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Polymer Materials for Application in Additive Manufacturing, 2nd Edition

A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Polymer Processing and Engineering".

Deadline for manuscript submissions: 30 September 2026 | Viewed by 2142

Special Issue Editor


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Guest Editor
ABB Corporate Technology Center, 31-038 Kraków, Poland
Interests: thin films and nanotechnology; material characterization; materials; nanomaterials; solar cells; thin film deposition; advanced materials ;conducting polymers hybrid materials; carbon nanomaterials
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Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) has been a promising technology in various applications, including aeronautics, civil engineering, automotive engineering, and medicine. Compared to traditional subtractive manufacturing, AM enables the automatic fabrication of products or functional components with complex shapes at a low manufacturing cost. Various commercially available AM methods include fused deposition modeling (FDM), inkjet printing (IP), selective laser sintering (SLS), laminated object manufacturing (LOM), and stereolithography (STL). AM solutions are available for several materials, including metals, alloys, ceramics, and polymers. Due to the low cost of fabrication, the use of polymers can vary between cheap substitutes of natural products and high-quality products for many resource-based applications. AM provides a viable manufacturing solution for polymer-based products with a reduced fabrication time and cost. In addition to the many advantages of using polymers as one of the primary AM materials, there are also shortcomings related to the topology, strength, microstructure, bonding, and functionality of polymer-based structures. The particular features, properties, and limitations of polymers in the various AM technologies also vary. The manufacturing and fabrication of components using polymers with sandwich-structured specimens with different material combinations are also growing research areas.

This Special Issue of Polymers aims to cover the state of the art of polymer-based materials in additive manufacturing, with a special emphasis on novel functional polymers. Furthermore, perspectives and critical reviews on current limitations, future directions, and emerging applications in the field are welcome.

Dr. Andrzej Rybak
Guest Editor

Manuscript Submission Information

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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. Polymers 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 2700 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

  • additive manufacturing
  • fused deposition modeling (FDM)
  • fiber reinforcement
  • filament improvement
  • functional materials
  • three-dimensional printing technologies
  • structural design

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Published Papers (2 papers)

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21 pages, 13356 KB  
Article
In Situ Casting Integrated with FDM 3D Printing: Curing Behavior, Process Constraints, and Mechanical Demonstration
by Supatpromrungsee Saetia, Pimolkan Piankitrungreang and Ratchatin Chancharoen
Polymers 2026, 18(8), 1003; https://doi.org/10.3390/polym18081003 - 21 Apr 2026
Viewed by 663
Abstract
Dispensing-based in situ casting offers a practical route for introducing dense or mechanically distinct polymer regions into fused deposition modeling (FDM) parts during fabrication. This study investigates the curing-dependent process constraints governing stable integration of in situ casting within an FDM workflow. In [...] Read more.
Dispensing-based in situ casting offers a practical route for introducing dense or mechanically distinct polymer regions into fused deposition modeling (FDM) parts during fabrication. This study investigates the curing-dependent process constraints governing stable integration of in situ casting within an FDM workflow. In the proposed process, FDM is used to fabricate thermoplastic confinement geometries, after which liquid polymer is dispensed into selected cavities and cured before printing resumes. Two representative curing systems were examined: a UV-curable photopolymer and a two-component epoxy resin. The experimental program included UV curing characterization under perpendicular 405 nm exposure, infrared thermal imaging of curing-induced heat generation and dissipation, confined curing of epoxy resin, layer-wise integration within an FDM-printed cavity, and a representative mechanical linkage demonstration. The results show that UV-based in situ casting is constrained by the coupled effects of curing depth, peak temperature, and visible deformation, making staged curing with intermediate thermal relaxation necessary for stable operation. In contrast, the epoxy system enabled bulk cavity filling with lower peak temperature, but required substantially longer curing time, introducing a different process limitation. A layer-wise UV curing strategy enabled successful stacking of four cast layers within an FDM-printed confinement without visible leakage or shell collapse. Mechanical testing of hybrid linkage specimens further showed that localized casting can modify structural stiffness through selective reinforcement. These findings demonstrate that dispensing-based in situ casting can be integrated into FDM when thermal, temporal, and filling constraints are explicitly managed, and they provide practical process guidance for hybrid polymer fabrication involving confined casting during printing. Full article
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19 pages, 5123 KB  
Article
Additive Manufacturing of a PA11 Prototype Fabricated via Selective Laser Sintering for Advanced Industrial Applications
by Giovanna Colucci, Domenico Riccardi, Alberto Giubilini and Massimo Messori
Polymers 2025, 17(23), 3111; https://doi.org/10.3390/polym17233111 - 24 Nov 2025
Cited by 2 | Viewed by 1095
Abstract
Selective Laser Sintering (SLS) is an Additive Manufacturing (AM) technology that is receiving considerable attention in the scientific and industrial communities due to its great ability to efficiently produce functional and complex parts. The present work aims to fabricate a real prototype via [...] Read more.
Selective Laser Sintering (SLS) is an Additive Manufacturing (AM) technology that is receiving considerable attention in the scientific and industrial communities due to its great ability to efficiently produce functional and complex parts. The present work aims to fabricate a real prototype via SLS, such as a hose reel for industrial applications, using polyamide 11 (PA11) as a starting material. Characterization of the PA11 powder properties was first carried out from a thermal and morphological viewpoint to determine the powder’s thermal stability by TGA, the sintering window and degree of crystallinity by DSC, and the microstructure by SEM, PSD, and XRD analyses. The results revealed that PA11 has a 45-micron average particle size, circularity close to 1, and a Hausner ratio of 1.17. Together, these parameters ensure that PA11 powder flows smoothly, packs uniformly, and forms dense and defect-free layers during the SLS process, directly contributing to high part quality, dimensional precision, and stable process performance. The printability of the PA11 was optimized for the realization of 3D-printed parts for industrial applications. Finally, the quality of the printed samples and the mechanical and thermal performance were investigated. Several PA11-based parts were fabricated via SLS, showing a high level of complexity and definition, ideal for industrial applications, as confirmed by the predominantly green areas of the colored maps of X-CT. A complete prototypal case for a hose reel was assembled by using the parts realized, and it was chosen as a technological demonstrator to verify the feasibility of PA11 powder in the production of industrial professional components. Full article
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