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3D-Printed Composite Structures: Design, Properties and Application
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3D-Printed Composite Structures: Design, Properties and Application

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 March 2025) | Viewed by 9152

Special Issue Editors

Prof. Dr. Hongyong Jiang

E-Mail Website
Guest Editor
School of Mechanical Engineering and Electronic Information, China University of Geosciences, Wuhan 430074, China
Interests: 3D printing of continuous fiber composite; mechanics and design of composite structures; multi-scale modeling
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Guangchao Han

E-Mail Website
Guest Editor
School of Mechanical Engineering and Electronic Information, China University of Geosciences, Wuhan 430074, China
Interests: micro structured metal 3D printing forming; special energy field assisted forming manufacturing process; selective laser melting (SLM)
Special Issues, Collections and Topics in MDPI journals
Dr. Fuchu Liu

E-Mail Website
Guest Editor
School of Mechanical Engineering and Electronic Information, China University of Geosciences, Wuhan 430074, China
Interests: 3D printing of ceramics; direct ink writing (DIW); fused deposition modeling (FDM)
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Composite structures have received widespread attention due to their high mechanical properties and lightweight. Thus, they show great potential applications in automotive, aerospace and other industries. However, processing complicated composite structures is still limited by traditional manufacturing methods which also require expensive equipment and complex preparation process. Three-dimensional printing, also known as additive manufacturing, provides solutions for the rapid manufacturing of complex composite structures with integrated forming. Therefore, the development of 3D printing technology has stimulated the advanced design and improvements in mechanical properties and wider applications of composite structures.

The Special Issue of Materials, “Three-Dimensional-Printed Composite Structures: Design, Properties and Application”, aims to present the latest advances focusing on 3D-printed composite structures with polymer, geopolymer, multi-material metal, ceramics, short fiber, continuous fiber, hybrid fiber, etc. In this Special Issue, we invite you to submit a manuscript studying the following, but not limited, topics: 3D printing process, trajectory planning, design, mechanics, structural optimization, etc. In this Special Issue, original research articles and reviews are welcome. Research areas may include (but not limited to) the following:

  • Materials characterization for 3D printing (e.g., polymer, geopolymer, metal, ceramics, short fiber-reinforced composite, continuous fiber-reinforced composite, hybrid fiber reinforced composite, etc.);
  • Advanced pre-processing and post-processing technology for 3Dprinting (e.g., heat treatment, surface treatment, hot pressing, prepreg treatment, etc.);
  • Structural design (e.g., porous structure, honeycomb, lattice, auxetic structure, topology-optimized structure, bio-inspired structure, etc.);
  • Mechanical properties (e.g., tensile, compressive, bending, impact, vibration, heat transfer, etc.);
  • 3D printing process and trajectory planning;
  • 3D-printing mechanism and theoretical modeling.

Prof. Dr. Hongyong Jiang
Prof. Dr. Guangchao Han
Dr. Fuchu Liu
Guest Editors

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.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • 3D printing/additive manufacturing
  • composite structure
  • 3D printing processing
  • structural design
  • mechanical property

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Related Special Issue

Published Papers (7 papers)

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Research

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14 pages, 4489 KiB  
Article
Preparation and Properties of PETG Filament Modified with a Metallic Additive
by Piotr Zmuda Trzebiatowski, Tomasz Królikowski, Agnieszka Ubowska and Katarzyna Wilpiszewska
Materials 2025, 18(6), 1203; https://doi.org/10.3390/ma18061203 - 7 Mar 2025
Viewed by 868
Abstract
The materials used as filaments for additive techniques should exhibit various properties depending on the application and the requirements. The motivation for this study was the need to obtain a filament exhibiting appropriate aesthetic (metal-like) and mechanical properties. Glycol-modified poly(ethylene terephthalate) copolymer (PETG) [...] Read more.
The materials used as filaments for additive techniques should exhibit various properties depending on the application and the requirements. The motivation for this study was the need to obtain a filament exhibiting appropriate aesthetic (metal-like) and mechanical properties. Glycol-modified poly(ethylene terephthalate) copolymer (PETG) and micrometric steel powder were used for composite preparation. Subsequently, the obtained material was used as a filament for 3D printing, i.e., by fused deposition modeling (FDM) technique. The physicochemical properties of the obtained filaments were determined, such as morphology (roughness), moisture sorption ability, thermal properties, and mechanical performance (tensile and compressive strength). Importantly, the metal filler did not modify the thermal properties of the polyester matrix, indicating that the filament containing steel microfiller could be processed using the same parameters as for neat PETG. The thermal stability was slightly enhanced after steel powder addition (for 13 wt.% content, the temperature of 75% weight loss was 466 °C; for comparison, that for the reference sample was 446 °C). The reinforcing effect of steel microfiller was noted based on mechanical performance measurements. The steel particles acted as a stiffening agent; the highest maximal tensile strength was observed for the composite with 3 wt.% steel powder content (ca. 68 MPa). Further increasing the microfiller load resulted in a slight decrease in the value of this parameter. A different trend was reported considering the compressive strength, i.e., the value of this parameter increased with steel content. Based on the obtained results, the new PETG composites could be applied as structural materials. Full article
(This article belongs to the Special Issue 3D-Printed Composite Structures: Design, Properties and Application)
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21 pages, 5640 KiB  
Article
Experiment and Simulation Study on the Crashworthiness of Markforged 3D-Printed Carbon/Kevlar Hybrid Continuous Fiber Composite Honeycomb Structures
by Jinlong Ju, Nana Yang, Lei Yu, Zhe Zhang, Hongyong Jiang, Wenhua Wu and Guolu Ma
Materials 2025, 18(1), 192; https://doi.org/10.3390/ma18010192 - 5 Jan 2025
Viewed by 923
Abstract
Fiber hybridization can effectively solve the localized brittle fracture problem of composite honeycomb, but the interaction between different fibers leads to a very complex failure mechanism. Hence, 3D-printed hybrid continuous fiber composite honeycombs with a combination of carbon and Kevlar fibers are designed [...] Read more.
Fiber hybridization can effectively solve the localized brittle fracture problem of composite honeycomb, but the interaction between different fibers leads to a very complex failure mechanism. Hence, 3D-printed hybrid continuous fiber composite honeycombs with a combination of carbon and Kevlar fibers are designed to study the structural failure behaviors by the experiment and simulation method. The experimental samples, including Onyx, carbon, Kevlar, carbon/Kevlar, and Kevlar/carbon composites, are fabricated based on Markforged 3D printing technology, and the crushing tests are conducted to evaluate the failure behaviors. An equivalence finite element modeling method to replace the heterogeneous microstructure of hybrid composites is proposed to analyze the failure behaviors. Results indicate that carbon/Kevlar honeycomb exhibits the highest energy absorption and cost effectiveness, while CFRP honeycomb demonstrates the highest load-carrying capacity. It is found that carbon/Kevlar and Kevlar/carbon honeycombs have significant hybrid effects compared to single-fiber honeycombs, which also reveals the hybrid mechanisms between carbon and Kevlar fibers. Furthermore, the Onyx honeycomb, lacking long fibers, exhibits brittle collapse, whereas other honeycombs show ductile collapse due to the presence of Kevlar fibers. Combining the simulation studies, the damage evolution mechanisms of honeycombs, including fiber/matrix tension and compression, shear damage, interface damage, etc., are further revealed. This work provides valuable insights into the design and failure analysis of 3D-printed hybrid fiber composite honeycombs. Full article
(This article belongs to the Special Issue 3D-Printed Composite Structures: Design, Properties and Application)
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17 pages, 3346 KiB  
Article
The Use of 3D Printing Filaments to Build Moisture Sensors in Porous Materials
by Magdalena Paśnikowska-Łukaszuk, Joanna Szulżyk-Cieplak, Magda Wlazło, Jarosław Zubrzycki, Ewa Łazuka, Arkadiusz Urzędowski and Zbigniew Suchorab
Materials 2025, 18(1), 115; https://doi.org/10.3390/ma18010115 - 30 Dec 2024
Viewed by 873
Abstract
This study explores the application of materials used in 3D printing to manufacture the housings of non-invasive sensors employed in measurements using a TDR (Time Domain Reflectometry) meter. The research investigates whether sensors designed with 3D printing technology can serve as viable alternatives [...] Read more.
This study explores the application of materials used in 3D printing to manufacture the housings of non-invasive sensors employed in measurements using a TDR (Time Domain Reflectometry) meter. The research investigates whether sensors designed with 3D printing technology can serve as viable alternatives to conventional invasive and non-invasive sensors. This study focuses on innovative approaches to designing humidity sensors, utilizing Fused Deposition Modeling (FDM) technology to create housings for non-invasive sensors compatible with TDR devices. The paper discusses the use of 3D modeling technology in sensor design, with particular emphasis on materials used in 3D printing, notably polylactic acid (PLA). Environmental factors, such as moisture in building materials, are characterized, and the need for dedicated sensor designs is highlighted. The software utilized in the 3D modeling and printing processes is also described. The Materials and Methods Section provides a detailed account of the construction process for the non-invasive sensor housing and the preparation for moisture measurement in silicate materials using the designed sensor. A prototype sensor was successfully fabricated through 3D printing. Using the designed sensor, measurements were conducted on silicate samples soaked in aqueous solutions with water absorption levels ranging from 0% to 10%. Experimental validation involved testing silicate samples with the prototype sensor to evaluate its effectiveness. The electrical permittivity of the material was calculated, and the root-mean-square error (RMSE) was determined using classical computational methods and machine learning techniques. The RMSE obtained using the classical method was 0.70. The results obtained were further analyzed using machine learning models, including Gaussian Process Regression (GPR) and Support Vector Machine (SVM). The GPR model achieved an RMSE of 0.15, while the SVM model yielded an RMSE of 0.25. These findings confirm the sensor’s effectiveness and its potential for further research and practical applications. Full article
(This article belongs to the Special Issue 3D-Printed Composite Structures: Design, Properties and Application)
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18 pages, 5494 KiB  
Article
Three-Dimensional-Printed Composite Structures: The Effect of LSCF Slurry Solid Loading, Binder, and Direct-Write Process Parameters
by Man Yang, Santosh Kumar Parupelli, Zhigang Xu and Salil Desai
Materials 2024, 17(12), 2822; https://doi.org/10.3390/ma17122822 - 10 Jun 2024
Cited by 2 | Viewed by 1160
Abstract
In this research, a direct-write 3D-printing method was utilized for the fabrication of inter-digitized solid oxide fuel cells (SOFCs) using ceramic materials. The cathode electrode was fabricated using the LSCF (La0.6Sr0.2Fe0.8Co0.2O3-δ) slurry loading [...] Read more.
In this research, a direct-write 3D-printing method was utilized for the fabrication of inter-digitized solid oxide fuel cells (SOFCs) using ceramic materials. The cathode electrode was fabricated using the LSCF (La0.6Sr0.2Fe0.8Co0.2O3-δ) slurry loading and the Polyvinyl butyral (PVB) binder. The rheological parameters of slurries with varying LSCF slurry loading and PVB binder concentration were evaluated to determine their effect on the cathode trace performance in terms of microstructure, size, and resistance. Additionally, the dimensional shrinkage of LSCF lines after sintering was investigated to realize their influence on cathode line width and height. Moreover, the effect of the direct-write process parameters such as pressure, distance between the nozzle and substrate, and speed on the cathode line dimensions and resistance was evaluated. LSCF slurry with 50% solid loading, 12% binder, and 0.2% dispersant concentration was determined to be the optimal value for the fabrication of SOFCs using the direct-write method. The direct-write process parameters, in addition to the binder and LSCF slurry concentration ratios, had a considerable impact on the microstructure of cathode lines. Based on ANOVA findings, pressure and distance had significant effects on the cathode electrode resistance. An increase in the distance between the nozzle and substrate, speed, or extrusion pressure of the direct writing process increased the resistance of the cathode lines. These findings add to the ongoing effort to refine SOFC fabrication techniques, opening the avenues for advanced performance and efficiency of SOFCs in energy applications. Full article
(This article belongs to the Special Issue 3D-Printed Composite Structures: Design, Properties and Application)
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16 pages, 4174 KiB  
Article
Comparative Life Cycle Assessment of SLS and mFFF Additive Manufacturing Techniques for the Production of a Metal Specimen
by Andrea Presciutti, Elisa Gebennini, Federica Liberti, Francesca Nanni and Mario Bragaglia
Materials 2024, 17(1), 78; https://doi.org/10.3390/ma17010078 - 23 Dec 2023
Cited by 5 | Viewed by 1976
Abstract
This work is part of a research project aimed at developing a bio-based binder, composed mainly of polylactic acid (PLA), to produce Ti6Al4V feedstock suitable for use in MAM (Metal Additive Manufacturing) via mFFF (metal Fused Filament Fabrication), in order to manufacture a [...] Read more.
This work is part of a research project aimed at developing a bio-based binder, composed mainly of polylactic acid (PLA), to produce Ti6Al4V feedstock suitable for use in MAM (Metal Additive Manufacturing) via mFFF (metal Fused Filament Fabrication), in order to manufacture a titanium alloy specimen. While in Bragaglia et al. the mechanical characteristics of this sample were analyzed, the aim used of this study is to compare the mentioned mFFF process with one of the most used MAM processes in aerospace applications, known as Selective Laser Sintering (SLS), based on the Life Cycle Assessment (LCA) method. Despite the excellent properties of the products manufactured via SLS, this 3D printing technology involves high upfront capital costs while mFFF is a cheaper process. Moreover, the mFFF process has the advantage of potentially being exported for production in microgravity or weightless environments for in-space use. Nevertheless, most scientific literature shows comparisons of the Fused Filament Fabrication (FFF) printing stage with other AM technologies, and there are no comparative LCA “Candle to Gate” studies with mFFF processes to manufacture the same metal sample. Therefore, both MAM processes are analyzed with the LCA “Candle to Gate” method, from the extraction of raw materials to the production of the finished titanium alloy sample. The main results demonstrate a higher impact (+50%) process for mFFF and higher electrical energy consumption (7.31 kWh) compared to SLS (0.32 kWh). After power consumption, the use of titanium becomes the main contributor of Global Warming Potential (GWP) and Abiotic Depletion Potential (ADP) for both processes. Finally, an alternative scenario is evaluated in which the electrical energy is exclusively generated through photovoltaics. In this case, the results show how the mFFF process develops a more sustainable outcome than SLS. Full article
(This article belongs to the Special Issue 3D-Printed Composite Structures: Design, Properties and Application)
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15 pages, 8801 KiB  
Article
Surface Texture Designs to Improve the Core–Veneer Bond Strength of Zirconia Restorations Using Digital Light Processing
by Kang Dai, Jiang Wu, Zhen Zhao, Hai Yu, Zhe Zhao and Bo Gao
Materials 2023, 16(18), 6072; https://doi.org/10.3390/ma16186072 - 5 Sep 2023
Cited by 6 | Viewed by 1778
Abstract
Veneered zirconia ceramics are widely used for dental restorations. However, the relatively poor bonding strength between the ceramic core and veneer porcelain remains a common problem in clinical applications. To address this issue, this study focused on enhancing the core–veneer bond strength of [...] Read more.
Veneered zirconia ceramics are widely used for dental restorations. However, the relatively poor bonding strength between the ceramic core and veneer porcelain remains a common problem in clinical applications. To address this issue, this study focused on enhancing the core–veneer bond strength of zirconia restorations through the implementation of surface textures using digital light processing (DLP) technology. The light intensity was precisely tuned to optimize mechanical strength and minimize light scattering. Subsequently, hexagonal or square grids were printed on the surface of the zirconia ceramic core. Following veneering procedures, the shear bond strength (SBS) test was conducted using a universal testing machine. Dates were compared using analysis of variance (ANOVA) and the least significant difference (LSD) test. Furthermore, optical microscopy and scanning electron microscopy (SEM) were used to examine the failure modes and observe the cross-sectional structures, respectively. The results indicated that the presence of a 0.09 mm high hexagon grid led to a significant 21% increase in the SBS value. However, grids with heights of 0.2 and 0.3 mm showed less improvement, owing to the formation of large defects at the interface during the fusion process. This study demonstrated the potential of DLP technology in preparing zirconia ceramics with complex structures and high mechanical strength, thereby offering promising solutions for overcoming challenges associated with dental applications. Full article
(This article belongs to the Special Issue 3D-Printed Composite Structures: Design, Properties and Application)
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Review

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32 pages, 5864 KiB  
Review
Flexible Strain Sensors Based on Printing Technology: Conductive Inks, Substrates, Printability, and Applications
by Xue Qi, Jingjing Luo, Haipeng Liu, Shuheng Fan, Zhongqi Ren, Peike Wang, Suzhu Yu and Jun Wei
Materials 2025, 18(9), 2113; https://doi.org/10.3390/ma18092113 - 4 May 2025
Viewed by 573
Abstract
Printing technology has revolutionized manufacturing by enabling high-volume, multipurpose, low-cost production with minimal environmental impact. This advancement has led to the integration of flexible electronic devices, such as displays, actuators, and sensors, into various consumer markets. Over the past few decades, printed electronics [...] Read more.
Printing technology has revolutionized manufacturing by enabling high-volume, multipurpose, low-cost production with minimal environmental impact. This advancement has led to the integration of flexible electronic devices, such as displays, actuators, and sensors, into various consumer markets. Over the past few decades, printed electronics have garnered significant interest from both academic and industrial communities. Among these, flexible strain sensors stand out due to their adaptability and potential for large-scale applications. However, a comprehensive analysis of their sensing performance, particularly with respect to printability, remains lacking. This review aims to systematically explore the development of flexible strain sensors produced through printing technology, focusing on key aspects such as the formulation of conductive inks, the use of diverse substrate materials, and the challenges associated with printability. Additionally, it delves into the practical applications of these sensors across multiple industries. By providing an in-depth examination of these factors, this review offers valuable insights into the current state of printed electronics and highlights their future potential in advancing flexible sensing technologies. Full article
(This article belongs to the Special Issue 3D-Printed Composite Structures: Design, Properties and Application)
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