synthetic and Hybrid Scaffolds in Cartilage Tissue Engineering

Cartilage tissue is under extensive investigation in tissue engineering and regenerative medicine studies because of its limited regenerative potential. Currently, many scaffolds are undergoing scientific and clinical research. A key for appropriate scaffolding is the assurance of a temporary cellular environment that allows the cells to function as in native tissue. These scaffolds should meet the relevant requirements, including appropriate architecture and physicochemical and biological properties. This is necessary for proper cell growth, which is associated with the adequate regeneration of cartilage. This paper presents a review of the development of scaffolds from synthetic polymers and hybrid materials employed for the engineering of cartilage tissue and regenerative medicine. Initially, general information on articular cartilage and an overview of the clinical strategies for the treatment of cartilage defects are presented. Then, the requirements for scaffolds in regenerative medicine, materials intended for membranes, and methods for obtaining them are briefly described. We also describe the hybrid materials that combine the advantages of both synthetic and natural polymers, which provide better properties for the scaffold. The last part of the article is focused on scaffolds in cartilage tissue engineering that have been confirmed by undergoing preclinical and clinical tests.

The Transferability and Design of Commercial Printer Settings in PLA/PBAT Fused Filament Fabrication

In many fused filament fabrication (FFF) processes, commercial printers are used, but rarely are printer settings transferred from one commercial printer to the other to give similar final tensile part performance. Here, we report such translation going from the Felix 3.0 to Prusa i3 MK3 printer by adjusting the flow rate and overlap of strands, utilizing an in-house developed blend of polylactic acid (PLA) and poly(butylene adipate-co-terephthalate) (PBAT). We perform a sensitivity analysis for the Prusa printer, covering variations in nozzle temperature, nozzle diameter, layer thickness, and printing speed (Tnozzle, dnozzle, LT, and vprint), aiming at minimizing anisotropy and improving interlayer bonding. Higher mass, larger width, and thickness are obtained with larger dnozzle, lower vprint, higher LT, and higher Tnozzle. A higher vprint results in less tensile strain at break, but it remains at a high strain value for samples printed with dnozzle equal to 0.5 mm. vprint has no significant effect on the tensile modulus and tensile and impact strength of the samples. If LT is fixed, an increased dnozzle is beneficial for the tensile strength, ductility, and impact strength of the printed sample due to better bonding from a wider raster structure, while an increased LT leads to deterioration of mechanical properties. If the ratio dnozzle/LT is greater than 2, a good tensile performance is obtained. An improved Tnozzle leads to a sufficient flow of material, contributing to the performance of the printed device. The considerations brought forward result in a deeper understanding of the FFF process and offer guidance about parameter selection. The optimal dnozzle/vprint/LT/Tnozzle combination is 0.5 mm/120 mm s-1/0.15 mm/230 °C.

Parameters Affecting the Mechanical Properties of Three-Dimensional (3D) Printed Carbon Fiber-Reinforced Polylactide Composites

Three-dimensional (3D) printing is a manufacturing technology which creates three-dimensional objects layer-by-layer or drop-by-drop with minimal material waste. Despite the fact that 3D printing is a versatile and adaptable process and has advantages in establishing complex and net-shaped structures over conventional manufacturing methods, the challenge remains in identifying the optimal parameters for the 3D printing process. This study investigated the influence of processing parameters on the mechanical properties of Fused Deposition Modelling (FDM)-printed carbon fiber-filled polylactide (CFR-PLA) composites by employing an orthogonal array model. After printing, the tensile and impact strengths of the printed composites were measured, and the effects of different parameters on these strengths were examined. The experimental results indicate that 3D-printed CFR-PLA showed a rougher surface morphology than virgin PLA. For the variables selected in this analysis, bed temperature was identified as the most influential parameter on the tensile strength of CFR-PLA-printed parts, while bed temperature and print orientation were the key parameters affecting the impact strengths of printed composites. The 45° orientation printed parts also showed superior mechanical strengths than the 90° printed parts.

Integration of 3D-printing for a desorption electrospray ionization source for mass spectrometry

The field of ambient ionization mass spectrometry has witnessed the development of many novel and capable methods for the analysis and imaging of surfaces, with desorption electrospray ionization being a prominent technique that has been commercialized. The adaptation of this technique to existing mass spectrometry platforms requires a laboratory-built solution manufactured with the capability of fine, stable adjustments of the electrospray emitter for liquid or solid sampling purposes. The development, fabrication, and machining require tens of hours of labor for many custom solutions. Herein described is a highly modifiable alternative approach for the fabrication of a desorption electrospray ionization source, using computer-aided design and fused deposition modeling to three-dimensionally print a source platform that utilizes standard accessories of a commercial Bruker Daltonics mass spectrometer. Three-dimensional printing allows for the inexpensive, rapid development of highly modifiable plastic parts, with the total printing time of the apparatus requiring a singular day and only a few dollars of material using a consumer grade printer. To demonstrate the utility of this printed desorption electrospray ionization source, it was fitted on an unmodified Fourier transform ion cyclotron resonance mass spectrometer for a lipid fingerprint analysis in serial sections of rat brain tissue, with the acquisition of line scans of dye-coated slides for the demonstration of serial acquisition.

Recent advances in additive manufacturing of engineering thermoplastics: challenges and opportunities

There are many limitations within three-dimensional (3D) printing that hinder its adaptation into industries such as biomedical, cosmetic, processing, automotive, aerospace, and electronics. The disadvantages of 3D printing include the inability of parts to function in weight-bearing applications, reduced mechanical performance from anisotropic properties of printed products, and limited intrinsic material performances such as flame retardancy, thermal stability, and/or electrical conductivity. Many of these shortcomings have prevented the adaptation of 3D printing into product development, especially with few novel researched materials being sold commercially. In many cases, high-performance engineering thermoplastics (ET) provide a basis for increased thermal and mechanical performances to address the shortcomings or limitations of both selective laser sintering and extrusion 3D printing. The first strategy to combat these limitations is to fabricate blends or composites. Novel printing materials have been implemented to reduce anisotropic properties and losses in strength. Additives such as flame retardants generate robust materials with V0 flame retardancy ratings, and compatibilizers can improve thermal or dimensional stability. To serve the electronic industry better, the addition of carbon black at only 4 wt%, to an ET matrix has been found to improve the electrical conductivity by five times the magnitude. Surface modifications such as photopolymerization have improved the usability of ET in automotive applications, whereas the dynamic chemical processes increased the biocompatibility of ET for medical device materials. Thermal resistant foam from polyamide 12 and fly ash spheres were researched and fabricated as possible insulation materials for automotive industries. These works and others have not only generated great potential for additive manufacturing technologies, but also provided solutions to critical challenges of 3D printing.

Tribological and Dynamical Mechanical Behavior of Prototyped PLA-Based Polymers

It is essential to combine current state-of-the-art technologies such as additive manufacturing with current ecological needs. Due to the increasing demand for non-toxic biodegradable materials and products, human society has been searching for new materials. Consequently, it is compulsory to identify the qualities of these materials and their behavior when subjected to various external factors, to find their optimal solutions for application in various fields. This paper refers to the biodegradable Polylactic acid (PLA)-based filament (commercially known as Extrudr BDP (Biodegradable Plastic) Flax) compared with the biodegradable composite material PLA-lignin filament whose constituent's trade name is Arboblend V2 Nature as a lignin base material and reinforcement with Extrudr BDP Pearl, a PLA based polymer, 3D printed by Fused Deposition Modeling technology. Certain mechanical properties (tensile strength, bending strength and DMA-Dynamic Mechanical Analysis) were also determined. The tribology behavior (friction coefficient and wear), the structure and the chemical composition of the biodegradable materials were investigated by SEM-Scanning Electron Microscopy, EDX-Energy Dispersive X-Ray Analysis, XRD-X-Ray Diffraction Analysis, FTIR-Fourier Transform Infrared Spectrometer and TGA-Thermogravimetric Analysis. The paper also refers to the influence of technological parameters on the 3D printed filaments made of Extrudr BDP Flax and the optimization those of technological parameters. The thermal behavior during the heating of the sample was analyzed by Differential scanning calorimetry (DSC). As a result of the carried-out research, we intend to recommend these biodegradable materials as possible substituents for plastics in as many fields of activity as possible.

Estimation of the Adhesion Interface Performance in Aluminum-PLA Joints by Thermographic Monitoring of the Material Extrusion Process

Using additive manufacturing to generate a polymer-metal structure offers the potential to achieve a complex customized polymer structure joined to a metal base of high stiffness and strength. A tool to evaluate the generated interface during the process is of fundamental interest, as the sequential deposition of the polymer as well as temperature gradients within the substrate lead to local variations in adhesion depending on the local processing conditions. On preheated aluminum substrates, 0.3 and 0.6 mm high traces of polylactic acid (PLA) were deposited. Based on differential scanning calorimetry (DSC) and rheometry measurements, the substrate temperature was varied in between 150 and 200 °C to identify an optimized manufacturing process. Decreasing the layer height and increasing the substrate temperature promoted wetting and improved the adhesion interface performance as measured in a single lap shear test (up to 7 MPa). Thermographic monitoring was conducted at an angle of 25° with respect to the substrate surface and allowed a thermal evaluation of the process at any position on the substrate. Based on the thermographic information acquired during the first second after extrusion and the preset shape of the polymer trace, the resulting wetting and shear strength were estimated.

Study on the 3D printability of poly(3-hydroxybutyrate-co-3-hydroxyvalerate)/poly(lactic acid) blends with chain extender using fused filament fabrication

In this study, the 3D printability of a series of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV)/poly(lactic acid) (PLA) blends were investigated using fused filament fabrication (FFF). The studied blends suffered from poor 3D printability due to differences in compatibility and low thermal resistance. These shortcomings were addressed by incorporating a functionalized styrene-acrylate copolymer with oxirane moieties as a chain extender (CE). To enhance mechanical properties, the synergistic effect of 3D printing parameters such as printing temperature and speed, layer thickness and bed temperature were explored. Rheological analysis showed improvement in the 3D printability of PHBV:PLA:CE blend by allowing a higher printing temperature (220 °C) and sufficient printing speed (45 mm s⁻¹). The surface morphology of fractured tensile specimens showed good bonding between layers when a bed temperature of 60 °C was used and a layer thickness of 0.25 mm was designed. The optimized printing samples shown higher storage modulus and strength, resulting in stiffer and stronger parts. The crystallinity, morphology and performance of the 3D printed products were correlated to share key methods to improve the 3D printability of PHBV:PLA based blends which may be implemented in other biopolymer blends, and further highlight how process parameters enhance the mechanical performance of 3D printed products.

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.