Search Results (46)

Additive manufacturing (AM) is increasingly recognized as a critical enabler for sustainable space exploration, offering on-demand fabrication, reduced reliance on Earth-based resupply, and enhanced mission autonomy. Over the past decade, in-space AM has progressed from early polymer extrusion experiments aboard the International Space Station (ISS) to the demonstration of multi-material capabilities involving polymers, metals, ceramics, recycling systems, and in situ resource utilization (ISRU) concepts. This review provides a comprehensive synthesis of AM technologies developed for space applications, with emphasis on demonstrated flight heritage, process behavior under microgravity and vacuum conditions, and materials validated in orbit. The paper surveys major AM process families relevant to space, including fused filament fabrication, directed energy deposition, ceramic stereolithography, bioprinting, and closed-loop recycling systems. Key ISS-based platforms—such as the Additive Manufacturing Facility, Ceramic Manufacturing Module, and Refabricator—are reviewed to assess technological maturity and system-level integration. Materials performance across polymers, metals, ceramics, and regolith-based feedstocks is discussed, highlighting the influence of microgravity, thermal transport, and environmental exposure. By comparing in-space results with terrestrial and reduced-gravity studies, this review identifies consistent trends, critical limitations, and remaining knowledge gaps, providing a structured perspective on the readiness of in-space additive manufacturing for future orbital and deep-space missions. Full article

This paper presents an evaluation of two new approaches to improve the surface quality and the mechanical properties of ceramic parts printed by fused deposition of ceramic (FDC). Dip-coating and aerosol-treatment are performed in order to reduce the staircase effect in the vertical printing direction, which typically represents the weakest orientation in most additive manufacturing processes, particularly in fused filament fabrication (FFF). The post-treatments are applied on two highly filled alumina feedstocks. A commercial aerosol-treatment machine for fused deposition modeling is used with ethanol as solvent. A suspension composition for dip-coating is developed to reduce the surface roughness without compromising the printing resolution. The influence of these post-processing steps on the mechanical properties and surface roughness of the green and sintered parts is investigated using perthometer measurements and four-point bending tests in the vertical build direction on as-processed, aerosol-treated, and dip-coated samples. The mechanical results are compared to extruded strand samples. An improvement in surface quality is achievable by dip-coating despite reduction in the parts strength, with a reduction of 65% of the R_z values in the sintered state compared to untreated samples. Aerosol-treatment neither improves the surface quality nor the mechanical properties of the parts. The feedstock and post-processing steps developed in this research aim at printing dense ceramic parts with high surface quality, serving as a basis for developing ceramic parts with higher strength. This advancement will facilitate the utilization of FDC in structural and aesthetic design applications. Full article

The global polymer waste burden has catalyzed a shift from linear “production–use–disposal” systems to circular models that prioritize recycling, reuse, and value retention. This article proposes an integrated, technology-ready roadmap for mechanical recycling and reuse of commodity and bio-based polymers via filament re-extrusion and Additive Manufacturing (AM). Building upon recent findings on performance envelopes of virgin vs. recycled Polylactic Acid (PLA) filaments processed by Fused Deposition Modeling (FDM), process parameter sensitivities (layer height, infill density) and their statistical optimization, and functional reinforcement routes (aluminum: Al, alumina: Al₂O₃, titanium: Ti, and Nano Boron Nitride: nano-BN), we articulate (1) a process–structure–property (PSP) mapping; (2) a low-defect, low-energy filament re-extrusion protocol; and (3) a graded-value strategy for upcycling mixed polymer streams. Across case analyses, we show that recycled PLA can achieve near-parity with virgin PLA when extrusion quality and printing parameters are controlled, and that ceramic/metal nanofillers enable thermal management and biocompatibility benefits crucial for durable reuse scenarios. Full article

This study investigated the fabrication and characterization of polylactic acid (PLA)-based ceramic composite filaments for fused deposition modeling (FDM) 3D printing. Boron carbide (B₄C) and silicon carbide (SiC) were incorporated into PLA at various weight fractions (1–40 wt. % for B₄C and 1–20 wt. % for SiC) to produce composite filaments using a commercial extruder. The rheological properties, thermal stability, and printability of the filaments were evaluated. Filaments with low ceramic content exhibited satisfactory quality, whereas those with higher loadings required reprocessing to improve their dimensional stability and surface morphology. Successful printing was achieved with SiC contents of up to 8 wt. % using single-extruded filaments and up to 20 wt. % using double-extruded filaments. Rheological tests revealed that filaments with low ceramic content exhibited shear-thinning behavior, whereas those with higher loadings displayed nearly Newtonian-like behavior. Thermal analysis using thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) determined the optimal processing temperature range for the composite filaments to be between 200 °C and 270 °C. High-temperature microscopy was used to study the temperature behavior of the B₄C-containing filaments and set the optimum printing temperature. The results demonstrate the feasibility of producing PLA-based ceramic composite filaments for FDM 3D printing with the potential to tailor the thermal and functional properties of the printed parts for specific applications. Full article

Additive manufacturing (AM), commonly known as 3D printing, is revolutionizing modern dentistry, introducing high-precision, patient-specific, and digital-driven workflows across prosthodontics, orthodontics, implantology, and maxillofacial surgery. Extensive analysis explores the leading platforms in 3D printing such as stereolithography (SLA), fused deposition modeling (FDM), selective laser sintering (SLS), digital light processing (DLP), and PolyJet which all achieve superior performance across multiple areas including resolution capabilities, material compatibility options, clinical application readiness, and cost-effectiveness. Additionally, an extensive overview of common materials, including biocompatible polymers (PLA, PMMA, PEEK), metals (titanium, cobalt-chromium), and ceramics (zirconia, alumina, glass-ceramics), sheds light on the critical role of material selection for patient safety, durability, and functional performance. The review explores new advancements such as 4D printing with shape-adaptive smart biomaterials as well as artificial intelligence-enabled digital processes and prosthesis design for the transformation of regenerative dentistry and intraoral drug delivery operations into new domains and the automation of clinical planning. Equally groundbreaking are 3D printing applications in pediatric dentistry, surgical simulation, and dental education. However, full-scale adoption of AM technology is not without challenges, including material toxicity, regulatory hurdles for approval, high initial investments, and the need for extensive digital expertise training. Sustainability concerns are also being addressed, with recycled materials and circular economy models gaining traction. In conclusion, this article advocates for a future where dentistry is shaped by interdisciplinary collaboration, intelligent automation, and hyper-personalized biocompatible solutions, with 3D printing firmly established as the backbone of next-generation dental care. Full article

Yttria-stabilized zirconia (YSZ) has attracted attention as a ceramic implant material owing to its excellent mechanical strength, biocompatibility, and aesthetic properties. However, YSZ is bioinert and lacks the ability to directly bond with bone. This study aims to enhance the bioactivity of 3D-printed porous YSZ through modified simulated body fluid (m-SBF) pretreatments. The porous YSZ substrates fabricated by fused deposition modeling were first etched with hydrofluoric acid (HF) to increase the surface roughness, followed by immersion in CO₃²⁻, Mg²⁺, and/or Zn²⁺ ion-incorporated m-SBFs. Among the tested solutions, the apatite coating formed in Mg²⁺- and Zn²⁺-containing m-SBF within one day, exhibiting uniform precipitation and a reduced tetragonal-to-monoclinic (t→m) transition. The incorporated Mg²⁺ and Zn²⁺ ions were successfully detected on the apatite coating, with Mg/Ca and Zn/Ca ratios of approximately 4.82% and 3.33%, respectively. Mg²⁺ is known to stimulate osteogenesis, while Zn²⁺ exhibits antibacterial activity. Furthermore, compared with standard SBF under high-temperature and high-pH conditions, the m-SBF induced markedly less t→m phase transition on YSZ substrates, suggesting that m-SBF, as a biomimetic medium for imparting bioactivity, provides a more suitable environment for YSZ substrates. This study demonstrates that HF surface treatment combined with Mg²⁺- and Zn²⁺-containing m-SBF pretreatment effectively imparts bioactivity to 3D-printed YSZ, offering a promising approach for next-generation osteoconductive ceramic implants. Full article

This study investigates seven advanced hybrid composite thermal protection system (TPS) prototypes, featuring an innovative internal air chamber design that reduces heat conduction and enhances overall thermal protection performance. Specimens were manufactured by fused deposition modeling (FDM), an additive manufacturing technique, using a fire-retardant thermoplastic. Selected configurations were reinforced with continuous carbon or glass fibers, coated with ceramic surface layer, or hybridized with carbon fiber reinforced polymer (CFRP) layers or a CFRP laminate disk. To validate performance, a harsh oxy-acetylene torch (OAT) protocol was implemented, deliberately designed to exceed the severity of most reported typical ablative assessments. The exposed surface of each specimen was subjected to direct flame at a 50 mm distance, recording peak temperatures of 1600 ± 50 °C. Two samples of each configuration were tested under 60 and 90 s exposures. Back-face thermal readings at potential payload sites consistently remained below 85 °C, well under the 200 °C maximum standard threshold for TPS applications. Several configurations preserved structural integrity despite the extreme environment. Prototypes 4.1 and 4.2 demonstrate the most favorable performance, maintaining structural integrity and low back-face temperatures despite substantial thickness loss. By contrast, specimen 6.2 exhibited rapid degradation following 60 s of exposure, which served as a rigorous and selective early-stage screening tool for evaluating polymer-based ablative TPS architectures. Full article

Additive manufacturing (AM) has significant potential for rapid prototyping of intricate 3-dimensional geometries, yet its adoption in RF and microwave applications remains limited. Key barriers include inadequate material characterization, high dielectric losses, poor thermal stability, and challenges with multi-material integration. This work addresses these issues by developing a high-k, low-loss composite filament with a reduced coefficient of thermal expansion (CTE), specifically formulated for fused deposition modelling (FDM). By varying filler volume fractions (30%, 40%, and 50% v/v) and surfactant content, their impact on thermal stability and CTE was investigated and measured by thermomechanical analysis (TMA). XRD, Pycnometry, and EDS analysis were performed to verify the effect of the calcination process on ceramic microfillers. The B.E.T. method (Brunauer–Emmet–Teller) was utilized to calculate the specific surface area of the samples with N₂ uptake. SEM images of the different composites were presented to visually demonstrate the homogeneous distribution of microfillers in the thermoplastic matrix. Titania was evaluated as the ceramic filler. Titania composites demonstrated decreased CTE values (35.93 ppm/°C at 50% v/v filler coated with surfactant) compared to composites without surfactant. A dielectric waveguide (DWG) printed with the T30S composite achieved an insertion loss of 0.46 dB at 17.23 GHz, significantly outperforming a commercially available ABS450-based DWG (0.95 dB at 16.88 GHz). Measurements aligned closely with 3D electromagnetic simulations, confirming dielectric properties (ε_r = 5.55, tan δ = 0.0009) suitable for advanced RF and microwave devices and advanced packaging applications. Full article

The research investigated the potential of five novel additively manufactured (AM) fiber-reinforced thermoplastic composite (FRTPC) configurations as alternatives for ablative thermal protection system (TPS) applications. The thermal stability and ablative behavior of ten samples developed via fused deposition modeling (FDM) three-dimensional (3D) printing out of fire-retardant thermoplastics were investigated using an in-house oxyacetylene torch bench. All samples featured an innovative internal thermal management architecture with three air chambers. Furthermore, the enhancement of thermal benefits was achieved through several approaches: ceramic coating, mechanical hybridization, or continuous fiber reinforcement. For each configuration, two samples were exposed to flame at 1450 ± 50 °C for 30 s and 60 s, respectively, with the front surface subjected to direct exposure at a distance of 100 mm during the ablation tests. Internal temperatures recorded at two back-side contact points remained below 50 °C, well under the 180 °C maximum allowable back-face temperature for TPS during testing. Continuous reinforced configurations 4 and 5 displayed higher thermal stability the lowest values in terms of thickness, mass loss, and recession rates. Both configurations showed half of the weight losses measured for the other tested configurations, ranging from approximately 5% (30 s) to 10–12% (60 s), confirming the trend observed in the thickness loss measurements. However, continuous glass-reinforced configuration 5 exhibited the lowest weight loss values for both exposure durations, benefiting from its non-combustible nature, low thermal conductivity, and high abrasion resistance intrinsic characteristics. In particular, the Al₂O₃ surface coated configuration 1 showed a mass loss comparable to reinforced configurations, indicating that an enhanced surface coat adhesion could provide a potential benefit. A key outcome of the study was the synergistic effect of the novel air chamber architecture, which reduces thermal conductivity by forming small internal air pockets, combined with the continuous front-wall fiber reinforcement functioning as a thermal and abrasion barrier. This remains a central focus for future research and optimization. Full article

The production of ultra-high-temperature ceramic parts, like ZrB₂, is very challenging, as they cannot be conventionally sintered without using significant amounts of additives, which reduce their high-temperature properties. However, it is possible to sinter these ceramics using spark plasma sintering (SPS) without additives or with minimal amounts. The challenge, then, lies in obtaining complex shapes. In this work, we report a solution for the fabrication of ZrB₂ gears through the use of PLA-printed interfaces and graphite powder. This process is relatively simple and utilizes a fused deposition modeling (FDM) printer. The pros and cons of this approach are discussed with the aim of identifying what shapes can be produced using this method. Full article

Micromixing is a crucial process in microfluidic systems. In biochemical and chemical analysis, the sample is usually tested with reagents. These solutions must be well mixed for the reaction to be possible, generally using micromixers manufactured with sophisticated and expensive technology. The present work shows the design and evaluation of micromixers fabricated with LTCC (low-temperature co-fired ceramics) and FDM (fused deposition modeling) technologies for the development of functional and complex geometries. Two-dimensional planar serpentine and 3D chaotic convection serpentine micromixers were manufactured and implemented in an automated microanalytical system using photometric methods. To evaluate the performance of the micromixers, flow, mixing and absorbance measurements were carried out. Green tape and PP materials were used and showed good resistance to the acidic chemical solutions. The devices presented achieved mixing times in seconds, a reduced dispersion due to their aspect ratio, high sensitivity, and precision in photometric measurement. The optical sensing cells stored sample volumes in a range of 10 to 600 µL, which allowed the reduction of reagent consumption and waste generation. These are ideal characteristics for in situ measurement, portable, and low-cost applications focused on green chemistry and biochemistry. Full article

This study explores the use of advanced 3D imaging and printing technologies to digitally document and physically replicate cultural artifacts from the Archaeological Museum of Alexandroupolis. By employing structured light scanning and additive manufacturing techniques, detailed digital models and precise physical replicas of two significant artifacts were created—a humanoid ceramic vessel and a glass cup. A handheld 3D scanner was utilized for capturing intricate surface details, with post-processing methods to refine and colorize the digital models. Regarding 3D printing, both Fused Deposition Modeling (FDM) and Stereolithography (SLA) were employed, tailored to the artifacts’ unique requirements for resolution and material properties. This dual approach supports heritage preservation by generating tangible educational resources and providing alternative exhibits to safeguard original artifacts. Our results demonstrate that integrating 3D scanning and printing effectively enhances the accessibility, durability, and educational utility of cultural heritage assets, offering a sustainable model for artifact preservation and study. Full article

In the domain of metal casting, investment casting is recognized for its proficiency in producing high-quality castings. This method involves the utilization of a melt out, burnout, or soluble patterns to create ceramic molds. The present investigation explored the potential of utilizing fused deposition modeling (FDM) patterns fabricated from polyvinyl alcohol (PVA). An examination of the structural characteristics and properties of several commercially available PVA filaments, along with an evaluation of the as-printed samples, were provided in this study. It was demonstrated that commercial PVA filaments may contain additives that can lead to elevated ash content following pattern burnout and reduced strength in as-printed samples. Experiments on PVA dissolution in water revealed that, for high dissolution rates of the pattern, not only high temperature, but also water medium mixing was necessary. The colloidal silica binder, a common component in ceramic mold manufacturing, exhibited effective wetting properties of the patterns, while generally preventing significant dissolution, which can adversely impact pattern quality. The PVA filaments under investigation were utilized to fabricate patterns for the impeller cast parts. Subsequent to this, ceramic molds were obtained, and castings made of nickel superalloy were produced. The investigation revealed that the Bambu Lab filament, which is PVA without additives, exhibited the lowest defect rate in both the mold and the casting. In summary, this study demonstrates that the 3D printing of investment casting patterns holds considerable promise as a rapid casting technique. Full article

In this work, ceramic monolithic catalyst carriers based on zirconium dioxide (ZrO₂) were produced using fused filament fabrication (FFF). The active catalyst components were deposited on the resulting carriers using the wet impregnation method. The activity of the prepared monolithic catalysts was evaluated by catalytic oxidation of a mixture of aromatic volatile organic compounds: benzene, toluene, ethylbenzene, and o-xylene (BTEX). The efficiency of the prepared monolithic catalysts was investigated as a function of the geometry of the monolithic carrier (ZDP, Z, and M) and the chemical composition of the catalytically active component (MnFeO_x, MnCuO_x, and MnNiO_x) during the catalytic oxidation of BTEX compounds. The mechanical stability of the catalyst layer and the dimensional stability of the 3D-printed monolithic catalyst carriers were investigated prior to the kinetic measurements. In addition, thorough characterization of the commercial ZrO₂-based filament was carried out. The results of the efficiency of the prepared monolithic catalysts for the catalytic oxidation of BTEX showed that the 3D-printed model M, which contained MnFeO_x as the catalytically active component, was the most successful catalyst for the oxidation of BTEX compounds. The mentioned catalyst enables the catalytic oxidation of all components of the BTEX mixture (>99% efficiency) at a temperature of 177 °C. Full article

The process of creating ceramic items using fused deposition modelling (FDM) enables the creation of intricate shapes for a variety of purposes, including tooling and prototyping. However, due to the numerous variables involved in the process, it is challenging to discern the impact of each parameter on the final characteristics of FDM components, which impedes the advancement of this technology. This paper deals with the application of statistical analysis in the study of the dependence of the flexural strength of sintered zirconia disks on the printing parameters (nozzle diameter, layer thickness, and infill pattern) of the fused deposition method printing of a ceramic–polymer filament containing 80 wt.% zirconia and 20 wt.% polylactide. X-ray-computed tomography and diffraction systems, scanning electron microscopy combined with energy-dispersive spectroscopy, were used for a microstructural analysis of the sintered samples. It was found that the nozzle diameter and infill pattern have no significant influence on the flexural strength values. It was assumed that this is due to the heterogeneous distribution of the ceramic phase in the manufactured filament during extrusion. On the other hand, correlation analysis and analysis of correlation diagrams have shown that the thickness of the filling layer has the greatest effect on flexural strength. The maximum (684 MPa) strength value was found in a sample printed with a layer thickness of 0.2 mm. The minimum layer thickness ensures a more uniform distribution of ceramic particles and minimizes defects in samples that occur during FDM printing. The results obtained make it possible to optimize the considered process of manufacturing ceramic products from ZrO₂ printed using FDM technology from extruded composite filaments. Full article