scholarly journals Mechanical Performance of Fused Filament Fabricated and 3D-Printed Polycarbonate Polymer and Polycarbonate/Cellulose Nanofiber Nanocomposites

Fibers ◽  
2021 ◽  
Vol 9 (11) ◽  
pp. 74
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Emmanouil Velidakis ◽  
Mariza Spiridaki ◽  
John D. Kechagias
Keyword(s):  
3D Printing ◽  
Mechanical Performance ◽  
Matrix Material ◽  
Mechanical Analysis ◽  
Cellulose Nanofiber ◽  
Fused Filament Fabrication ◽  
Melt Mixing ◽  
The Matrix ◽  
3D Printed ◽  
Printing Parameters

In this study, nanocomposites were fabricated with polycarbonate (PC) as the matrix material. Cellulose Nanofiber (CNF) at low filler loadings (0.5 wt.% and 1.0 wt.%) was used as the filler. Samples were produced using melt mixing extrusion with the Fused Filament Fabrication (FFF) process. The optimum 3D-printing parameters were experimentally determined and the required specimens for each tested material were manufactured using FFF 3D printing. Tests conducted for mechanical performance were tensile, flexural, impact, and Dynamic Mechanical Analysis (DMA) tests, while images of the side and the fracture area of the specimens were acquired using Scanning Electron Microscopy (SEM), aiming to determine the morphology of the specimens and the fracture mechanism. It was concluded that the filler’s ratio addition of 0.5 wt.% created the optimum performance when compared to pure PC and PC CNF 1.0 wt.% nanocomposite material.

Bending performance enhancement by nanoparticles for FFF 3D printed nylon and nylon/Kevlar composites

2020 ◽  
pp. 002199832096352
Author(s):  
Yachao Wang ◽  
Jing Shi ◽  
Zhihui Liu
Keyword(s):  
Flexural Strength ◽  
Performance Enhancement ◽  
Matrix Material ◽  
Extrusion Process ◽  
Thermoplastic Composites ◽  
Fused Filament Fabrication ◽  
Bending Performance ◽  
Bending Modulus ◽  
The Matrix ◽  
3D Printed

Fused filament fabrication (FFF) has been a major 3D printing technique for making thermoplastic products for decades. However, FFF printing for thermoplastic composites with aligned continuous fibers has been reported with limited success for only several years. In this study, we introduce an enhanced FFF-based approach by incorporating nanoparticles to the thermoplastic composites with continuous fibers. Our investigation focuses on the bending properties of FFF-printed fiber reinforced composites with and without nanoparticles. With Nylon 6 (PA 6) being the matrix material, nanocomposite filaments are obtained by adding carbon nanotubes (CNTs), graphene nano platelets (GNPs), or amino (NH2-) functionalized GNPs. Various PA 6 matrix nanocomposite filaments are prepared through mixing and filament extrusion process. The nanocomposite filaments are then 3D printed with or without continuous Kevlar fiber prepreg filaments. For 3D printed pure PA 6, the addition of 1 wt% GNP-NH2 increases the flexural strength and bending modulus by 334% and 315%, respectively. For 3D printed PA 6/Kevlar composite, the addition of 1 wt% GNP-NH2 increases the flexural strength and bending modulus by 195% and 35%, respectively. However, the addition of CNTs or GNPs (up to 1 wt%) is less effective as compared with GNP-NH2. The underlying mechanisms are discussed based on the matrix/fiber interfacial analysis.

scholarly journals Mechanical Performance of 3D-Printed Biocompatible Polycarbonate for Biomechanical Applications

Polymers ◽  
2021 ◽  
Vol 13 (21) ◽  
pp. 3669
Author(s):  
Giovanni Gómez-Gras ◽  
Manuel D. Abad ◽  
Marco A. Pérez
Keyword(s):  
Mechanical Performance ◽  
Cost Savings ◽  
Bone Scaffold ◽  
Fused Filament Fabrication ◽  
Synthetic Materials ◽  
3D Printed ◽  
Biomedical Industry ◽  
Manufacturing Techniques ◽  
Manufacturing Time ◽  
Printing Parameters

Additive manufacturing has experienced remarkable growth in recent years due to the customisation, precision, and cost savings compared to conventional manufacturing techniques. In parallel, materials with great potential have been developed, such as PC-ISO polycarbonate, which has biocompatibility certifications for use in the biomedical industry. However, many of these synthetic materials are not capable of meeting the mechanical stresses to which the biological structure of the human body is naturally subjected. In this study, an exhaustive characterisation of the PC-ISO was carried out, including an investigation on the influence of the printing parameters by fused filament fabrication on its mechanical behaviour. It was found that the effect of the combination of the printing parameters does not have a notable impact on the mass, cost, and manufacturing time of the specimens; however, it is relevant when determining the tensile, bending, shear, impact, and fatigue strengths. The best combinations for its application in biomechanics are proposed, and the need to combine PC-ISO with other materials to achieve the necessary strengths for functioning as a bone scaffold is demonstrated.

scholarly journals Mechanical Properties of 3D-Printed Acrylonitrile–Butadiene–Styrene TiO2 and ATO Nanocomposites

Polymers ◽  
2020 ◽  
Vol 12 (7) ◽  
pp. 1589 ◽  
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Athena Maniadi ◽  
Emmanuel Koudoumas ◽  
Marco Liebscher ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Mechanical Performance ◽  
Sno2 Nanoparticles ◽  
Three Dimensional ◽  
Acrylonitrile Butadiene Styrene ◽  
International Standards ◽  
Fused Filament Fabrication ◽  
Melt Mixing ◽  
3D Printed ◽  
Butadiene Styrene

In order to enhance the mechanical performance of three-dimensional (3D) printed structures fabricated via commercially available fused filament fabrication (FFF) 3D printers, novel nanocomposite filaments were produced herein following a melt mixing process, and further 3D printed and characterized. Titanium Dioxide (TiO2) and Antimony (Sb) doped Tin Oxide (SnO2) nanoparticles (NPs), hereafter denoted as ATO, were selected as fillers for a polymeric acrylonitrile butadiene styrene (ABS) thermoplastic matrix at various weight % (wt%) concentrations. Tensile and flexural test specimens were 3D printed, according to international standards. It was proven that TiO2 filler enhanced the overall tensile strength by 7%, the flexure strength by 12%, and the micro-hardness by 6%, while for the ATO filler, the corresponding values were 9%, 13%, and 6% respectively, compared to unfilled ABS. Atomic force microscopy (AFM) revealed the size of TiO2 (40 ± 10 nm) and ATO (52 ± 11 nm) NPs. Raman spectroscopy was performed for the TiO2 and ATO NPs as well as for the 3D printed nanocomposites to verify the polymer structure and the incorporated TiO2 and ATO nanocrystallites in the polymer matrix. The scope of this work was to fabricate novel nanocomposite filaments using commercially available materials with enhanced overall mechanical properties that industry can benefit from.

scholarly journals Optimization of the Filler Concentration on Fused Filament Fabrication 3D Printed Polypropylene with Titanium Dioxide Nanocomposites

Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 3076
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Emmanouil Velidakis ◽  
Lazaros Tzounis ◽  
Nikolaos Mountakis ◽  
...  
Keyword(s):  
Titanium Dioxide ◽  
Extrusion Process ◽  
Mechanical Analysis ◽  
International Standards ◽  
Volume Index ◽  
Filler Concentration ◽  
Fused Filament Fabrication ◽  
Melt Mixing ◽  
Force Microscopy ◽  
3D Printed

Polypropylene (PP) is an engineered thermoplastic polymer widely used in various applications. This work aims to enhance the properties of PP with the introduction of titanium dioxide (TiO2) nanoparticles (NPs) as nanofillers. Novel nanocomposite filaments were produced at 0.5, 1, 2, and 4 wt.% filler concentrations, following a melt mixing extrusion process. These filaments were then fed to a commercially available fused filament fabrication (FFF) 3D printer for the preparation of specimens, to be assessed for their mechanical, viscoelastic, physicochemical, and fractographic properties, according to international standards. Tensile, flexural, impact, and microhardness tests, as well as dynamic mechanical analysis (DMA), Raman, scanning electron microscopy (SEM), melt flow volume index (MVR), and atomic force microscopy (AFM), were conducted, to fully characterize the filler concentration effect on the 3D printed nanocomposite material properties. The results revealed an improvement in the nanocomposites properties, with the increase of the filler amount, while the microstructural effect and processability of the material was not significantly affected, which is important for the possible industrialization of the reported protocol. This work showed that PP/TiO2 can be a novel nanocomposite system in AM applications that the polymer industry can benefit from.

scholarly journals On the Mechanical Response of Silicon Dioxide Nanofiller Concentration on Fused Filament Fabrication 3D Printed Isotactic Polypropylene Nanocomposites

Polymers ◽  
2021 ◽  
Vol 13 (12) ◽  
pp. 2029
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Emmanouil Velidakis ◽  
Lazaros Tzounis ◽  
Nikolaos Mountakis ◽  
...  
Keyword(s):  
3D Printing ◽  
Silicon Dioxide ◽  
Mechanical Response ◽  
Mechanical Performance ◽  
Microstructural Analysis ◽  
Melt Flow Index ◽  
International Standards ◽  
Flow Index ◽  
Fused Filament Fabrication ◽  
Melt Mixing

Utilization of advanced engineering thermoplastic materials in fused filament fabrication (FFF) 3D printing process is critical in expanding additive manufacturing (AM) applications. Polypropylene (PP) is a widely used thermoplastic material, while silicon dioxide (SiO2) nanoparticles (NPs), which can be found in many living organisms, are commonly employed as fillers in polymers to improve their mechanical properties and processability. In this work, PP/SiO2 nanocomposite filaments at various concentrations were developed following a melt mixing extrusion process, and used for FFF 3D printing of specimens’ characterization according to international standards. Tensile, flexural, impact, microhardness, and dynamic mechanical analysis (DMA) tests were conducted to determine the effect of the nanofiller loading on the mechanical and viscoelastic properties of the polymer matrix. Scanning electron microscopy (SEM), Raman spectroscopy and atomic force microscopy (AFM) were performed for microstructural analysis, and finally melt flow index (MFI) tests were conducted to assess the melt rheological properties. An improvement in the mechanical performance was observed for silica loading up to 2.0 wt.%, while 4.0 wt.% was a potential threshold revealing processability challenges. Overall, PP/SiO2 nanocomposites could be ideal candidates for advanced 3D printing engineering applications towards structural plastic components with enhanced mechanical performance.

scholarly journals Real-Time 3D Printing Remote Defect Detection (Stringing) with Computer Vision and Artificial Intelligence

Processes ◽  
2020 ◽  
Vol 8 (11) ◽  
pp. 1464
Author(s):  
Konstantinos Paraskevoudis ◽  
Panagiotis Karayannis ◽  
Elias P. Koumoulos
Keyword(s):  
Neural Networks ◽  
Computer Vision ◽  
3D Printing ◽  
Large Scale ◽  
Video Camera ◽  
Fused Filament Fabrication ◽  
Printing Process ◽  
3D Printed ◽  
Live Environment ◽  
Printing Parameters

This work describes a novel methodology for the quality assessment of a Fused Filament Fabrication (FFF) 3D printing object during the printing process through AI-based Computer Vision. Specifically, Neural Networks are developed for identifying 3D printing defects during the printing process by analyzing video captured from the process. Defects are likely to occur in 3D printed objects during the printing process, with one of them being stringing; they are mostly correlated to one of the printing parameters or the object’s geometries. The defect stringing can be on a large scale and is usually located in visible parts of the object by a capturing camera. In this case, an AI model (Deep Convolutional Neural Network) was trained on images where the stringing issue is clearly displayed and deployed in a live environment to make detections and predictions on a video camera feed. In this work, we present a methodology for developing and deploying deep neural networks for the recognition of stringing. The trained model can be successfully deployed (with appropriate assembly of required hardware such as microprocessors and a camera) on a live environment. Stringing can be then recognized in line with fast speed and classification accuracy. Furthermore, this approach can be further developed in order to make adjustments to the printing process. Via this, the proposed approach can either terminate the printing process or correct parameters which are related to the identified defect.

scholarly journals Interfacial Transcrystallization and Mechanical Performance of 3D-Printed Fully Recyclable Continuous Fiber Self-Reinforced Composites

Polymers ◽  
2021 ◽  
Vol 13 (18) ◽  
pp. 3176
Author(s):  
Manyu Zhang ◽  
Xiaoyong Tian ◽  
Dichen Li
Keyword(s):  
3D Printing ◽  
Mechanical Performance ◽  
Three Dimensional ◽  
Thermoplastic Composites ◽  
Reinforced Composites ◽  
Continuous Fiber ◽  
The Matrix ◽  
Potential Applications ◽  
3D Printed ◽  
Qualitative Relationship

To fully exploit the preponderance of three-dimensional (3D)-printed, continuous, fiber-reinforced, thermoplastic composites (CFRTPCs) and self-reinforced composites (which exhibit excellent interfacial affinity and are fully recyclable), an approach in which continuous fiber self-reinforced composites (CFSRCs) can be fabricated by 3D printing is proposed. The influence of 3D-printing temperature on the mechanical performance of 3D-printed CFSRCs based on homogeneous, continuous, ultra-high-molecular-weight polyethylene (UHMWPE) fibers and high-density polyethylene (HDPE) filament, utilized as a reinforcing phase and matrix, respectively, was studied. Experimental results showed a qualitative relationship between the printing temperature and the mechanical properties. The ultimate tensile strength, as well as Young’s modulus, were 300.2 MPa and 8.2 GPa, respectively. Furthermore, transcrystallization that occurred in the process of 3D printing resulted in an interface between fibers and the matrix. Finally, the recyclability of 3D-printed CFSRCs has also been demonstrated in this research for potential applications of green composites.

scholarly journals Fused Filament Fabrication Three-Dimensional Printing Multi-Functional of Polylactic Acid/Carbon Black Nanocomposites

2021 ◽  
Vol 7 (3) ◽  
pp. 52
Author(s):  
Nectarios Vidakis ◽  
Markos Petousis ◽  
Emmanuel Velidakis ◽  
Nikolaos Mountakis ◽  
Peder Erik Fischer-Griffiths ◽  
...  
Keyword(s):  
3D Printing ◽  
Carbon Black ◽  
Polylactic Acid ◽  
Complex Geometry ◽  
Three Dimensional ◽  
Antibacterial Properties ◽  
Fused Filament Fabrication ◽  
Melt Mixing ◽  
Screening Process ◽  
3D Printed

Conductive Polymer Composites (CPCs) have recently gained an extensive scientific interest as feedstock materials in Fused Filament Fabrication (FFF) Three-dimensional (3D) printing. Polylactic Acid (PLA), widely used in FFF 3D printing, as well as its Carbon Black (CB) nanocomposites at different weight percentage (wt.%) filler loadings (0.5, 1.0, 2.5 and 5.0 wt.%), were prepared via a melt mixing filament extrusion process in this study and utilized to manufacture FFF 3D printed specimens. The nanocomposites were examined for their electrical conductivity. The highest loaded 3D printed CPC (5.0 wt.%) was tested as an electrothermal Joule heating device. Static tensile, flexural, Charpy’s impact and Vickers microhardness mechanical properties were investigated for the neat and PLA/CB 3D printed nanocomposites. Dynamic Mechanical Analysis (DMA) revealed a stiffening mechanism for the PLA/CB nanocomposites. Scanning Electron Microscopy (SEM) elucidated the samples’ internal and external microstructural characteristics. The PLA/CB 5.0 wt.% nanocomposite demonstrated also antibacterial properties, when examined with a screening process, against Escherichia coli (E. coli) and Staphylococcus aureus (S. aureus). It can be envisaged that the 3D printed PLA/CB CPCs exhibited a multi-functional performance, and could open new avenues towards low-cost personalized biomedical objects with complex geometry, amongst others, i.e., surgery tools, splints, wearables, etc.

scholarly journals Self-Reinforced Nylon 6 Composite for Smart Vibration Damping

Polymers ◽  
2021 ◽  
Vol 13 (8) ◽  
pp. 1235
Author(s):  
Bidita Salahuddin ◽  
Rahim Mutlu ◽  
Tajwar A. Baigh ◽  
Mohammed N. Alghamdi ◽  
Shazed Aziz
Keyword(s):  
Matrix Material ◽  
Nylon 6 ◽  
Vibration Damping ◽  
Vibration Energy ◽  
Damping Factor ◽  
Passive Vibration Control ◽  
Reinforced Composite ◽  
Coiled Structure ◽  
The Matrix ◽  
3D Printed

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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