Viscoelastic Properties of Cell Structures Manufactured Using a Photo-Curable Additive Technology-PJM

Mathematical Modeling of Initial Exothermic Behavior and Thixotropic Properties in Nanoclay-Enhanced Cementitious Materials

In the realm of cementitious materials, integrating nanoclay shows promise in enhancing properties relevant to additive manufacturing. This paper presents a novel mathematical model that combines simple empirical dissolution/nucleation Avrami-like kinetics with a thixotropic kinetics equation. To analyze the initial exothermic peak, two sets of the calculation parameter function are built to describe the exothermic rate as a function of time, following an exponential pattern. This allows for the prediction of the changes in cumulative heat and heat rate during hydration, considering different concentrations of nanoclay. In the rheological aspect, the relationship between shear stress, shear rate, and time is modeled as a combination of exponential dependencies. This enables the prediction of the variations in shear stress with one variable while holding the other constant (either time or shear rate). By integrating these aspects, this model effectively describes both the first exothermal peak and the rheological behavior during cement hydration with the inclusion of nanoclay. Validated against experimental results, these models demonstrate good accuracy (overall below 3% error), reliability, and applicability. The findings offer valuable insights into the thermal and rheological aspects of concrete printing, enabling informed design decisions for both scientific and industrial applications.

Selected Mechanical and Rheological Properties of Medical Resin MED610 in PolyJet Matrix Three-Dimensional Printing Technology in Quality Aspects

In connection with the growing demand of the medical and medicine-related industry for materials exhibiting biocompatible properties used as part of three-dimensional (3D) printing additive technologies. The article presents research results concerning rheological and selected mechanical properties of a modern, photocurable MED610 resin, which is also used mainly in medicine, as well as dentistry. The article also shows extensive results of testing bending stress relaxation and creep, as well as the tensile strength of samples created with the PolyJet Matrix (PJM) technology. The authors used various sample types, including ones of unique shape and a hexagonal cellular structure. The analysis of the impact of element orientation on the working platform of the machine (3D printer) on the obtained test results (so-called printing direction-Pd) was also taken into account as a key technological parameter of the 3D printing process. Experimental rheological curves were matched with theoretical curves resulting from the application of a five-parameter Maxwell-Wiechert (M-W) model in the case of stress relaxation and a five-parameter Kelvin-Voigt model for creep. Very good matches were achieved, mean coefficients Chi2 = 0.0014 and R2 = 0.9956 for matching the five-parameter M-W model and mean coefficients Chi2 = 0.000006 and R2 = 0.9992 enable recommending the obtained results to be used for various engineering calculations, especially computer simulations. Moreover, the use of relaxation curves can significantly increase the construction capabilities within the design process, which includes the MED610 material.

2D and 3D Electrospinning of Nanofibrous Structures by Far-Field Jet Writing

Electrospinning offers remarkable versatility in producing superfine fibrous materials and is hence widely used in many applications such as tissue scaffolds, filters, electrolyte fuel cells, biosensors, battery electrodes, and separators. Nevertheless, it is a challenge to print pre-designed 2D/3D nanofibrous structures using electrospinning due to its inherent jet instability. Here, we report on a novel far-field jet writing technique for precisely controlling the polymer jet in nanofiber deposition, which was achieved through a combination of reducing the nozzle voltage, adjusting the electric field, and applying a set of passively focusing electrostatic lenses. By optimizing the applied voltage, the circular aperture of lenses, and the distance between the adjacent lenses, the best precision achieved using this technique was approximately 200 μm, similar to that of a conventional polymer-based 3D printer. This development makes it possible for printing 2D/3D nanofibrous structures by far-field jet writing for different applications with enhanced performance.

Adjusting Surface Models of Cellular Structures for Making Physical Models Using FDM Technology

In the planning stage of the fabrication process of physical models of cellular structures, a surface model of the structure needs to be adjusted to acquire the requisite properties, but errors emerge frequently at this stage. The main objective of this research was to repair or reduce the impact of deficiencies and errors before the fabrication of physical models. For this purpose, it was necessary to design models of cellular structures with different accuracy settings in PTC Creo and then compare them after the tessellation process using GOM Inspect. Subsequently, it was necessary to locate the errors occurring in the process of preparing models of cellular structures and propose an appropriate method of their repair. It was found that the Medium Accuracy setting is adequate for the fabrication of physical models of cellular structures. Subsequently, it was found that within regions where mesh models merged, duplicate surfaces emerged, and the entire model could be considered as manifesting non-manifold geometry. The manufacturability check showed that in the regions with duplicate surfaces inside the model, the toolpath creation strategy changed, causing local anisotropy within 40% of the fabricated model. A non-manifold mesh was repaired in the proposed manner of correction. A method of smoothing the model's surface was proposed, reducing the polygon mesh density and the file size. The findings and proposed methods of designing cellular models, error repair and smoothing methods of the models can be used to fabricate higher-quality physical models of cellular structures.

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.

Non-Isothermal Crystallization Kinetics of Polyether-Ether-Ketone Nanocomposites and Analysis of the Mechanical and Electrical Conductivity Performance

High-performance polyether-ether-ketone (PEEK) is highly desirable for a plethora of engineering applications. The incorporation of conductive carbon nanotubes (CNTs) into PEEK can impart electrical conductivity to the otherwise non-conductive matrix, which can further expand the application realm for PEEK composites. However, a number of physical properties, which are central to the functionalities of the composite, are affected by the complex interplay of the crystallinity and presence of the nanofillers, such as CNTs. It is therefore of paramount importance to conduct an in-depth investigation to identify the process that optimizes the mechanical and electrical performance. In this work, PEEK/CNTs composites with different carbon nanotubes (CNTs) content ranging from 0.5 to 10.0 wt% are prepared by a parallel twin-screw extruder. The effects of CNTs content and annealing treatment on the crystallization behavior, mechanical properties and electrical conductivity of the PEEK/CNTs composites are investigated in detail. A non-isothermal crystallization kinetics test reveals a substantial loss in the composites’ crystallinity with the increased CNTs content. On the other hand, mechanical tests show that with 5.0 wt% CNTs content, the tensile strength reaches a maximum at 118.2 MPa, which amounts to a rise of 30.3% compared with the neat PEEK sample after annealing treatment. However, additional annealing treatment decreases the electrical conductivity as well as EMI shielding performance. Such a decrease is mainly attributed to the relatively small crystal size of PEEK, which excludes the conductive fillers to the boundaries and disrupts the otherwise conductive networks.

Magnetic 3D-Printed Composites-Production and Applications

Three-dimensional printing enables building objects shaped with a large degree of freedom. Additional functionalities can be included by modifying the printing material, e.g., by embedding nanoparticles in the molten polymer feedstock, the resin, or the solution used for printing, respectively. Such composite materials may be stronger or more flexible, conductive, magnetic, etc. Here, we give an overview of magnetic composites, 3D-printed by different techniques, and their potential applications. The production of the feedstock is described as well as the influence of printing parameters on the magnetic and mechanical properties of such polymer/magnetic composites.

Mechanical Response of Carbon Composite Octet Truss Structures Produced via Axial Lattice Extrusion

Engineered lattice structures fabricated via additive manufacturing (AM) technologies are of great interest for many applications that require high strength and/or stiffness with minimum mass. This paper studies a novel axial lattice extrusion (ALE) AM technique that greatly enhances mechanical properties of polymeric lattice structures. When the novel ALE process was used to produce 84 mm × 84 mm × 84 mm octet truss lattice samples using fiber reinforced ABS, a total of 219,520 polymer interfaces in the lattice beams were eliminated relative to the conventional 3D printing alternative. Microscopic examination revealed near perfect alignment of the chopped carbon fibers with axes of the cylindrical beams that make up the lattice structure. The greatly enhanced beam quality with fiber reinforcement resulted in excellent mechanical properties. Compression testing yielded an average relative compressive strength of 17.4 MPa and an average modulus of 162.8 MPa. These properties rate very strongly relative to other published work, and indicate that the ALE process shows great potential for fabrication of high-strength, lightweight, large-scale, carbon-fiber composite components. The paper also contributes a modeling approach to finite element analysis (FEA) that captures the highly orthotropic properties of carbon fiber lattice beams. The diagonal shear failure mode predicted via the FEA model was in good agreement with experimentally observed results.

Comparative Analysis of Polymer Composites Produced by FFF and PJM 3D Printing and Electrospinning Technologies for Possible Filter Applications

Three-dimensional printing technologies are mainly used to build objects with complex shapes and geometry, largely prototypes, and thanks to the possibility of building very thin layers of material with small pores, electrospinning technology allows for the creation of structures with filtration properties, in particular very small particles. The combination of these technologies creates new possibilities for building complex-shape composites that have not been comprehensively tested so far. The article describes the results of research on composites manufactured by combining samples prepared with two 3D printing technologies, Fused Filament Fabrication (FFF) and Photo-Curing of Liquid Polymer Resins (PJM) in combination with electrospinning (ES) technology. The surface morphology of composites manufactured from biocompatible materials was investigated using confocal laser scanning microscopy (CLSM) and contact angle measurements, and chemical composition analysis was studied using Fourier transform infrared spectroscopy (FTIR). This approach to creating composites appears to be an alternative to developing research for filtration applications. The article presents basic research illustrating the quality of composites produced by combining two unconventional technologies: 3D printing and electrospinning (ES). The analysis of the research results showed clear differences in the structure of composites produced with the use of various 3D printing technologies. The CLSM analysis showed a much better orientation of the fibers in the MED610 + PAN/gelatin composite, and the measurement of the contact angle and its indirect interpretation also for this composite allows for the conclusion that it will be characterized by a higher value of adhesion force. Moreover, such composites could be used in the future for the construction of filtering devices and in medical applications.

Morphology of Models Manufactured by SLM Technology and the Ti6Al4V Titanium Alloy Designed for Medical Applications

This paper presents the results of an experimental study to evaluate the possibility of using SLM additive technology to produce structures with specific surface morphological features. Qualitative and quantitative tests were conducted on samples fabricated by 3D printing from titanium (Ti6Al4V)-powder-based material and analysed in direct relation to the possibility of their use in medicine for the construction of femoral stem and models with a specific degree of porosity predicted by process-control in the self-decision-making 3D printing machine. This paper presents the results of the study, limitations of the method, recommendations that should be used in the design of finished products, and design proposals to support the fabrication process of 3D printers. Furthermore, the study contains an evaluation of how the printing direction affects the formation of certain structures on the printed surface. The research can be used in the development of 3D printing standardization, particularly in the consideration of process control and surface control.