Rational Design and Characterization of Materials for Optimized Additive Manufacturing by Digital Light Processing

A Review on Additive Manufactured Engineering Materials for Enhanced Road Safety and Transportation Applications

Road safety systems are critical engineering solutions designed to minimize the effects of traffic accidents and increase the safety of transportation infrastructures. Traditional road safety structures are generally manufactured using steel, concrete and polymer materials. However, manufacturing processes with these materials are high-cost, limited in terms of design flexibility and can lead to material waste. In recent years, rapidly developing additive manufacturing (AM) technologies stand out as an important alternative in the production of road safety systems. AM enables the production of complex geometries and enables the development of lightweight and high-strength structures that can absorb impact energy more effectively. This study focuses on the use of AM methods in road safety systems, examining the performance and applicability of polymer, metal and composite materials. The advantages of AM-produced road safety barriers, traffic signs, speed bumps and shock absorbing structures, depending on the material type, are evaluated. In addition, the advantages offered by AM, such as design flexibility, sustainable production processes and material efficiency, are discussed, and technical challenges and applicability limitations are also discussed. This review evaluates the current and potential applications of AM for road safety systems, providing insights into how this technology can be used more effectively in the future. The findings of the study provide significant contributions towards improving the integration of AM technologies into road safety systems from both academic and industrial perspectives. The findings of the study provide important contributions to the development of the integration of AM technologies into road safety systems from both academic and industrial perspectives. Future research can further enhance the innovative potential of AM in road safety systems, with a particular focus on sustainable material use, design optimization and energy efficiency in manufacturing processes. However, overcoming technical challenges in large-scale applications and compliance with regulatory standards are critical research areas for the widespread adoption of this technology.

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Adjustment of Mechanical Properties of 3D Printed Continuous Carbon Fiber-Reinforced Thermoset Composites by Print Parameter Adjustments

Reinforcing thermoset polymers with continuous carbon fiber (CF) tow has emerged as a promising avenue to overcome the thermal and mechanical performance limitations of 3D printed polymeric structures for load-bearing applications. Unlike traditional methods, manufacturing continuous fiber-reinforced composites by 3D printing has the unique capability of locally varying the mechanical properties of the composites. In this study, continuous CF thermoset composite specimens were printed with varying line spacing, resin flow rate, and nozzle sizes. The resin flow rates for different line spacings and nozzle sizes were optimized by topographic analysis. Printed composite mechanical properties were evaluated, and their trends were correlated with the trend of print parameter changes. Results showed that tensile strength and modulus could be altered and improved by ~50% by adjusting the printing process parameters. Higher composite strength and modulus were obtained by shortening the line spacing and nozzle diameter.

3D-Printed Eosin Y-Based Heterogeneous Photocatalyst for Organic Reactions

Heterogenization of Eosin Y by 3D-printing and its application in photocatalysis are reported. The approach allows a fine tuning of the photocatalyst morphology and its rapid preparation. Photocatalytic activity was evaluated through model organic reactions involving oxidation, reduction, and photosensitization pathways. The efficiency, recyclability and stability of 3D printed EY is remarkable paving the way to new generation of heterogeneous photocatalysts with a perfect control of their shape and adaptable to any photoreactors.

Results of an interlaboratory study on the working curve in vat photopolymerization

The working curve informs resin properties and print parameters for stereolithography, digital light processing, and other photopolymer additive manufacturing (PAM) technologies. First demonstrated in 1992, the working curve measurement of cure depth vs radiant exposure of light is now a foundational measurement in the field of PAM. Despite its widespread use in industry and academia, there is no formal method or procedure for performing the working curve measurement, raising questions about the utility of reported working curve parameters. Here, an interlaboratory study (ILS) is described in which 24 individual laboratories performed a working curve measurement on an aliquot from a single batch of PAM resin. The ILS reveals that there is enormous scatter in the working curve data and the key fit parameters derived from it. The measured depth of light penetration Dp varied by as much as 7x between participants, while the critical radiant exposure for gelation Ec varied by as much as 70x. This significant scatter is attributed to a lack of common procedure, variation in light engines, epistemic uncertainties from the Jacobs equation, and the use of measurement tools with insufficient precision. The ILS findings highlight an urgent need for procedural standardization and better hardware characterization in this rapidly growing field.

Enhanced Mechanical Properties of PUMA/SiO2 Ceramic Composites via Digital Light Processing

This study aims to enhance the mechanical properties of additively manufactured polymer parts by incorporating ceramic particles (SiO2) into diluted urethane methacrylate (UDMA) photopolymer resin using digital light processing (DLP) technology. The resulting PUMA/SiO2 composites, featuring varying SiO2 contents (16.7, 28.5, and 37.5 wt%) and processed under different conditions, underwent a comprehensive series of mechanical, thermal, and chemical tests. Hardness tests showed that composites with 37.5 wt% SiO2 demonstrated superior hardness with low sensitivity to processing conditions. Bending tests indicated that elevated vat temperatures tended to degrade flexural properties, yet this degradation was mitigated in the case of the 37.5 wt% SiO2 composition. Tensile tests revealed a transition from viscoelastic to linear elastic behaviors with increasing SiO2 content, with high tensile strength sustained at low vat temperatures (<35 °C) when the SiO2 content exceeded 28.5 wt%. Thermogravimetric analysis supported these findings, indicating that increased SiO2 content ensured a more uniform dispersion, enhancing mechanical properties consequently. Thermal tests showed augmented thermal conductivity and diffusivity with reduced specific heat in SiO2-inclusive composites. This study provides guidelines for optimal PUMA/SiO2 composite utilization that emphasizes high SiO2 content and low vat temperature, offering comprehensive insights for high-performance ceramic composite fabrication in functional applications.

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

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