Controllable interfacial adhesion behaviors of polymer-on-polymer surfaces during fused deposition modeling 3D printing process

Fused Deposition Modeling of Polymer Composites: Development, Properties and Applications

This review summarizes recent research advancements in thermoplastic composites used in Fused Deposition Modeling (FDM) processes. Since its development in 1988, FDM has emerged as one of the primary emerging technologies of Industry 4.0, receiving attention in fields such as industrial manufacturing, automotive, aerospace, and others, particularly for rapid prototyping and customization. The intention is to make available a guideline for 3D printing researchers, analyzing the properties and performance characteristics of different polymers and polymeric composites. The review analysis covers various reinforcing agents, including particles/nanoparticles, short fibers, and long fibers, identifying critical parameters of the FDM process which affect printed part quality, integrity and final geometry. Major attention is devoted to the different techniques employed for composite filament fabrication, mostly for structural elements and parts. An extensive overview of various FDM composites and fiber-reinforced composites by polymer matrices such as PLA, ABS, and PEEK is presented, with their mechanical and thermal properties reported for specific applications. Current challenges and prospective future research directions are also outlined, mainly focusing on the enhancement of material performance and sustainability.

Fused-Deposition Modeling 3D Printing of Short-Cut Carbon-Fiber-Reinforced PA6 Composites for Strengthening, Toughening, and Light Weighting

Additive manufacturing of carbon-fiber-reinforced polymer (CFRP) has been widely used in many fields. However, issues such as inconsistent fiber orientation distribution and void formation during the layer stacking process have hindered the further optimization of the composite material's performance. This study aimed to address these challenges by conducting a comprehensive investigation into the influence of carbon fiber content and printing parameters on the micro-morphology, thermal properties, and mechanical properties of PA6-CF composites. Additionally, a heat treatment process was proposed to enhance the interlayer bonding and tensile properties of the printed composites in the printing direction. The experimental results demonstrate that the PA6-CF25 composite achieved the highest tensile strength of 163 MPa under optimal heat treatment conditions: 120 °C for 7.5 h. This corresponds to a significant tensile strength enhancement of 406% compared to the unreinforced composites, which represents the highest reported improvement in the current field of CFRP-fused deposition 3D printing. Additionally, we have innovatively developed a single-layer monofilament CF-OD model to quantitatively analyze the influence of fiber orientation distribution on the properties of the composite material. Under specific heat treatment conditions, the sample exhibits an average orientation angle μ of 0.43 and an orientation angle variance of 8.02. The peak frequency of fiber orientation closely aligns with 0°, which corresponds to the printing direction. Finally, the study explored the lightweight applications of the composite material, showcasing the impressive specific energy absorption (SEA) value of 17,800 J/kg when implementing 3D-printed PA6-CF composites as fillers in automobile crash boxes.

The Micro-Macro Interlaminar Properties of Continuous Carbon Fiber-Reinforced Polyphenylene Sulfide Laminates Made by Thermocompression to Simulate the Consolidation Process in FDM

Three-dimensional (3D) printing of continuous fiber-reinforced composites has been developed in recent decades as an alternative means to handle complex structures with excellent design flexibility and without mold forming. Although 3D printing has been increasingly used in the manufacturing industry, there is still room for the development of theories about how the process parameters affect microstructural properties to meet the mechanical requirements of the printed parts. In this paper, we investigated continuous carbon fiber-reinforced polyphenylene sulfide (CCF/PPS) as feedstock for fused deposition modeling (FDM) simulated by thermocompression. This study revealed that the samples manufactured using a layer-by-layer process have a high tensile strength up to 2041.29 MPa, which is improved by 68.8% compared with those prepared by the once-stacked method. Moreover, the mechanical–microstructure characterization relationships indicated that the compactness of the laminates is higher when the stacked CCF/PPS are separated, which can be explained based on both the void formation and the nanoindentation results. These reinforcements confirm the potential of remodeling the layer-up methods for the development of high-performance carbon fiber-reinforced thermoplastics. This study is of great significance to the improvement of the FDM process and opens broad prospects for the aerospace industry and continuous fiber-reinforced polymer matrix materials.

Challenges of fused deposition modeling 3D printing in pharmaceutical applications: Where are we now?

In recent years, fused deposition modeling has become one of the most used three-dimensional printing technologies in the pharmaceutical field. The production of personalized dosage forms for individualized therapy and the modification of the drug release profile by the elaboration of complex geometries make fused deposition modeling a promising tool for small-scale production. However, fused deposition modeling has a considerable number of challenges to overcome. They are divided into three categories of parameters. Material-specific parameters encompass the physicochemical properties of the filament, like thermal, mechanical and rheological properties. They determine the feasibility of the printing process. Operation-specific parameters relate to the processing conditions of printing, such as printing temperature and infill density, which have an influence on the final quality and on the dissolution behavior of the objects. The printer equipment is defined by the machine-specific parameters. Some modifications of this equipment also enhance the performance of the printing process. The aim of this review is to highlight the major fused deposition modeling critical process parameters in the pharmaceutical field and possible solutions in order to speed up the development of objects in the pharmaceutical market.

A Review of Conductive Carbon Materials for 3D Printing: Materials, Technologies, Properties, and Applications

Carbon material is widely used and has good electrical and thermal conductivity. It is often used as a filler to endow insulating polymer with electrical and thermal conductivity. Three-dimensional printing technology is an advance in modeling and manufacturing technology. From the forming principle, it offers a new production principle of layered manufacturing and layer by layer stacking formation, which fundamentally simplifies the production process and makes large-scale personalized production possible. Conductive carbon materials combined with 3D printing technology have a variety of potential applications, such as multi-shape sensors, wearable devices, supercapacitors, and so on. In this review, carbon black, carbon nanotubes, carbon fiber, graphene, and other common conductive carbon materials are briefly introduced. The working principle, advantages and disadvantages of common 3D printing technology are reviewed. The research situation of 3D printable conductive carbon materials in recent years is further summarized, and the performance characteristics and application prospects of these conductive carbon materials are also discussed. Finally, the potential applications of 3D printable conductive carbon materials are concluded, and the future development direction of 3D printable conductive carbon materials has also been prospected.

Fused Deposition Modeling of Polyamides: Crystallization and Weld Formation

International newspapers and experts have called 3D printing the industrial revolution of this century. Among all its available variants, the fused deposition modeling (FDM) technique is of greater interest since its application is possible using simple desktop printers. FDM is a complex process, characterized by a large number of parameters that influence the quality and final properties of the product. In particular, in the case of semicrystalline polymers, which afford better mechanical properties than amorphous ones, it is necessary to understand the crystallization kinetics as the processing conditions vary, in order to be able to develop models that allow having a better control over the process and consequently on the final properties of the material. In this work it was proposed to study the crystallization kinetics of two different polyamides used for FDM 3D printing and to link it to the microstructure and properties obtained during FDM. The kinetics are studied both in isothermal and fast cooling conditions, thanks to a home-built device which allows mimicking the quenching experienced during filament deposition. The temperature history of a single filament is then determined by mean of a micro-thermocouple and the final crystallinity of the sample printed in a variety of conditions is assessed by differential scanning calorimetry. It is found that the applied processing conditions always allowed for the achievement of the maximum crystallinity, although in one condition the polyamide mesomorphic phase possibly develops. Despite the degree of crystallinity is not a strong function of printing variables, the weld strength of adjacent layers shows remarkable variations. In particular, a decrease of its value with printing speed is observed, linked to the probable development of molecular anisotropy under the more extreme printing conditions.