Implementing FDM 3D Printing Strategies Using Natural Fibers to Produce Biomass Composite

Challenges to Improve Extrusion-Based Additive Manufacturing Process of Thermoplastics toward Sustainable Development

This review aims to present the different approaches to lessen the environmental impact of the extrusion-based additive manufacturing (MEX) process of thermoplastic-based resins and protect the ecosystem. The benefits and drawbacks of each alternative, including the use of biomaterials or recycled materials as feedstock, energy efficiency, and polluting emissions reduction, have been examined. First, the technological option of using a pellet-fed printer was compared to a filament-fed printer. Then, common biopolymers utilized in MEX applications are discussed, along with methods for improving the mechanical properties of associated printed products. The introduction of natural fillers in thermoplastic resins and the use of biocomposite filaments have been proposed to improve the specific performance of printed items, highlighting the numerous challenges related to their extrusion. Various polymers and fillers derived from recycling are presented as feeding raw materials for printers to reduce waste accumulation, showing the inferior qualities of the resulting goods when compared to printed products made from virgin materials. Finally, the energy consumption and emissions released into the atmosphere during the printing process are discussed, with the potential for both aspects to be controlled through material selection and operating conditions.

Effect of chemical treatments of arundo donax L. fibre on mechanical and thermal properties of the PLA/PP blend composite filament for FDM 3D printing

Arundo donax L. is investigated in this study as a suitable reinforcing agent for PLA/PP waste blend 3D printing filament. To improve the compatibility of the fibre and polymer, the Arundo fibre was chemically modified using alkali and silane treatment. Untreated and treated fibres were extruded with Polymer blends before being 3D printed. Effect of chemical treatment on thermal, mechanical, and morphological properties of the composites was investigated. The tensile, Izod impact, and water absorption of the 3D printed specimens were also tested. The Alkali treated (ALK) and combination of alkali and silane treatment (SLN) composites displayed good results. Tensile strength and modulus of the materials increased, as well as their maintained stability in the Izod impact test, demonstrating that the incorporation of ArF did not result in a loss in performance. SEM examination supported these findings by confirming the creation of beneficial interfacial contacts between the matrix and fibre components, as demonstrated by the lack of void between the matrix and the fibre surface. Furthermore, the alkali treatment of the ArF resulted in a considerable reduction in water absorption inside the biocomposite, with a 64% reduction seen in ALK composite comparison to the untreated composite (Un). After the 43-day assessment period.

Drug-Eluting Sutures by Hot-Melt Extrusion: Current Trends and Future Potentials

Surgical site infections (SSIs) may result from surgical procedures requiring a secondary administration of drugs at site or systemically in treating the infection. Drug-eluting sutures containing antimicrobial agents symbolise a latent strategy that precludes a secondary drug administration. It also offers the possibility of delivering a myriad of therapeutic agents to a localised wound site to effect analgesia, anti-inflammation, or the deployment of proteins useful for wound healing. Further, the use of biodegradable drug-eluting sutures eliminates the need for implanting foreign material into the wound, which needs to be removed after healing. In this review, we expound on recent trends in the manufacture of drug-eluting sutures with a focus on the hot-melt extrusion (HME) technique. HME provides a solvent-free, continuous one-step manufacturing conduit for drug-eluting sutures, hence, there is no drying step, which can be detrimental to the drug or suture threads and, thus, environmentally friendly. There is the possibility of combining the technology with additive manufacturing platforms to generate personalised drug-loaded implantable devices through prototyping and scalability. The review also highlights key material requirements for fabricating drug-eluting sutures by HME, as well as quality attributes. Finally, a preview of emerging drug-eluting sutures and advocacy for harmonisation of quality assurance by regulatory authorities that permits quality evaluation of novelty sutures is presented.

Cashew Nutshells: A Promising Filler for 3D Printing Filaments

Cashew nutshells from the northern region of Colombia were prepared to assess their potential use as a filler in polymer matrix filaments for 3D printing. After drying and grinding processes, cashew nutshells were characterized using scanning electron microscopy (SEM), attenuated total reflectance Fourier-transform infrared (ATR-FTIR), and thermogravimetric analyses (TGA). Three different filaments were fabricated from polylactic acid pellets and cashew nutshell particles at 0.5, 1.0, and 2.0 weight percentages using a single-screw extruder. Subsequently, single-filament tensile tests were carried out on them. SEM images showed rough and porous particles composed of an arrangement of cellulose microfibrils embedded in a hemicellulose and lignin matrix, the typical microstructure reported for natural fibers. These characteristics observed in the particles are favorable for improving filler-matrix adhesion in polymer matrix composites. In addition, their low density of 0.337 g/cm3 makes them attractive for lightweight applications. ATR-FTIR spectra exhibited specific functional groups attributed to hemicellulose, cellulose, and lignin, as well as a possible transformation to crystalline cellulose during drying treatment. According to TGA analyses, the thermal stability of cashew nutshell particles is around 320 °C. The three polylactic acid-cashew nutshell particle filaments prepared in this work showed higher tensile strength and elongation at break when compared to polylactic acid filament. The characteristics displayed by these cashew nutshell particles make them a promising filler for 3D printing filaments.

Innovative Polymer Composites with Natural Fillers Produced by Additive Manufacturing (3D Printing)-A Literature Review

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.

Literature Review on the Utilization of Rice Husks: Focus on Application of Materials for Digital Fabrication

To achieve a sustainable society, it is important to use biological resources effectively to the extent that they are renewable. Rice husk, which is abundantly produced in various regions, is a useful biomass resource. To promote their use further, it is important to expand the fields in which they are used. Therefore, this study reviews the research on rice-husk-based materials that can be used in digital fabrication, such as those used with 3D printers and Computer Numerical Control (CNC) machines, which have become increasingly popular in recent years. After outlining the characteristics of each machining method, the authors surveyed and analyzed the original research on rice-husk-based materials for 3D printers and particleboard available in digital fabrication machines for 2D machining. This review identifies issues and proposes solutions for expanding the use of rice-husk-based materials. It also indicates the need for further research on various aspects, such as the workability and maintainability of the equipment.

Biomass 3D Printing: Principles, Materials, Post-Processing and Applications

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.

The potential of adopting natural fibers reinforcements for fused deposition modeling: Characterization and implications

Natural fibers or their derivatives have gained significant attention as green fillers or reinforcement materials due to their abundant availability, environment-friendly nature and biodegradability for sustainable development. Despite the availability of modern alternatives such as concrete, glass-fiber/resin composites, steel, and plastics, there is still considerable demand for naturally occurring based materials for different applications due to their low cost, durability, strength, heat, sound, and fire-resistance characteristics. 3D printing has provided a novel approach to the development and advancement of natural fiber-based composite materials, as well as an important platform for the advancement of biomass materials toward intelligentization and industrialization. The features of 3D printing, particularly fast prototyping and small start-up, allow the easy fabrication of materials for a wide range of applications. This review highlights the current progress and potential commercial applications of 3D printed composites reinforced with natural fibers or biomass. This study discussed that 3D printing technology can be effectively utilized for different applications, including producing electroactive papers, fuel cell membranes, adhesives, wastewater treatment, biosensors, and its potential applications in the automobile, building, and construction industries. The research in the literature showed that even if the field of 3D printing has advanced significantly, problems still need to be solved, such as material incompatibility and material cost. Further studies could be conducted to improve and adapt the methods to work with various materials. More effort should be put into developing affordable printer technologies and materials that work with these printers to broaden the applications for 3D printed objects.

Colombian Sustainability Perspective on Fused Deposition Modeling Technology: Opportunity to Develop Recycled and Biobased 3D Printing Filaments

In the context of the preservation of natural resources, researchers show a growing interest in developing eco-friendly materials based on recycled polymers and natural fiber biocomposites to minimize plastic and agroindustrial waste pollution. The development of new materials must be integrated within the circular economy concepts to guarantee sustainable production. In parallel, fused deposition modeling, an additive manufacturing technology, provides the opportunity to use these new materials in an efficient and sustainable manner. This review presents the context of plastics and agro-industrial fiber pollution, followed by the opportunity to give them added value by applying circular economy concepts and implementing these residues to develop new materials for the manufacture of fused deposition modeling 3D printing technique feedstock. Colombian perspective is highlighted since 3D printing technology is growing there, and Colombian biodiversity represents a high reservoir of materials. Also, recycling in Colombia promotes compliance with the 2030 Agenda and the Sustainable Development Goals.

FDM-based additive manufacturing of recycled thermoplastics and associated composites

Hailed since the fourth industrial revolution, three-dimensional (3D) printing or additive manufacturing (AM) has been extensively implemented in various manufacturing sectors. This process is popular for generating regular products and incorporating innovative designs into the components like auxetic structures, such as fabrication of engineering products, customized implants and sophisticated biomedical devices. Over the years, one of the interesting outputs of this emerging technology is the reuse of waste thermoplastic materials to produce competent products through the fused deposition modeling (FDM) technique. The strength of FDM components produced from thermoplastic waste is lower than that of virgin plastic FDM counterparts. So, there is a need to understand the significant changes in the recycled thermoplastic material during subsequent extrusions, which are chain scission, change in viscosity and breaking strength. The use of additives has been a promising solution to improve the performance of recycled material for 3D printing applications. Hence, this study aims to provide an overview of reusing plastic waste through FDM-based 3D printing. This review summarizes the current knowledge about the effect of processing on thermo-mechanical properties of recycled plastic FDM parts and the use of various additives to improve the overall quality. In addition, two case studies from open literature have been demonstrated to explain the use of FDM and associated technology for plastic recycling.

Natural Alternatives to Non-biodegradable Polymers in 3D Printing of Pharmaceuticals

BACKGROUND

Due to potential toxicity, non-biodegradable polymers used in 3D (3-dimensional) printing of drugs could be dangerous for patient safety and the environment.

OBJECTIVE

This review aims to investigate the toxicity of non-biodegradable polymers and investigate the use of natural materials as an alternative in 3D printing medicines. The study evaluates the dangers connected to 3D printing.

METHODS

A review of the literature on various 3D printing processes, such as inkjet printing, fused filament manufacturing, and extrusion-related 3DP systems, was done for this study. Also, the use of cellulose derivatives and natural materials in 3D printing and their potential as active excipients was proposed.

RESULTS

The review identified potential toxicity risks linked to non-biodegradable polymers used in drug 3D printing. As a potential fix for this issue, the use of natural materials with improved mechanical and thermal properties was explored. The use of cellulose derivatives as an alternative to non-biodegradable polymers in 3D printing pharmaceuticals was also investigated in the study.

CONCLUSION

This study emphasises the significance of evaluating the risks connected to drug 3D printing and recommends using natural materials as an alternative to non-biodegradable polymers. More study is required to create secure and reliable 3D printing processes for pharmaceuticals.

Development and Mechano-Chemical Characterization of Polymer Composite Sheets Filled with Silica Microparticles with Potential in Printing Industry

Polymer composite sheets using a low-cost filler (local natural sand) and polymer (high-density polyethylene, HDPE) as a replacement of the traditionally used wood-fiber-based sheets for paper-based applications were developed. The sand/polymer composite sheets were prepared by melt extrusion in a melt blender followed by compression molding. The effects of varying particle size, concentration, and the use of a compatibilizer (polyethylene-grafted maleic anhydride) was studied on the mechano-chemical performance properties of the composite sheets such as morphology, thermal and mechanical properties, and wettability characteristics used in the printing industry. In terms of thermal stability, filler (sand) or compatibilizer addition did not alter the crystallization, melting, or degradation temperatures significantly, thereby promoting good thermal stability of the prepared sheets. Compatibilization improved anti-wetting property with water. Additionally, for the compatibilized sheets prepared from 25 µm sand particles, at 35 wt%, the contact angle with printing ink decreased from 44° to 38.30°, suggesting improved ink-wetting performance. A decrease in the elastic modulus was also observed with the addition of the compatibilizer, with comparable results to commercial stone paper. Results from this study will be considered as a first step towards understanding compatibility of local natural sand and polymers for paper-based application.

Solid Dispersion Formulations by FDM 3D Printing-A Review

Additive manufacturing (AM) is revolutionizing the way medicines are designed, manufactured, and utilized. Perhaps, AM appears to be ideal for the fit-for-purpose manufacturing of medicines in contrast to the several disadvantages associated with the conventional fit-for-all mass production that accounts for less than 50% of pharmacotherapeutic treatment/management of diseases especially among children and elderly patients, as well as patients with special needs. In this review, we discuss the current trends in the application of additive manufacturing to prepare personalized dosage forms on-demand focusing the attention on the relevance of coupling solid dispersion with FDM 3D printing. Combining the two technologies could offer many advantages such as to improve the solubility, dissolution, and oral bioavailability of poorly soluble drugs in tandem with the concept of precision medicine and personalized dosing and to address the dilemma of commercial availability of FDM filaments loaded with Class II and/or Class IV drugs. However, thermal treatment especially for heat-sensitive drugs, regulatory, and ethical obligations in terms of quality control and quality assurance remain points of concern. Hence, a concerted effort is needed between the scientific community, the pharmaceutical industries, the regulatory agencies, the clinicians and clinical pharmacists, and the end-users to address these concerns.

Values of Selected Strength Parameters of Miscanthus × Giganteus Stalk Depending on Water Content and Internode Number

So far, there are no results for research on the biomechanical parameters of giant miscanthus stalks taking into account both the influence of moisture content and the internode, from which the samples were taken. Therefore, the aim of the research was to comprehensively investigate the influence of the internode number (NrNod) and water content (MC) on the values of selected biomechanical parameters (modulus of elasticity and maximum stress) determined using various stress tests (three-point bending and compression along the fibers). The research was carried out for dry stalks of different humidities and for different internodes. The results obtained in this study proved that the independent variables of the water content and the internode number cause a statistically significant influence on the values of the examined biomechanical parameters of the miscanthus stem: the modulus of elasticity in compression, the maximum stress in compression, the modulus of elasticity in bending and the maximum stress in bending. The values of the modulus of elasticity (MOE) increase when increasing the NrNod. For individual internodes, MOE values are higher with a higher MC. The values of the maximum stress (σ) also increase when increasing the internode number. For individual internodes, the σ values are lower with a higher MC.

ABS/Silicon Dioxide Micro Particulate Composite from 3D Printing Polymeric Waste

In this paper, Acrylonitrile-Butadiene-Styrene matrix composites reinforced with Nano-silica dioxide particles were examined and prepared to study their mechanical properties. The composite sheets were pre-prepared using the hot extrusion process. Due to its wide characteristics, silica dioxide additions can strengthen the usability and mechanical features of composite thermoplastics and polymers. Furthermore, introducing silica dioxide as a filler in various attributes can help to maintain the smooth flow of sufficient powders, reduce caking, and manage viscoelasticity. Despite its advantages, 3D printing generates a significant amount of waste due to limited prints or destroyed support structures. ABS is an ideal material to use because it is a thermoplastic and amorphous polymer with outstanding thermal properties that is also applicable with the FFF (Fused Filament Fabrication) technique. The findings showed that increasing the silica dioxide content reduces the tensile strength to 22.4 MPa at 10 wt%. Toughness, ductility, and yield stress values of ABS/silica dioxide composites at 15 wt% increased, indicating that the composite material reinforced by the silica dioxide particles improved material characteristics. It is essential to consider the impact of recycling in polymer reinforcement with fillers. Furthermore, the improved mechanical qualities of the composite material encourages successful ABS recycling from 3D printing, as well as the possibility of reusing it in a similar application.

Dimensional Stability of 3D Printed Objects Made from Plastic Waste Using FDM: Potential Construction Applications

Construction projects are often challenged by tight budgets and limited time and resources. Contractors are, therefore, looking for ways to become competitive by improving efficiency and using cost-effective materials. Using three-dimensional (3D) printing for shaping materials to produce cost-effective construction elements is becoming a feasible option to make contractors more competitive locally and globally. The process capabilities for 3D printers and related devices have been tightened in recent years with the booming of 3D printing industries and applications. Contractors are attempting to improve production skills to satisfy firm specifications and standards, while attempting to have costs within competitive ranges. The aim of this research is to investigate and test the production process capability (Cp) of 3D printers using fused deposition modeling (FDM) to manufacture 3D printed parts made from plastic waste for use in the construction of buildings with different infill structures and internal designs to reduce cost. This was accomplished by calculating the actual requirement capabilities of the 3D printers under consideration. The production capabilities and requirements of FDM printers are first examined to develop instructions and assumptions to assist in deciphering the characteristics of the 3D printers that will be used. Possible applications in construction are then presented. As an essential outcome of this study, it was noticed that the 3D printed parts made from plastic waste using FDM printers are less expensive than using traditional lightweight non-load bearing concrete hollow masonry blocks, hourdi slab hollow bocks, and concrete face bricks.

Hygromorphic Response Dynamics of 3D-Printed Wood-PLA Composite Bilayer Actuators

The use of wood particles in wood-plastic composites (WPC) is well known and similar use could occur in materials for fused deposition modeling (FDM) 3D printing. Wood particles could be one of the possible solutions in the search for natural-based materials to minimize the use of synthetic-origin materials in additive manufacturing. Wood particles for 3D printing filaments can be made from wood waste and could serve as a cheap filler or as a value-added reinforcing component, depending on their properties and incorporation. The disadvantages of wood (dimensional changes due to water adsorption and desorption) could be used as functions when dimensional change is desirable, such as in shape-changing 4D printing materials. In this research, FDM printing materials made of polylactic acid (PLA), with different amounts of wood particles, were used to design moisture-induced shape-changing bilayer actuators, which could serve as a principle for active façade or ventilation valves. The initial research shows that the wood content in the WPC causes dimensional changes and thus shape changes of the designed actuators under changing climates. The shape change depends on the ratio of the materials in the two-layered actuator and the wood content in the wood-PLA composite used, and thus on sorption. The rate of the shape change behaves in the same way: the higher the wood content, the greater the change observed. The dynamics of the hygromorphism of bimaterial composites is greater with a small amount of added hygromechanically active material.

Development and Characterization of a 3D Printed Cocoa Bean Shell Filled Recycled Polypropylene for Sustainable Composites

Natural filler-based composites are an environmentally friendly and potentially sustainable alternative to synthetic or plastic counterparts. Recycling polymers and using agro-industrial wastes are measures that help to achieve a circular economy. Thus, this work presents the development and characterization of a 3D printing filament based on recycled polypropylene and cocoa bean shells, which has not been explored yet. The obtained composites were thermally and physically characterized. In addition, the warping effect, mechanical, and morphological analyses were performed on 3D printed specimens. Thermal analysis exhibited decreased thermal stability when cacao bean shell (CBS) particles were added due to their lignocellulosic content. A reduction in both melting enthalpy and crystallinity percentage was identified. This is caused by the increase in the amorphous structures present in the hemicellulose and lignin of the CBS. Mechanical tests showed high dependence of the mechanical properties on the 3D printing raster angle. Tensile strength increased when a raster angle of 0° was used, compared to specimens printed at 90°, due to the load direction. Tensile strength and fracture strain were improved with CBS addition in specimens printed at 90°, and better bonding between adjacent layers was achieved. Electron microscope images identified particle fracture, filler-matrix debonding, and matrix breakage as the central failure mechanisms. These failure mechanisms are attributed to the poor interfacial bonding between the CBS particles and the matrix, which reduced the tensile properties of specimens printed at 0°. On the other hand, the printing process showed that cocoa bean shell particles reduced by 67% the characteristic warping effect of recycled polypropylene during 3D printing, which is advantageous for 3D printing applications of the rPP. Thereby, potential sustainable natural filler composite filaments for 3D printing applications with low density and low cost can be developed, adding value to agro-industrial and plastic wastes.

Harnessing 3D Printing of Plastics in Construction-Opportunities and Limitations

Additive manufacturing has been of increasing interest to the construction industry for the last ten years. The subject of the research is the printing of concrete, metals, and plastics. In their analysis and research, authors have focused on printing plastics. 3D printing of reinforcement of concrete elements made of plastics can significantly improve the efficiency of their erection, reduce the amount of waste, and optimize their shape. In this paper, recent developments in the 3D printing of plastics for construction are reviewed. Various applications were discussed, including unconventional spatial reinforcement (impossible to achieve in a traditional way), printed permanent formwork, etc. The challenges for further research and practical applications of such solutions were also discussed.

Polymer Composites Based on Polycarbonate (PC) Applied to Additive Manufacturing Using Melted and Extruded Manufacturing (MEM) Technology

As part of the present work, polymer composites used in 3D printing technology, especially in Melted and Extruded Manufacturing (MEM) technology, were obtained. The influence of modified fillers such as alumina modified silica, quaternary ammonium bentonite, lignin/silicon dioxide hybrid filler and unmodified multiwalled carbon nanotubes on the properties of polycarbonate (PC) composites was investigated. In the first part of the work, the polymer and its composites containing 0.5–3 wt.% filler were used to obtain a filament using the proprietary technological line. The moldings for testing functional properties were obtained with the use of 3D printing and injection molding techniques. In the next part of the work, the rheological properties—mass flow rate (MFR) and mechanical properties—Rockwell hardness, Charpy impact strength and static tensile strength with Young’s modulus were examined. The structure of the obtained composites was also described and determined using scanning electron microscopy (SEM). The porosity, roughness and dimensional stability of samples obtained by 3D printing were also determined. On the other hand, the physicochemical properties were presented on the basis of the research results using thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), wide angle X-ray scattering analysis (WAXS) and Fourier Transform infrared spectroscopy (FT-IR). Additionally, the electrical conductivity of the obtained composites was investigated. On the basis of the obtained results, it was found that both the amount and the type of filler significantly affected the functional properties of the composites tested in the study.

Comprehensive Characterization of Polymeric Composites Reinforced with Silica Microparticles Using Leftover Materials of Fused Filament Fabrication 3D Printing

Silica exhibits properties such that its addition into polymeric materials can result in an enhanced overall quality and improved characteristics and as a result silica has been widely used as a filler material for improving the rheological properties of polymeric materials. The usage of polymers in three-dimensional printing technology has grown exponentially, which has increased the amount of waste produced during this process. Several polymers, such as polypropylene (PP), polyvinyl alcohol (PVA), polylactic acid (PLA), and nylon, are applied in this emerging technology. In this study, the effect of the addition of silica as a filler on the mechanical, thermal, and bulk density properties of the composites prepared from the aforementioned polymeric waste was studied. In addition, the morphology of the composite materials was characterized via scanning electron microscopy. The composite samples were prepared with various silica concentrations using a twin extruder followed by hot compression. Generally, the addition of silica increased the tensile strength of the polymers. For instance, the tensile strength of PVA with 5 wt% filler increased by 76 MPa, whereas those of PP and PLA with 10 wt% filler increased by 7.15 and 121.03 MPa, respectively. The crystallinity of the prepared composite samples ranged from 14% to 35%, which is expected in a composite system. Morphological analysis revealed the random dispersion of silica particles and agglomerate formation at high silica concentrations. The bulk density of the samples decreased with increased amount of filler addition. The addition of silica influenced the changes in the characteristics of the polymeric materials. Furthermore, the properties presented in this study can be used to further study the engineering design, transportation, and production processes, promoting the recycling and reuse of such waste in the same technology with the desired properties.

Undergraduate Research Program to Recycle Composite Waste

With the rapid growth in the manufacturing industry and increased urbanization, higher amounts of composite material waste are being produced, causing severe threats to the environment. These environmental concerns, coupled with the fact that undergraduate students typically have minimal experience in research, have initiated the need at the UAE University to promote research among undergraduate students, leading to the development of a summer undergraduate research program. In this study, a recycling methodology is presented to test lab-fabricated Carbon-Fiber-Reinforced Polymer (CFRP) for potential applications in industrial composite waste. The work was conducted by two groups of undergraduate students at the UAE University. The methodology involved the chemical dissolution of the composite waste, followed by compression molding and adequate heat treatment for rapid curing of CFRP. Subsequently, the CFRP samples were divided into three groups based on their geometrical distinctions. The mechanical properties (i.e., modulus of elasticity and compressive strength) were determined through material testing, and the results were then compared with steel for prompt reference. The results revealed that the values of mechanical properties range from 2 to 4.3 GPa for the modulus of elasticity and from 203.7 to 301.5 MPa for the compressive strength. These values are considered competitive and optimal, and as such, carbon fiber waste can be used as an alternate material for various structural applications. The inconsistencies in the values are due to discrepancies in the procedure as a result of the lack of specialized equipment for handling CFRP waste material. The study concluded that the properties of CFRP composite prepreg scrap tend to be reusable instead of disposable. Despite the meager experimental discrepancies, test values and mechanical properties indicate that CFRP composite can be successfully used as a material for nonstructural applications.

Embracing Additive Manufacturing Technology through Fused Filament Fabrication for Antimicrobial with Enhanced Formulated Materials

Antimicrobial materials produced by 3D Printing technology are very beneficial, especially for biomedical applications. Antimicrobial surfaces specifically with enhanced antibacterial property have been prepared using several quaternary salt-based agents, such as quaternary ammonium salts and metallic nanoparticles (NPs), such as copper and zinc, which are incorporated into a polymeric matrix mainly through copolymerization grafting and ionic exchange. This review compared different materials for their effectiveness in providing antimicrobial properties on surfaces. This study will help researchers choose the most suitable method of developing antimicrobial surfaces with the highest efficiency, which can be applied to develop products compatible with 3D Printing Technology.

Effect of Sanding and Plasma Treatment of 3D-Printed Parts on Bonding to Wood with PVAc Adhesive

Additive manufacturing is becoming increasingly important for manufacturing end products, not just prototyping. However, the size of 3D-printed products is limited due to available printer sizes and other technological limitations. For example, making furniture from 3D-printed parts and wooden elements requires adequate adhesive joints. Since materials for 3D printing usually do not bond very well with adhesives designed for woodworking, they require special surface preparation to improve adhesion. In this study, fused deposition modelling (FDM) 3D-printed parts made of polylactic acid (PLA), polylactic acid with wood flour additive (Wood-PLA), and acrylonitrile-butadiene-styrene (ABS) polymers were bonded to wood with polyvinyl acetate (PVAc) adhesive. The surfaces of the samples were bonded as either non-treated, sanded, plasma treated, or sanded and plasma treated to evaluate the effect of each surface preparation on the bondability of the 3D-printed surfaces. Different surface preparations affected the bond shear strength in different ways. The plasma treatment significantly reduced water contact angles on all tested printing materials and increased the bond tensile shear strength of the adhesive used. The increase in bond strength was highest for the surfaces that had been both sanded and plasma treated. The highest increase was found for the ABS material (untreated 0.05 MPa; sanded and plasma treated 4.83 MPa) followed by Wood-PLA (from 0.45 MPa to 3.96 MPa) and PLA (from 0.55 MPa to 3.72 MPa). Analysis with a scanning electron microscope showed the smooth surfaces of the 3D-printed parts, which became rougher with sanding with more protruded particles, but plasma treatment partially melted the surface structures on the thermoplastic polymer surfaces.

Development and Characterization of Rice Husk and Recycled Polypropylene Composite Filaments for 3D Printing

Nowadays the use of natural fiber composites has gained significant interest due to their low density, high availability, and low cost. The present study explores the development of sustainable 3D printing filaments based on rice husk (RH), an agricultural residue, and recycled polypropylene (rPP) and the influence of fiber weight ratio on physical, thermal, mechanical, and morphological properties of 3D printing parts. Thermogravimetric analysis revealed that the composite's degradation process started earlier than for the neat rPP due to the lignocellulosic fiber components. Mechanical tests showed that tensile strength increased when using a raster angle of 0° than specimens printed at 90°, due to the weaker inter-layer bonding compared to in-layer. Furthermore, inter layer bonding tensile strength was similar for all tested materials. Scanning electron microscope (SEM) images revealed the limited interaction between the untreated fiber and matrix, which led to reduced tensile properties. However, during the printing process, composites presented lower warping than printed neat rPP. Thus, 3D printable ecofriendly natural fiber composite filaments with low density and low cost can be developed and used for 3D printing applications, contributing to reduce the impact of plastic and agricultural waste.

3D Printing PLA Waste to Produce Ceramic Based Particulate Reinforced Composite Using Abundant Silica-Sand: Mechanical Properties Characterization

Due to the significant properties of silica, thermostatics can be enhanced using silica-additives to maximize the quality of polymer compounds and transform plastics into tailored properties. The silica additives can enhance the handling and quality performance of composites and thermoplastic polymers due to their diverse potential. Besides, using silica as an additive in different characteristics can allow granulates and powders to flow easily, minimize caking, and control rheology. On the other hand, the eruption of 3D printing technology has led to a massive new waste source of plastics, especially the polylactic acid (PLA) that is associated with the fused deposition modeling (FDM) process. In this paper, the impact on the mechanical properties when silica is mixed with waste PLA from 3D printing was studied. The PLA/silica mixtures were prepared using different blends through twin extruders and a Universal Testing Machine was used for the mechanical characterization. The result indicated that increasing silica composition resulted in the increase of the tensile strength to 121.03 MPa at 10 wt%. Similar trends were also observed for the toughness, ductility, and the yield stress values of the PLA/silica blends at 10 wt%, which corresponds to the increased mechanical property of the composite material reinforced by the silica particles. Improvement in the mechanical properties of the developed composite material promotes the effective recycling of PLA from applications such as 3D printing and the potential of reusing it in the same application.