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Jamal MA, Shah OR, Ghafoor U, Qureshi Y, Bhutta MR. Additive Manufacturing of Continuous Fiber-Reinforced Polymer Composites via Fused Deposition Modelling: A Comprehensive Review. Polymers (Basel) 2024; 16:1622. [PMID: 38931971 PMCID: PMC11207325 DOI: 10.3390/polym16121622] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/29/2024] [Revised: 05/27/2024] [Accepted: 05/27/2024] [Indexed: 06/28/2024] Open
Abstract
Additive manufacturing (AM) has arisen as a transformative technology for manufacturing complex geometries with enhanced mechanical properties, particularly in the realm of continuous fiber-reinforced polymer composites (CFRPCs). Among various AM techniques, fused deposition modeling (FDM) stands out as a promising method for the fabrication of CFRPCs due to its versatility, ease of use, flexibility, and cost-effectiveness. Several research papers on the AM of CFRPs via FDM were summarized and therefore this review paper provides a critical examination of the process-printing parameters influencing the AM process, with a focus on their impact on mechanical properties. This review covers details of factors such as fiber orientation, layer thickness, nozzle diameter, fiber volume fraction, printing temperature, and infill design, extracted from the existing literature. Through a visual representation of the process parameters (printing and material) and properties (mechanical, physical, and thermal), this paper aims to separate out the optimal processing parameters that have been inferred from various research studies. Furthermore, this analysis critically evaluates the current state-of-the-art research, highlighting advancements, applications, filament production methods, challenges, and opportunities for further development in this field. In comparison to short fibers, continuous fiber filaments can render better strength; however, delamination issues persist. Various parameters affect the printing process differently, resulting in several limitations that need to be addressed. Signifying the relationship between printing parameters and mechanical properties is vital for optimizing CFRPC fabrication via FDM, enabling the realization of lightweight, high-strength components for various industrial applications.
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Affiliation(s)
- Muhammad Azfar Jamal
- Department of Mechanical Engineering, Institute of Space Technology, Islamabad 44000, Pakistan; (M.A.J.); (O.R.S.); (Y.Q.)
| | - Owaisur Rahman Shah
- Department of Mechanical Engineering, Institute of Space Technology, Islamabad 44000, Pakistan; (M.A.J.); (O.R.S.); (Y.Q.)
| | - Usman Ghafoor
- Department of Logistics & Supply Chain Management, NUST Business School, National University of Science and Technology, Islamabad 44000, Pakistan
| | - Yumna Qureshi
- Department of Mechanical Engineering, Institute of Space Technology, Islamabad 44000, Pakistan; (M.A.J.); (O.R.S.); (Y.Q.)
| | - M. Raheel Bhutta
- Department of Electrical and Computer Engineering, University of Utah, Asia Campus, Incheon 21985, Republic of Korea
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Ralls AM, Monette Z, Kasar AK, Menezes PL. Enhancing Tribological Performance of Self-Lubricating Composite via Hybrid 3D Printing and In Situ Spraying. MATERIALS (BASEL, SWITZERLAND) 2024; 17:2601. [PMID: 38893868 PMCID: PMC11173934 DOI: 10.3390/ma17112601] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/13/2024] [Revised: 05/13/2024] [Accepted: 05/21/2024] [Indexed: 06/21/2024]
Abstract
In this work, a self-lubricating composite was manufactured using a novel hybrid 3D printing/in situ spraying process that involved the printing of an acrylonitrile butadiene styrene (ABS) matrix using fused deposition modeling (FDM), along with the in situ spraying of alumina (Al2O3) and hexagonal boron nitride (hBN) reinforcements during 3D printing. The results revealed that the addition of the reinforcement induced an extensive formation of micropores throughout the ABS structure. Under tensile-loading conditions, the mechanical strength and cohesive interlayer bonding of the composites were diminished due to the presence of these micropores. However, under tribological conditions, the presence of the Al2O3 and hBN reinforcement improved the frictional resistance of ABS in extreme loading conditions. This improvement in frictional resistance was attributed to the ability of the Al2O3 reinforcement to support the external tribo-load and the shearing-like ability of hBN reinforcement during sliding. Collectively, this work provides novel insights into the possibility of designing tribologically robust ABS components through the addition of in situ-sprayed ceramic and solid-lubricant reinforcements.
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Affiliation(s)
| | | | | | - Pradeep L. Menezes
- Department of Mechanical Engineering, University of Nevada Reno, Reno, NV 89557, USA; (A.M.R.); (Z.M.); (A.K.K.)
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Anwajler B, Witek-Krowiak A. Three-Dimensional Printing of Multifunctional Composites: Fabrication, Applications, and Biodegradability Assessment. MATERIALS (BASEL, SWITZERLAND) 2023; 16:7531. [PMID: 38138674 PMCID: PMC10744785 DOI: 10.3390/ma16247531] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/05/2023] [Revised: 11/30/2023] [Accepted: 12/04/2023] [Indexed: 12/24/2023]
Abstract
Additive manufacturing, with its wide range of printable materials, and ability to minimize material usage, reduce labor costs, and minimize waste, has sparked a growing enthusiasm among researchers for the production of advanced multifunctional composites. This review evaluates recent reports on polymer composites used in 3D printing, and their printing techniques, with special emphasis on composites containing different types of additives (inorganic and biomass-derived) that support the structure of the prints. Possible applications for additive 3D printing have also been identified. The biodegradation potential of polymeric biocomposites was analyzed and possible pathways for testing in different environments (aqueous, soil, and compost) were identified, including different methods for evaluating the degree of degradation of samples. Guidelines for future research to ensure environmental safety were also identified.
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Affiliation(s)
- Beata Anwajler
- Department of Energy Conversion Engineering, Faculty of Mechanical and Power Engineering, Wroclaw University of Science and Technology, 27 Wybrzeze Wyspianskiego Street, 50-370 Wroclaw, Poland
| | - Anna Witek-Krowiak
- Department of Advanced Material Technologies, Faculty of Chemistry, Wroclaw University of Science and Technology, 27 Wybrzeze Wyspianskiego Street, 50-370 Wroclaw, Poland;
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Marshall H, Selvan T, Ahmad R, Bento M, Veiga C, Sands G, Malone C, King RB, Clark CH, McGarry CK. Evaluation of a novel phantom for the quality assurance of a six-degree-of-freedom couch 3D-printed at multiple centres. Phys Med 2023; 114:103136. [PMID: 37769414 DOI: 10.1016/j.ejmp.2023.103136] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Submit a Manuscript] [Subscribe] [Scholar Register] [Received: 04/03/2023] [Revised: 08/18/2023] [Accepted: 09/13/2023] [Indexed: 09/30/2023] Open
Abstract
This study aimed to validate a bespoke 3D-printed phantom for use in quality assurance (QA) of a 6 degrees-of-freedom (6DoF) treatment couch. A novel phantom design comprising a main body with internal cube structures, was fabricated at five centres using Polylactic Acid (PLA) material, with an additional phantom produced incorporating a PLA-stone hybrid material. Correctional setup shifts were determined using image registration by 3D-3D matching of high HU cube structures between obtained cone-beam computer tomography (CBCT) images to reference CTs, containing cubes with fabricated rotational offsets of 3.5°, 1.5° and -2.5° in rotation, pitch, and roll, respectively. Average rotational setup shifts were obtained for each phantom. The reproducibility of 3D-printing was probed by comparing the internal cube size as well as Hounsfield Units between each of the uniquely produced phantoms. For the five PLA phantoms, the average rot, pitch and roll correctional differences from the fabricated offsets were -0.3 ± 0.2°, -0.2 ± 0.5° and 0.2 ± 0.3° respectively, and for the PLA hybrid these differences were -0.09 ± 0.14°, 0.30 ± 0.00° and 0.03 ± 0.10°. There was found to be no statistically significant difference in average cube size between the five PLA printed phantoms, with the significant difference (P < 0.05) in HU of one phantom compared to the others attributed to setup choice and material density. This work demonstrated the capability producing a novel 3D-printed 6DoF couch QA phantom design, at multiple centres, with each unique model capable of sub-degree couch correction.
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Affiliation(s)
- Hannah Marshall
- Patrick G. Johnston Centre for Cancer Research, Queen's University Belfast, Belfast, UK.
| | - Tamil Selvan
- Department of Radiotherapy Physics, Northern Ireland Cancer Centre, Belfast Health and Social Care Trust, Belfast, UK
| | - Reem Ahmad
- Department of Medical Physics and Biomedical Engineering, University College London, London, UK
| | - Mariana Bento
- Department of Medical Physics and Biomedical Engineering, University College London, London, UK
| | - Catarina Veiga
- Department of Medical Physics and Biomedical Engineering, University College London, London, UK
| | - Gordon Sands
- Radiotherapy Physics, UCLH NHS Foundation Trust, London, UK
| | - Ciaran Malone
- Radiotherapy Physics, St. Luke's Radiation Oncology Network, Dublin, Ireland
| | - Raymond B King
- Department of Radiotherapy Physics, Northern Ireland Cancer Centre, Belfast Health and Social Care Trust, Belfast, UK
| | - Catharine H Clark
- Department of Medical Physics and Biomedical Engineering, University College London, London, UK; Radiotherapy Physics, UCLH NHS Foundation Trust, London, UK; Metrology for Medical Physics, National Physical Laboratory, Teddington, UK
| | - Conor K McGarry
- Patrick G. Johnston Centre for Cancer Research, Queen's University Belfast, Belfast, UK; Department of Radiotherapy Physics, Northern Ireland Cancer Centre, Belfast Health and Social Care Trust, Belfast, UK
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Anwajler B, Zdybel E, Tomaszewska-Ciosk E. Innovative Polymer Composites with Natural Fillers Produced by Additive Manufacturing (3D Printing)-A Literature Review. Polymers (Basel) 2023; 15:3534. [PMID: 37688160 PMCID: PMC10489793 DOI: 10.3390/polym15173534] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/31/2023] [Revised: 08/18/2023] [Accepted: 08/23/2023] [Indexed: 09/10/2023] Open
Abstract
In recent years, plastics recycling has become one of the leading environmental and waste management issues. Along with the main advantage of plastics, which is undoubtedly their long life, the problem of managing their waste has arisen. Recycling is recognised as the preferred option for waste management, with the aim of reusing them to create new products using 3D printing. Additive manufacturing (AM) is an emerging and evolving rapid tooling technology. With 3D printing, it is possible to achieve lightweight structures with high dimensional accuracy and reduce manufacturing costs for non-standard geometries. Currently, 3D printing research is moving towards the production of materials not only of pure polymers but also their composites. Bioplastics, especially those that are biodegradable and compostable, have emerged as an alternative for human development. This article provides a brief overview of the possibilities of using thermoplastic waste materials through the application of 3D printing, creating innovative materials from recycled and naturally derived materials, i.e., biomass (natural reinforcing fibres) in 3D printing. The materials produced from them are ecological, widely available and cost-effective. Research activities related to the production of bio-based materials have gradually increased over the last two decades, with the aim of reducing environmental problems. This article summarises the efforts made by researchers to discover new innovative materials for 3D printing.
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Affiliation(s)
- Beata Anwajler
- Faculty of Mechanical and Power Engineering, Wroclaw University of Science and Technology, 27 Wybrzeze Wyspianskiego Street, 50-370 Wroclaw, Poland
| | - Ewa Zdybel
- Department of Food Storage and Technology, Wroclaw University of Environmental and Life Sciences, 25 Norwida Street, 50-375 Wroclaw, Poland; (E.Z.); (E.T.-C.)
| | - Ewa Tomaszewska-Ciosk
- Department of Food Storage and Technology, Wroclaw University of Environmental and Life Sciences, 25 Norwida Street, 50-375 Wroclaw, Poland; (E.Z.); (E.T.-C.)
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Li Y, Ren X, Zhu L, Li C. Biomass 3D Printing: Principles, Materials, Post-Processing and Applications. Polymers (Basel) 2023; 15:2692. [PMID: 37376338 DOI: 10.3390/polym15122692] [Citation(s) in RCA: 7] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/01/2023] [Revised: 06/12/2023] [Accepted: 06/13/2023] [Indexed: 06/29/2023] Open
Abstract
Under the background of green and low-carbon era, efficiently utilization of renewable biomass materials is one of the important choices to promote ecologically sustainable development. Accordingly, 3D printing is an advanced manufacturing technology with low energy consumption, high efficiency, and easy customization. Biomass 3D printing technology has attracted more and more attentions recently in materials area. This paper mainly reviewed six common 3D printing technologies for biomass additive manufacturing, including Fused Filament Fabrication (FFF), Direct Ink Writing (DIW), Stereo Lithography Appearance (SLA), Selective Laser Sintering (SLS), Laminated Object Manufacturing (LOM) and Liquid Deposition Molding (LDM). A systematic summary and detailed discussion were conducted on the printing principles, common materials, technical progress, post-processing and related applications of typical biomass 3D printing technologies. Expanding the availability of biomass resources, enriching the printing technology and promoting its application was proposed to be the main developing directions of biomass 3D printing in the future. It is believed that the combination of abundant biomass feedstocks and advanced 3D printing technology will provide a green, low-carbon and efficient way for the sustainable development of materials manufacturing industry.
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Affiliation(s)
- Yongxia Li
- National Forestry and Grassland Engineering Technology Center for Wood Resources Recycling, College of Materials Science and Technology, Beijing Forestry University, Beijing 100083, China
| | - Xueyong Ren
- National Forestry and Grassland Engineering Technology Center for Wood Resources Recycling, College of Materials Science and Technology, Beijing Forestry University, Beijing 100083, China
| | - Lin Zhu
- National Forestry and Grassland Engineering Technology Center for Wood Resources Recycling, College of Materials Science and Technology, Beijing Forestry University, Beijing 100083, China
| | - Chunmiao Li
- National Forestry and Grassland Engineering Technology Center for Wood Resources Recycling, College of Materials Science and Technology, Beijing Forestry University, Beijing 100083, China
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Fogarasi M, Snodderly K, Herman A, Guha S, Porter D. Benchtop assessment of sealing efficacy and breathability of additively manufactured (AM) face masks. ADDITIVE MANUFACTURING 2023; 67:103468. [PMID: 36925558 PMCID: PMC9974208 DOI: 10.1016/j.addma.2023.103468] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 05/16/2022] [Revised: 01/20/2023] [Accepted: 02/23/2023] [Indexed: 05/23/2023]
Abstract
The onset of the 2019 novel coronavirus disease (COVID-19) led to a shortage of personal protective equipment (PPE), medical devices, and other medical supplies causing many stakeholders and the general public alike to turn to additive manufacturing (AM) as a stopgap when normally accessible devices were not available. However, without a method to test these AM constructs, there continued to be a disconnect between AM suppliers and the community's needs. The objective of this study was to characterize the pressure drop and leakage of four different publicly available AM face mask models with two filter material combinations, as well as to investigate the impact of frame modification techniques including the use of foam strips and hot-water face forming to improve fit when the masks are donned on manikin head forms. AM face mask frame designs were downloaded from public repositories during the early stages of the COVID-19 pandemic. AM face masks were fabricated and tested on manikin head forms within a custom chamber containing dry aerosolized NaCl. Pressure drops, particle penetration, and leakage were evaluated for various flow rates and NaCl concentrations. Results indicated that filter material combination and frame modification played a major role in the overall performance of the AM face masks studied. Filter material combinations showed improved performance when high filtration fabric was used, and the cross-sectional area of the fabric was increased. AM frame modifications appeared to improve AM face mask leakage performance by as much as 69.6%.
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Affiliation(s)
- Magdalene Fogarasi
- Division of Applied Mechanics, Office of Science and Engineering Laboratories, Center for Devices and Radiological Health, United States Food and Drug Administration, Silver Spring, MD 20993, USA
| | - Kirstie Snodderly
- Division of Applied Mechanics, Office of Science and Engineering Laboratories, Center for Devices and Radiological Health, United States Food and Drug Administration, Silver Spring, MD 20993, USA
| | - Alexander Herman
- Division of Applied Mechanics, Office of Science and Engineering Laboratories, Center for Devices and Radiological Health, United States Food and Drug Administration, Silver Spring, MD 20993, USA
| | - Suvajyoti Guha
- Division of Applied Mechanics, Office of Science and Engineering Laboratories, Center for Devices and Radiological Health, United States Food and Drug Administration, Silver Spring, MD 20993, USA
| | - Daniel Porter
- Division of Applied Mechanics, Office of Science and Engineering Laboratories, Center for Devices and Radiological Health, United States Food and Drug Administration, Silver Spring, MD 20993, USA
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Experimental Study on the Possibilities of FDM Direct Colour Printing and Its Implications on Mechanical Properties and Surface Quality of the Resulting Parts. Polymers (Basel) 2022; 14:polym14235173. [PMID: 36501568 PMCID: PMC9741394 DOI: 10.3390/polym14235173] [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: 11/14/2022] [Revised: 11/24/2022] [Accepted: 11/25/2022] [Indexed: 11/30/2022] Open
Abstract
The present paper aims to contribute to the methodology of 3D printing in-process colouring and study its implications and impact on the tensile strength and surface quality of the obtained parts. The proposed study was based on a Taguchi L27 DOE plan using standardised EN ISO 527-2 type 1B-shaped specimens, in which four factors on three levels were considered. The obtained results highlight the possibility of using the presented in-process colouring method. Different materials (PLA, PLA+, and PETG) with varying infill densities (15%, 30%, and 50%), colour distribution (33%, 66%, and 99%), and colour pigments (blue, green, and red) were studied and the results highlighted that the most influential parameter on the tensile strength of the parts was infill density, followed by the tested material, colour pigment, and colouring percentage; regarding surface roughness, the most influential parameter was infill density, followed by colouring percentage, colour pigment, and material. Moreover, the values resulting from the Taguchi DOE were compared to uncoloured parts, from which it could be concluded that the colouring of the parts had direct implications (negative for tensile strength and positive for surface roughness).
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Tosto C, Bragaglia M, Nanni F, Recca G, Cicala G. Fused Filament Fabrication of Alumina/Polymer Filaments for Obtaining Ceramic Parts after Debinding and Sintering Processes. MATERIALS (BASEL, SWITZERLAND) 2022; 15:7399. [PMID: 36295462 PMCID: PMC9607584 DOI: 10.3390/ma15207399] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/08/2022] [Revised: 10/14/2022] [Accepted: 10/19/2022] [Indexed: 06/16/2023]
Abstract
In this paper, a hybrid commercially available alumina/polymer filament was 3D printed and thermally treated (debinding and sintering) to obtain ceramic parts. Microscopic and spectroscopic analysis was used to thoroughly characterize the green and sintered parts in terms of their mesostructured, as well as their flexural properties. The sintered samples show an α alumina crystalline phase with a mean density of 3.80 g/cm3, a tensile strength of 232.6 ± 12.3 MPa, and a Vickers hardness of 21 ± 0.7 GPa. The mean thermal conductivity value at room temperature was equal to 21.52 ± 0.02 W/(mK). The values obtained through FFF production are lower than those obtained by conventional processes as the 3D-printed samples exhibited imperfect interlayer bonding and voids similar to those found in the structures of polymeric FFFs. Nonetheless, the highly filled ceramic filament is suitable for use in affordable and easy-to-operate FFF machines, as shown by the cost analysis of a real printed and sintered FFF part.
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Affiliation(s)
- Claudio Tosto
- Department of Civil Engineering and Architecture, University of Catania, Viale Andrea Doria 6, 95125 Catania, Italy
| | - Mario Bragaglia
- Department of Enterprise Engineering “Mario Lucertini”, University of Rome “Tor Vergata”, INSTM RU Roma—Tor Vergata, Via del Politecnico 1, 00133 Rome, Italy
| | - Francesca Nanni
- Department of Enterprise Engineering “Mario Lucertini”, University of Rome “Tor Vergata”, INSTM RU Roma—Tor Vergata, Via del Politecnico 1, 00133 Rome, Italy
| | - Giuseppe Recca
- Institute for Polymers, Composites and Biomaterials, IPCB-CNR, Via Gaifami 18, 95126 Catania, Italy
| | - Gianluca Cicala
- Department of Civil Engineering and Architecture, University of Catania, Viale Andrea Doria 6, 95125 Catania, Italy
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