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

Effect of heat treatment on mechanical properties and dimensional accuracy of 3D-Printed black carbon fiber HTPLA

This present study investigated how heat treatment affects the mechanical properties of 3D-printed black carbon fiber HTPLA by manipulating two parameters: heating temperature and holding time. The mechanical properties of 3D-printed black carbon fiber HTPLA components are crucial for assessing their structural integrity and performance. The shrinkage and dimensional accuracy of the 3D-printed parts were also explored using a vernier caliper. The microstructure of both heat-treated and non-heat-treated HTPLA black carbon fiber 3D-printed parts was examined using scanning electron microscopy. Samples were prepared, printed, heat-treated, and mechanically tested, and their microstructure was observed and recorded. The results showed that heat treatment improved the material's strength, hardness, and crystallinity, leading to better mechanical properties. However, statistical analysis indicates no clear evidence that the two factors, optimum heating temperature and holding time, affect the mechanical properties of heat-treated printed parts. Nonetheless, further study suggests that these factors might be important in optimizing the heat treatment process.

Additive Manufacturing of Continuous Fiber-Reinforced Polymer Composites via Fused Deposition Modelling: A Comprehensive Review

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.

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.

Enhancing Tribological Performance of Self-Lubricating Composite via Hybrid 3D Printing and In Situ Spraying

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.

Surface Thermodynamic Properties of Poly Lactic Acid by Inverse Gas Chromatography

Poly lactic acid (PLA) is one of the most commonly used bio-derived thermoplastic polymers in 3D and 4D printing applications. The determination of PLA surface properties is of capital importance in 3D/4D printing technology. The surface thermodynamic properties of PLA polymers were determined using the inverse gas chromatography (IGC) technique at infinite dilution. The determination of the retention volume of polar and non-polar molecules adsorbed on the PLA particles filling the column allowed us to obtain the dispersive, polar, and Lewis's acid-base surface properties at different temperatures from 40 °C to 100 °C. The applied surface method was based on our recent model that used the London dispersion equation, the new chromatographic parameter function of the deformation polarizability, and the harmonic mean of the ionization energies of the PLA polymer and organic molecules. The application of this new method led to the determination of the dispersive and polar free surface energy of the adsorption of molecules on the polymeric material, as well as the glass transition and the Lewis acid-base constants. Four interval temperatures were distinguished, showing four zones of variations in the surface properties of PLA as a function of the temperature before and after the glass transition. The acid-base parameters of PLA strongly depend on the temperature. The accurate determination of the dispersive and polar surface physicochemical properties of PLA led to the work of adhesion of the polar organic solvents adsorbed on PLA. These results can be very useful for achieving reliable and functional 3D and 4D printed components.

Mechanical and Electrical Properties of Polyethylene Terephthalate Glycol/Antimony Tin Oxide Nanocomposites in Material Extrusion 3D Printing

In this study, poly (ethylene terephthalate) (PETG) was combined with Antimony-doped Tin Oxide (ATO) to create five different composites (2.0-10.0 wt.% ATO). The PETG/ATO filaments were extruded and supplied to a material extrusion (MEX) 3D printer to fabricate the specimens following international standards. Various tests were conducted on thermal, rheological, mechanical, and morphological properties. The mechanical performance of the prepared nanocomposites was evaluated using flexural, tensile, microhardness, and Charpy impact tests. The dielectric and electrical properties of the prepared composites were evaluated over a broad frequency range. The dimensional accuracy and porosity of the 3D printed structure were assessed using micro-computed tomography. Other investigations include scanning electron microscopy and energy-dispersive X-ray spectroscopy, which were performed to investigate the structures and morphologies of the samples. The PETG/6.0 wt.% ATO composite presented the highest mechanical performance (21% increase over the pure polymer in tensile strength). The results show the potential of such nanocomposites when enhanced mechanical performance is required in MEX 3D printing applications, in which PETG is the most commonly used polymer.

Additive Manufacturing: A Comprehensive Review

Additive manufacturing has revolutionized manufacturing across a spectrum of industries by enabling the production of complex geometries with unparalleled customization and reduced waste. Beginning as a rapid prototyping tool, additive manufacturing has matured into a comprehensive manufacturing solution, embracing a wide range of materials, such as polymers, metals, ceramics, and composites. This paper delves into the workflow of additive manufacturing, encompassing design, modeling, slicing, printing, and post-processing. Various additive manufacturing technologies are explored, including material extrusion, VAT polymerization, material jetting, binder jetting, selective laser sintering, selective laser melting, direct metal laser sintering, electron beam melting, multi-jet fusion, direct energy deposition, carbon fiber reinforced, laminated object manufacturing, and more, discussing their principles, advantages, disadvantages, material compatibilities, applications, and developing trends. Additionally, the future of additive manufacturing is projected, highlighting potential advancements in 3D bioprinting, 3D food printing, large-scale 3D printing, 4D printing, and AI-based additive manufacturing. This comprehensive survey aims to underscore the transformative impact of additive manufacturing on global manufacturing, emphasizing ongoing challenges and the promising horizon of innovations that could further elevate its role in the manufacturing revolution.

Composite PCL Scaffold With 70% β-TCP as Suitable Structure for Bone Replacement

OBJECTIVES

The purpose of this work was to optimise printable polycaprolactone (PCL)/β-tricalcium phosphate (β-TCP) biomaterials with high percentages of β-TCP endowed with balanced mechanical characteristics to resemble human cancellous bone, presumably improving osteogenesis.

METHODS

PCL/β-TCP scaffolds were obtained from customised filaments for fused deposition modelling (FDM) 3D printing with increasing amounts of β-TCP. Samples mechanical features, surface topography and wettability were evaluated as well as cytocompatibility assays, cell adhesion and differentiation.

RESULTS

The parameters of the newly fabricated materila were optimal for PCL/β-TCP scaffold fabrication. Composite surfaces showed higher hydrophilicity compared with the controls, and their surface roughness sharply was higher, possibly due to the presence of β-TCP. The Young's modulus of the composites was significantly higher than that of pristine PCL, indicating that the intrinsic strength of β-TCP is beneficial for enhancing the elastic modulus of the composite biomaterials. All novel composite biomaterials supported greater cellular growth and stronger osteoblastic differentiation compared with the PCL control.

CONCLUSIONS

This project highlights the possibility to fabricat, through an FDM solvent-free approach, PCL/β-TCP scaffolds of up to 70 % concentrations of β-TCP. overcoming the current lmit of 60 % stated in the literature. The combination of 3D printing and customised biomaterials allowed production of highly personalised scaffolds with optimal mechanical and biological features resembling the natural structure and the composition of bone. This underlines the promise of such structures for innovative approaches for bone and periodontal regeneration.

Programmable and Modularized Gas Sensor Integrated by 3D Printing

The rapid advancement of intelligent manufacturing technology has enabled electronic equipment to achieve synergistic design and programmable optimization through computer-aided engineering. Three-dimensional (3D) printing, with the unique characteristics of near-net-shape forming and mold-free fabrication, serves as an effective medium for the materialization of digital designs into usable devices. This methodology is particularly applicable to gas sensors, where performance can be collaboratively optimized by the tailored design of each internal module including composition, microstructure, and architecture. Meanwhile, diverse 3D printing technologies can realize modularized fabrication according to the application requirements. The integration of artificial intelligence software systems further facilitates the output of precise and dependable signals. Simultaneously, the self-learning capabilities of the system also promote programmable optimization for the hardware, fostering continuous improvement of gas sensors for dynamic environments. This review investigates the latest studies on 3D-printed gas sensor devices and relevant components, elucidating the technical features and advantages of different 3D printing processes. A general testing framework for the performance evaluation of customized gas sensors is proposed. Additionally, it highlights the superiority and challenges of programmable and modularized gas sensors, providing a comprehensive reference for material adjustments, structure design, and process modifications for advanced gas sensor devices.

Electrically Conductive Polymers for Additive Manufacturing

The use of electrically conductive polymers (CPs) in the development of electronic devices has attracted significant interest due to their unique intrinsic properties, which result from the synergistic combination of physicochemical properties in conventional polymers with the electronic properties of metals or semiconductors. Most conventional methods adopted for the fabrication of devices with nonplanar morphologies are still challenged by the poor ionic/electronic mobility of end products. Additive manufacturing (AM) brings about exciting prospects to the realm of CPs by enabling greater design freedom, more elaborate structures, quicker prototyping, relatively low cost, and more environmentally friendly electronic device creation. A growing variety of AM technologies are becoming available for three-dimensional (3D) printing of conductive devices, i.e., vat photopolymerization (VP), material extrusion (ME), powder bed fusion (PBF), material jetting (MJ), and lamination object manufacturing (LOM). In this review, we provide an overview of the recent research progress in the area of CPs developed for AM, which advances the design and development of future electronic devices. We consider different AM techniques, vis-à-vis, their development progress and respective challenges in printing CPs. We also discuss the material requirements and notable advances in 3D printing of CPs, as well as their potential electronic applications including wearable electronics, sensors, energy storage and conversion devices, etc. This review concludes with an outlook on AM of CPs.

The Mechanical Properties of 3D-Printed Polylactic Acid/Polyethylene Terephthalate Glycol Multi-Material Structures Manufactured by Material Extrusion

The mechanical properties of polylactic acid (PLA), polyethylene terephthalate glycol (PETG), and PLA/PETG structures manufactured using the multi-material additive manufacturing (MMAM) method were studied in this work. Material extrusion additive manufacturing was used to print PLA/PETG samples with various PLA and PETG layer numbers. By varying the top and bottom layer numbers of two thermoplastics, the effect of layer number on the mechanical properties of 3D-printed structures was investigated. The chemical and thermal characteristics of PLA and PETG were investigated using Fourier transform infrared spectroscopy and differential scanning calorimetry. Tensile and flexural strength of 3D-printed PLA, PETG, and PLA/PETG samples were determined using tensile and three-point bending tests. The fracture surfaces of the samples were evaluated using optical microscopy. The results indicated that multi-material part containing 13 layers of PLA and 3 layers of PETG exhibited the highest ultimate tensile strength (65.4 MPa) and a good flexural strength (91.4 MPa). MMAM was discovered to be a viable way for producing PLA/PETG materials with great mechanical performance.

Effect of 3D-Printed Honeycomb Core on Compressive Property of Hybrid Energy Absorbers: Experimental Testing and Optimization Analysis

This paper presents an innovative method of constructing energy absorbers, whose primary function is to effectively transform kinetic energy into strain energy in events with high deformation rates. Hybrid specimens are proposed considering thin-walled windowed metallic tubes filled with 3D-printed hexagonal honeycombs made of PET-G and ABS thermoplastic. The patterned windows dimensions vary from 20 × 20, 20 × 30, 15 × 20 and 15 × 30 mm2. Although using polymers in engineering and thin-walled sections is not new, their combination has not been explored in this type of structure designed to withstand impacts. Specimens resist out-of-plane quasi-static axial loading, and test results are analyzed, demonstrating that polymer core gives the samples better performance parameters than unfilled samples regarding energy absorption (Ea), load rate (LR), and structural effectiveness (η). An optimization procedure using specialized software was applied to evaluate experimental results, which led to identifying the optimal window geometry (16.4 × 20 mm2, in case) and polymer to be used (ABS). The optimized sample was constructed and tested for axial compression to validate the optimization outcomes. The results reveal that the optimal sample performed similarly to the estimated parameters, making this geometry the best choice under the test conditions.

Recent advances in lignin-based 3D printing materials: A mini-review

With the growing global population and rapid economic development, the demand for energy and raw materials is increasing, and the supply of fossil resources as the main source of energy and raw materials has reached a critical juncture. However, our overexploitation and overconsumption of fossil resources have led to serious problems, including environmental pollution, climate change, and ecosystem destruction. In the face of these challenges, we must recognize the negative impacts of the shortage of fossil resources and actively seek sustainable alternative sources of energy and resources to protect our environment and sustainable development in the future. Three-dimensional (3D) printing, an additive manufacturing technology, has been used in many fields to manufacture complex and high-precision products. While traditional manufacturing processes typically produce large amounts of waste and emissions that are harmful to the environment, 3D printing is much more energy efficient compared to traditional manufacturing methods, which helps to lower energy costs and reduce reliance on non-renewable energy sources. The development of low-carbon and environmentally friendly 3D printing materials can help to reduce carbon emissions and environmental pollution and realize the goal of sustainable development. Lignin, as the second largest renewable green biomass resource after cellulose, has great potential for manufacturing low-carbon and environmentally friendly 3D printing materials. This review presents some recent studies on the applications of lignin and its derivatives in photo-curing 3D printing, including the preparation and performance of lignin-based photosensitive prepolymers, lignin-based reactive diluents, lignin-based photo-initiators, and lignin-based additive. This review also provides recent studies on the preparation and performance of lignin-based thermoplastic polymer for Fused Deposition Modeling (FDM) 3D printing. Finally, the future challenges and industrialization prospects of lignin-based 3D printing materials are discussed.

A survey regarding the organizational aspects and quality systems of in-house 3D printing in oral and maxillofacial surgery in Germany

PURPOSE

The aim of the study was to get a cross-sectional overview of the current status of specific organizational procedures, quality control systems, and standard operating procedures for the use of three-dimensional (3D) printing to assist in-house workflow using additive manufacturing in oral and maxillofacial surgery (OMFS) in Germany.

METHODS

An online questionnaire including dynamic components containing 16-29 questions regarding specific organizational aspects, process workflows, quality controls, documentation, and the respective backgrounds in 3D printing was sent to OMF surgeons in university and non-university hospitals as well as private practices with and without inpatient treatment facilities. Participants were recruited from a former study population regarding 3D printing; all participants owned a 3D printer and were registered with the German Association of Oral and Maxillofacial Surgery.

RESULTS

Sixty-seven participants answered the questionnaires. Of those, 20 participants ran a 3D printer in-unit. Quality assurance measures were performed by 13 participants and underlying processes by 8 participants, respectively. Standard operating procedures regarding computer-aided design and manufacturing, post-processing, use, or storage of printed goods were non-existent in most printing units. Data segmentation as well as computer-aided design and manufacturing were conducted by a medical doctor in most cases (n = 19, n = 18, n = 8, respectively). Most participants (n = 8) stated that "medical device regulations did not have any influence yet, but an adaptation of the processes is planned for the future."

CONCLUSION

The findings demonstrated significant differences in 3D printing management in OMFS, especially concerning process workflows, quality control, and documentation. Considering the ever-increasing regulations for medical devices, there might be a necessity for standardized 3D printing recommendations and regulations in OMFS.

Legibility of 3D printed typography at smaller sizes

The aim of the research was to investigate the usability and legibility of 3D printed typeface characters in smaller sizes. In the experimental investigation two software programs for letter modelling, three typefaces, three type sizes, two weight options, and two printing materials were tested. The samples were analysed visually and with image analysis. The legibility tests were conducted in laboratory conditions and testing chamber. The participants were asked to read pangrams and answer close-ended questions. The reading speed and understanding of the text were measured and analysed. It was found that the success of printing parts of letters, as well as their recognition and visual evaluation, is most often influenced by two analysed factors, i.e. weight option and type size, in all three typefaces. We established that the type size is statistically significant, and that the typographic tonal density is influenced by the typeface and the material used.Practitioner summary: The research presents the investigation of usability and legibility of 3D printed typefaces at smaller sizes. Five variables were analysed visually and with image analysis. Typographic tonal density, reading speed, and text comprehension were evaluated. The findings demonstrated that weight option, type size, and material influence the reading speed and text comprehension.HIGHLIGHTSFive different parameters were investigated regarding usability of 3D printed typeface.Legibility of different typefaces, weight options, and type sizes were tested.Typographic tonal density was evaluated with image analysis.Print quality of different materials using an FDM technology printer was evaluated.

Recent Progress of 3D Printing of Polymer Electrolyte Membrane-Based Fuel Cells for Clean Energy Generation

This review summarizes recent advances in the application of 3D printing (additive manufacturing) for the fabrication of various components of hydrogen fuel cells with a polymer electrolyte membrane (HFC-PEMs). This type of fuel cell is an example of green renewable energy, but its active implementation into the real industry is fraught with a number of problems, including rapid degradation and low efficiency. The application of 3D printing is promising for improvement in HFC-PEM performance due to the possibility of creating complex geometric shapes, the exact location of components on the substrate, as well as the low-cost and simplicity of the process. This review examines the use of various 3D printing techniques, such as inkjet printing, fused deposition modeling (FDM) and stereolithography, for the production/modification of electrodes, gas diffusion and catalyst layers, as well as bipolar plates. In conclusion, the challenges and possible solutions of the identified drawbacks for further development in this field of research are discussed. It is expected that this review article will benefit both representatives of applied science interested in specific engineering solutions and fundamental science aimed at studying the processes occurring in the fuel cell.

Spatial 3D Printing of Continuous Fiber-Reinforced Composite Multilayer Truss Structures with Controllable Structural Performance

Continuous fiber-reinforced composite truss structures have broad application prospects in aerospace engineering owing to their high structural bearing efficiency and multifunctional applications. This paper presents the design and fabrication of multilayer truss structures with controlled mechanical properties based on continuous fiber-reinforced thermoplastic composite 3D printing. Continuous fiber composite pyramid trusses fabricated by 3D printing have high specific stiffness and strength, with maximum equivalent compression modulus and strength of 401.91 MPa and 30.26 MPa, respectively. Moreover, the relative density of a truss structure can be as low as 1.45%. Additionally, structural units can be extended in any direction to form a multilayer truss structure. Structural performance can be controlled by designing the parameters of each layer. This study offers a novel approach for designing a multifunctional multilayer truss structure, a structure with low-density needs and unique load-bearing effects.

Photocurable Polymer-Based 3D Printing: Advanced Flexible Strain Sensors for Human Kinematics Monitoring

Vat photopolymerization-based additive manufacturing (AM) is critical in improving solutions for wearable sensors. The ability to add nanoparticles to increase the polymer resin's mechanical, electrical, and chemical properties creates a strong proposition for investigating custom nanocomposites for the medical field. This work uses a low-cost biocompatible polymer resin enhanced with multi-walled carbon nanotubes (MWCNTs), and a digital light processing-based AM system to develop accurate strain sensors. These sensors demonstrate the ability to carry a 244% maximum strain while lasting hundreds of cycles without degradation at lower strain ranges. In addition, the printing process allows for detailed prints to be accomplished at a sub-30 micron spatial resolution while also assisting alignment of the MWCNTs in the printing plane. Moreover, high-magnification imagery demonstrates uniform MWCNT dispersion by utilizing planetary shear mixing and identifying MWCNT pullout at fracture locations. Finally, the proposed nanocomposite is used to print customized and wearable strain sensors for finger motion monitoring and can detect different amounts of flexion and extension. The 3D printed nanocomposite sensors demonstrate characteristics that make it a strong candidate for the applications of human kinematics monitoring and sensing.

Structural and Dimensional Analysis by Computed Tomography of a Multi Geometric Template Manufactured by Fused Deposition Modeling

As a consequence of the development of AM, strategies have been developed to optimize the printing process, which focuses on reducing manufacturing time, such as using genetic algorithms (GAs), among others. The effect caused by the modification of path patterns is an effect of interest in two aspects: dimensional assurance focused on the compliance of the dimensions of the components in comparison with the digital design of the components, and the structural composition and resistance that the printing process itself can generate. This paper aims to present the effect of optimizing the path of fused filament fabrication (FFF) equipment on the dimensional finish and structural quality of a multi-geometric component using computed tomography. For this purpose, a template composed of 23 geometric elements, printed using FFF technology and PLA as the base material, is used. The results show an 11% reduction in the total process time required to print the component. The effect on the dimensional precision of different geometric elements was identified. In addition, it was possible to ensure that the structural quality of the multi-geometric component was not affected by the modification of the path required by the printing process.

Preparation and Characterization of Polycarbonate-Based Blend System with Favorable Mechanical Properties and 3D Printing Performance

Recently, material extrusion (MEX) 3D printing technology has attracted extensive attention. However, some high-performance thermoplastic polymer resins, such as polycarbonate (PC), cannot be processed by conventional MEX printing equipment due to poor processing performance. In order to develop new PC-based printing materials suitable for MEX, PC/poly(butylene adipate-co-terephthalate) (PBAT) blends were prepared using a simple polymer blending technique. It was found that the addition of PBAT component significantly improved processing performance of the PC, making the blends processable at 250 °C. More importantly, the PC was completely compatible with the PBAT, and the PBAT effectively reduced the Tg of the blends, endowing the blends with essential 3D printing performance. Furthermore, methyl methacrylate-butadiene-styrene terpolymer (MBS) was introduced into the PC/PBAT blends to improve toughness. SEM observations demonstrated that MBS particles, as stress concentration points, triggered shear yielding of polymer matrix and absorbed impact energy substantially. In addition, the MBS had little effect on the 3D printing performance of the blends. Thus, a PC/PBAT/MBS blend system with favorable comprehensive mechanical properties and 3D printing performance was achieved. This work can provide guidance for the development of novel MEX printing materials and is of great significance for expanding the variety of MEX printing materials.

Evaluation of flexible three-dimensionally printed occlusal splint materials: An in vitro study

OBJECTIVE

To evaluate and compare the mechanical properties, water sorption, water solubility, and degree of double bond conversion of three different commercially available three-dimensional (3D) printing resins used for the fabrication of flexible occlusal splints.

METHODS

A digital printer was used to generate specimens from the evaluated splint materials (KeySplint Soft, IMPRIMO LC Splint flex, and V-Print splint comfort). The specimens were equally divided and tested either dry or after water storage at 37 °C for 30 days. A three-point bending test was used to assess flexural strength, elastic modulus, and fracture toughness. A two-body wear test was performed using a dual-axis chewing simulator. Water sorption and water solubility were measured after 30 days. The degree of double bond conversion was determined by FTIR-spectrometry. All data for the evaluated properties were collected and statistically analyzed.

RESULTS

Both material and storage conditions had a significant effect on the flexural strength (P < 0.001), elastic modulus (P < 0.001), fracture toughness (P < 0.001), and wear (P < 0.001). The highest water sorption was noticed with IMPRIMO LC Splint flex (1.9 ± 0.0 %), while V-Print splint comfort displayed the lowest water solubility (0.2 ± 0.0 %). For the degree of conversion, it was statistically non-significant among the different materials (P = 0.087).

SIGNIFICANCE

Different flexible 3D-printed splints available in the market displayed variations in the evaluated properties and clinicians should consider these differences when choosing occlusal device materials. Among the tested flexible splint materials, KeySplint Soft had the greatest flexural strength, elastic modulus, fracture toughness, wear resistance, and degree of conversion. It also showed the lowest water sorption.

Fabrication and evaluation of PLA/MgAl2O4 scaffolds manufactured through 3D printing method

In this study, we synthesized magnesium aluminate spinel (MgAl2O4) with a particle size ranging from 35 to 70 nm using a facile combustion approach. Then, we used a 3D printing (FDM) machine to produce PLA/x wt% MgAl2O4 (x = 0, 2, 4, 6, and 8) scaffolds. To investigate the crystal structure, microstructure, biodegradability, and thermal characteristics of the produced materials, we employed X-ray diffraction analysis (XRD), field emission scanning electron microscope (FESEM), Inductively Coupled Plasma (ICP), Simultaneous Thermal Analysis (STA), and compressive strength analyses. The results showed that PLA/6 wt% MgAl2O4 scaffolds possess the highest amounts of compressive strength. We evaluated the bio-activation and biodegradability of scaffolds by immersing them in simulated body fluid (SBF) for four weeks. Interestingly, the highest strength was achieved in PLA/6 wt% MgAl2O4 scaffolds, while the improper dispersion of ceramic particles happened on the polymer substrate in cases where x>6. ICP analysis showed that the addition of spinel nanoparticles to PLA increased the biodegradability of the scaffolds. Our FESEM results supported this finding and also revealed that the dispersion of ceramic particles on the polymer substrate was not uniform in cases where x>6. Also, according to the results of STA, the presence of MgAl2O4 nanoparticles effectively reduces the rate of thermal decomposition from 95 to 85 percent.

Rapid Prototyping Technologies: 3D Printing Applied in Medicine

Three-dimensional printing technology has been used for more than three decades in many industries, including the automotive and aerospace industries. So far, the use of this technology in medicine has been limited only to 3D printing of anatomical models for educational and training purposes, which is due to the insufficient functional properties of the materials used in the process. Only recent advances in the development of innovative materials have resulted in the flourishing of the use of 3D printing in medicine and pharmacy. Currently, additive manufacturing technology is widely used in clinical fields. Rapid development can be observed in the design of implants and prostheses, the creation of biomedical models tailored to the needs of the patient and the bioprinting of tissues and living scaffolds for regenerative medicine. The purpose of this review is to characterize the most popular 3D printing techniques.

Thermal and Mechanical Properties of Reprocessed Polylactide/Titanium Dioxide Nanocomposites for Material Extrusion Additive Manufacturing

Polylactic acid (PLA) is a biodegradable polymer that can replace petroleum-based polymers and is widely used in material extrusion additive manufacturing (AM). The reprocessing of PLA leads to a downcycling of its properties, so strategies are being sought to counteract this effect, such as blending with virgin material or creating nanocomposites. Thus, two sets of nanocomposites based respectively on virgin PLA and a blend of PLA and reprocessed PLA (rPLA) with the addition of 0, 3, and 7 wt% of titanium dioxide nanoparticles (TiO2) were created via a double screw extruder system. All blends were used for material extrusion for 3D printing directly from pellets without difficulty. Scanning electron micrographs of fractured samples' surfaces indicate that the nanoparticles gathered in agglomerations in some blends, which were well dispersed in the polymer matrix. The thermal stability and degree of crystallinity for every set of nanocomposites have a rising tendency with increasing nanoparticle concentration. The glass transition and melting temperatures of PLA/TiO2 and PLA/rPLA/TiO2 do not differ much. Tensile testing showed that although reprocessed material implies a detriment to the mechanical properties, in the specimens with 7% nano-TiO2, this effect is counteracted, reaching values like those of virgin PLA.

3D-Printed Thermoplastic Polyurethane Electrodes for Customizable, Flexible Lithium-Ion Batteries with an Ultra-Long Lifetime

3D printing technology has demonstrated great potential in fabricating flexible and customizable high-performance batteries, which are highly desired in the forthcoming intelligent and ubiquitous energy era. However, a significant performance gap, especially in cycling stability, still exists between the 3D-printed and conventional electrodes, seriously limiting the practical applications of 3D-printed batteries. Here, for the first time, a series of thermoplastic polyurethane (TPU)-based 3D-printed electrodes is developed via fused deposition modeling for flexible and customizable high-performance lithium-ion batteries. The TPU-based electrode filaments in kilogram order are prepared via a facile extrusion method. As a result, the electrodes are well-printed with high dimensional accuracy, flexibility, and mechanical stability. Notably, 3D-printed TPU-LFP electrodes exhibit a capacity retention of 100% after 300 cycles at 1C, which is among the best cycling performance of all the reported 3D-printed electrodes. Such excellent performance is associated with the superb stress cushioning properties of the TPU-based electrodes that can accommodate the volume change during the cycling and thus significantly prevent the collapse of 3D-printed electrode structures. The findings not only provide a new avenue to achieve customizable and flexible batteries but also guide a promising way to erase the performance gap between 3D-printed and conventional lithium-ion batteries.

Effects of Annealing for Strength Enhancement of FDM 3D-Printed ABS Reinforced with Recycled Carbon Fiber

This study investigates the effect of annealing on the mechanical properties of fused deposition modeling (FDM) 3D-printed recycled carbon fiber (rCF)-reinforced composites. In this study, filaments for FDM 3D printers are self-fabricated from pure acrylonitrile butadiene styrene (ABS) and ABS reinforced with fiber content of 10 wt% and 20 wt% rCF. This study explores the tensile and flexural properties as a function of the annealing temperature and time for the three different fiber content values. In addition, dimensional measurements of the shape changes are performed to determine the suitability of applying annealing in practical manufacturing processes. The results show that annealing improves the mechanical properties by narrowing the voids between the beads, which occur during the FDM process, and by reducing the gaps between the fibers and polymer. Following annealing, the largest tensile and flexural strength improvements are 12.64% and 42.33%, respectively, for the 20 wt% rCF content samples. Moreover, compared with the pure ABS samples, the annealing effect improves the mechanical properties of the rCF-reinforced samples more effectively, and they have higher dimensional stability, indicating their suitability for annealing. These results are expected to expand the application fields of rCF and greatly increase the potential use of FDM-printed parts.

Nanomaterials Reinforced Polymer Filament for Fused Deposition Modeling: A State-of-the-Art Review

For the past years, fused deposition modeling (FDM) technology has received increased attention in the applications of industrial manufacturing fields, particularly for rapid prototyping, small batch production and highly customized products, owing to the merits of low-cost, user-friendliness and high design freedom. To further expand the application potential and promote the performance of the as-manufactured products, many efforts have been spent on the development of suitable materials for FDM applications. In recent years, the involvement of nanomaterials in the FDM-based polymer matrix, which has been demonstrated with great opportunities to enhance the performance and versatility of FDM printed objects, has attracted more and more research interest and the trend is expected to be more pronounced in the next few years. This paper attempts to provide a timely review regarding the current research advances in the use of nanomaterials to reinforce polymer filaments for the FDM technique. Polymer composite filaments based on nanomaterials such as carbon nanotubes, nanoclay, carbon fibers, graphene, metal nanoparticles and oxides are discussed in detail regarding their properties and applications. We also summarized the current research challenges and outlooked the future research trends in this field. This paper aims at providing a useful reference and guidance for skilled researchers and also beginners in related fields. Hopefully, more research advances can be stimulated in the coming years.

Additive Manufacturing of Advanced Ceramics Using Preceramic Polymers

Ceramic materials are used in various industrial applications, as they possess exceptional physical, chemical, thermal, mechanical, electrical, magnetic, and optical properties. Ceramic structural components, especially those with highly complex structures and shapes, are difficult to fabricate with conventional methods, such as sintering and hot isostatic pressing (HIP). The use of preceramic polymers has many advantages, such as excellent processibility, easy shape change, and tailorable composition for fabricating high-performance ceramic components. Additive manufacturing (AM) is an evolving manufacturing technique that can be used to construct complex and intricate structural components. Integrating polymer-derived ceramics and AM techniques has drawn significant attention, as it overcomes the limitations and challenges of conventional fabrication approaches. This review discusses the current research that used AM technologies to fabricate ceramic articles from preceramic feedstock materials, and it demonstrates that AM processes are effective and versatile approaches for fabricating ceramic components. The future of producing ceramics using preceramic feedstock materials for AM processes is also discussed at the end.

Metal and Polymer Based Composites Manufactured Using Additive Manufacturing-A Brief Review

This review examines the mechanical performance of metal- and polymer-based composites fabricated using additive manufacturing (AM) techniques. Composite materials have significantly influenced various industries due to their exceptional reliability and effectiveness. As technology advances, new types of composite reinforcements, such as novel chemical-based and bio-based, and new fabrication techniques are utilized to develop high-performance composite materials. AM, a widely popular concept poised to shape the development of Industry 4.0, is also being utilized in the production of composite materials. Comparing AM-based manufacturing processes to traditional methods reveals significant variations in the performance of the resulting composites. The primary objective of this review is to offer a comprehensive understanding of metal- and polymer-based composites and their applications in diverse fields. Further on this review delves into the intricate details of metal- and polymer-based composites, shedding light on their mechanical performance and exploring the various industries and sectors where they find utility.

Improving the Mechanical Properties of CCFRPLA by Enhancing the Interface Binding Energy and Strengthening the Anti-Separation Ability of a PLA Matrix

Additive manufacturing (AM) can produce almost any product shape through layered stacking. The usability of continuous fiber-reinforced polymers (CFRP) fabricated by AM, however, is restricted owing to the limitations of no reinforcing fibers in the lay-up direction and weak interface bonding between the fibers and matrix. This study presents molecular dynamics in conjunction with experiments to explore how ultrasonic vibration enhances the performance of continuous carbon fiber-reinforced polylactic acid (CCFRPLA). Ultrasonic vibration improves the mobility of PLA matrix molecular chains by causing alternative fractures of chains, promoting crosslinking infiltration among polymer chains, and facilitating interactions between carbon fibers and the matrix. The increase in entanglement density and conformational changes enhanced the density of the PLA matrix and strengthened its anti-separation ability. In addition, ultrasonic vibration shortens the distance between the molecules of the fiber and matrix, improving the van der Waals force and thus promoting the interface binding energy between them, which ultimately achieves an overall improvement in the performance of CCFRPLA. The bending strength and interlaminar shear strength of the specimen treated with 20 W ultrasonic vibration reached 111.5 MPa and 10.16 MPa, respectively, 33.11% and 21.5% higher than those of the untreated specimen, consistent with the molecular dynamics simulations, and confirmed the effectiveness of ultrasonic vibration in improving the flexural and interlaminar properties of the CCFRPLA.

Effect of ultrasonic vibration on the mechanical properties of 3D printed acrylonitrile butadiene styrene and polylactic acid samples

Fused deposition modeling (FDM) is an extrusion-based AM process that is widely used due to its cost-effectiveness and user friendly. However, FDM also has some limitations such as the appearance of seam lines between layers and the production of excess material residue leading to poor surface finish, poor bonding between layers and porosity. This paper presents the findings on the application of ultrasonic vibration in an open-source FDM 3D printer to investigate its effect on the mechanical properties and microstructure of acrylonitrile butadiene styrene (ABS) and Polylactic Acid (PLA) samples. Two units of ultrasonic piezoelectric transducer were clamped horizontally on the surface of the 3D printer platform. The ultrasonic vibration was transmitted directly to the platform while the sample received vibration with a specific frequency while the printing process commences. Two process parameters, namely build orientation and ultrasonic vibration were selected to analyze their significance and optimization on the mechanical properties and the microstructure of the printed samples. High compressive and low surface roughness are required to have the best properties for the printed sample. Therefore, the optimization parameters are performed with these settings where the compressive strength is maximized and the surface roughness is minimized. The result shows that the overall compressive strength in ABS and PLA samples created in the Z-axis orientation is higher than in the X-axis orientation. However, the compressive strength of ABS and PLA samples is not much different after the ultrasonic vibration was applied during the printing process. The microstructure analysis shows that bonding between the layers is similar when applying ultrasonic vibration for both ABS and PLA samples. Furthermore, the result indicates that the surface roughness increased at 10 kHz and then decreased or became smoother at 20 kHz for both ABS and PLA material samples. The analysis shows that the build orientation significantly affects the compressive strength in ABS and PLA samples. However, the ultrasonic vibration has no considerable impact. In surface roughness, the build orientation and ultrasonic vibration significantly affect ABS samples. However, the PLA samples are only slightly affected. The optimum parameters for both materials are found where Z-axis orientation and 0 kHz of the ultrasonic vibration samples gave the best compressive strength and surface roughness value.

Influence of 3D Printing Conditions on Some Physical-Mechanical and Technological Properties of PCL Wood-Based Polymer Parts Manufactured by FDM

The paper investigates the influence of some 3D printing conditions on some physical-mechanical and technological properties of polycaprolactone (PCL) wood-based biopolymer parts manufactured by FDM. Parts with 100% infill and the geometry according to ISO 527 Type 1B were printed on a semiprofessional desktop FDM printer. A full factorial design with three independent variables at three levels was considered. Some physical-mechanical properties (weight error, fracture temperature, ultimate tensile strength) and technological properties (top and lateral surface roughness, cutting machinability) were experimentally assessed. For the surface texture analysis, a white light interferometer was used. Regression equations for some of the investigated parameters were obtained and analysed. Higher printing speeds than those usually reported in the existing literature dealing with wood-based polymers' 3D printing had been tested. Overall, the highest level chosen for the printing speed positively influenced the surface roughness and the ultimate tensile strength of the 3D-printed parts. The cutting machinability of the printed parts was investigated by means of cutting force criteria. The results showed that the PCL wood-based polymer analysed in this study had lower machinability than natural wood.

Flexural properties of porcupine quill-inspired sandwich panels

This paper presents the bending behaviour of the porcupine quill and bioinspired Voronoi sandwich panels, aiming to explore the effect of geometrical design on the bending performance of the inspired structures. Through the x-ray micro-computed tomography, the internal morphology of the quill is explored. The longitudinal cross-section of the porcupine quill revealed a functionally graded design in the foam structure. Based on this observation, Voronoi sandwich panels are designed by incorporating the Voronoi seed distribution strategy and gradient transition design configurations. Porcupine-inspired sandwich panels with various core designs are fabricated via material jetting technique and tested under three-point bending condition. Results show that the sample failed at the bottom face panels for uniform sandwich panels, whereas graded samples failed in the core panel. The bending behaviour developed via simulation software shows a good agreement with the experimental results. The parametric study provides insights into structural designs for engineering applications, particularly in the aerospace and automobile industries.

Flexural Properties of Lattices Fabricated with Planar and Curved Layered Fused Filament Fabrication

The use of curved layers in fused filament fabrication could lead to various advantages in surface finishing and mechanical properties. Here, the influence of three different structural and manufacturing parameters (volume fraction, raster arrangement, and the use of curved or planar layers) on the mechanical properties of lattice structures under three-point bending is studied. Two different raster arrangements were considered, i.e., those with rasters at planes parallel to the principal axes of the samples and those diagonally arranged, all at four different volume fractions. All different samples were additively manufactured using planar and curved layers. Samples were further dimensionally inspected to refine the computational models before their analysis via finite element simulations. The linear elastic region of the load-displacement curves was further analyzed numerically via finite element models. Predictions with finite element models resulted in good agreement with errors below 10%. Samples with diagonal rasters were 70% softer than those parallel to the principal axes.

Achieving effective interlayer bonding of PLA parts during the material extrusion process with enhanced mechanical properties

The additive manufacturing technique of material extrusion has challenge of excessive process defects and not achieving the desired mechanical properties. The industry is trying to develop certification to better control variations in mechanical attributes. The current study is a progress towards understanding the evolution of processing defects and the correlation of mechanical behavior with the process parameters. Modeling of the 3D printing process parameters such as layer thickness, printing speed, and printing temperature is carried out through L27 orthogonal array using Taguchi approach. In addition, CRITIC embedded WASPAS is adopted to optimize the parts' mechanical attributes and overcome the defects. Flexural and tensile poly-lactic acid specimens are printed according to ASTM standards D790 and D638, respectively, and thoroughly analyzed based on the surface morphological analysis to characterize defects. The parametric significance analysis is carried out to explore process science where the layer thickness, print speed, and temperature significantly control the quality and strength of the parts. Mathematical optimization results based on composite desirability show that layer thickness of 0.1 mm, printing speed of 60 mm/s, and printing temperature of 200 °C produce significantly desirable results. The validation experiments yielded the maximum flexural strength of 78.52 MPa, the maximum ultimate tensile strength of 45.52 MPa, and maximum impact strength of 6.21 kJ/m². It is established that multiple fused layers restricted the propagation of cracks with minimum thickness due to enhanced diffusion between the layers.

Effect of UV-C Radiation on 3D Printed ABS-PC Polymers

During the initial stages of the COVID-19 pandemic, healthcare facilities experienced severe shortages of personal protective equipment (PPE) and other medical supplies. Employing 3D printing to rapidly fabricate functional parts and equipment was one of the emergency solutions used to tackle these shortages. Using ultraviolet light in the UV-C band (wavelengths of 200 nm to 280 nm) might prove useful in sterilizing 3D printed parts, enabling their reusability. Most polymers, however, degrade under UV-C radiation, so it becomes necessary to determine what 3D printing materials can withstand the conditions found during medical equipment sterilization with UV-C. This paper analyzes the effect of accelerated aging through prolonged exposure to UV-C on the mechanical properties of parts 3D printed from a polycarbonate and acrylonitrile butadiene styrene polymer (ABS-PC). Samples 3D printed using a material extrusion process (MEX) went through a 24-h UV-C exposure aging cycle and then were tested versus a control group for changes in tensile strength, compressive strength and some selected material creep characteristics. Testing showed minimal mechanical property degradation following the irradiation procedure, with tensile strength being statistically the same for irradiated parts as those in the control group. Irradiated parts showed small losses in stiffness (5.2%) and compressive strength (6.5%). Scanning electron microscopy (SEM) was employed in order to assess if any changes occurred in the material structure.

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

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

Process Parameter Prediction for Fused Deposition Modeling Using Invertible Neural Networks

Additive manufacturing has revolutionized prototyping and small-scale production in the past years. By creating parts layer by layer, a tool-less production technology is established, which allows for rapid adaption of the manufacturing process and customization of the product. However, the geometric freedom of the technologies comes with a large number of process parameters, especially in Fused Deposition Modeling (FDM), all of which influence the resulting part's properties. Since those parameters show interdependencies and non-linearities, choosing a suitable set to create the desired part properties is not trivial. This study demonstrates the use of Invertible Neural Networks (INN) for generating process parameters objectively. By specifying the desired part in the categories of mechanical properties, optical properties and manufacturing time, the demonstrated INN generates process parameters capable of closely replicating the desired part. Validation trials prove the precision of the solution with measured properties achieving the desired properties to up to 99.96% and a mean accuracy of 85.34%.

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.

Disulfiram 3D printed film produced via hot-melt extrusion techniques as a potential anticervical cancer candidate

Cervical cancer is known globally as one of the most common health problems in women. Indeed, one of the most convenient approaches for its treatment is an appropriate bioadhesive vaginal film. This approach provides a local treatment modality, which inevitably decreases dosing frequency and improves patient compliance. Recently, disulfiram (DSF) has been investigated and demonstrated to possess anticervical cancer activity; therefore, it is employed in this work. The current study aimed to produce a novel, personalized three-dimensional (3D) printed DSF extended-release film using the hot-melt extrusion (HME) and 3D printing technologies. The optimization of the formulation composition and the HME and 3D printing processing temperatures was an important factor for overcoming the DSF heat-sensitivity issue. In addition, the 3D printing speed was specifically the most crucial parameter for alleviating heat-sensitivity concerns, which led to the production of films (F1 and F2) with an acceptable DSF content and good mechanical properties. The bioadhesion film study using sheep cervical tissue indicated a reasonable adhesive peak force (N) of 0.24 ± 0.08 for F1 and 0.40 ± 0.09 for F2, while the work of adhesion (N.mm) for F1 and F2 was 0.28 ± 0.14 and 0.54 ± 0.14, respectively. Moreover, the cumulative in vitro release data indicated that the printed films released DSF for up to 24 h. HME-coupled 3D printing successfully produced a patient-centric and personalized DSF extended-release vaginal film with a reduced dose and longer dosing interval.

Effect of Short Glass Fiber Addition on Flexural and Impact Behavior of 3D Printed Polymer Composites

Fused deposition modeling (FDM), one of the most widely used additive manufacturing (AM) processes, is used for fabrication of 3D models from computer-aided design data using various materials for a wide scope of applications. The principle of FDM or, in general, AM plays an important role in minimizing the ill effects of manufacturing on the environment. Among the various available reinforcements, short glass fiber (SGF), one of the strong reinforcement materials available, is used as a reinforcement in the acrylonitrile butadiene styrene (ABS) matrix. At the outset, very limited research has been carried out till date in the analysis of the impact and flexural strength of the SGF-reinforced ABS polymer composite developed by the FDM process. In this regard, the present research investigates the impact and flexural strength of SGF-ABS polymer composites by the addition of 15 and 30 wt % SGF to ABS. The tests were conducted as per ASTM standards. Increments in flexural and impact properties were observed with the addition of SGF to ABS. The increment of 42% in impact strength was noted for the addition of 15 wt % SGF and 54% increase with the addition of 30 wt % SGF. On similar lines, flexural properties also showed improved values of 44 and 59% for the addition of 15 and 30 wt % SGF to ABS. SGF addition greatly enhanced the properties of flexural and impact strength and has paved the path for the exploration of varied values of reinforcement into the matrix.

A Mechanical Performance Study of Dual Cured Thermoset Resin Systems 3D-Printed with Continuous Carbon Fiber Reinforcement

Additive manufacturing (AM) is one of the fastest-growing manufacturing technologies in modern times. One of the major challenges in the application of 3D-printed polymeric objects is expanding the applications to structural components, as they are often limited by their mechanical and thermal properties. To enhance the mechanical properties of 3D-printed thermoset polymer objects, reinforcing the polymer with continuous carbon fiber (CF) tow is an expanding direction of research and development. A 3D printer was constructed capable of printing with a continuous CF-reinforced dual curable thermoset resin system. Mechanical performance of the 3D-printed composites varied with the utilization of different resin chemistries. Three different commercially available violet light curable resins were mixed with a thermal initiator to improve curing by overcoming the shadowing effect of violet light by the CF. The resulting specimens’ compositions were analyzed, and then the specimens were mechanically characterized for comparison in tensile and flexural performance. The 3D-printed composites’ compositions were correlated to the printing parameters and resin characteristics. Slight enhancements in tensile and flexural properties from some commercially available resins over others appeared to be the result of better wet-out and adhesion.

Experimental Analysis of Fiber Reinforcement Rings' Effect on Tensile and Flexural Properties of Onyx™-Kevlar® Composites Manufactured by Continuous Fiber Reinforcement

Additive manufacturing of composite materials is progressing in the world of 3D printing technologies; composite materials allow the combination of the physical and mechanical properties of two or more constituents to create a new material that meets the required properties of several applications. In this research, the impact of adding Kevlar^® reinforcement rings on the tensile and flexural properties of the Onyx™ (nylon with carbon fibers) matrix was analyzed. Parameters such as infill type, infill density and fiber volume percentage were controlled to determine the mechanical response in tensile and flexural tests of the additive manufactured composites. The tested composites showed an increment of four times the tensile modulus and 1.4 times the flexural modulus of pure Onyx™ matrix when compared with that of the Onyx™-Kevlar^®. The experimental measurements demonstrated that Kevlar^® reinforcement rings can increase the tensile and flexural modulus of Onyx™-Kevlar^® composites using low fiber volume percentages (lower than 19% in both samples) and 50% of rectangular infill density. However, the appearance of some defects, such as delamination, was observed and should be further analyzed to obtain products that are errorless and can be reliable for real functions as in automotive or aeronautical industries.

A comparative analysis of the effect of post production treatments and layer thickness on tensile and impact properties of additively manufactured polymers

In recent years, additive manufacturing (AM) technologies have become greatly popular in the polymer, metal, and composite industries because of the capability for rapid prototyping, and appropriateness for the production of complex shapes. In this study, a comprehensive comparative analysis focusing on the influence of post-processing types (heat treatment and water absorption) on tensile and impact responses was carried out on 3D printed PETG, PLA, and ABS. In addition, layer thickness levels (0.2, 0.3, and 0.4 mm) were selected as a major production parameter and their effect on mechanical properties was combined with post-processing type for the first time. The results showed that both tensile and impact resistance of the printed polymers increased thanks to the heat treatment. The highest tensile strength was measured for heat-treated PLA, while the peak impact endurance level was reached for heat-treated PETG. Also, water absorption caused a mass increment in all samples and induced higher tensile elongation values. Decreasing layer thickness had a positive effect on tensile features, but impact strength values dropped. On the other hand, all samples were subjected to macro and micro failure analyses to understand the deformation mechanism. These inspections indicated that for impact samples straight crack lines converted to zigzag style separation lines after the heat treatment. As for the tensile samples, the exact location of the main damage zone altered with the production stability, the water absorption capacity of the polymer, and the thermal diffusion ability of the filament.

Fused Deposition Modelling of Polymeric Auxetic Structures: A Review

Additive Manufacturing (AM) techniques have recently attracted the attention of scientists for the development of prototypes with complex or particular geometry in a fast and cheap way. Among the different AM processes, the Fused Deposition Modelling process (FDM) offers several advantages in terms of costs, implementation features and design freedom. Recently, it has been adopted to realise auxetic structures, which are characterised by negative Poisson ratio, enhanced mechanical properties, and a higher compression resistance than conventional structures. This review outlines the use of AM processes, in particular FDM, to design and obtain auxetic structures, with the final aim to exploit their applications in different fields. The first part of this work presents a brief classification of auxetic structures and materials. Subsequently, a summary of additive manufacturing processes is presented, focusing on the use of FDM and its limitations. Finally, the studies on the use of additive manufacturing to produce auxetic structures are shown, evidencing the potential of the concurrent combination of a fast prototyping technique such as FDM and the characteristics of polymer- and/or composite-based auxetic structures. Indeed, this new technological field opens the possibility of realising novel structures with integrated smart behaviour, multifunctional properties, compression resistance, and a tailored microstructure and shape.

Enhancement of 3D Printability by FDM and Electrical Conductivity of PLA/MWCNT Filaments Using Lignin as Bio-Dispersant

To increase the applications of FDM (fusion deposition modeling) 3D printing in electronics, it is necessary to develop new filaments with good electrical properties and suitable processability. In this work, polymer composites filament-shaped with superior electrical performance based on polylactic acid (PLA) carbon nanotubes and lignin blends have been studied by combining solution mixing and melt blending. The results showed that composites achieve electrical percolation from 5 wt.% of nanotubes, with high electrical conductivity. Moreover, the introduction of a plasticizing additive, lignin, improved the printability of the material while increasing its electrical conductivity (from (1.5 ± 0.9)·10^-7 S·cm^-1 to (1.4 ± 0.9)·10^-1 S cm^-1 with 5 wt.% carbon nanotubes and 1 wt.% lignin) maintaining the mechanical properties of composite without additive. To validate lignin performance, its effect on PLA/MWCNT was compare with polyethylene glycol. PEG is a well-known commercial additive, and its use as dispersant and plasticizer in PLA/MWCNT composites has been proven in bibliography. PLA/MWCNT composites display easier processability by 3D printing and more adhesion between the printed layers with lignin than with PEG. In addition, the polyethylene glycol produces a plasticizing effect in the PLA matrix reducing the composite stiffness. Finally, an interactive electronic prototype was 3D printed to assess the printability of the new conducting filaments with 5 wt.% of MWCNT.