1
|
Shah M, Ullah A, Azher K, Rehman AU, Juan W, Aktürk N, Tüfekci CS, Salamci MU. Vat photopolymerization-based 3D printing of polymer nanocomposites: current trends and applications. RSC Adv 2023; 13:1456-1496. [PMID: 36686959 PMCID: PMC9817086 DOI: 10.1039/d2ra06522c] [Citation(s) in RCA: 5] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/17/2022] [Accepted: 12/15/2022] [Indexed: 01/09/2023] Open
Abstract
The synthesis and manufacturing of polymer nanocomposites have garnered interest in recent research and development because of their superiority compared to traditionally employed industrial materials. Specifically, polymer nanocomposites offer higher strength, stronger resistance to corrosion or erosion, adaptable production techniques, and lower costs. The vat photopolymerization (VPP) process is a group of additive manufacturing (AM) techniques that provide the benefit of relatively low cost, maximum flexibility, high accuracy, and complexity of the printed parts. In the past few years, there has been a rapid increase in the understanding of VPP-based processes, such as high-resolution AM methods to print intricate polymer parts. The synergistic integration of nanocomposites and VPP-based 3D printing processes has opened a gateway to the future and is soon expected to surpass traditional manufacturing techniques. This review aims to provide a theoretical background and the engineering capabilities of VPP with a focus on the polymerization of nanocomposite polymer resins. Specifically, the configuration, classification, and factors affecting VPP are summarized in detail. Furthermore, different challenges in the preparation of polymer nanocomposites are discussed together with their pre- and post-processing, where several constraints and limitations that hinder their printability and photo curability are critically discussed. The main focus is the applications of printed polymer nanocomposites and the enhancement in their properties such as mechanical, biomedical, thermal, electrical, and magnetic properties. Recent literature, mainly in the past three years, is critically discussed and the main contributing results in terms of applications are summarized in the form of tables. The goal of this work is to provide researchers with a comprehensive and updated understanding of the underlying difficulties and potential benefits of VPP-based 3D printing of polymer nanocomposites. It will also help readers to systematically reveal the research problems, gaps, challenges, and promising future directions related to polymer nanocomposites and VPP processes.
Collapse
Affiliation(s)
- Mussadiq Shah
- Additive Manufacturing Technologies Application and Research Center-EKTAM Ankara Turkey
- Department of Mechanical Engineering, Faculty of Engineering, Gazi University Ankara Turkey
- State Key Laboratory for Mechanical Behavior of Materials, School of Materials Science and Engineering, Xi'an Jiaotong University P. R. China
| | - Abid Ullah
- Additive Manufacturing Technologies Application and Research Center-EKTAM Ankara Turkey
- Department of Mechanical Engineering, Faculty of Engineering, Gazi University Ankara Turkey
- CAS Key Laboratory of Mechanical Behavior and Design of Materials, Department of Modern Mechanics, University of Science and Technology of China P. R China
| | - Kashif Azher
- Additive Manufacturing Technologies Application and Research Center-EKTAM Ankara Turkey
- Department of Mechanical Engineering, Faculty of Engineering, Gazi University Ankara Turkey
| | - Asif Ur Rehman
- Additive Manufacturing Technologies Application and Research Center-EKTAM Ankara Turkey
- Department of Mechanical Engineering, Faculty of Engineering, Gazi University Ankara Turkey
- ERMAKSAN Bursa 16065 Turkey
| | - Wang Juan
- Department of Industrial Engineering, Nanchang Hangkong University Nanchang P. R China
| | - Nizami Aktürk
- Additive Manufacturing Technologies Application and Research Center-EKTAM Ankara Turkey
- Department of Mechanical Engineering, Faculty of Engineering, Gazi University Ankara Turkey
| | - Celal Sami Tüfekci
- Advanced Manufacturing Technologies Center of Excellence-URTEMM Ankara Turkey
| | - Metin U Salamci
- Additive Manufacturing Technologies Application and Research Center-EKTAM Ankara Turkey
- Department of Mechanical Engineering, Faculty of Engineering, Gazi University Ankara Turkey
- Advanced Manufacturing Technologies Center of Excellence-URTEMM Ankara Turkey
| |
Collapse
|
2
|
Silicone glue-based graphite ink incorporated on paper platform as an affordable approach to construct stable electrochemical sensors. Talanta 2022; 251:123812. [DOI: 10.1016/j.talanta.2022.123812] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/03/2022] [Revised: 07/29/2022] [Accepted: 08/02/2022] [Indexed: 11/22/2022]
|
3
|
de C. Costa BM, Griveau S, Bedioui F, Orlye FD, da Silva JAF, Varenne A. Stereolithography based 3D-printed microfluidic device with integrated electrochemical detection. Electrochim Acta 2022. [DOI: 10.1016/j.electacta.2022.139888] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
|
4
|
Ghimire R, Liou F. Quasi-Static Multifunctional Characterization of 3D-Printed Carbon Fiber Composites for Compressive-Electrical Properties. Polymers (Basel) 2022; 14:polym14020328. [PMID: 35054735 PMCID: PMC8778783 DOI: 10.3390/polym14020328] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/23/2021] [Revised: 11/16/2021] [Accepted: 11/23/2021] [Indexed: 01/31/2023] Open
Abstract
Multifunctional carbon fiber composites provide promising results such as high strength-to-weight ratio, thermal and electrical conductivity, high-intensity radiated field, etc. for aerospace applications. Tailoring the electrical and structural properties of 3D-printed composites is the critical step for multifunctional performance. This paper presents a novel method for evaluating the effects of the coating material system on the continuous carbon fiber strand on the multifunctional properties of 3D-printed composites and the material's microstructure. A new method was proposed for the quasi-static characterization of the Compressive-Electrical properties on the additively manufactured continuous carbon fiber solid laminate composites. In this paper, compressive and electrical conductivity tests were simultaneously conducted on the 3D-printed test coupons at ambient temperature. This new method modified the existing method of addressing monofunctional carbon fiber composites by combining the monofunctionality of two or more material systems to achieve the multifunctional performance on the same component, thereby reducing the significant weight. The quasi-static multifunctional properties reported a maximum compressive load of 4370 N, ultimate compressive strength of 136 MPa, and 61.2 G Ohms of electrical resistance. The presented method will significantly reduce weight and potentially replace the bulky electrical wires in spacecraft, unmanned aircraft systems (UAS), and aircraft.
Collapse
|
5
|
Azlin MNM, Ilyas RA, Zuhri MYM, Sapuan SM, Harussani MM, Sharma S, Nordin AH, Nurazzi NM, Afiqah AN. 3D Printing and Shaping Polymers, Composites, and Nanocomposites: A Review. Polymers (Basel) 2022; 14:180. [PMID: 35012202 PMCID: PMC8747384 DOI: 10.3390/polym14010180] [Citation(s) in RCA: 26] [Impact Index Per Article: 13.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/20/2021] [Revised: 11/11/2021] [Accepted: 11/13/2021] [Indexed: 02/04/2023] Open
Abstract
Sustainable technologies are vital due to the efforts of researchers and investors who have allocated significant amounts of money and time to their development. Nowadays, 3D printing has been accepted by the main industry players, since its first establishment almost 30 years ago. It is obvious that almost every industry is related to technology, which proves that technology has a bright future. Many studies have shown that technologies have changed the methods for developing particular products. Three-dimensional printing has evolved tremendously, and currently, many new types of 3D printing machines have been introduced. In this paper, we describe the historical development of 3D printing technology including its process, types of printing, and applications on polymer materials.
Collapse
Affiliation(s)
- M. N. M. Azlin
- Department of Textile Technology, School of Industrial Technology, Universiti Teknologi MARA, Cawangan Negeri Sembilan, Kampus Kuala Pilah, Kuala Pilah 72000, Malaysia
- Institute of Tropical Forestry and Forest Products, Universiti Putra Malaysia, Serdang 43400, Malaysia
| | - R. A. Ilyas
- Faculty of Engineering, School of Chemical and Energy Engineering, Universiti Teknologi Malaysia (UTM), Johor Bahru 81310, Malaysia;
- Centre for Advanced Composite Materials (CACM), Universiti Teknologi Malaysia (UTM), Johor Bahru 81310, Malaysia
| | - M. Y. M. Zuhri
- Institute of Tropical Forestry and Forest Products, Universiti Putra Malaysia, Serdang 43400, Malaysia
- Advanced Engineering Materials and Composites Research Centre (AEMC), Department of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia, Serdang 43400, Malaysia; (M.M.H.); (A.N.A.)
| | - S. M. Sapuan
- Institute of Tropical Forestry and Forest Products, Universiti Putra Malaysia, Serdang 43400, Malaysia
- Advanced Engineering Materials and Composites Research Centre (AEMC), Department of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia, Serdang 43400, Malaysia; (M.M.H.); (A.N.A.)
| | - M. M. Harussani
- Advanced Engineering Materials and Composites Research Centre (AEMC), Department of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia, Serdang 43400, Malaysia; (M.M.H.); (A.N.A.)
| | - Shubham Sharma
- Department of Mechanical Engineering, IK Gujral Punjab Technical University, Main Campus, Kapurthala 144603, India;
- Department of Mechanical Engineering, University Centre for Research and Development and Chandigarh Universiti, Pubjab 140413, India
| | - A. H. Nordin
- Faculty of Engineering, School of Chemical and Energy Engineering, Universiti Teknologi Malaysia (UTM), Johor Bahru 81310, Malaysia;
| | - N. M. Nurazzi
- Centre for Defence Foundation Studies, Universiti Pertahanan Nasional Malaysia (UPNM), Kem Perdana Sungai Besi, Kuala Lumpur 57000, Malaysia;
| | - A. N. Afiqah
- Advanced Engineering Materials and Composites Research Centre (AEMC), Department of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia, Serdang 43400, Malaysia; (M.M.H.); (A.N.A.)
| |
Collapse
|
6
|
Mitkus R, Scharnofske M, Sinapius M. Characterization 0.1 wt.% Nanomaterial/Photopolymer Composites with Poor Nanomaterial Dispersion: Viscosity, Cure Depth and Dielectric Properties. Polymers (Basel) 2021; 13:3948. [PMID: 34833246 PMCID: PMC8618496 DOI: 10.3390/polym13223948] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/02/2021] [Revised: 11/11/2021] [Accepted: 11/12/2021] [Indexed: 11/16/2022] Open
Abstract
Notably, 3D printing techniques such as digital light processing (DLP) have the potential for the cost-effective and flexible production of polymer-based piezoelectric composites. To improve their properties, conductive nanomaterials can be added to the photopolymer to increase their dielectric properties. In this study, the microstructure, viscosity, cure depth, and dielectric properties of ultraviolet (UV) light curable 0.1 wt.% nanomaterial/photopolymer composites are investigated. The composites with multi-walled carbon nanotubes (MWCNTs), graphene nanoplatelets (GNPs), and carbon black (CB) are pre-dispersed in different solvents (acetone, isopropyl alcohol, and ethanol) before adding photopolymer and continuing dispersion. For all prepared suspensions, a reduction in viscosity is observed, which is favorable for 3D printing. In contrast, the addition of 0.1 wt.% nanomaterials, even with poor dispersion, leads to curing depth reduction up to 90% compared to pristine photopolymer, where the nanomaterial dispersion is identified as a contributing factor. The formulation of MWCNTs dispersed in ethanol is found to be the most promising for increasing the dielectric properties. The post-curing of all composites leads to charge immobility, resulting in decreased relative permittivity.
Collapse
Affiliation(s)
- Rytis Mitkus
- Technische Universität Braunschweig, Institute of Mechanics and Adaptronics, Langer Kamp 6, 38106 Braunschweig, Germany; (M.S.); (M.S.)
| | | | | |
Collapse
|
7
|
Carbon Nanotube Reinforced Poly(ε-caprolactone)/Epoxy Blends for Superior Mechanical and Self-Sensing Performance in Multiscale Glass Fiber Composites. Polymers (Basel) 2021; 13:polym13183159. [PMID: 34578059 PMCID: PMC8471913 DOI: 10.3390/polym13183159] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/31/2021] [Revised: 09/09/2021] [Accepted: 09/13/2021] [Indexed: 11/16/2022] Open
Abstract
In this paper, a novel carbon nanotube (CNT) polycaprolactone (PCL), epoxy, and glass fiber (GF) composite is reported. Here, the nanoreinforced composites show a flexural strength increase of around 30%, whereas the interlaminar shear strength increases by 10-15% in comparison to unenhanced samples. This occurs because the addition of the CNTs induces a better PCL/epoxy/GF interaction. Furthermore, the nanoparticles also give novel functionalities to the multiscale composite, such as strain and damage monitoring. Here, the electrical response of the tensile- and compressive-subjected faces was simultaneously measured during flexural tests as well as the transverse conductivity in interlaminar tests, showing an exceptional capability for damage detection. Moreover, it was observed that the electrical sensitivity increases with PCL content due to a higher efficiency of the dispersion process that promotes the creation of a more uniform electrical network.
Collapse
|
8
|
Assessment of Manufacturing Parameters for New 3D-Printed Heating Circuits Based on CNT-Doped Nanocomposites Processed by UV-Assisted Direct Write. APPLIED SCIENCES-BASEL 2021. [DOI: 10.3390/app11167534] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/07/2023]
Abstract
This work consists of the development of an easy strategy to transform any structure into an efficient surface heater by the application of a low voltage over 3D printed nanocomposite circuits. To this end, the electrical conductivity and self-heating capabilities of UV-Assisted Direct Write 3D printed circuits doped with carbon nanotubes were widely explored as a function of the number of printed layers. Moreover, an optimization of the printing process was carried out by comparing the accuracy and printability obtained when printing with two different configurations: extruding and curing the ink in the same stage or curing the extruded ink in a second stage, after the whole layer was deposited. In this regard, the great homogeneity and repeatability of the heating showed by the four-layer printed circuits, together with their excellent performance for long heating times, proved their applicability to convert any structure to a surface heater. Finally, the deicing capability of the four-layer circuit was demonstrated, being able to remove a 2.5 mm thick ice layer in 4 min and 4 s.
Collapse
|
9
|
Complex Geometry Strain Sensors Based on 3D Printed Nanocomposites: Spring, Three-Column Device and Footstep-Sensing Platform. NANOMATERIALS 2021; 11:nano11051106. [PMID: 33922883 PMCID: PMC8146940 DOI: 10.3390/nano11051106] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/02/2021] [Revised: 04/18/2021] [Accepted: 04/20/2021] [Indexed: 12/01/2022]
Abstract
Electromechanical sensing devices, based on resins doped with carbon nanotubes, were developed by digital light processing (DLP) 3D printing technology in order to increase design freedom and identify new future and innovative applications. The analysis of electromechanical properties was carried out on specific sensors manufactured by DLP 3D printing technology with complex geometries: a spring, a three-column device and a footstep-sensing platform based on the three-column device. All of them show a great sensitivity of the measured electrical resistance to the applied load and high cyclic reproducibility, demonstrating their versatility and applicability to be implemented in numerous items in our daily lives or in industrial devices. Different types of carbon nanotubes—single-walled, double-walled and multi-walled CNTs (SWCNTs, DWCNTs, MWCNTs)—were used to evaluate the effect of their morphology on electrical and electromechanical performance. SWCNT- and DWCNT-doped nanocomposites presented a higher Tg compared with MWCNT-doped nanocomposites due to a lower UV light shielding effect. This phenomenon also justifies the decrease of nanocomposite Tg with the increase of CNT content in every case. The electromechanical analysis reveals that SWCNT- and DWCNT-doped nanocomposites show a higher electromechanical performance than nanocomposites doped with MWCNTs, with a slight increment of strain sensitivity in tensile conditions, but also a significant strain sensitivity gain at bending conditions.
Collapse
|
10
|
Bae JH, Won JC, Lim WB, Lee JH, Min JG, Kim SW, Kim JH, Huh P. Highly Flexible and Photo-Activating Acryl-Polyurethane for 3D Steric Architectures. Polymers (Basel) 2021; 13:polym13060844. [PMID: 33801858 PMCID: PMC7999262 DOI: 10.3390/polym13060844] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/04/2021] [Revised: 03/04/2021] [Accepted: 03/08/2021] [Indexed: 12/15/2022] Open
Abstract
An acryl-functionalized polyurethane (PU) series was successfully synthesized using poly(tetramethylene ether) glycol-methylene diphenyl diisocyanate (PTMG-MDI) oligomer based on urethane methacrylates to control the flexibility of photo-cured 3D printing architectures. The mass ratio of acryl-urethane prepolymer: 1,4-butanediol (BD) chain-extender: diphenyl(2,4,6-trimethylbenzoyl) phosphine oxide (TPO) photoinitiator was 10:0.25:1. To produce suitably hard and precisely curved 3D architectures, the optimal UV absorbance and exposure energy of the acryl-PTMG-MDI resin were controlled precisely. Owing to the optimized viscosity of the acryl-PTMG-MDI resins, they could be printed readily by digital light processing (DLP) to form precisely curved 3D architectures after mixing with 1,6-hexanediol diacrylate (HDDA). The acryl-PTMG-MDI formulations showed much better flexural resolution than the neat resins. The printed 3D structure exhibited high surface hardness, good mechanical strength, and high elasticity for flexible applications in consumer/industrial and biomedical fields.
Collapse
Affiliation(s)
| | | | | | | | | | | | | | - PilHo Huh
- Correspondence: ; Tel.: +82-51-510-3637
| |
Collapse
|
11
|
Bae JH, Won JC, Lim WB, Min JG, Lee JH, Kwon CR, Lee GH, Huh P. Synthesis and Characteristics of Eco-Friendly 3D Printing Material Based on Waterborne Polyurethane. Polymers (Basel) 2020; 13:polym13010044. [PMID: 33374360 PMCID: PMC7794856 DOI: 10.3390/polym13010044] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/25/2020] [Revised: 12/17/2020] [Accepted: 12/23/2020] [Indexed: 11/23/2022] Open
Abstract
Photo-cured 3D architectures are successfully printed using the designed waterborne polyurethane-acrylate (WPUA) formulation. A WPUA series is synthesized in the presence of polycaprolactone diol (PCL) and 4,4′-methylene dicyclohexyl diisocyanate (H12MDI) as the soft segment part, dimethylolbutanoic acid (DMBA) as the emulsifier, and triethylamine (TEA) as the neutralizer, as a function of prepolymer molecular weight. The compatibility of WPUA and the photo-activating acryl monomer is as a key factor to guarantee the high resolution of 3D digital light processing (DLP) printing. The optimized blending formulations are tuned by using triacrylate monomers instead of diacrylate derivatives. For the high-accuracy and fine features of 3D DLP printing, WPUA are designed to be a suitable molecular structure for a 385 nm wavelength source, and the target viscosity is achieved in the range from 150 to 250 Cp. Photo-cured 3D architectures based on WPUA exhibit good flexural strength and high resolution.
Collapse
Affiliation(s)
| | | | | | | | | | | | | | - Pilho Huh
- Correspondence: ; Tel.: +82-51-510-3637
| |
Collapse
|