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Sultan R, Skrifvars M, Khalili P. 3D printing of polypropylene reinforced with hemp fibers: Mechanical, water absorption and morphological properties. Heliyon 2024; 10:e26617. [PMID: 38420479 PMCID: PMC10900766 DOI: 10.1016/j.heliyon.2024.e26617] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/10/2023] [Revised: 02/15/2024] [Accepted: 02/16/2024] [Indexed: 03/02/2024] Open
Abstract
The aim of this study was to develop and additively manufacture polypropylene-hemp fiber (PPHF) composites, which were composed of polypropylene (PP) and hemp fibers (HF) in various percentages (5%, 10%, and 20%). The objective was to examine the mechanical properties and water absorption behaviors of extruded PP, conventional filament PP and PPHF composites. The findings of the flexural and tensile tests provided important valuable information. In comparison to the other materials examined, extruded PP had the highest flexural modulus and strength, but filament PP had the lowest mechanical properties. The results showed that the 5% hemp PP composite exhibited the highest tensile strength, and the 20% hemp PP composite showed the highest Young's modulus. These results highlight how crucial hemp fiber content is in modifying the mechanical characteristics of a polymeric material to obtain the material with desirable properties for specific industry requirements.
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Affiliation(s)
- Raffay Sultan
- Swedish Centre for Resource recovery, Faculty of Textiles, Engineering and Business, University of Borås, SE-50190, Borås, Sweden
| | - Mikael Skrifvars
- Swedish Centre for Resource recovery, Faculty of Textiles, Engineering and Business, University of Borås, SE-50190, Borås, Sweden
| | - Pooria Khalili
- Swedish Centre for Resource recovery, Faculty of Textiles, Engineering and Business, University of Borås, SE-50190, Borås, Sweden
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2
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Parvanda R, Kala P, Sharma V. Bibliometric Analysis-Based Review of Fused Deposition Modeling 3D Printing Method (1994-2020). 3D PRINTING AND ADDITIVE MANUFACTURING 2024; 11:383-405. [PMID: 38389670 PMCID: PMC10880680 DOI: 10.1089/3dp.2021.0046] [Citation(s) in RCA: 1] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/24/2024]
Abstract
This study aimed at the detailed bibliometric analysis (BA) of fused deposition modeling (FDM) to understand the trend and research area. Web of Science database was used for extracting data using keywords, and 2793 documents were analyzed. From the analysis, the most influential and productive authors, countries, sources, and so on were identified and corresponding interrelations were represented by a three-field plot. Lotka's law was derived for author productivity and its reliability was verified by the Kolmogorov-Smirnov (K-S) test. Bradford's law was used for identifying the core sources contributing to the field of FDM. From the trend topic analysis, it was found that initially the research was focused upon removing error related to deposition as well as part orientation, but with the course of time, it diversified to include topics such as optimization of printing parameters, materials, and applications. Based on the inferences from BA, the article also discusses on current research trend and highlights certain future areas for research work.
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Affiliation(s)
- Rishi Parvanda
- Mechanical Engineering Department, BITS Pilani, Pilani, India
| | - Prateek Kala
- Mechanical Engineering Department, BITS Pilani, Pilani, India
| | - Varun Sharma
- Mechanical and Industrial Engineering Department, IIT Roorkee, Roorkee, India
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3
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Jambhulkar S, Ravichandran D, Zhu Y, Thippanna V, Ramanathan A, Patil D, Fonseca N, Thummalapalli SV, Sundaravadivelan B, Sun A, Xu W, Yang S, Kannan AM, Golan Y, Lancaster J, Chen L, Joyee EB, Song K. Nanoparticle Assembly: From Self-Organization to Controlled Micropatterning for Enhanced Functionalities. SMALL (WEINHEIM AN DER BERGSTRASSE, GERMANY) 2024; 20:e2306394. [PMID: 37775949 DOI: 10.1002/smll.202306394] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/27/2023] [Revised: 09/02/2023] [Indexed: 10/01/2023]
Abstract
Nanoparticles form long-range micropatterns via self-assembly or directed self-assembly with superior mechanical, electrical, optical, magnetic, chemical, and other functional properties for broad applications, such as structural supports, thermal exchangers, optoelectronics, microelectronics, and robotics. The precisely defined particle assembly at the nanoscale with simultaneously scalable patterning at the microscale is indispensable for enabling functionality and improving the performance of devices. This article provides a comprehensive review of nanoparticle assembly formed primarily via the balance of forces at the nanoscale (e.g., van der Waals, colloidal, capillary, convection, and chemical forces) and nanoparticle-template interactions (e.g., physical confinement, chemical functionalization, additive layer-upon-layer). The review commences with a general overview of nanoparticle self-assembly, with the state-of-the-art literature review and motivation. It subsequently reviews the recent progress in nanoparticle assembly without the presence of surface templates. Manufacturing techniques for surface template fabrication and their influence on nanoparticle assembly efficiency and effectiveness are then explored. The primary focus is the spatial organization and orientational preference of nanoparticles on non-templated and pre-templated surfaces in a controlled manner. Moreover, the article discusses broad applications of micropatterned surfaces, encompassing various fields. Finally, the review concludes with a summary of manufacturing methods, their limitations, and future trends in nanoparticle assembly.
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Affiliation(s)
- Sayli Jambhulkar
- Systems Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Dharneedar Ravichandran
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Yuxiang Zhu
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Varunkumar Thippanna
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Arunachalam Ramanathan
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Dhanush Patil
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Nathan Fonseca
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Sri Vaishnavi Thummalapalli
- Manufacturing Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Barath Sundaravadivelan
- Department of Mechanical and Aerospace Engineering, School for Engineering of Matter, Transport & Energy, Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Tempe, AZ, 85281, USA
| | - Allen Sun
- Department of Chemistry, Stony Brook University, Stony Brook, NY, 11794, USA
| | - Weiheng Xu
- Systems Engineering, School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Sui Yang
- Materials Science and Engineering, School for Engineering of Matter, Transport and Energy (SEMTE), Arizona State University (ASU), Tempe, AZ, 85287, USA
| | - Arunachala Mada Kannan
- The Polytechnic School (TPS), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
| | - Yuval Golan
- Department of Materials Engineering and the Ilse Katz Institute for Nanoscale Science and Technology, Ben-Gurion University of the Negev, Beer Sheva, 8410501, Israel
| | - Jessica Lancaster
- Department of Immunology, Mayo Clinic Arizona, 13400 E Shea Blvd, Scottsdale, AZ, 85259, USA
| | - Lei Chen
- Mechanical Engineering, University of Michigan-Dearborn, 4901 Evergreen Rd, Dearborn, MI, 48128, USA
| | - Erina B Joyee
- Mechanical Engineering and Engineering Science, University of North Carolina, Charlotte, 9201 University City Blvd, Charlotte, NC, 28223, USA
| | - Kenan Song
- School of Environmental, Civil, Agricultural, and Mechanical Engineering (ECAM), College of Engineering, University of Georgia (UGA), Athens, GA, 30602, USA
- Adjunct Professor of School of Manufacturing Systems and Networks (MSN), Ira A. Fulton Schools of Engineering, Arizona State University (ASU), Mesa, AZ, 85212, USA
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Anwajler B, Witek-Krowiak A. Three-Dimensional Printing of Multifunctional Composites: Fabrication, Applications, and Biodegradability Assessment. MATERIALS (BASEL, SWITZERLAND) 2023; 16:7531. [PMID: 38138674 PMCID: PMC10744785 DOI: 10.3390/ma16247531] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 11/05/2023] [Revised: 11/30/2023] [Accepted: 12/04/2023] [Indexed: 12/24/2023]
Abstract
Additive manufacturing, with its wide range of printable materials, and ability to minimize material usage, reduce labor costs, and minimize waste, has sparked a growing enthusiasm among researchers for the production of advanced multifunctional composites. This review evaluates recent reports on polymer composites used in 3D printing, and their printing techniques, with special emphasis on composites containing different types of additives (inorganic and biomass-derived) that support the structure of the prints. Possible applications for additive 3D printing have also been identified. The biodegradation potential of polymeric biocomposites was analyzed and possible pathways for testing in different environments (aqueous, soil, and compost) were identified, including different methods for evaluating the degree of degradation of samples. Guidelines for future research to ensure environmental safety were also identified.
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Affiliation(s)
- Beata Anwajler
- Department of Energy Conversion Engineering, Faculty of Mechanical and Power Engineering, Wroclaw University of Science and Technology, 27 Wybrzeze Wyspianskiego Street, 50-370 Wroclaw, Poland
| | - Anna Witek-Krowiak
- Department of Advanced Material Technologies, Faculty of Chemistry, Wroclaw University of Science and Technology, 27 Wybrzeze Wyspianskiego Street, 50-370 Wroclaw, Poland;
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Mann M, Davies R, Lawrence C, Ghita O. Prototype Design for Grading Structures in Powder Bed Fusion Processes. 3D PRINTING AND ADDITIVE MANUFACTURING 2023; 10:1320-1335. [PMID: 38116209 PMCID: PMC10726185 DOI: 10.1089/3dp.2022.0063] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/21/2023]
Abstract
While targeted alignment in certain additive manufacturing (AM) methods such as material extrusion (MEX) and stereolithography (SLA) has been well documented in the research community, a method for targeted alignment of added fillers or fibrous materials in powder bed fusion (PBF) AM devices has yet to be successfully achieved. Similarly, incorporation of multimaterials does not work easily with any of the AM technologies. This study creates a prototype design that could be integrated into a PBF system to allow for multimaterial layer deposition and alignment of powders and powder blends. The rheological properties of polyamide powder and a range of polyamide composite blends (incorporating milled carbon fibre, graphite flakes, polytetrafluoroethylene, and glass microspheres) in different concentrations were studied, and together with the particle size distribution and particle morphology analysis were applied for the design of a prototype hopper for incorporation in the PBF system to create targeted multimaterial deposition. Different concept designs, multichambered and multi-hopper with hopper angles calculated specifically for the composite blend powders selected, were proposed. Initial deposition trials outside a PBF process were tested, and the deposited layers were measured.
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Affiliation(s)
- Maria Mann
- Centre for Additive Layer Manufacturing, Exeter Technologies Group, Streatham Campus, University of Exeter, Exeter, United Kingdom
| | - Richard Davies
- Centre for Additive Layer Manufacturing, Exeter Technologies Group, Streatham Campus, University of Exeter, Exeter, United Kingdom
| | - Chris Lawrence
- QinetiQ, Advanced Services and Products, Cody Technology Park, Ively Road, Farnborough, United Kingdom
| | - Oana Ghita
- Centre for Additive Layer Manufacturing, Exeter Technologies Group, Streatham Campus, University of Exeter, Exeter, United Kingdom
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Keshavamurthy R, Tambrallimath V, Patil S, Rajhi AA, Duhduh AA, Khan TMY. Mechanical and Wear Studies of Boron Nitride-Reinforced Polymer Composites Developed via 3D Printing Technology. Polymers (Basel) 2023; 15:4368. [PMID: 38006092 PMCID: PMC10675459 DOI: 10.3390/polym15224368] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/12/2023] [Revised: 10/27/2023] [Accepted: 10/31/2023] [Indexed: 11/26/2023] Open
Abstract
In the realm of 3D printing, polymers serve as fundamental materials offering versatility to cater to a diverse array of final product properties and tailored to the specific needs of the creator. Polymers, as the building blocks of 3D printing, inherently possess certain mechanical and wear properties that may fall short of ideal. To address this limitation, the practice of reinforcing polymer matrices with suitable materials has become a common approach. One such reinforcement material is boron nitride (BN), lauded for its remarkable mechanical attributes. The integration of BN as a reinforcing element has yielded substantial enhancements in the properties of polylactic acid (PLA). The central objective of this research endeavor is the development of polymer composites based on PLA and fortified with boron nitride. This study undertakes the comprehensive exploration of the compatibility and synergy between BN and PLA with a keen focus on examining their resultant properties. To facilitate this, various percentages of boron nitride were incorporated into the PLA matrix, specifically at 5% and 10% by weight. The compounding process involved the blending of PLA and boron nitride followed by the creation of composite filaments measuring 1.75 mm in diameter and optimized for 3D printing. Subsequently, test specimens were meticulously fabricated in adherence with ASTM standards to evaluate the ultimate tensile strength, dimensional accuracy, wear characteristics, and surface roughness. The findings from these assessments were systematically compared to the wear properties and mechanical behavior of PLA composites reinforced with boron nitride and the unreinforced PLA material. This study serves as a foundational resource that offers insights into the feasibility and methodologies of incorporating boron nitride into PLA matrices, paving the way for enhanced polymer composite development.
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Affiliation(s)
- Ramaiah Keshavamurthy
- Department of Mechanical Engineering, Dayananda Sagar College of Engineering, Bangalore 560078, India; (R.K.); (S.P.)
| | - Vijay Tambrallimath
- Department of Automobile Engineering, Dayananda Sagar College of Engineering, Bangalore 560078, India
| | - Swetha Patil
- Department of Mechanical Engineering, Dayananda Sagar College of Engineering, Bangalore 560078, India; (R.K.); (S.P.)
| | - Ali A. Rajhi
- Department of Mechanical Engineering, College of Engineering, King Khalid University, Abha 62529, Saudi Arabia; (A.A.R.); (A.A.D.)
| | - Alaauldeen A. Duhduh
- Department of Mechanical Engineering Technology, CAIT, Jazan University, Prince Mohammed Street, P.O. Box 114, Jazan 45142, Saudi Arabia;
| | - T. M. Yunus Khan
- Department of Mechanical Engineering, College of Engineering, King Khalid University, Abha 62529, Saudi Arabia; (A.A.R.); (A.A.D.)
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Robles Poblete F, Ireland M, Slattery L, Davids WG, Lopez-Anido RA. In Situ, Real-Time Temperature Mapping and Thermal FE Simulations of Large-Format 3D Printed PETG/CF Vertical Wall. MATERIALS (BASEL, SWITZERLAND) 2023; 16:6486. [PMID: 37834624 PMCID: PMC10573507 DOI: 10.3390/ma16196486] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/15/2023] [Revised: 08/31/2023] [Accepted: 09/04/2023] [Indexed: 10/15/2023]
Abstract
This work focuses on simulating the thermal history of a vertical wall consisting of a thermoplastic composite material, poly(ethylene terephthalate) glycol (PETG) with short carbon fiber reinforcement, manufactured using a Big Area Additive Manufacturing (BAAM) system. The incremental deposition process used in additive manufacturing, which corresponds to the repeated deposition of hot material onto cooler material, contributes to the presence of residual stresses and part warping. The prediction of these mechanisms is dependent on thermal history of the part, and the major motivation of this work was to improve the accuracy of finite element (FE) models used to quantify the thermal history of large-format additively manufactured parts. Thermocouples were placed throughout the part at varying heights to measure temperature as a function of time. The FE model developed found a thermal contact conductance between the printed part and the bed of 10 W/m2K and convection coefficient values that linearly varied from 3 to 15 W/m2K through the wall height when making a temperature comparison with the output from the thermocouples. It is also demonstrated that the FE model with a constant convection coefficient under-predicts model temperature at the beginning of the manufacturing process when compared against the model with a variable convection coefficient. The impact of this difference was seen in the stress values, which were larger for the model with a constant convection coefficient. Finally, a correlation equation was derived which allows the findings to be generalized to other vertical structures manufactured on the BAAM. In summary, this work offers valuable insights on material characterization, real-time thermocouple placement, and FE modeling of large-format additively manufactured parts.
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Affiliation(s)
- Felipe Robles Poblete
- Advanced Structures and Composites Center (ASCC), University of Maine, Orono, ME 04469, USA; (F.R.P.); (M.I.)
| | - Matthew Ireland
- Advanced Structures and Composites Center (ASCC), University of Maine, Orono, ME 04469, USA; (F.R.P.); (M.I.)
| | - Lucinda Slattery
- Department of Physics and Astronomy, University of Maine, Orono, ME 04469, USA;
| | - William G. Davids
- Department of Civil and Environmental Engineering, University of Maine, Orono, ME 04469, USA;
| | - Roberto A. Lopez-Anido
- Department of Civil and Environmental Engineering, University of Maine, Orono, ME 04469, USA;
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Ismail KI, Pang R, Ahmed R, Yap TC. Tensile Properties of In Situ 3D Printed Glass Fiber-Reinforced PLA. Polymers (Basel) 2023; 15:3436. [PMID: 37631493 PMCID: PMC10458518 DOI: 10.3390/polym15163436] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/22/2023] [Revised: 08/08/2023] [Accepted: 08/10/2023] [Indexed: 08/27/2023] Open
Abstract
A 3D printed composite via the fused filament fabrication (FFF) technique has potential to enhance the mechanical properties of FFF 3D printed parts. The most commonly employed techniques for 3D composite printing (method 1) utilized premixed composite filaments, where the fibers were integrated into thermoplastic materials prior to printing. In the second method (method 2), short fibers and thermoplastic were mixed together within the extruder of a 3D printer to form a composite part. However, no research has been conducted on method 3, which involves embedding short fibers into the printed object during the actual printing process. A novel approach concerning 3D printing in situ fiber-reinforced polymer (FRP) by embedding glass fibers between deposited layers during printing was proposed recently. An experimental investigation has been undertaken to evaluate the tensile behavior of the composites manufactured by the new manufacturing method. Neat polylactic acid (PLA) and three different glass fiber-reinforced polylactic acid (GFPLA) composites with 1.02%, 2.39%, and 4.98% glass fiber contents, respectively, were 3Dprinted. Tensile tests were conducted with five repetitions for each sample. The fracture surfaces of the samples were then observed under scanning electron microscopy (SEM). In addition, the porosities of the 3D printed samples were measured with a image processing software (ImageJ 1.53t). The result shows that the tensile strengths of GFPLA were higher than the neat PLA. The tensile strength of the composites increased from GFPLA-1 (with a 1.02% glass fiber content) to GFPLA-2.4 (with a 2.39% glass fiber content), but drastically dropped at GFPLA-5 (with a 4.98% glass fiber content). However, the tensile strength of GFPLA-5 is still higher than the neat PLA. The fracture surfaces of tensile samples were observed under scanning electron microscopy (SEM). The SEM images showed the average line width of the deposited material increased as glass fiber content increased, while layer height was maintained. The intralayer bond of the deposited filaments improved via the new fiber embedding method. Hence, the porosity area is reduced as glass fiber content increased.
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Affiliation(s)
- Khairul Izwan Ismail
- School of Engineering and Physical Sciences, Heriot-Watt University Malaysia, No. 1, Jalan Venna P5/2, Precinct 5, Putrajaya 62200, Malaysia;
| | - Rayson Pang
- School of Engineering and Physical Sciences, Heriot-Watt University Malaysia, No. 1, Jalan Venna P5/2, Precinct 5, Putrajaya 62200, Malaysia;
| | - Rehan Ahmed
- School of Engineering and Physical Sciences, Heriot-Watt University, Edinburgh EH14 4AS, UK;
| | - Tze Chuen Yap
- School of Engineering and Physical Sciences, Heriot-Watt University Malaysia, No. 1, Jalan Venna P5/2, Precinct 5, Putrajaya 62200, Malaysia;
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Seok W, Jeon E, Kim Y. Effects of Annealing for Strength Enhancement of FDM 3D-Printed ABS Reinforced with Recycled Carbon Fiber. Polymers (Basel) 2023; 15:3110. [PMID: 37514499 PMCID: PMC10384234 DOI: 10.3390/polym15143110] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/06/2023] [Revised: 07/20/2023] [Accepted: 07/20/2023] [Indexed: 07/30/2023] Open
Abstract
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.
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Affiliation(s)
- Wonseok Seok
- Department of Future Convergence Engineering, Kongju National University, Cheonan 31080, Republic of Korea
| | - Euysik Jeon
- Department of Future Convergence Engineering, Kongju National University, Cheonan 31080, Republic of Korea
| | - Youngshin Kim
- Graduate Program for Eco-Friendly Future Automotive Technology, Kongju National University, Cheonan 31080, Republic of Korea
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Luo X, Cheng H, Wu X. Nanomaterials Reinforced Polymer Filament for Fused Deposition Modeling: A State-of-the-Art Review. Polymers (Basel) 2023; 15:2980. [PMID: 37514370 PMCID: PMC10383500 DOI: 10.3390/polym15142980] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/11/2023] [Revised: 07/04/2023] [Accepted: 07/06/2023] [Indexed: 07/30/2023] Open
Abstract
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.
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Affiliation(s)
- Xinchun Luo
- School of Chemical Engineering and Technology, Sun Yat-sen University, Zhuhai 519082, China
| | - Hailong Cheng
- School of Chemical Engineering and Technology, Sun Yat-sen University, Zhuhai 519082, China
| | - Xin Wu
- School of Chemical Engineering and Technology, Sun Yat-sen University, Zhuhai 519082, China
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11
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Hou Y, Panesar A. Effect of Manufacture-Induced Interfaces on the Tensile Properties of 3D Printed Polyamide and Short Carbon Fibre-Reinforced Polyamide Composites. Polymers (Basel) 2023; 15:polym15030773. [PMID: 36772073 PMCID: PMC9919073 DOI: 10.3390/polym15030773] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/26/2022] [Revised: 01/28/2023] [Accepted: 01/30/2023] [Indexed: 02/05/2023] Open
Abstract
This study aims to elucidate the structure-property-process relationship of 3D printed polyamide and short carbon fibre-reinforced polyamide composites. The macroscopic properties (tensile modulus) of the 3D printed samples are quantitatively correlated to the printing process-induced intrinsic microstructure with multiple interfaces. The samples were printed with different layer thicknesses (0.1, 0.125 and 0.2 mm) to obtain the varied number of interface densities (number of interfaces per unit sample thickness). The result shows that the printed short carbon fibre-reinforced polyamide composites had inferior partially bonded interfaces compared to the printed polyamide, and consequently exhibited interface-dependent elastic performance. The tensile modulus of 3 mm thick composites decreased up to 18% as a function of interface density, whilst the other influencing aspects including porosity, crystallinity and fibre volume fraction (9%) were the same. Injection moulding was also employed to fabricate samples without induced interfaces, and their tensile properties were used as a benchmark. Predictions based on the shear-lag model were in close agreement (<5%) with the experimental data for the injection-moulded composites, whereas the tensile modulus of the printed composites was up to 38% lower than the predicted modulus due to the partial bonded interfaces.
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12
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Adil S, Lazoglu I. A review on additive manufacturing of carbon fiber‐reinforced polymers: Current methods, materials, mechanical properties, applications and challenges. J Appl Polym Sci 2022. [DOI: 10.1002/app.53476] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/23/2022]
Affiliation(s)
- Samia Adil
- Manufacturing and Automation Research Center Koç University Istanbul Turkey
| | - Ismail Lazoglu
- Manufacturing and Automation Research Center Koç University Istanbul Turkey
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Talha Junaid M, Shweiki A, Barakat S, Alhalabi M, Mostafa O. Flexural characterization and ductility assessment of small-scale mortar beams reinforced with 3D-printed polymers. STRUCTURES 2022; 45:1751-1761. [DOI: 10.1016/j.istruc.2022.10.007] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 09/01/2023]
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14
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Ismail KI, Yap TC, Ahmed R. 3D-Printed Fiber-Reinforced Polymer Composites by Fused Deposition Modelling (FDM): Fiber Length and Fiber Implementation Techniques. Polymers (Basel) 2022; 14:4659. [PMID: 36365656 PMCID: PMC9653924 DOI: 10.3390/polym14214659] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/08/2022] [Revised: 10/26/2022] [Accepted: 10/30/2022] [Indexed: 08/27/2023] Open
Abstract
Fused Deposition Modelling (FDM) is an actively growing additive manufacturing (AM) technology due to its ability to produce complex shapes in a short time. AM, also known as 3-dimensional printing (3DP), creates the desired shape by adding material, preferably by layering contoured layers on top of each other. The need for low cost, design flexibility and automated manufacturing processes in industry has triggered the development of FDM. However, the mechanical properties of FDM printed parts are still weaker compared to conventionally manufactured products. Numerous studies and research have already been carried out to improve the mechanical properties of FDM printed parts. Reinforce polymer matrix with fiber is one of the possible solutions. Furthermore, reinforcement can enhance the thermal and electrical properties of FDM printed parts. Various types of fibers and manufacturing methods can be adopted to reinforce the polymer matrix for different desired outcomes. This review emphasizes the fiber types and fiber insertion techniques of FDM 3D printed fiber reinforcement polymer composites. A brief overview of fused deposition modelling, polymer sintering and voids formation during FDM printing is provided, followed by the basis of fiber reinforced polymer composites, type of fibers (synthetic fibers vs. natural fibers, continuous vs. discontinuous fiber) and the composites' performance. In addition, three different manufacturing methods of fiber reinforced thermoplastics based on the timing and location of embedding the fibers, namely 'embedding before the printing process (M1)', 'embedding in the nozzle (M2)', and 'embedding on the component (M3)', are also briefly reviewed. The performance of the composites produced by three different methods were then discussed.
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Affiliation(s)
- Khairul Izwan Ismail
- School of Engineering and Physical Sciences, Heriot-Watt University Malaysia, No. 1, Jalan Venna P5/2, Precinct 5, Putrajaya 62200, Malaysia
| | - Tze Chuen Yap
- School of Engineering and Physical Sciences, Heriot-Watt University Malaysia, No. 1, Jalan Venna P5/2, Precinct 5, Putrajaya 62200, Malaysia
| | - Rehan Ahmed
- School of Engineering and Physical Sciences, Heriot-Watt University, Edinburgh EH14 4AS, UK
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Yin Z, Ding A, Zhang H, Zhang W. The Relevant Approaches for Aligning Carbon Nanotubes. MICROMACHINES 2022; 13:1863. [PMID: 36363883 PMCID: PMC9696039 DOI: 10.3390/mi13111863] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 10/06/2022] [Revised: 10/24/2022] [Accepted: 10/28/2022] [Indexed: 06/16/2023]
Abstract
Carbon-nanotube (CNT) is a promising material owing to its compelling mechanical, thermal and electrical properties and has been applied in a broad variety of fields such as composite, fiber, film and microelectronic. Although the introductions of CNT have brought huge improvement for many applications, these properties of macrostructures prepared by CNTs still cannot meet those of individual CNT. Disordered alignment of CNTs in the matrix results in degradation of performance and hinders further application. Nowadays, quantities of methods are being researched to realize alignments of CNTs. In this paper, we introduce the application of CNTs and review some typical pathways for vertical and horizontal alignment, including chemical vapor disposition, vertical self-assembly, external force, film assisted, electric field, magnetic field and printing. Besides that, advantages and disadvantages of specific methods are also discussed. We believe that these efforts will contribute to further understanding the nature of aligned CNT and generating more effective ideas to the relevant workers.
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Affiliation(s)
- Zhifu Yin
- State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, Donghua University, Shanghai 201620, China
- School of Mechanical and Aerospace Engineering, Jilin University, Changchun 130000, China
| | - Ao Ding
- School of Mechanical and Aerospace Engineering, Jilin University, Changchun 130000, China
| | - Hui Zhang
- State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, Donghua University, Shanghai 201620, China
| | - Wang Zhang
- School of Mechanical and Aerospace Engineering, Jilin University, Changchun 130000, China
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16
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Affiliation(s)
- Abhishek Patel
- Department of mechanical engineering, Maulana Azad National Institute of Technology, Bhopal, India
| | - Mohammad Taufik
- Department of mechanical engineering, Maulana Azad National Institute of Technology, Bhopal, India
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17
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Development and Processing of New Composite Materials Based on High-Performance Semicrystalline Polyimide for Fused Filament Fabrication (FFF) and Their Biocompatibility. Polymers (Basel) 2022; 14:polym14183803. [PMID: 36145948 PMCID: PMC9505884 DOI: 10.3390/polym14183803] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/01/2022] [Revised: 09/08/2022] [Accepted: 09/09/2022] [Indexed: 11/17/2022] Open
Abstract
Samples of composite materials based on high-performance semicrystalline polyimide R-BAPB (based on the dianhydride R: 1,3-bis-(3′,4,-dicarboxyphenoxy)benzene and diamine BAPB: 4,4′-bis-(4″-aminophenoxy)diphenyl)) filled with carbon nanofibers and micron-sized discrete carbon fibers were obtained by FFF printing for the first time. The viscosity of melts of the composites based on R-BAPB, thermal, mechanical characteristics of the obtained composite samples, their internal structure, and biocompatibility were studied. Simultaneously with FFF printing, samples were obtained by injection molding. The optimal concentrations of carbon fillers in polyimide R-BAPB for their further use in FFF printing were determined. The effect of the incorporation of carbon fillers on the porosity of the printed samples was investigated. It was shown that the incorporation of carbon nanofibers reduces the porosity of the printed samples, which leads to an increase in deformation at break. Modification of polyimide with discrete carbon fibers increases the strength and Young’s modulus sufficiently but decreases the deformation at break. The cytotoxicity analysis showed that the obtained composite materials are bioinert.
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18
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Rimkus A, Farh MM, Gribniak V. Continuously Reinforced Polymeric Composite for Additive Manufacturing—Development and Efficiency Analysis. Polymers (Basel) 2022; 14:polym14173471. [PMID: 36080547 PMCID: PMC9459897 DOI: 10.3390/polym14173471] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/03/2022] [Revised: 08/22/2022] [Accepted: 08/23/2022] [Indexed: 11/20/2022] Open
Abstract
Additive manufacturing (AM) is a rapidly growing technology, referring to a 3D design process by which digital data builds a physical object in layers by depositing the printed material. The AM has evolved in the aviation, automotive, and medical industries. The AM development for fiber-reinforced composites is the point of current interest, with most research focused on using short fibers. However, notwithstanding particular technological complexities, continuous filaments have superior tensile properties compared to short fibers. Therefore, this manuscript develops an adaptive continuous reinforcement approach for AM based on polymeric material extrusion (ME) technology. It combines the raw material production process, including the ability to vary constituents (e.g., filament materials, reinforcement percentage, and recycled plastic replacement ratio), and the reinforcement efficiency analysis regarding the experimentally verified numerical model. The literature review has identified compatible materials for ensuring sustainable and high-performance plastic composites reinforced with continuous fibers. In addition, it identified the applicability of recycled polymers in developing ME processes. Thus, the study includes an experimental program to investigate the mechanical performance of 3D printed samples (polylactic acid, PLA, matrix reinforced with continuous aramid filament) through a tensile test. Recycled polymer replaced 40% of the virgin PLA. The test results do not demonstrate the recycled polymer’s negative effect on the mechanical performance of the printed samples. Moreover, the recycled material reduced the PLA cost by almost twice. However, together with the potential efficiency of the developed adaptive manufacturing technology, the mechanical characteristics of the printed material revealed room for printing technology improvement, including the aligned reinforcement distribution in the printed product and printing parameters’ setup.
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Affiliation(s)
- Arvydas Rimkus
- Laboratory of Innovative Building Structures, Vilnius Gediminas Technical University (VILNIUS TECH), LT-10223 Vilnius, Lithuania
- Department of Steel and Composite Structures, Vilnius Gediminas Technical University (VILNIUS TECH), LT-10223 Vilnius, Lithuania
| | - Mahmoud M. Farh
- Laboratory of Innovative Building Structures, Vilnius Gediminas Technical University (VILNIUS TECH), LT-10223 Vilnius, Lithuania
- Department of Steel and Composite Structures, Vilnius Gediminas Technical University (VILNIUS TECH), LT-10223 Vilnius, Lithuania
| | - Viktor Gribniak
- Laboratory of Innovative Building Structures, Vilnius Gediminas Technical University (VILNIUS TECH), LT-10223 Vilnius, Lithuania
- Department of Steel and Composite Structures, Vilnius Gediminas Technical University (VILNIUS TECH), LT-10223 Vilnius, Lithuania
- Correspondence: ; Tel.: +370-6-134-6759
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Verma N, Awasthi P, Pandey PM, Banerjee SS. Development of material extrusion
3D
printing compatible tailorable thermoplastic elastomeric materials from acrylonitrile butadiene styrene and styrene‐(ethylene‐butylene)‐styrene block copolymer blends. J Appl Polym Sci 2022. [DOI: 10.1002/app.53039] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/07/2023]
Affiliation(s)
- Nandishwar Verma
- Department of Materials Science and Engineering Indian Institute of Technology Delhi Hauz Khas India
| | - Pratiksha Awasthi
- Department of Materials Science and Engineering Indian Institute of Technology Delhi Hauz Khas India
| | - Pulak Mohan Pandey
- Department of Mechanical Engineering Indian Institute of Technology Delhi Hauz Khas India
| | - Shib Shankar Banerjee
- Department of Materials Science and Engineering Indian Institute of Technology Delhi Hauz Khas India
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20
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Mirzaali MJ, Moosabeiki V, Rajaai SM, Zhou J, Zadpoor AA. Additive Manufacturing of Biomaterials-Design Principles and Their Implementation. MATERIALS (BASEL, SWITZERLAND) 2022; 15:ma15155457. [PMID: 35955393 PMCID: PMC9369548 DOI: 10.3390/ma15155457] [Citation(s) in RCA: 15] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 06/30/2022] [Revised: 07/25/2022] [Accepted: 07/28/2022] [Indexed: 05/04/2023]
Abstract
Additive manufacturing (AM, also known as 3D printing) is an advanced manufacturing technique that has enabled progress in the design and fabrication of customised or patient-specific (meta-)biomaterials and biomedical devices (e.g., implants, prosthetics, and orthotics) with complex internal microstructures and tuneable properties. In the past few decades, several design guidelines have been proposed for creating porous lattice structures, particularly for biomedical applications. Meanwhile, the capabilities of AM to fabricate a wide range of biomaterials, including metals and their alloys, polymers, and ceramics, have been exploited, offering unprecedented benefits to medical professionals and patients alike. In this review article, we provide an overview of the design principles that have been developed and used for the AM of biomaterials as well as those dealing with three major categories of biomaterials, i.e., metals (and their alloys), polymers, and ceramics. The design strategies can be categorised as: library-based design, topology optimisation, bio-inspired design, and meta-biomaterials. Recent developments related to the biomedical applications and fabrication methods of AM aimed at enhancing the quality of final 3D-printed biomaterials and improving their physical, mechanical, and biological characteristics are also highlighted. Finally, examples of 3D-printed biomaterials with tuned properties and functionalities are presented.
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21
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Numerical Simulation and Experimental Study the Effects of Process Parameters on Filament Morphology and Mechanical Properties of FDM 3D Printed PLA/GNPs Nanocomposite. Polymers (Basel) 2022; 14:polym14153081. [PMID: 35956594 PMCID: PMC9370291 DOI: 10.3390/polym14153081] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/07/2022] [Revised: 07/25/2022] [Accepted: 07/26/2022] [Indexed: 12/04/2022] Open
Abstract
The selection of optimal process parameters has a decisive effect on the quality of 3D printing. In this work, the numerical and experimental methods were employed to investigate the FDM printing deposition process of PLA/GNPs nanocomposite. The effect of process parameters on cross-sectional morphology and dimension of the deposited filament, as well as the mechanical property of the FDM printed specimens were studied. The extrusion and the deposition process of the molten PLA/GNPs nanocomposite was simulated as a fluid flow by the paradigm of CFD, the effects of printing temperature and shear rate on thermal-physical properties, such as viscosity and surface tension, were considered in models. Under the assumptions of non-Newtonian fluid and creep laminar flow, the deposition flow was controlled by two key parameters: the nozzle temperature and the nozzle velocity. The numerical model was verified by experiments from four aspects of thickness, width, area, and compactness of the deposited PLA/GNPs nanocomposite filament cross-section. Both the numerical simulation and experiment results show that with the increase of nozzle temperature and nozzle velocity, the thickness, area, and compactness of the deposited filament decreases. While the width of deposited filament increased with the increase of nozzle temperature and decrease of nozzle velocity. The decrease in thickness and the increase in width caused by the change of process parameters reached 10.5% and 24.7%, respectively. The tensile strength of the printed PLA/GNPs specimen was about 61.8 MPa under the higher nozzle temperatures and velocity condition, an improvement of 18.6% compared to specimen with the tensile strength of 52.1 MPa under the lower nozzle temperatures and velocity condition. In addition, the experimental results indicated that under the low nozzle velocity and nozzle temperature condition, dimensional standard deviation of the printed specimens decreased by 52.2%, 62.7%, and 68.3% in X, Y, and Z direction, respectively.
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22
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Research on a Fiber Corner Compensation Algorithm in a 3D Printing Layer of Continuous Fiber-Reinforced Composite Materials. APPLIED SCIENCES-BASEL 2022. [DOI: 10.3390/app12136687] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 02/04/2023]
Abstract
Fused filament fabrication (FFF) 3D printing technology for continuous fiber-reinforced composite (CFRC) printing has become a trend. This article is based on ‘independent extrusion’ FFF CFRC printing. The continuous fiber-reinforced filament (CFRF) printing solution is the contour offset method for obtaining executable g-code. When the CFRCF prints at the corner, it is found that the actual CFRC printing trajectory is inconsistent with the ideal laying trajectory. The causes of the error are analyzed, and an angle optimization algorithm is proposed. The corner optimization algorithm is verified by theoretical analysis and experimental analysis. From the experimental results, the corner optimization algorithm improves the 30° angle fit of CFRF printing by 90% and reliability has also been improved. When the printing length is 127,200 mm, there are 960 printing corners, and the failure rate is 0.
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23
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Ahrens JH, Uzel SGM, Skylar-Scott M, Mata MM, Lu A, Kroll KT, Lewis JA. Programming Cellular Alignment in Engineered Cardiac Tissue via Bioprinting Anisotropic Organ Building Blocks. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2022; 34:e2200217. [PMID: 35451188 DOI: 10.1002/adma.202200217] [Citation(s) in RCA: 33] [Impact Index Per Article: 16.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/09/2022] [Revised: 04/05/2022] [Indexed: 06/14/2023]
Abstract
The ability to replicate the 3D myocardial architecture found in human hearts is a grand challenge. Here, the fabrication of aligned cardiac tissues via bioprinting anisotropic organ building blocks (aOBBs) composed of human induced pluripotent stem cell derived cardiomyocytes (hiPSC-CMs) is reported. A bioink composed of contractile cardiac aOBBs is first generated and aligned cardiac tissue sheets with linear, spiral, and chevron features are printed. Next, aligned cardiac macrofilaments are printed, whose contractile force and conduction velocity increase over time and exceed the performance of spheroid-based cardiac tissues. Finally, the ability to spatially control the magnitude and direction of contractile force by printing cardiac sheets with different aOBB alignment is highlighted. This research opens new avenues to generating functional cardiac tissue with high cell density and complex cellular alignment.
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Affiliation(s)
- John H Ahrens
- John A. Paulson School of Engineering and Applied Sciences and Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
- Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
| | - Sebastien G M Uzel
- John A. Paulson School of Engineering and Applied Sciences and Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
- Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
| | - Mark Skylar-Scott
- John A. Paulson School of Engineering and Applied Sciences and Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
- Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
| | - Mariana M Mata
- John A. Paulson School of Engineering and Applied Sciences and Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
- Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
| | - Aric Lu
- John A. Paulson School of Engineering and Applied Sciences and Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
- Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
| | - Katharina T Kroll
- John A. Paulson School of Engineering and Applied Sciences and Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
- Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
| | - Jennifer A Lewis
- John A. Paulson School of Engineering and Applied Sciences and Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
- Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
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24
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Kim S, Rahman MA, Arifuzzaman M, Gilmer DB, Li B, Wilt JK, Lara-Curzio E, Saito T. Closed-loop additive manufacturing of upcycled commodity plastic through dynamic cross-linking. SCIENCE ADVANCES 2022; 8:eabn6006. [PMID: 35658043 PMCID: PMC9166624 DOI: 10.1126/sciadv.abn6006] [Citation(s) in RCA: 12] [Impact Index Per Article: 6.0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/07/2021] [Accepted: 04/18/2022] [Indexed: 05/25/2023]
Abstract
A sustainable closed-loop manufacturing would become reality if commodity plastics can be upcycled into higher-performance materials with facile processability. Such circularity will be realized when the upcycled plastics can be (re)processed into custom-designed structures through energy/resource-efficient additive manufacturing methods, especially by approachable and scalable fused filament fabrication (FFF). Here, we introduce a circular model epitomized by upcycling a prominent thermoplastic, acrylonitrile butadiene styrene (ABS) into a recyclable, robust adaptive dynamic covalent network (ABS-vitrimer) (re)printable via FFF. The full FFF processing of ABS-vitrimer overcomes the major challenge of (re)printing cross-linked materials and produces stronger, tougher, solvent-resistant three-dimensional objects directly reprintable and separable from unsorted plastic waste. This study thus offers an imminently adoptable approach for advanced manufacturing toward the circular plastics economy.
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Affiliation(s)
- Sungjin Kim
- Chemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USA
| | - Md Anisur Rahman
- Chemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USA
| | - Md Arifuzzaman
- Chemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USA
| | - Dustin B. Gilmer
- Bredesen Center for Interdisciplinary Research and Graduate Education, University of Tennessee, Knoxville, TN 37996, USA
| | - Bingrui Li
- Bredesen Center for Interdisciplinary Research and Graduate Education, University of Tennessee, Knoxville, TN 37996, USA
| | - Jackson K. Wilt
- Chemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USA
| | - Edgar Lara-Curzio
- Materials Sciences and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USA
| | - Tomonori Saito
- Chemical Sciences Division, Oak Ridge National Laboratory, Oak Ridge, TN 37831, USA
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25
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Moslehi A, Ajji A, Heuzey M, Rahimizadeh A, Lessard L. Polylactic acid/recycled wind turbine glass fiber composites with enhanced mechanical properties and toughness. J Appl Polym Sci 2022. [DOI: 10.1002/app.51934] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Affiliation(s)
- Amirhosein Moslehi
- Département de génie chimique Polytechnique Montréal Montréal Quebec Canada
| | - Abdellah Ajji
- Département de génie chimique Polytechnique Montréal Montréal Quebec Canada
| | | | | | - Larry Lessard
- Department of Mechanical Engineering McGill University Montreal Quebec Canada
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26
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Derivation and Validation of Linear Elastic Orthotropic Material Properties for Short Fibre Reinforced FLM Parts. JOURNAL OF COMPOSITES SCIENCE 2022. [DOI: 10.3390/jcs6040101] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
Additively manufactured parts play an increasingly important role in structural applications. Fused Layer Modeling (FLM) has gained popularity due to its cost-efficiency and broad choice of materials, among them, short fibre reinforced filaments with high specific stiffness and strength. To design functional FLM parts, adequate material models for simulations are crucial, as these allow for reliable simulation within virtual product development. In this contribution, a new approach to derive FLM material models for short fibre reinforced parts is presented; it is based on simultaneous fitting of the nine orthotropic constants of a linear elastic material model using six specifically conceived tensile specimen geometries with varying build direction and different extrusion path patterns. The approach is applied to a 15 wt.% short carbon-fibre reinforced PETG filament with own experiments, conducted on a Zwick HTM 5020 servo-hydraulic high-speed testing machine. For validation, the displacement behavior of a geometrically more intricate demonstrator part, printed upright, under bending is predicted using simulation and compared to experimental data. The workflow proves stable and functional in calibration and validation. Open research questions are outlined.
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27
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Han R, Yang Q, Wang Z, Cao D, Li G, Zheng L, Peng B, Gao X, Chen G. 3D printing-enabled self-assembling β-nucleating agent alignment: Structural evolution and mechanical performances. POLYMER 2022. [DOI: 10.1016/j.polymer.2022.124736] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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28
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Radiative Thermal Effects in Large Scale Additive Manufacturing of Polymers: Numerical and Experimental Investigations. MATERIALS 2022; 15:ma15031052. [PMID: 35160995 PMCID: PMC8838097 DOI: 10.3390/ma15031052] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/02/2021] [Revised: 01/19/2022] [Accepted: 01/27/2022] [Indexed: 11/17/2022]
Abstract
The present paper addresses experimental and numerical investigations of a Large Scale Additive Manufacturing (LSAM) process using polymers. By producing large components without geometrical constraints quickly and economically, LSAM processes have the capability to revolutionize many industries. Accurate prediction and control of the thermal history is key for a successful manufacturing process and for achieving high quality and good mechanical properties of the manufactured part. During the LSAM process, the heat emitted by the nozzle leads to an increase in the temperature of the previously deposited layer, which prepares the surface for better adhesion of the new layer. It is therefore necessary to take into account this part of heat source in the transient heat transfer equation to correctly and completely describe the process and predict the temperature field of the manufactured part. The present study contributes to experimental investigations and numerical analysis during the LSAM process. During the process, two types of measurements are performed: firstly, the heat emitted by the nozzle is measured via a radiative heat sensor; secondly, the temperature field is measured using an infrared camera while varying the process speed. At the same time, a numerical simulation model is developed in order to validate the experimental results. The temperature fields of the manufactured parts computed by numerical simulations are in very good agreement with the temperature fields measured by infrared thermograph with the contribution of the nozzle’s heat exchange.
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29
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Elastic Modulus and Flatwise (Through-Thickness) Tensile Strength of Continuous Carbon Fibre Reinforced 3D Printed Polymer Composites. MATERIALS 2022; 15:ma15031002. [PMID: 35160944 PMCID: PMC8840265 DOI: 10.3390/ma15031002] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/15/2021] [Revised: 01/20/2022] [Accepted: 01/21/2022] [Indexed: 02/01/2023]
Abstract
Additively manufactured composite specimens exhibit anisotropic properties, meaning that the elastic response changes with respect to orientation. Both in-plane and out-of-plane mechanical properties are important for designing purpose. Recent studies have characterised the in-plane performance. In this study, however, through-thickness tensile strength of 3D polymer composites were determined by printing of continuous carbon fibre reinforced thermoplastic polyamide-based composite, manufactured using a Markforged Two 3D printer. This paper discusses sample fabrication and geometry, adhesive used, and testing procedure. Test standards used to determine out-of-plane properties are tedious as most of the premature failures occur between the specimens and the tabs. Two types of samples were printed according to ASTM flatwise tension standard and the results were compared to determine the geometry effect on the interlaminar strength. This test method consists of subjecting the printed sample to a uniaxial tensile force normal to the plane. With this method, the acceptable failure modes for tensile strength must be internal to the structure, not between the sample and the end tabs. Micro-computed tomography (µCT) was carried out to observe the porosity. Surface behaviour was studied using scanning electron microscopy (SEM) to see the voids and the distribution of the fibres in the samples. The results showed consistent values for tensile strength and elastic modulus for Araldite glue after initial trials (with some other adhesives) to determine a suitable choice of adhesive for bonding the samples with the tabs. Circular specimens have higher tensile strength and elastic modulus as compared to rectangular specimens.
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30
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Wang P, Pan A, Xia L, Cao Y, Zhang H, Wu W. Effect of process parameters of fused deposition modeling on mechanical properties of poly-ether-ether-ketone and carbon fiber/poly-ether-ether-ketone. HIGH PERFORM POLYM 2022. [DOI: 10.1177/09540083211067388] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
As a rapidly developing additive manufacturing technology, fused deposition modeling (FDM) has become widespread in many industry fields. It can fabricate complicated geometries using filament of thermoplastic materials such as PP, polylactic acid, acrylonitrile butadiene styrene, etc. However, poor mechanical properties of raw materials limit their application. Poly-ether-ether-ketone is a type of special engineering plastic with high performance, which could be further reinforced by adding carbon fibers (CFs). During FDM process, the mechanical properties of printed parts are largely subject to careful selection of process parameters. To improve the mechanical properties of PEEK and CF/PEEK 3D-printed parts, the effects of various process parameters including building orientation, raster angle, nozzle temperature, platform temperature, ambient temperature, printing speed, layer thickness, infill density, and number of printed parts on mechanical properties were investigated. The tensile fracture interfaces of printed parts were observed by scanning electron microscope (SEM) to explain the influence mechanism of process parameters. In the single factor experiments, flat and on-edge specimens show the best tensile and flexural strength, respectively; the specimens with raster angle ±45° and 0° show the best tensile and flexural strength, respectively. When the nozzle temperature at 500°C, platform temperature at 200°C, ambient temperature at 150°C, printing speed is 20 mm/s, layer thickness is 0.2 mm, and infill density is 100%, the printed parts exhibit the best mechanical properties.
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Affiliation(s)
- Pei Wang
- School of Mechatronical Engineering, Beijing Institute of Technology, Beijing, China
| | - Aigang Pan
- School of Mechatronical Engineering, Beijing Institute of Technology, Beijing, China
| | - Liu Xia
- School of Mechatronical Engineering, Beijing Institute of Technology, Beijing, China
| | - Yitao Cao
- Unmanned System Research Institute, Northwestern Polytechnical University, Shaanxi, China
| | - Hongjie Zhang
- Beijing Institute of Spacecraft System Engineering, Beijing, China
| | - Weichao Wu
- School of Mechatronical Engineering, Beijing Institute of Technology, Beijing, China
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Sayam A, Rahman ANMM, Rahman MS, Smriti SA, Ahmed F, Rabbi MF, Hossain M, Faruque MO. A review on carbon fiber-reinforced hierarchical composites: mechanical performance, manufacturing process, structural applications and allied challenges. CARBON LETTERS 2022; 32:1173-1205. [PMCID: PMC9172091 DOI: 10.1007/s42823-022-00358-2] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 02/04/2022] [Revised: 05/14/2022] [Accepted: 05/16/2022] [Indexed: 06/15/2023]
Abstract
The utilization of carbonaceous reinforcement-based polymer matrix composites in structural applications has become a hot topic in composite research. Although conventional carbon fiber-reinforced polymer composites (CFRPs) have revolutionized the composite industry by offering unparalleled features, they are often plagued with a weak interface and lack of toughness. However, the promising aspects of carbon fiber-based fiber hybrid composites and hierarchical composites can compensate for these setbacks. This review provides a meticulous landscape and recent progress of polymer matrix-based different carbonaceous (carbon fiber, carbon nanotube, graphene, and nanodiamond) fillers reinforced composites’ mechanical properties. First, the mechanical performance of neat CFRP was exhaustively analyzed, attributing parameters were listed down, and CFRPs’ mechanical performance barriers were clearly outlined. Here, short carbon fiber-reinforced thermoplastic composite was distinguished as a prospective material. Second, the strategic advantages of fiber hybrid composites over conventional CFRP were elucidated. Third, the mechanical performance of hierarchical composites based on carbon nanotube (1D), graphene (2D) and nanodiamond (0D) was expounded and evaluated against neat CFRP. Fourth, the review comprehensively discussed different fabrication methods, categorized them according to performance and suggested potential future directions. From here, the review sorted out three-dimensional printing (3DP) as the most futuristic fabrication method and thoroughly delivered its pros and cons in the context of the aforementioned carbonaceous materials. To conclude, the structural applications, current challenges and future prospects pertinent to these carbonaceous fillers reinforced composite materials were elaborated.
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Affiliation(s)
- Abdullah Sayam
- Department of Fabric Engineering, Faculty of Textile Engineering, Bangladesh University of Textiles (BUTEX), 92, Shaheed Tajuddin Ahmed Avenue, Tejgaon I/A, Dhaka, 1208 Bangladesh
| | - A. N. M. Masudur Rahman
- Department of Fabric Engineering, Faculty of Textile Engineering, Bangladesh University of Textiles (BUTEX), 92, Shaheed Tajuddin Ahmed Avenue, Tejgaon I/A, Dhaka, 1208 Bangladesh
- Department of Textile Engineering, Donghua University, Shanghai, People’s Republic of China
| | - Md. Sakibur Rahman
- Department of Fabric Engineering, Faculty of Textile Engineering, Bangladesh University of Textiles (BUTEX), 92, Shaheed Tajuddin Ahmed Avenue, Tejgaon I/A, Dhaka, 1208 Bangladesh
| | - Shamima Akter Smriti
- Department of Fabric Engineering, Faculty of Textile Engineering, Bangladesh University of Textiles (BUTEX), 92, Shaheed Tajuddin Ahmed Avenue, Tejgaon I/A, Dhaka, 1208 Bangladesh
| | - Faisal Ahmed
- Department of Fabric Engineering, Faculty of Textile Engineering, Bangladesh University of Textiles (BUTEX), 92, Shaheed Tajuddin Ahmed Avenue, Tejgaon I/A, Dhaka, 1208 Bangladesh
- Department of Family and Consumer Sciences, University of Wyoming, Laramie, WY USA
| | - Md. Fogla Rabbi
- Department of Fabric Engineering, Faculty of Textile Engineering, Bangladesh University of Textiles (BUTEX), 92, Shaheed Tajuddin Ahmed Avenue, Tejgaon I/A, Dhaka, 1208 Bangladesh
| | - Mohammad Hossain
- Department of Fabric Engineering, Faculty of Textile Engineering, Bangladesh University of Textiles (BUTEX), 92, Shaheed Tajuddin Ahmed Avenue, Tejgaon I/A, Dhaka, 1208 Bangladesh
| | - Md. Omar Faruque
- Department of Fabric Engineering, Faculty of Textile Engineering, Bangladesh University of Textiles (BUTEX), 92, Shaheed Tajuddin Ahmed Avenue, Tejgaon I/A, Dhaka, 1208 Bangladesh
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32
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Zhou X, Ren L, Liu Q, Song Z, Wu Q, He Y, Li B, Ren L. Advances in Field-Assisted 3D Printing of Bio-Inspired Composites: From Bioprototyping to Manufacturing. Macromol Biosci 2021; 22:e2100332. [PMID: 34784100 DOI: 10.1002/mabi.202100332] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/20/2021] [Revised: 10/21/2021] [Indexed: 02/04/2023]
Abstract
Biocomposite systems evolve to superior structural strategies in adapting to their living environments, using limited materials to form functionality superior to their inherent properties. The synergy of physical-field and Three-dimensional (3D) printing technologies creates unprecedented opportunities that overcome the limitations of traditional manufacturing methods and enable the precise replication of bio-enhanced structures. Here, an overview of typical structural designs in biocomposite systems, their functions and properties, are provided and the recent advances in bio-inspired composites using mechanical, electrical, magnetic, and ultrasound-field-assisted 3D printing techniques are highlighted. Finally, in order to realize the preparation of bionic functional devices and equipment with more superior functions, here an outlook on the development of field-assisted 3D printing technology from three aspects are provided: Materials, technology, and post-processing.
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Affiliation(s)
- Xueli Zhou
- Key Laboratory of Bionic Engineering (Ministry of Education), Jilin University, Changchun, 130022, P. R. China
| | - Luquan Ren
- Key Laboratory of Bionic Engineering (Ministry of Education), Jilin University, Changchun, 130022, P. R. China
| | - Qingping Liu
- Key Laboratory of Bionic Engineering (Ministry of Education), Jilin University, Changchun, 130022, P. R. China
| | - Zhengyi Song
- Key Laboratory of Bionic Engineering (Ministry of Education), Jilin University, Changchun, 130022, P. R. China
| | - Qian Wu
- Key Laboratory of Bionic Engineering (Ministry of Education), Jilin University, Changchun, 130022, P. R. China
| | - Yulin He
- Key Laboratory of Bionic Engineering (Ministry of Education), Jilin University, Changchun, 130022, P. R. China
| | - Bingqian Li
- Key Laboratory of Bionic Engineering (Ministry of Education), Jilin University, Changchun, 130022, P. R. China
| | - Lei Ren
- Key Laboratory of Bionic Engineering (Ministry of Education), Jilin University, Changchun, 130022, P. R. China.,School of Mechanical, Aerospace and Civil Engineering, University of Manchester, Manchester, M13 9PL, UK
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33
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Xu W, Jambhulkar S, Ravichandran D, Zhu Y, Kakarla M, Nian Q, Azeredo B, Chen X, Jin K, Vernon B, Lott DG, Cornella JL, Shefi O, Miquelard-Garnier G, Yang Y, Song K. 3D Printing-Enabled Nanoparticle Alignment: A Review of Mechanisms and Applications. SMALL (WEINHEIM AN DER BERGSTRASSE, GERMANY) 2021; 17:e2100817. [PMID: 34176201 DOI: 10.1002/smll.202100817] [Citation(s) in RCA: 29] [Impact Index Per Article: 9.7] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 02/08/2021] [Revised: 04/05/2021] [Indexed: 05/12/2023]
Abstract
3D printing (additive manufacturing (AM)) has enormous potential for rapid tooling and mass production due to its design flexibility and significant reduction of the timeline from design to manufacturing. The current state-of-the-art in 3D printing focuses on material manufacturability and engineering applications. However, there still exists the bottleneck of low printing resolution and processing rates, especially when nanomaterials need tailorable orders at different scales. An interesting phenomenon is the preferential alignment of nanoparticles that enhance material properties. Therefore, this review emphasizes the landscape of nanoparticle alignment in the context of 3D printing. Herein, a brief overview of 3D printing is provided, followed by a comprehensive summary of the 3D printing-enabled nanoparticle alignment in well-established and in-house customized 3D printing mechanisms that can lead to selective deposition and preferential orientation of nanoparticles. Subsequently, it is listed that typical applications that utilized the properties of ordered nanoparticles (e.g., structural composites, heat conductors, chemo-resistive sensors, engineered surfaces, tissue scaffolds, and actuators based on structural and functional property improvement). This review's emphasis is on the particle alignment methodology and the performance of composites incorporating aligned nanoparticles. In the end, significant limitations of current 3D printing techniques are identified together with future perspectives.
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Affiliation(s)
- Weiheng Xu
- The Polytechnic School (TPS), Ira A. Fulton Schools for Engineering, Arizona State University, 6075 S. Innovation Way West, Mesa, AZ, 85212, USA
| | - Sayli Jambhulkar
- The Polytechnic School (TPS), Ira A. Fulton Schools for Engineering, Arizona State University, 6075 S. Innovation Way West, Mesa, AZ, 85212, USA
| | - Dharneedar Ravichandran
- The Polytechnic School (TPS), Ira A. Fulton Schools for Engineering, Arizona State University, 6075 S. Innovation Way West, Mesa, AZ, 85212, USA
| | - Yuxiang Zhu
- The Polytechnic School (TPS), Ira A. Fulton Schools for Engineering, Arizona State University, 6075 S. Innovation Way West, Mesa, AZ, 85212, USA
| | - Mounika Kakarla
- Department of Materials Science and Engineering, Ira A. Fulton Schools for Engineering, Arizona State University, Tempe, 501 E. Tyler Mall, Tempe, AZ, 85287, USA
| | - Qiong Nian
- Department of Mechanical Engineering, and Multi-Scale Manufacturing Material Processing Lab (MMMPL), Ira A. Fulton Schools for Engineering, Arizona State University, 501 E. Tyler Mall, Tempe, AZ, 85287, USA
| | - Bruno Azeredo
- The Polytechnic School (TPS), Ira A. Fulton Schools for Engineering, Arizona State University, 6075 S. Innovation Way West, Mesa, AZ, 85212, USA
| | - Xiangfan Chen
- Advanced Manufacturing and Functional Devices (AMFD) Laboratory, Ira A. Fulton Schools for Engineering, Arizona State University, 6075 Innovation Way W., Mesa, AZ, 85212, USA
| | - Kailong Jin
- Department of Chemical Engineering, School for Engineering Matter, Transport and Energy (SEMTE), and Biodesign Institute Center for Sustainable Macromolecular Materials and Manufacturing (BCSM3), Arizona State University, 501 E. Tyler St., Tempe, AZ, 85287, USA
| | - Brent Vernon
- Department of Biomedical Engineering, Biomaterials Lab, School of Biological and Health Systems Engineering, Arizona State University, 427 E Tyler Mall, Tempe, AZ, 85281, USA
| | - David G Lott
- Department Otolaryngology, Division of Laryngology, College of Medicine, and Mayo Clinic Arizona Center for Regenerative Medicine, 13400 E Shea Blvd, Scottsdale, AZ, 85259, USA
| | - Jeffrey L Cornella
- Professor of Obstetrics and Gynecology, Mayo Clinic College of Medicine, Division of Gynecologic Surgery, Mayo Clinic, 13400 E Shea Blvd, Scottsdale, AZ, 85259, USA
| | - Orit Shefi
- Department of Engineering, Neuro-Engineering and Regeneration Laboratory, Bar Ilan Institute of Nanotechnologies and Advanced Materials, Bar-Ilan University, Building 1105, Ramat Gan, 52900, Israel
| | - Guillaume Miquelard-Garnier
- laboratoire PIMM, UMR 8006, Arts et Métiers Institute of Technology, CNRS, CNAM, Hesam University, 151 boulevard de l'Hôpital, Paris, 75013, France
| | - Yang Yang
- Additive Manufacturing & Advanced Materials Lab, Department of Mechanical Engineering, San Diego State University, 5500 Campanile Drive, San Diego, CA, 92182-1323, USA
| | - Kenan Song
- Department of Manufacturing Engineering, Advanced Materials Advanced Manufacturing Laboratory (AMAML), Ira A. Fulton Schools for Engineering, Arizona State University, 6075 Innovation Way W., Mesa, AZ, 85212, USA
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Silva LEJ, Volnistem EA, Dias GS, Cótica LF, Santos IA, Fiorentin ER, de Oliveira MA, Witchemichen DH, Freitas VF, Bonadio TGM. Polyvinylidene fluoride - Hydroxyapatite 0-3 biocomposite filaments processed by twin-screw extrusion. J Mech Behav Biomed Mater 2021; 125:104891. [PMID: 34689030 DOI: 10.1016/j.jmbbm.2021.104891] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/25/2021] [Revised: 10/08/2021] [Accepted: 10/10/2021] [Indexed: 10/20/2022]
Abstract
Polyvinylidene fluoride - hydroxyapatite composite filaments were processed by twin-screw extrusion at different processing angular velocities and characterized by scanning electron and atomic force microscopies, differential scanning calorimetry and tensile tests. Polymer-ceramic composites with a 0-3 connectivity were successfully obtained. Regardless of the used processing parameters, all composite filaments present very similar melting (∼152°C) and solidification (∼139°C) points and elastic moduli (∼1.0 GPa) for hydroxyapatite as dispersed phase in the composite with concentrations up to 25 wt%, indicating that they are adequate for twin-screw extrusion and 3D printing. However, the yield strength (∼29 MPa), ultimate tensile strength (∼36 MPa) and tensile point (∼29 MPa) parameters are similar only for hydroxyapatite concentrations up to 15 wt%, once higher concentrations of hydroxyapatite as dispersed phase result in fragile samples (∼50% lower for each studied property).
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Affiliation(s)
- L E J Silva
- Graduate Program in Mechanical Engineering, State University of Maringá, Av. Colombo 5790, Maringá, PR, Brazil
| | - E A Volnistem
- Department of Physics, State University of Maringá, Av. Colombo 5790, Maringá, PR, Brazil
| | - G S Dias
- Department of Physics, State University of Maringá, Av. Colombo 5790, Maringá, PR, Brazil
| | - L F Cótica
- Department of Physics, State University of Maringá, Av. Colombo 5790, Maringá, PR, Brazil
| | - I A Santos
- Graduate Program in Mechanical Engineering, State University of Maringá, Av. Colombo 5790, Maringá, PR, Brazil; Department of Physics, State University of Maringá, Av. Colombo 5790, Maringá, PR, Brazil.
| | - E R Fiorentin
- Department of Physics, Midwestern Paraná State University, Al. Élio A. D. Vecchia 838, Guarapuava, PR, Brazil
| | - M A de Oliveira
- Department of Physics, Midwestern Paraná State University, Al. Élio A. D. Vecchia 838, Guarapuava, PR, Brazil
| | - D H Witchemichen
- Department of Physics, Midwestern Paraná State University, Al. Élio A. D. Vecchia 838, Guarapuava, PR, Brazil
| | - V F Freitas
- Department of Physics, Midwestern Paraná State University, Al. Élio A. D. Vecchia 838, Guarapuava, PR, Brazil
| | - T G M Bonadio
- Department of Physics, Midwestern Paraná State University, Al. Élio A. D. Vecchia 838, Guarapuava, PR, Brazil
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35
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Additive manufacturing: a review on mechanical properties of polyjet and FDM printed parts. Polym Bull (Berl) 2021. [DOI: 10.1007/s00289-021-03899-0] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/25/2022]
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36
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Belka M, Bączek T. Additive manufacturing and related technologies – The source of chemically active materials in separation science. Trends Analyt Chem 2021. [DOI: 10.1016/j.trac.2021.116322] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/21/2022]
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37
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Optimisation of Strength Properties of FDM Printed Parts-A Critical Review. Polymers (Basel) 2021; 13:polym13101587. [PMID: 34069144 PMCID: PMC8157110 DOI: 10.3390/polym13101587] [Citation(s) in RCA: 43] [Impact Index Per Article: 14.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/14/2021] [Revised: 05/06/2021] [Accepted: 05/10/2021] [Indexed: 02/07/2023] Open
Abstract
Additive Manufacturing is currently growing fast, especially fused deposition modeling (FDM), also known as fused filament fabrication (FFF). When manufacturing parts use FDM, there are two key parameters—strength of the part and dimensional accuracy—that need to be considered. Although FDM is a popular technology for fabricating prototypes with complex geometry and other part product with reduced cycle time, it is also limited by several drawbacks including inadequate mechanical properties and reduced dimensional accuracy. It is evident that part qualities are greatly influenced by the various process parameters, therefore an extensive review of the effects of the following process parameters was carried out: infill density, infill patterns, extrusion temperature, layer thickness, nozzle diameter, raster angle and build orientation on the mechanical properties. It was found from the literature that layer thickness is the most important factor among the studied ones. Although manipulation of process parameters makes significant differences in the quality and mechanical properties of the printed part, the ideal combination of parameters is challenging to achieve. Hence, this study also includes the influence of pre-processing of the printed part to improve the part strength and new research trends such as, vacuum-assisted FDM that has shown to improve the quality of the printing due to improved bonding between the layers. Advances in materials and technologies that are currently under development are presented. For example, the pre-deposition heating method, using an IR lamp of other technologies, shows a positive impact on the mechanical properties of the printed parts.
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38
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Kasmi S, Ginoux G, Allaoui S, Alix S. Investigation of
3D
printing strategy on the mechanical performance of coextruded continuous carbon fiber reinforced
PETG. J Appl Polym Sci 2021. [DOI: 10.1002/app.50955] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/02/2023]
Affiliation(s)
- Samir Kasmi
- Institut de Thermique, Mécanique, Matériaux Université de Reims Champagne‐Ardenne Charleville‐Mézières France
| | - Geoffrey Ginoux
- Institut de Thermique, Mécanique, Matériaux Université de Reims Champagne‐Ardenne Charleville‐Mézières France
| | - Samir Allaoui
- Institut de Thermique, Mécanique, Matériaux Université de Reims Champagne‐Ardenne Charleville‐Mézières France
| | - Sébastien Alix
- Institut de Thermique, Mécanique, Matériaux Université de Reims Champagne‐Ardenne Charleville‐Mézières France
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39
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Salahuddin B, Mutlu R, Baigh TA, Alghamdi MN, Aziz S. Self-Reinforced Nylon 6 Composite for Smart Vibration Damping. Polymers (Basel) 2021; 13:polym13081235. [PMID: 33920385 PMCID: PMC8069404 DOI: 10.3390/polym13081235] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/13/2021] [Revised: 04/06/2021] [Accepted: 04/08/2021] [Indexed: 12/21/2022] Open
Abstract
Passive vibration control using polymer composites has been extensively investigated by the engineering community. In this paper, a new kind of vibration dampening polymer composite was developed where oriented nylon 6 fibres were used as the reinforcement, and 3D printed unoriented nylon 6 was used as the matrix material. The shape of the reinforcing fibres was modified to a coiled structure which transformed the fibres into a smart thermoresponsive actuator. This novel self-reinforced composite was of high mechanical robustness and its efficacy was demonstrated as an active dampening system for oscillatory vibration of a heated vibrating system. The blocking force generated within the reinforcing coiled actuator was responsible for dissipating vibration energy and increase the magnitude of the damping factor compared to samples made of non-reinforced nylon 6. Further study shows that the appropriate annealing of coiled actuators provides an enhanced dampening capability to the composite structure. The extent of crystallinity of the reinforcing actuators is found to directly influence the vibration dampening capacity.
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Affiliation(s)
- Bidita Salahuddin
- ARC Centre of Excellence for Electromaterials Science and Intelligent Polymer Research Institute, University of Wollongong, Innovation Campus, Squires Way, North Wollongong, NSW 2522, Australia
- Correspondence: (B.S.); (R.M.); (S.A.)
| | - Rahim Mutlu
- ARC Centre of Excellence for Electromaterials Science and Intelligent Polymer Research Institute, University of Wollongong, Innovation Campus, Squires Way, North Wollongong, NSW 2522, Australia
- School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong, Wollongong, NSW 2522, Australia
- Correspondence: (B.S.); (R.M.); (S.A.)
| | - Tajwar A. Baigh
- Department of Mechanical and Production Engineering, Islamic University of Technology, Gazipur 1704, Bangladesh;
| | - Mohammed N. Alghamdi
- Department of Mechanical Engineering Technology, Yanbu Industrial College, Yanbu Al-Sinaiyah City 41912, Saudi Arabia;
| | - Shazed Aziz
- School of Chemical Engineering, The University of Queensland, Brisbane, QLD 4072, Australia
- Correspondence: (B.S.); (R.M.); (S.A.)
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3D Printed Hierarchical Honeycombs with Carbon Fiber and Carbon Nanotube Reinforced Acrylonitrile Butadiene Styrene. JOURNAL OF COMPOSITES SCIENCE 2021. [DOI: 10.3390/jcs5020062] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
The mechanical properties of Fused Filament Fabrication (FFF) 3D printed specimens of acrylonitrile butadiene styrene (ABS), ABS reinforced with carbon fibers (ABS/CFs) and ABS reinforced with carbon nanotubes (ABS/CNTs) are investigated in this paper using various experimental tests. In particular, the mechanical performance of the fabricated specimens was determined by conducting compression and cyclic compression testing, as well as nanoindentation tests. In addition, the design and the manufacturing of hierarchical honeycomb structures are presented using the materials under study. The 3D printed honeycomb structures were examined by uniaxial compressive tests to review the mechanical behavior of such cellular structures. The compressive performance of the hierarchical honeycomb structures was also evaluated with finite element analysis (FEA) in order to extract the stress-strain response of these structures. The results revealed that the 2nd order hierarchy displayed increased stiffness and strength as compared with the 0th and the 1st hierarchies. Furthermore, the addition of carbon fibers in the ABS matrix improved the stiffness, the strength and the hardness of the FFF printed specimens as well as the compression performance of the honeycomb structures.
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41
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Fused Deposition Modelling of Fibre Reinforced Polymer Composites: A Parametric Review. JOURNAL OF COMPOSITES SCIENCE 2021. [DOI: 10.3390/jcs5010029] [Citation(s) in RCA: 16] [Impact Index Per Article: 5.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/11/2022]
Abstract
Fused deposition modelling (FDM) is a widely used additive layer manufacturing process that deposits thermoplastic material layer-by-layer to produce complex geometries within a short time. Increasingly, fibres are being used to reinforce thermoplastic filaments to improve mechanical performance. This paper reviews the available literature on fibre reinforced FDM to investigate how the mechanical, physical, and thermal properties of 3D-printed fibre reinforced thermoplastic composite materials are affected by printing parameters (e.g., printing speed, temperature, building principle, etc.) and constitutive materials properties, i.e., polymeric matrices, reinforcements, and additional materials. In particular, the reinforcement fibres are categorized in this review considering the different available types (e.g., carbon, glass, aramid, and natural), and obtainable architectures divided accordingly to the fibre length (nano, short, and continuous). The review attempts to distil the optimum processing parameters that could be deduced from across different studies by presenting graphically the relationship between process parameters and properties. This publication benefits the material developer who is investigating the process parameters to optimize the printing parameters of novel materials or looking for a good constituent combination to produce composite FDM filaments, thus helping to reduce material wastage and experimental time.
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42
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Preparation and Evaluation of the Tensile Characteristics of Carbon Fiber Rod Reinforced 3D Printed Thermoplastic Composites. JOURNAL OF COMPOSITES SCIENCE 2020. [DOI: 10.3390/jcs5010008] [Citation(s) in RCA: 10] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
Abstract
The most common method to fabricate both simple and complex structures in the additive manufacturing process is fused deposition modeling (FDM). Many researchers have studied the strengthening of FDM components by adding short carbon fibers (CF) or by reinforcing solid carbon fiber rods. In the current research, we sought to enhance the mechanical properties of FDM components by adding bioinspired solid CF rods during the fabrication process. An effective bonding interface of bioinspired CF rods and polylactic acid (PLA) was achieved by triangular interlocking sutures and by employing synthetic glue as the binding agent. In particular, the tensile strength of solid CF rod reinforced PLA samples was studied. Critical parameters such as layer thickness, extruder temperature, extruder speed, and shell thickness were considered for optimization. Significant process parameters were identified through leverage plots using the response surface methodology (RSM). The optimum parameters were found to be layer thickness of 0.04 mm, extruder temperature of 215 °C, extruder speed of 60 mm/s, and shell thickness of 1.2 mm. The results revealed that the bioinspired solid CF rod reinforced PLA (CFRPLA) composite exhibited a tensile strength of 82.06 MPa, which was approximately three times higher than the pure PLA (28 MPa, 66% lower than CFRPLA), acrylonitrile butadiene styrene (ABS) (28 MPa, 66% lower than CFRPLA), polyethylene terephthalate glycol (PETG) (34 MPa, 60% lower than CFRPLA), and nylon (34 MPa, 60% lower than CFRPLA) samples.
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43
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Enhancing Structural Performance of Short Fiber Reinforced Objects through Customized Tool-Path. APPLIED SCIENCES-BASEL 2020. [DOI: 10.3390/app10228168] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
Fused deposition modeling (FDM) is one of the most common additive manufacturing (AM) technologies for thermoplastic materials. With the development of carbon fiber-reinforced polymer (CFRP) filament for FDM, AM parts with improved strength and functionality can be realized. CFRP is anisotropic material and its mechanical properties have been well studied, however, AM printing strategy for CFRP parts has not been developed. This paper proposes a systematic optimization of the FDM 3D printing process for CFRP. Starting with standard coupon specimen tests to obtain mechanical properties of CFRP, finite element analyses (FEA) were conducted to find principal directions of the AM part and utilized to determine fiber orientations. A specific tool-path algorithm has been developed to distribute fibers with the desired orientations. To predict/assess the mechanical behavior of the AM part, the 3D printing process was simulated to obtain the anisotropic mechanical behavior induced by the customized tool-path printing. Bolt hole plate and spur gear were selected as case studies. FE simulations and associated experiments were conducted to assess their performance. CFRP parts printed by the optimized tool-path shows about 8% higher stiffness than those printed at regular infill patterns. In summary, assisted by FEA, a customized 3D printing tool-path for CFRP has been developed with case studies to verify the proposed AM design optimization methodology for FDM.
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44
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Nath SD, Nilufar S. An Overview of Additive Manufacturing of Polymers and Associated Composites. Polymers (Basel) 2020; 12:E2719. [PMID: 33212903 PMCID: PMC7698427 DOI: 10.3390/polym12112719] [Citation(s) in RCA: 30] [Impact Index Per Article: 7.5] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/08/2020] [Revised: 11/05/2020] [Accepted: 11/11/2020] [Indexed: 12/26/2022] Open
Abstract
Additive manufacturing is rapidly evolving and opening new possibilities for many industries. This article gives an overview of the current status of additive manufacturing with polymers and polymer composites. Various types of reinforcements in polymers and architectured cellular material printing including the auxetic metamaterials and the triply periodic minimal surface structures are discussed. Finally, applications, current challenges, and future directions are highlighted here.
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Affiliation(s)
| | - Sabrina Nilufar
- Department of Mechanical Engineering and Energy Processes, Southern Illinois University Carbondale, Carbondale, IL 62901, USA;
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45
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Ginoux G, Vroman I, Alix S. Influence of fused filament fabrication parameters on tensile properties of polylactide/layered silicate nanocomposite using response surface methodology. J Appl Polym Sci 2020. [DOI: 10.1002/app.50174] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
Affiliation(s)
- Geoffrey Ginoux
- Institut de Thermique, Mécanique Matériaux – Université de Reims Champagne‐Ardenne Reims France
| | - Isabelle Vroman
- Institut de Thermique, Mécanique Matériaux – Université de Reims Champagne‐Ardenne Reims France
| | - Sébastien Alix
- Institut de Thermique, Mécanique Matériaux – Université de Reims Champagne‐Ardenne Reims France
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Wang B, Chen Y, Qu T, Li F. Structure and Properties of Multi-walled Carbon Nanotube/Acrylonitrile Butadiene Styrene Nanocomposite Specimens Prepared by Fused Deposition Modeling. J MACROMOL SCI B 2020. [DOI: 10.1080/00222348.2020.1824756] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/23/2022]
Affiliation(s)
- Biao Wang
- State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, College of Material Science and Engineering, Donghua University, Shanghai, PR China
| | - Yankun Chen
- State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, College of Material Science and Engineering, Donghua University, Shanghai, PR China
| | - Tongqing Qu
- State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, College of Material Science and Engineering, Donghua University, Shanghai, PR China
| | - Fengmei Li
- State Key Laboratory for Modification of Chemical Fibers and Polymer Materials, College of Material Science and Engineering, Donghua University, Shanghai, PR China
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3D Printing of Fibre-Reinforced Thermoplastic Composites Using Fused Filament Fabrication-A Review. Polymers (Basel) 2020; 12:polym12102188. [PMID: 32987905 PMCID: PMC7601740 DOI: 10.3390/polym12102188] [Citation(s) in RCA: 35] [Impact Index Per Article: 8.8] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/26/2020] [Revised: 09/18/2020] [Accepted: 09/20/2020] [Indexed: 02/07/2023] Open
Abstract
Three-dimensional (3D) printing has been successfully applied for the fabrication of polymer components ranging from prototypes to final products. An issue, however, is that the resulting 3D printed parts exhibit inferior mechanical performance to parts fabricated using conventional polymer processing technologies, such as compression moulding. The addition of fibres and other materials into the polymer matrix to form a composite can yield a significant enhancement in the structural strength of printed polymer parts. This review focuses on the enhanced mechanical performance obtained through the printing of fibre-reinforced polymer composites, using the fused filament fabrication (FFF) 3D printing technique. The uses of both short and continuous fibre-reinforced polymer composites are reviewed. Finally, examples of some applications of FFF printed polymer composites using robotic processes are highlighted.
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48
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Investigation of the Mechanical Properties of a Carbon Fibre-Reinforced Nylon Filament for 3D Printing. MACHINES 2020. [DOI: 10.3390/machines8030052] [Citation(s) in RCA: 16] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
Additive manufacturing (i.e., 3D printing) has rapidly developed in recent years. In the recent past, many researchers have highlighted the development of in-house filaments for fused filament fabrication (FFF), which can extend the corresponding field of application. Due to the limited mechanical properties and deficient functionality of printed polymer parts, there is a need to develop printable polymer composites that exhibit high performance. This study analyses the actual mechanical characteristics of parts fabricated with a low-cost printer from a carbon fibre-reinforced nylon filament. The results show that the obtained values differ considerably from the values presented in the datasheets of various filament suppliers. Moreover, the hardness and tensile strength are influenced by the building direction, the infill percentage, and the thermal stresses, whereas the resilience is affected only by the building direction. Furthermore, the relationship between the mechanical properties and the filling factor is not linear.
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Pellejero I, Almazán F, Lafuente M, Urbiztondo MA, Drobek M, Bechelany M, Julbe A, Gandía LM. Functionalization of 3D printed ABS filters with MOF for toxic gas removal. J IND ENG CHEM 2020. [DOI: 10.1016/j.jiec.2020.05.013] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/19/2022]
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50
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Chu H, Yang W, Sun L, Cai S, Yang R, Liang W, Yu H, Liu L. 4D Printing: A Review on Recent Progresses. MICROMACHINES 2020; 11:E796. [PMID: 32842588 PMCID: PMC7570144 DOI: 10.3390/mi11090796] [Citation(s) in RCA: 51] [Impact Index Per Article: 12.8] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/12/2020] [Revised: 08/18/2020] [Accepted: 08/21/2020] [Indexed: 11/25/2022]
Abstract
Since the late 1980s, additive manufacturing (AM), commonly known as three-dimensional (3D) printing, has been gradually popularized. However, the microstructures fabricated using 3D printing is static. To overcome this challenge, four-dimensional (4D) printing which defined as fabricating a complex spontaneous structure that changes with time respond in an intended manner to external stimuli. 4D printing originates in 3D printing, but beyond 3D printing. Although 4D printing is mainly based on 3D printing and become an branch of additive manufacturing, the fabricated objects are no longer static and can be transformed into complex structures by changing the size, shape, property and functionality under external stimuli, which makes 3D printing alive. Herein, recent major progresses in 4D printing are reviewed, including AM technologies for 4D printing, stimulation method, materials and applications. In addition, the current challenges and future prospects of 4D printing were highlighted.
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Affiliation(s)
- Honghui Chu
- School of Electromechanical and Automotive Engineering, Yantai University, Yantai 264005, China; (H.C.); (L.S.); (R.Y.)
| | - Wenguang Yang
- School of Electromechanical and Automotive Engineering, Yantai University, Yantai 264005, China; (H.C.); (L.S.); (R.Y.)
| | - Lujing Sun
- School of Electromechanical and Automotive Engineering, Yantai University, Yantai 264005, China; (H.C.); (L.S.); (R.Y.)
| | - Shuxiang Cai
- School of Electromechanical and Automotive Engineering, Yantai University, Yantai 264005, China; (H.C.); (L.S.); (R.Y.)
| | - Rendi Yang
- School of Electromechanical and Automotive Engineering, Yantai University, Yantai 264005, China; (H.C.); (L.S.); (R.Y.)
| | - Wenfeng Liang
- School of Mechanical Engineering, Shenyang Jianzhu University, Shenyang 110016, China;
| | - Haibo Yu
- State Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, China; (H.Y.); (L.L.)
| | - Lianqing Liu
- State Key Laboratory of Robotics, Shenyang Institute of Automation, Chinese Academy of Sciences, Shenyang 110016, China; (H.Y.); (L.L.)
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