Application of Composite Materials in Additive Manufacturing

A special issue of Journal of Composites Science (ISSN 2504-477X). This special issue belongs to the section "Composites Manufacturing and Processing".

Deadline for manuscript submissions: 31 August 2025 | Viewed by 4631

Special Issue Editor


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Guest Editor
School of Science and Engineering, University of Dundee, Dundee, UK
Interests: bone implant; composite materials; 3D printing; piezoelectric materials; shape memory materials; sustanability; Net Zero
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Special Issue Information

Dear Colleagues,

Additive manufacturing (AM), commonly referred to as 3D printing, has revolutionised the manufacturing industry through enabling the creation of complex and customised components with high precision and minimal waste. One of the most exciting advancements in this field is integrating composite materials into additive manufacturing processes. Composite materials, engineered from two or more constituent materials with significantly different physical or chemical properties, offer superior mechanical, thermal, and electrical properties when compared to traditional materials. This synergy opens up new possibilities for developing high-performance products across various industries, including aerospace, automotive, medical, and consumer goods.

The scientific background of composite materials in additive manufacturing encompasses various disciplines, including materials science, mechanical engineering, and chemistry. Combining materials such as polymers, metals, ceramics, and fibres in a single manufacturing process allows for optimising properties tailored to specific applications. For example, using carbon fibre-reinforced polymers (CFRPs) in 3D printing has shown significant improvements in the strength-to-weight ratio, making them ideal for aerospace and automotive applications where weight reduction is critical.

This Special Issue on the "Application of Composite Materials in Additive Manufacturing" explores the latest advancements, challenges, and opportunities in this dynamic field. We aim to bring together cutting-edge research and reviews that highlight the interdisciplinary nature of this area and its relevance to the broader scope of materials science and engineering. By fostering a comprehensive understanding of the application of composite materials in additive manufacturing, this Special Issue will contribute to advancing knowledge and developing novel solutions that address the emerging needs of various industries.

The aim of this Special Issue on the "Application of Composite Materials in Additive Manufacturing" is to provide a comprehensive platform for disseminating pioneering research and advancements in integrating composite materials with additive manufacturing technologies. This Special Issue seeks to gather original research articles and reviews that explore innovative methodologies, material developments, and applications of composite materials in 3D printing. We aim to address the current challenges, uncover potential opportunities, and highlight the transformative impact of composite materials on additive manufacturing processes.

The subject matter of this Special Issue aligns closely with the scope of the Journal of Composites Science, which focuses on the design, development, and application of composite materials. By integrating additive manufacturing into this framework, we aim to advance the understanding of how these materials can be optimised and applied in various industrial contexts, thereby pushing the boundaries of traditional manufacturing techniques.

This Special Issue will cover a range of themes, including, but not limited to, the following:

  • Development of novel composite materials for additive manufacturing;
  • Mechanical, thermal, and electrical characterisation of 3D-printed composites;
  • Advances in additive manufacturing technologies for composites;
  • Applications of 3D-printed composites in aerospace, automotive, medical, and consumer industries;
  • Sustainable and environmentally friendly practises in the additive manufacturing of composites.

By fostering interdisciplinary collaboration and showcasing state-of-the-art research, this Special Issue aims to contribute significantly to composite materials and their applications in additive manufacturing, aligning with the journal's mission to advance scientific knowledge and practical applications in composites science.

We invite submissions of original research articles and comprehensive reviews that address a broad spectrum of topics related to the application of composite materials in additive manufacturing. Potential themes and topics include, but are not limited to, the following:

  1. Development of Novel Composite Materials:
    • Design and synthesis of new composite materials suitable for 3D printing.
    • Investigate the mechanical, thermal, and electrical properties of 3D-printed composites.
    • Exploration of hybrid composites combining multiple materials for enhanced performance.
  2. Additive Manufacturing Techniques:
    • Advances in additive manufacturing processes such as fused deposition modelling (FDM), selective laser sintering (SLS), stereolithography (SLA), and direct ink writing (DIW) for composite materials.
    • Process optimisation and parameter control for high-quality composite printing.
    • Development of multi-material printing techniques for functional gradation and complex architectures.
  3. Applications of 3D Printed Composites:
    • Aerospace: Lightweight and high-strength components and thermal management systems.
    • Automotive: Structural components, impact-resistant parts, and functional prototypes.
    • Medical: Biocompatible implants, prosthetics, and customised medical devices.
    • Consumer Goods: Wearable technology, sports equipment, and household items.
  4. Sustainability and Environmental Impact:
    • Use of recycled or bio-based materials in the 3D printing of composites.
    • Life cycle analysis and environmental impact assessments of 3D-printed composites.
    • Strategies for reducing waste and improving the sustainability of additive manufacturing processes.
  5. Characterisation and Testing:
    • Advanced techniques for characterising the microstructure and properties of 3D-printed composites.
    • Non-destructive testing methods for quality assurance of printed parts.
    • Long-term performance and durability studies of composite materials in various environments.
  6. Simulation and modelling:
    • Computational modelling of composite material behaviour during and after the printing process.
    • Simulation of process-structure-property relationships in 3D-printed composites.
    • Predictive modelling for optimising design and manufacturing processes.

We look forward to receiving your contributions that will not only advance the field of composite materials in additive manufacturing, but also demonstrate innovative solutions and applications that address current and future challenges in this dynamic and impactful area of research.

Dr. Bankole Oladapo
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

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Keywords

  • additive manufacturing
  • composite materials
  • 3D printing
  • fused deposition modelling (FDM)
  • selective laser sintering (SLS)
  • mechanical properties
  • sustainable manufacturing
  • biocompatible implants
  • hybrid composites

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Published Papers (4 papers)

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Research

13 pages, 14198 KiB  
Article
Mechanical Properties of Dispersion-Strengthened Iron-Based W+WC(Ni) Composite Produced by Combined Wire Electron-Beam Manufacturing with Powder Addition
by Andrey Vorontsov, Anna Zykova, Denis Gurianov, Nikolay Shamarin, Aleksandr Panfilov, Andrey Chumaevskii, Kirill Kalashnikov, Evgeny Kolubaev and Nikolai Savchenko
J. Compos. Sci. 2025, 9(4), 144; https://doi.org/10.3390/jcs9040144 - 21 Mar 2025
Viewed by 310
Abstract
The paper investigates the microstructure and mechanical properties of a steel matrix composite reinforced with tungsten (W) particles and a mixture of tungsten carbide and nickel (WC(Ni)) obtained by a hybrid additive manufacturing method using wire electron beam additive manufacturing with powder addition. [...] Read more.
The paper investigates the microstructure and mechanical properties of a steel matrix composite reinforced with tungsten (W) particles and a mixture of tungsten carbide and nickel (WC(Ni)) obtained by a hybrid additive manufacturing method using wire electron beam additive manufacturing with powder addition. The composite exhibits a gradient structure including three zones: a matrix of high alloy steel 401S45, a transition layer with a low concentration of W/WC(Ni) and a surface layer enriched with particles of reinforcing phases. SEM, TEM and XRD methods revealed a heterogeneous microstructure consisting of α-Fe (80 vol.%), γ-Fe (10 vol.%) and carbide phases, as well as suppression of the formation of brittle Me3C intermetallides due to the controlled diffusion of W, C and alloying elements. The microhardness of the composite increases from 350 HV (matrix) to 650 HV (reinforced layer) due to dispersion hardening and formation of the carbide skeleton. Compression tests showed record strength of the reinforced layer (1720 ± 60 MPa) due to effective load distribution by W/WC(Ni) particles, but brittle failure is observed in tensile tests due to stress concentration at the interfaces. Full article
(This article belongs to the Special Issue Application of Composite Materials in Additive Manufacturing)
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16 pages, 4374 KiB  
Article
Investigation of Short Carbon Fiber-Reinforced Polylactic Acid Composites Blades for Horizontal Axis Wind Turbines: Mechanical Strength and Energy Efficiency of Fused Filament Fabrication-Printed Blades
by Lotfi Ben Said, Sarhan Karray, Wissem Zghal, Hamdi Hentati, Badreddine Ayadi, Alaa Chabir and Muapper Alhadri
J. Compos. Sci. 2025, 9(3), 118; https://doi.org/10.3390/jcs9030118 - 4 Mar 2025
Cited by 2 | Viewed by 781
Abstract
The use of 3D printing is expanding in manufacturing wind turbine blades for renewable energy. This study examines the relationship between geometric parameters, mechanical strength, and aerodynamic performance in blades made from short carbon fiber-reinforced PLA (SCFR-PLA) composites. To achieve this, it includes [...] Read more.
The use of 3D printing is expanding in manufacturing wind turbine blades for renewable energy. This study examines the relationship between geometric parameters, mechanical strength, and aerodynamic performance in blades made from short carbon fiber-reinforced PLA (SCFR-PLA) composites. To achieve this, it includes a comparative evaluation of innovative blade designs and materials, aiming to enhance both the energy efficiency and mechanical durability of horizontal axis wind turbines (HAWTs). The numerical model of the wind turbine blade is validated against experimental results, which employed a NACA geometry and ABS polymer. Building upon this validation, a design of experiments (DOE) analysis is employed to explore the influence of fused filament fabrication (FFF) parameters on the mechanical properties of SCFR-PLA composites. A novel blade design, referred to as HAWTSav, is numerically evaluated using 3D-printed SCFR-PLA composites. Numerical simulations are conducted to evaluate the energy efficiency and structural integrity of the HAWTSav blade. A comparative analysis is then performed, contrasting the performance of the conventional NACA blade in ABS with the HAWTSav blade in SCFR-PLA composites. The findings highlight the potential of SCFR-PLA composites in the development of efficient and durable wind turbine blades, highlighting their applicability, particularly in small-scale wind energy systems. Full article
(This article belongs to the Special Issue Application of Composite Materials in Additive Manufacturing)
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16 pages, 15998 KiB  
Article
The Abrasive Water Jet Cutting Process of Carbon-Fiber-Reinforced Polylactic Acid Samples Obtained by Additive Manufacturing: A Comparative Analysis
by Sergio de la Rosa, Lucía Rodríguez-Parada, Moises Batista Ponce and Pedro F. Mayuet Ares
J. Compos. Sci. 2024, 8(10), 437; https://doi.org/10.3390/jcs8100437 - 21 Oct 2024
Cited by 1 | Viewed by 1238
Abstract
Carbon-fiber-reinforced polymer (CFRP) composites are widely used across industries due to their enhanced strength and stiffness properties. Fused deposition modeling (FDM) enables the cost-effective production of polymer samples, such as carbon-fiber-reinforced PLA (CFR-PLA). However, CFRP’s hardness and anisotropic nature present significant challenges in [...] Read more.
Carbon-fiber-reinforced polymer (CFRP) composites are widely used across industries due to their enhanced strength and stiffness properties. Fused deposition modeling (FDM) enables the cost-effective production of polymer samples, such as carbon-fiber-reinforced PLA (CFR-PLA). However, CFRP’s hardness and anisotropic nature present significant challenges in conventional machining, including rapid tool wear and thermal sensitivity. Consequently, abrasive water jet machining (AWJM) has proven to be an effective alternative for machining CFRP materials, offering benefits such as reduced tool wear, minimized thermal damage, and improved cutting quality. This study focuses on a comparative analysis of the effects of AWJM parameters on PLA and CFR-PLA samples, specifically to evaluate the influence of carbon fiber reinforcement on machining performance. The findings highlight the critical role of reinforcements in machining behavior. The results suggest that optimizing cutting parameters significantly reduces taper formation and improves machining accuracy. In particular, adjustments to process parameters resulted in lower taper angles and reduced surface roughness in the cutting zones of the CFR-PLA samples. Full article
(This article belongs to the Special Issue Application of Composite Materials in Additive Manufacturing)
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17 pages, 8517 KiB  
Article
Evaluation of Different ZX Tensile Coupon Designs in Additive Manufacturing of Amorphous and Semi-Crystalline Polymer Composites
by Raviteja Rayaprolu, Ajay Kumar Kadiyala and Joseph G. Lawrence
J. Compos. Sci. 2024, 8(9), 379; https://doi.org/10.3390/jcs8090379 - 22 Sep 2024
Cited by 1 | Viewed by 1539
Abstract
The layer-by-layer deposition of molten polymer filament in fused deposition modeling (FDM) has evolved as a disruptive technology for building complex parts. This technology has drawbacks such as the anisotropic property of the printed parts resulting in lower strength for parts printed in [...] Read more.
The layer-by-layer deposition of molten polymer filament in fused deposition modeling (FDM) has evolved as a disruptive technology for building complex parts. This technology has drawbacks such as the anisotropic property of the printed parts resulting in lower strength for parts printed in the vertical Z direction compared with the other two planes. In this manuscript, we attempt to address these challenges as well as the lack of standardization in sample preparation and mechanical testing of the printed parts. The paper focuses on process parameters and design optimization of the ZX build orientation. Type I tensile bars in ZX orientation were printed as per the ASTM D638 standard using two (2B) and four (4B) tensile bar designs. The proposed design reduces material loss and post-processing to extract the test coupons. Printing a type I tensile bar in the ZX orientation is more challenging than type IV and type V due to the increased length of the specimen and changes in additional heat buildup during layer-by-layer deposition. Three different polymer composite systems were studied: fast-crystallizing nanofiller-based high-temperature nylon (HTN), slow-crystallizing nanofiller-based polycyclohexylene diethylene terephthalate glycol-modified (PCTG), and amorphous carbon fiber-filled polyetherimide (PEI-CF). For all the polymer composite systems, the 2B showed the highest strength properties due to the shorter layer time aiding the diffusion in the interlayers. Further, rheological studies and SEM imaging were carried out to understand the influence of the two designs on fracture mechanics and interlayer bonding, providing valuable insights for the field of additive manufacturing and material science. Full article
(This article belongs to the Special Issue Application of Composite Materials in Additive Manufacturing)
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