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Advanced Materials in 3D Printing
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Advanced Materials in 3D Printing

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Additive Manufacturing Technologies".

Deadline for manuscript submissions: closed (20 May 2024) | Viewed by 12329

Special Issue Editors

Prof. Dr. Carlos Miguel Santos Vicente

E-Mail Website
Guest Editor
IDMEC, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisbon, Portugal
Interests: advanced materials; materials characterization; optics; photonics; thin films; integrated optics; polymers; composite materials; 3D printing
Prof. Dr. Marco Leite

E-Mail Website
Guest Editor
IDMEC, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal
Interests: materials and technology evaluation and selection; product development; composite materials; mechanical design; rapid prototyping; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM), commonly referred as 3D printing, plays an unquestionably important role in the world today. Cited by Forbes, Wohlers Report 2020 states that in 2019, the AM industry, consisting of all AM products and services worldwide, grew 25% to $12 billion. Besides the importance already achieved by AM at the present time, it is expected that its significance will increase in the future. AM’s contributions extend to several relevant fields such as aerospace, automotive, construction, electronics, energy, healthcare, and optics.

We have recently witnessed the rapid development of 3D printers, which has enabled the establishment of a coherent and systematic study of the relationship between the materials, processing, and properties of parts produced with conventional materials. These developments have allowed us to realize that materials play an essential role in 3D printing and strongly affect the performance of products obtained through these technologies. However, despite the advances made so far, the number of materials available for 3D printing is still quite limited, opening up a window of opportunity for the development of new advanced materials. These developments can potentially lead to to the manufacture of inovative products with improved performance and sustainability, propelling the growth of 3D printing technologies.

The aim of this Special Issue is to provide a scientific platform regarding the development of  advanced materials for 3D printing to discuss the present advances and challenges in 3D printing technologies. The Special Issue, entitled Advanced Materials in 3D Printing, is intended to be a broad spectrum forum for the presentation of publications in the form of original research articles or review papers addressing the most recent studies on the synthesis, processing, and characterization of advanced materials for 3D printing.

Prof. Dr. Carlos Miguel Santos Vicente
Prof. Dr. Marco Leite
Guest Editors

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Keywords

  • advanced materials
  • 3D printing
  • additive manufacturing
  • raw materials for 3D printing (powders, filaments, resins)
  • process validation of new 3D printing materials
  • 3D printing with composite materials
  • additive manufacturing of metals and alloys
  • high performance polymers
  • materials from renewable sources and recycling
  • conductive and magnetic materials for 3D printing

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Published Papers (5 papers)

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Research

11 pages, 4986 KiB  
Article
Electrical Resistance Response to Strain in 3D-Printed Conductive Thermoplastic Polyurethane (TPU)
by Axel Riddervold, Ole S. Nesheim, Sindre W. Eikevåg and Martin Steinert
Appl. Sci. 2024, 14(9), 3681; https://doi.org/10.3390/app14093681 - 26 Apr 2024
Cited by 1 | Viewed by 1252
Abstract
Additive manufacturing (AM) offers new possibilities in soft robotics as materials can easily be combined in multi-material designs. Proper sensing is essential for the soft actuators to interact with the surroundings successfully. By fabricating sensors through AM, sensors can be embedded directly into [...] Read more.
Additive manufacturing (AM) offers new possibilities in soft robotics as materials can easily be combined in multi-material designs. Proper sensing is essential for the soft actuators to interact with the surroundings successfully. By fabricating sensors through AM, sensors can be embedded directly into the components during manufacturing. This paper investigates NinjaTek Eels electrical resistance response to strain and the feasibility of using the material to create strain sensors. Strain sensors were 3D-printed out of NinjaTek Eel, a soft conductive TPU, and was tested during cyclic loading. A custom resistance–strain test rig was developed for measuring sensor behavior. The rig was calibrated for electric resistance, able to measure electric resistance as a function of strain. A parabolic response curve was observed during cyclic loading, which led to ambiguous readings. A 10-specimen validation test was conducted, evaluating the statistical variation for the first 100 loading cycles. The validation test showed that the sensor is capable of accurate and predictable readings during single load cases and cyclic loading, with the overall root mean square error being 66.9 Ω. Combining two sensors of different cross-sections gave promising results in terms of calibrating. By monitoring load cycles and strain rates, calibration can also be achieved by machine learning models by the microcontroller used to extract data. The presented work in this article explores the potential of using conductive TPUs as sensors embedded in products such as soft robotics, life monitoring of products with structural, and digital twins for live product to user feedback. Full article
(This article belongs to the Special Issue Advanced Materials in 3D Printing)
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21 pages, 13946 KiB  
Article
An Investigation of Quasi-Static Compression and Shock Responses under a Pneumatic Exciter on Brittle Truss Lattice Structures Fabricated with a Vat Photopolymer Resin
by Patchayaporn Doungkom, Thira Jearsiripongkul and Krit Jiamjiroch
Appl. Sci. 2023, 13(10), 6087; https://doi.org/10.3390/app13106087 - 16 May 2023
Cited by 2 | Viewed by 1718
Abstract
Shock attenuation is a significant aspect of shockproof design. The aim of this study is to explore the use of lattice structures for shock isolation applications. Five lattice structures were fabricated using photopolymer resin and subjected to quasi-static compression tests under a universal [...] Read more.
Shock attenuation is a significant aspect of shockproof design. The aim of this study is to explore the use of lattice structures for shock isolation applications. Five lattice structures were fabricated using photopolymer resin and subjected to quasi-static compression tests under a universal testing machine and shock response tests under a pneumatic exciter. The quasi-static compression tests provided preliminary data on the lattice structure’s collapse modes, stress, strain, and energy absorption. The shock test results revealed that the responses from the lattice structures were complex convolutions of the frequency. Moreover, the collapsed mode under the compression experiment did not guarantee the same outcome as in the shock impulse experiment. Amongst the lattice structures, the face-centred cubic with cubic perimeter (FCC + CP) structure exhibited the poorest shock isolation properties, with an ability to absorb only approximately one-third of the shock compared to solid structures. On the other hand, the body-centred cubic with cubic perimeter (BCC + CP) structure showed the highest impulse response with average shock transmissibility, making it a viable option for applications requiring shock insulation. However, it should be noted that this data may only be applicable for high acceleration with low degrees of force, less than 300 N. Full article
(This article belongs to the Special Issue Advanced Materials in 3D Printing)
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24 pages, 28969 KiB  
Article
Towards Self-Reinforced PLA Composites for Fused Filament Fabrication
by Neha Yadav, Tim Richter, Oliver Löschke, Bilen Emek Abali, Dietmar Auhl and Christina Völlmecke
Appl. Sci. 2023, 13(4), 2637; https://doi.org/10.3390/app13042637 - 18 Feb 2023
Cited by 5 | Viewed by 2561
Abstract
Aligned with the Sustainability Development Goals (SDGs), we present the complete methodology of preparing bio-based polymer filaments to be used in additive manufacturing, specifically by means of so-called Fused Filament Fabrication (FFF) in 3D printing. Filament production and 3D printing were both developed [...] Read more.
Aligned with the Sustainability Development Goals (SDGs), we present the complete methodology of preparing bio-based polymer filaments to be used in additive manufacturing, specifically by means of so-called Fused Filament Fabrication (FFF) in 3D printing. Filament production and 3D printing were both developed and optimised in this work. First, we focused on the steps of producing and optimising the extrusion process of unreinforced polylactic acid (PLA) composite filaments. Second, we studied the resulting material properties by discussing the selection of a specimen geometry and the international standards adequate for FFF 3D printing. Moreover, we investigated the process parameters in order to achieve reliable structures. Based on the reinforcement material (stereocomplex fibres (Sc-PLA fibre) and bi-component fibres (bi-co PLA fibre), base-matrices were selected for producing un-reinforced filaments. In this way, we present the complete preparation approach by identifying problems and pitfalls for fostering studies of bio-based polymer filaments. Full article
(This article belongs to the Special Issue Advanced Materials in 3D Printing)
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17 pages, 7505 KiB  
Article
Additive Manufacturing of Glass-Ceramic Parts from Recycled Glass Using a Novel Selective Powder Deposition Process
by João Vasconcelos, Manuel Sardinha, Carlos M. S. Vicente and Luís Reis
Appl. Sci. 2022, 12(24), 13022; https://doi.org/10.3390/app122413022 - 19 Dec 2022
Cited by 1 | Viewed by 2020
Abstract
Additive manufacturing technologies have been in continuous growth due to their advantages over traditional manufacturing. The iro3d is a powder deposition machine designed to build metal parts. This research work proposed the adaptation of the iro3d selective powder deposition process to allow the [...] Read more.
Additive manufacturing technologies have been in continuous growth due to their advantages over traditional manufacturing. The iro3d is a powder deposition machine designed to build metal parts. This research work proposed the adaptation of the iro3d selective powder deposition process to allow the production of glass-ceramic parts using recycled glass powders. Various specimens were produced using different deposition strategies such as build orientation and sintering holding times. Specimens were evaluated in terms of geometric distortions (shrinking and warping) and in terms of mechanical performance (flexural behavior and hardness). Two geometrically complex test parts were also produced to infer the minimum feature size capabilities of the process. The results denoted parts that displayed significant geometrical deviations, which could be correlated with some of the tested parameters. Through the addition of sand to the tested specimens, we demonstrated that distortions could be mitigated with proper control of the powder’s coalescence. In the end, the specimens’ fracture surfaces were examined, and the presence of porosities was correlated with their mechanical properties. The results demonstrated that the iro3d SPD process could be used to produce additively manufactured glass parts. Full article
(This article belongs to the Special Issue Advanced Materials in 3D Printing)
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11 pages, 2490 KiB  
Article
Characterization of Tissue Equivalent Materials Using 3D Printing for Patient-Specific DQA in Radiation Therapy
by Yona Choi, Young Jae Jang, Kum Bae Kim, Jungbae Bahng and Sang Hyoun Choi
Appl. Sci. 2022, 12(19), 9768; https://doi.org/10.3390/app12199768 - 28 Sep 2022
Cited by 5 | Viewed by 2601
Abstract
Three-dimensional printing technology has the advantage of facilitating the construction of complex three-dimensional shapes. For this reason, it is widely used in medical and radiological fields. However, few materials with high electron density similar to that of bone exist for fabricating a human [...] Read more.
Three-dimensional printing technology has the advantage of facilitating the construction of complex three-dimensional shapes. For this reason, it is widely used in medical and radiological fields. However, few materials with high electron density similar to that of bone exist for fabricating a human phantom. In this study, commercially available filament materials were used with an FDM 3D printer to perform delivery quality assurance (DQA) and were evaluated for medical use. For the bone filament material, BaSO4 was synthesized in five ratios of 2%, 4%, 6%, 8%, and 10% with 40% PBAT and 50~58% PLA. The electron density for the 3D printing material fabricated was obtained using kV energy CT and compared with the electron density of human organs and bones. The radiation beam properties of the 3D printed structures were analyzed as films for treatment using a linear accelerator. As a result, by changing the infill density of the material, it was possible to produce a material similar to the density of human organs, and a homogeneous bone material with HU values ranging from 371 ± 9 to 1013 ± 28 was produced. The 3D printing material developed in this study is expected to be usefully applied to the development of a patient-specific phantom to evaluate the accuracy of radiotherapy. Full article
(This article belongs to the Special Issue Advanced Materials in 3D Printing)
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