High Performance Polycarbonate Nanocomposites Mechanically Boosted with Titanium Carbide in Material Extrusion Additive Manufacturing

In Situ Investigation of Tensile Response for Inconel 718 Micro-Architected Materials Fabricated by Selective Laser Melting

Topology optimization enables the design of advanced architected materials with tailored mechanical properties and optimal material distribution. This method can result in the production of parts with uniform mechanical properties, reducing anisotropy effects and addressing a critical challenge in metal additive manufacturing (AM). The current study aims to examine the micro-tensile response of Inconel 718 architected materials utilizing the Selective Laser Melting Technique. In this context, three novel architected materials, i.e., Octet, Schwarz Diamond (SD), and hybrid Schwarz Diamond and Face Centered Cubic (FCC), were tested in three different relative densities. The specimens were then subjected to uniaxial quasi-static tensile tests to determine their key mechanical properties, including elastic modulus, yield strength, and ultimate tensile strength (UTS), as well as the scaling laws describing the tensile response of each architected material. In situ Scanning Electron Microscopy (SEM) has been performed to observe the structure and grain morphology of the 3D printed specimens along with the phase transitions (elastic, plastic), the crack propagation, and the overall failure mechanisms. The results highlight the effect of the lattice type and the relative density on the mechanical properties of architected materials. Topologically optimized structures presented a 70-80% reduction in overall strength, while the SD and SD&FCC structures presented higher stretching dominated behavior, which was also verified by the n-value range (1-2) extracted from the identification of the scaling laws.

Pulmonary evaluation of whole-body inhalation exposure of polycarbonate (PC) filament 3D printer emissions in rats

During fused filament fabrication (FFF) 3D printing with polycarbonate (PC) filament, a release of ultrafine particles (UFPs) and volatile organic compounds (VOCs) occurs. This study aimed to determine PC filament printing emission-induced toxicity in rats via whole-body inhalation exposure. Male Sprague Dawley rats were exposed to a single concentration (0.529 mg/m3, 40 nm mean diameter) of the 3D PC filament emissions in a time-course via whole body inhalation for 1, 4, 8, 15, and 30 days (4 hr/day, 4 days/week), and sacrificed 24 hr after the last exposure. Following exposures, rats were assessed for pulmonary and systemic responses. To determine pulmonary injury, total protein and lactate dehydrogenase (LDH) activity, surfactant proteins A and D, total as well as lavage fluid differential cells in bronchoalveolar lavage fluid (BALF) were examined, as well as histopathological analysis of lung and nasal passages was performed. To determine systemic injury, hematological differentials, and blood biomarkers of muscle, metabolic, renal, and hepatic functions were also measured. Results showed that inhalation exposure induced no marked pulmonary or systemic toxicity in rats. In conclusion, inhalation exposure of rats to a low concentration of PC filament emissions produced no significant pulmonary or systemic toxicity.

Thermomechanical Response of Polycarbonate/Aluminum Nitride Nanocomposites in Material Extrusion Additive Manufacturing

Polycarbonate-based nanocomposites were developed herein through a material extrusion (MEX) additive manufacturing (AM) process. The fabrication of the final nanocomposite specimens was achieved by implementing the fused filament fabrication (FFF) 3D printing process. The impact of aluminum nitride (AlN) nanoparticles on the thermal and mechanical behavior of the polycarbonate (PC) matrix was investigated thoroughly for the fabricated nanocomposites, carrying out a range of thermomechanical tests. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) provided information about the morphological and surface characteristics of the produced specimens. Using energy dispersive spectroscopy (EDS), the elemental composition of the nanocomposite materials was validated. Raman spectroscopy revealed no chemical interactions between the two material phases. The results showed the reinforcement of most mechanical properties with the addition of the AlN nanoparticles. The nanocomposite with 2 wt.% filler concentration exhibited the best mechanical performance overall, with the highest improvements observed for the tensile strength and toughness of the fabricated specimens, with a percentage of 32.8% and 51.6%, respectively, compared with the pure polymer. The successful AM of PC/AlN nanocomposites with the MEX process is a new paradigm, which expands 3D printing technology and opens a new route for the development of nanocomposite materials with multifunctional properties for industrial applications.

Silicon Carbide Nanoparticles as a Mechanical Boosting Agent in Material Extrusion 3D-Printed Polycarbonate

In this work, the effect of silicon carbide (carborundum, SiC), as a boosting agent of the mechanical response of the polycarbonate (PC) polymer, was investigated. The work aimed to fabricate nanocomposites with an improved mechanical performance and to further expand the utilization of 3D printing in fields requiring an enhanced material response. The nanocomposites were produced by a thermomechanical process in various SiC concentrations in order to evaluate the filler loading in the mechanical enhancement. The samples were 3D printed with the material extrusion (MEX) method. Their mechanical performance was characterized, following international standards, by using dynamic mechanical analysis (DMA) and tensile, flexural, and Charpy's impact tests. The microhardness of the samples was also measured. The morphological characteristics were examined, and Raman spectra revealed their structure. It was found that SiC can improve the mechanical performance of the PC thermoplastic. A 19.5% increase in the tensile strength was found for the 2 wt.% loading nanocomposite, while the 3 wt.% nanocomposite showed a 16% increase in the flexural strength and a 35.9% higher impact strength when compared to the unfilled PC. No processability issues were faced for the filler loadings that have been studied here.