Regulation of the Interface Compatibility of the 3D-Printing Interpenetration Networks Toward Reduced Structure Anisotropy and Enhanced Performances

Additive manufacturing of carbon fiber-reinforced thermoset composites via in-situ thermal curing

Fiber-reinforced polymer composites are lightweight structural materials widely used in the transportation and energy industries. Current approaches for the manufacture of composites require expensive tooling and long, energy-intensive processing, resulting in a high cost of manufacturing, limited design complexity, and low fabrication rates. Here, we report rapid, scalable, and energy-efficient additive manufacturing of fiber-reinforced thermoset composites, while eliminating the need for tooling or molds. Use of a thermoresponsive thermoset resin as the matrix of composites and localized, remote heating of carbon fiber reinforcements via photothermal conversion enables rapid, in-situ curing of composites without further post-processing. Rapid curing and phase transformation of the matrix thermoset, from a liquid or viscous resin to a rigid polymer, immediately upon deposition by a robotic platform, allows for the high-fidelity, freeform manufacturing of discontinuous and continuous fiber-reinforced composites without using sacrificial support materials. This method is applicable to a variety of industries and will enable rapid and scalable manufacture of composite parts and tooling as well as on-demand repair of composite structures.

Sericin from Bombyx Mori as a By-product for DLP 3D Printing in Pharmaceutical and Biomedical Applications

Sericin, a silk-derived protein, has emerged as a potential material for Digital Light Processing (DLP) printing, particularly in uses requiring biocompatibility and sustainability. Sericin is a candidate for developing durable and precise 3D-printed structures due to its natural origin and intrinsic properties like film-forming ability and cross-linking potential. Its biocompatibility makes it suitable for medical applications, such as targeted delivery of anticancer drugs or creation of therapeutic supports directly on affected skin, orthodontic and cosmetic biomaterials, disease modulation, wound healing, antioxidant and antimicrobial applications, and regenerative medicine. Additionally, sericin can strengthen and stabilize printed structures while maintaining environmental integrity, aligning with the growing demand for eco-friendly materials in advanced manufacturing. However, formulating sericin-based resins for DLP printing presents challenges, including optimizing cross-linking and curing processes for obtaining desired properties of material. Overcoming these challenges could unlock the full potential of sericin in diverse fields, such as tissue engineering, where biocompatibility and precise structural integrity are critical. This review investigates the potential of sericin-based resins for 3D printing, emphasizing the protein's compatibility with photopolymerizable systems and its capacity to improve the overall performance of DLP-printed materials. Further research is essential to refine sericin-based formulations, enabling their broader application in 3D printing technologies. By examining the unique characteristics of sericin, including its origins and material properties, this review underscores the protein's potential to drive innovation in sustainable manufacturing. Ultimately, sericin offers a viable alternative to synthetic resins and holds promise for advancing both biomedical and environmental applications through innovative 3D printing technologies.

The Investigation of Structural, Optical and Thermal Properties of Nickel Doped CeO2 Integrated PVC Nanocomposite

PVC nanocomposite (NC) films with cubic CeO2 and Ni-doped CeO2 (NDC) have been prepared using a conventional solution-casting technique. The prepared films were characterized with FT-IR spectrometer, X-ray diffraction (XRD), and scanning electron microscopy (SEM). The optical and thermal properties of the films were evaluated using a UV-visible spectrophotometer and TGA/DSC. The optical study revealed a decrease in optical band gap energies (4.19 to 4.06 eV) whereas the increase in other optical constraints such as optical conductivity, Urbach energy, dispersion energy, refractive index, and dielectric constant of PVC NCs than pristine PVC was observed. The XRD patterns showed the presence of cubic crystalline NDC with a relatively narrower principal diffraction peak in the PVC matrix and the nonexistence of unexpected vibrational peaks in the FTIR spectra of PVC NCs confirmed the successful incorporation of nanostructured CeO2 and NDC into PVC. Thermogravimetric analysis showed the higher thermal stability of NDC/PVC NC than PVC whereas differential scanning calorimetry declared no significant change in the glass transition temperature (Tg) of the NCs. Moreover, a good dispersion of Ni-doped CeO2 nanofiller was noticed in scanning electron micrographs.

Enhancing 3D Printing Copper-PLA Composite Fabrication via Fused Deposition Modeling through Statistical Process Parameter Study

The rapid advancement of additive manufacturing (AM) technologies has provided new avenues for creating three-dimensional (3D) parts with intricate geometries. Fused Deposition Modeling (FDM) is a prominent technology in this domain, involving the layer-by-layer fabrication of objects by extruding a filament comprising a blend of polymer and metal powder. This study focuses on the FDM process using a filament of Copper-Polylactic Acid (Cu-PLA) composite, which capitalizes on the advantageous properties of copper (high electrical and thermal conductivity, corrosion resistance) combined with the easily processable thermoplastic PLA material. The research delves into the impact of FDM process parameters, specifically, infill percentage (IP), infill pattern (P), and layer thickness (LT) on the maximum failure load (N), percentage of elongation at break, and weight of Cu-PLA composite filament-based parts. The study employs the response surface method (RSM) with Design-Expert V11 software. The selected parameters include infill percentage at five levels (10, 20, 30, 40, and 50%), fill patterns at five levels (Grid, Triangle, Tri-Hexagonal, Cubic-Subdivision, and Lines), and layer thickness at five levels (0.1, 0.2, 0.3, 0.4, and 0.5 mm). Also, the optimal factor values were obtained. The findings highlight that layer thickness and infill percentage significantly influence the weight of the samples, with an observed increase as these parameters are raised. Additionally, an increase in layer thickness and infill percentage corresponds to a higher maximum failure load in the specimens. The peak maximum failure load (230 N) is achieved at a 0.5 mm layer thickness and Tri-Hexagonal pattern. As the infill percentage changes from 10% to 50%, the percentage of elongation at break decreases. The maximum percentage of elongation at break is attained with a 20% infill percentage, 0.2 mm layer thickness, and 0.5 Cubic-Subdivision pattern. Using a multi-objective response optimization, the layer thickness of 0.152 mm, an infill percentage of 32.909%, and a Grid infill pattern was found to be the best configuration.

Multi-Material 3D Printing of Biobased Epoxy Resins

Additive manufacturing (AM) has revolutionised the manufacturing industry, offering versatile capabilities for creating complex geometries directly from a digital design. Among the various 3D printing methods for polymers, vat photopolymerisation combines photochemistry and 3D printing. Despite the fact that single-epoxy 3D printing has been explored, the fabrication of multi-material bioderived epoxy thermosets remains unexplored. This study introduces the feasibility and potential of multi-material 3D printing by means of a dual-vat Digital Light Processing (DLP) technology, focusing on bioderived epoxy resins such as ELO (epoxidized linseed oil) and DGEVA (vanillin alcohol diglycidyl ether). By integrating different materials with different mechanical properties into one sample, this approach enhances sustainability and offers versatility for different applications. Through experimental characterisation, including mechanical and thermal analysis, the study demonstrates the ability to produce structures composed of different materials with tailored mechanical properties and shapes that change on demand. The findings underscore the promising technology of dual-vat DLP technology applied to sustainable bioderived epoxy monomers, allowing sustainable material production and complex structure fabrication.

Skeletal muscle regeneration with 3D bioprinted hyaluronate/gelatin hydrogels incorporating MXene nanoparticles

There has been significant progress in the field of three-dimensional (3D) bioprinting technology, leading to active research on creating bioinks capable of producing structurally and functionally tissue-mimetic constructs. Ti3C2Tx MXene nanoparticles (NPs), promising two-dimensional nanomaterials, are being investigated for their potential in muscle regeneration due to their unique physicochemical properties. In this study, we integrated MXene NPs into composite hydrogels made of gelatin methacryloyl (GelMA) and hyaluronic acid methacryloyl (HAMA) to develop bioinks (namely, GHM bioink) that promote myogenesis. The prepared GHM bioinks were found to offer excellent printability with structural integrity, cytocompatibility, and microporosity. Additionally, MXene NPs within the 3D bioprinted constructs encouraged the differentiation of C2C12 cells into skeletal muscle cells without additional support of myogenic agents. Genetic analysis indicated that representative myogenic markers both for early and late myogenesis were significantly up-regulated. Moreover, animal studies demonstrated that GHM bioinks contributed to enhanced regeneration of skeletal muscle while reducing immune responses in mice models with volumetric muscle loss (VML). Our results suggest that the GHM hydrogel can be exploited to craft a range of strategies for the development of a novel bioink to facilitate skeletal muscle regeneration because these MXene-incorporated composite materials have the potential to promote myogenesis.

Maximizing performance and efficiency in 3D printing of polylactic acid biomaterials: Unveiling of microstructural morphology, and implications of process parameters and modeling of the mechanical strength, surface roughness, print time, and print energy for fused filament fabricated (FFF) bioparts

Medical stents, artificial teeth, and grafts are just some of the many applications for additive manufacturing techniques like bio-degradable polylactic acid 3D printing. However, there are drawbacks associated with fused filament fabrication-fabricated objects, including poor surface quality, insufficient mechanical strength, and a lengthy construction time for even a relatively small object. Thus, this study aims to identify the finest polylactic acid 3D printing parameters to maximize print quality while minimizing energy use, print time, flexural and tensile strengths, average surface roughness, and print time, respectively. Specifically, the infill density, printing speed, and layer thickness are all variables that were selected. A full-central-composite design generated 20 samples to test the prediction models' experimental procedures. Validation trial tests were used to show that the experimental findings agreed with the predictions, and analysis of variance was used to verify the importance of the performance characteristics (ANOVA). At layer thickness = 0.26 mm, infill density = 84 %, and print speed = 68.87 mm/s, the following optimized values were measured for PLA: flexural strength = 70.1 MPa, tensile strength = 39.2 MPa, minimum surface roughness = 7.8 μm, print time = 47 min, and print energy = 0.18 kwh. Firms and clinicians may benefit from utilizing the developed, model to better predict the required surface characteristic for various aspects afore trials.

Direct Pellet Three-Dimensional Printing of Polybutylene Adipate-co-Terephthalate for a Greener Future

The widespread use of conventional plastics in various industries has resulted in increased oil consumption and environmental pollution. To address these issues, a combination of plastic recycling and the use of biodegradable plastics is essential. Among biodegradable polymers, poly butylene adipate-co-terephthalate (PBAT) has attracted significant attention due to its favorable mechanical properties and biodegradability. In this study, we investigated the potential of using PBAT for direct pellet printing, eliminating the need for filament conversion. To determine the optimal printing temperature, three sets of tensile specimens were 3D-printed at varying nozzle temperatures, and their mechanical properties and microstructure were analyzed. Additionally, dynamic mechanical thermal analysis (DMTA) was conducted to evaluate the thermal behavior of the printed PBAT. Furthermore, we designed and printed two structures with different infill percentages (40% and 60%) to assess their compressive strength and energy absorption properties. DMTA revealed that PBAT's glass-rubber transition temperature is approximately -25 °C. Our findings demonstrate that increasing the nozzle temperature enhances the mechanical properties of PBAT. Notably, the highest nozzle temperature of 200 °C yielded remarkable results, with an elongation of 1379% and a tensile strength of 7.5 MPa. Moreover, specimens with a 60% infill density exhibited superior compressive strength (1338 KPa) and energy absorption compared with those with 40% infill density (1306 KPa). The SEM images showed that with an increase in the nozzle temperature, the quality of the print was greatly improved, and it was difficult to find microholes or even a layered structure for the sample printed at 200 °C.