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Polymers
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Latest Research on 3D Printing of Polymer and Polymer Composites
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Latest Research on 3D Printing of Polymer and Polymer Composites

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

Deadline for manuscript submissions: 20 March 2026 | Viewed by 5379

Special Issue Editors

Dr. Carmela Borriello

E-Mail Website
Guest Editor
Nanomaterials and Devices Laboratory, Department for Sustainability, Sustainability Materials Technology and Processes, ENEA, P.le E. Fermi, 1, 80055 Portici, Italy
Interests: 3D printing materials; polymer composites and nanocomposites; thermal and structural characterization; X-ray diffraction analysis; sustainability
Dr. Sabrina Portofino

E-Mail Website
Guest Editor
Nanomaterials and Devices Laboratory, Department for Sustainability, Sustainability Materials Technology and Processes, ENEA, P.le E. Fermi, 1, 80055 Portici, Italy
Interests: innovative and sustainable polymer-based materials for AM applications; thermal technologies for polymeric composites recycling and by-products valorization

Special Issue Information

Dear Colleagues,

In recent years, the field of additive manufacturing has offered unprecedented opportunities for innovation and customization, particularly in the 3D printing of polymers and polymer composites. due to their versatility, lightweight properties, and potential for high-performance applications. As industries increasingly seek sustainable and efficient production methods, the versatility of polymers in 3D printing has made them a focal point for researchers and engineers alike. In this context, this Special Issue aims to consolidate the latest research findings, methodologies, and technological innovations that are shaping the future of this dynamic field.

The contributions in this Special Issue will explore a wide range of topics, including new printing material formulations, enhancements in printing techniques, the optimization of material properties to meet specific application needs and the integration of advanced composite materials, which is paving the way for lighter, stronger, and more durable components, crucial for sectors such as aerospace, automotive, and healthcare.

In this way, the broad perspective offered by this Special Issue will be fundamental for achieving the goal of presenting an overview of the latest advancements and breakthroughs in the rapid evolving field of 3D printing technology for polymers and polymer composites.

Dr. Carmela Borriello
Dr. Sabrina Portofino
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. 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
  • 3D printing
  • polymer
  • composites
  • material properties
  • technological innovations
  • sustainability

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Published Papers (7 papers)

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Research

19 pages, 4723 KB  
Article
Design and Effect of a Resin Infiltration Method to Enhance the Interlayer Adhesion of Additively Manufactured PEEK Parts
by Francesco Tamburrino, Beatrice Aruanno, Alessandro Paoli, Armando V. Razionale and Sandro Barone
Polymers 2025, 17(21), 2819; https://doi.org/10.3390/polym17212819 - 23 Oct 2025
Viewed by 376
Abstract
This study investigates post-processing treatments aimed at enhancing the mechanical properties of Polyether Ether Ketone (PEEK) parts fabricated via Fused Filament Fabrication (FFF). FFF-printed PEEK components often exhibit anisotropy and weak interlayer adhesion, which limit their structural performance. To address these issues, a [...] Read more.
This study investigates post-processing treatments aimed at enhancing the mechanical properties of Polyether Ether Ketone (PEEK) parts fabricated via Fused Filament Fabrication (FFF). FFF-printed PEEK components often exhibit anisotropy and weak interlayer adhesion, which limit their structural performance. To address these issues, a resin infiltration treatment is proposed that yields improvements in flexural strength and strength-to-weight ratio across specimens with different infill percentages. The effectiveness of resin infiltration is compared to that of a thermal post-processing treatment. Experimental results indicate that, although thermal treatment enhances crystallinity, it does not substantially improve interlayer bonding or mitigate anisotropy. In contrast, resin infiltration significantly enhances flexural strength, particularly in specimens with lower infill percentages, by effectively filling pores and reinforcing interlayer adhesion. Overall, the findings demonstrate that vacuum-assisted thermosetting resin infiltration is a promising post-processing technique for improving the mechanical performance of 3D-printed PEEK, achieving a mean flexural strength of up to 34 MPa, approximately 80% higher than that of untreated specimens with 100% infill. Additionally, a cost analysis comparing both post-processing methods is presented, highlighting the cost-effectiveness of resin infiltration as a viable solution to overcome the inherent limitations of FFF-printed PEEK. Full article
(This article belongs to the Special Issue Latest Research on 3D Printing of Polymer and Polymer Composites)
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20 pages, 5591 KB  
Article
Mechanical Uniaxial Compression of 3D-Printed Non-Periodic ASA Lattice Structures Using Semi-Controlled Design Models
by Nebojša Rašović, Inga Krešić and Jasmin Kaljun
Polymers 2025, 17(20), 2775; https://doi.org/10.3390/polym17202775 - 16 Oct 2025
Viewed by 419
Abstract
This work examines the mechanical behaviour of 3D-printed stochastic lattice structures fabricated using a semi-controlled design. A primary goal is to predict and optimize the mechanical response of these Acrylic Styrene Acrylonitrile (ASA) filament structures when subjected to compressive stress. By transitioning from [...] Read more.
This work examines the mechanical behaviour of 3D-printed stochastic lattice structures fabricated using a semi-controlled design. A primary goal is to predict and optimize the mechanical response of these Acrylic Styrene Acrylonitrile (ASA) filament structures when subjected to compressive stress. By transitioning from a purely stochastic method to a semi-controlled tessellation approach within Rhinoceros 7 software, we effectively generated the proposed design models. This methodology results in mechanical responses that are both predictable and reliable. The design parameters, including nodal formation, strut thickness, and lattice generation based on a predefined geometric routine, are associated with the regulation of the relative density. This approach aims to minimize the effect of relative density on the actual stiffness and strength evaluation. Our findings are cantered on the compressive testing of structures, which were generated using a Voronoi population distributed along a parabolic curve. We analyzed their mechanical response to the point of failure by examining stress–strain fluctuations. Three distinct behaviour stages are observed: elastic range, plastic range, and collapse without densification. The influence of crosslink geometry on the elastic responses was highlighted, with parabolic configurations affecting the peak stresses and elastic line slopes. The structures exhibited purely brittle behaviour, characterized by abrupt local cracking and oscillatory plateau formation in the plastic stage. Full article
(This article belongs to the Special Issue Latest Research on 3D Printing of Polymer and Polymer Composites)
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Graphical abstract

26 pages, 21665 KB  
Article
Fabrication of PLA–Date Fiber Biocomposite via Extrusion Filament Maker for 3D Printing and Its Characterization for Eco-Friendly and Sustainable Applications
by Syed Hammad Mian, Abdulrahman bin Jumah, Mustafa Saleh and Jabair Ali Mohammed
Polymers 2025, 17(19), 2707; https://doi.org/10.3390/polym17192707 - 8 Oct 2025
Viewed by 877
Abstract
Biocomposites incorporating bio-based polymers and natural fibers hold great promise due to their environmental and economic benefits, though their commercial use is still limited by production challenges. This study reports the development of polylactic acid (PLA) composite filament reinforced with 5 wt% date [...] Read more.
Biocomposites incorporating bio-based polymers and natural fibers hold great promise due to their environmental and economic benefits, though their commercial use is still limited by production challenges. This study reports the development of polylactic acid (PLA) composite filament reinforced with 5 wt% date palm fibers for fused deposition modeling (FDM)-based 3D Printing. The biocomposite is fabricated through extrusion and 3D Printing, and its mechanical, thermal, and water absorption properties are characterized in this work. Fiber dispersion is examined using a scanning electron microscope (SEM), while tensile testing evaluates yield strength, tensile strength, and elongation at break. Fracture behavior and failure mechanisms are further analyzed through optical microscopy and SEM. The biocomposite shows higher yield strength (36.75 MPa) and tensile strength (53.69 MPa), representing improvements of 10.12% and 6.53%, respectively, compared to in-house extruded pure PLA. However, it exhibits lower ductility, as indicated by reduced elongation at break. Water absorption is also higher in the biocomposite (0.58%) than in pure PLA (0.10%). Both materials display similar thermal behavior and brittle fracture characteristics. These results highlight the reinforcing effect of date palm fibers and the role of processing on the behavior/performance of the biocomposite. Reinforcing PLA with a small fraction of date palm fibers, an abundant natural resource, offers a cost-effective and eco-friendly material, particularly suited for single-use plastic products where biodegradability and sustainability are essential. This study also confirms the suitability of PLA/date palm fiber filament for FDM-based 3D Printing. Full article
(This article belongs to the Special Issue Latest Research on 3D Printing of Polymer and Polymer Composites)
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Graphical abstract

22 pages, 10034 KB  
Article
Three-Dimensionally Printed Microstructured Hydrophobic Surfaces: Morphology and Wettability
by Loredana Tammaro, Sergio Galvagno, Giuseppe Pandolfi, Fausta Loffredo, Fulvia Villani, Anna De Girolamo Del Mauro, Pierpaolo Iovane, Sabrina Portofino, Paolo Tassini and Carmela Borriello
Polymers 2025, 17(19), 2570; https://doi.org/10.3390/polym17192570 - 23 Sep 2025
Viewed by 506
Abstract
This work presents the design and fabrication of microstructured hydrophobic surfaces via fused filament fabrication (FFF) 3D printing with polylactic acid (PLA). Three geometric patterns—triangular-based prisms (TG), truncated pyramids (TP), and truncated ellipsoidal cones (CET)—were developed to modify the surface wettability. Morphological analysis [...] Read more.
This work presents the design and fabrication of microstructured hydrophobic surfaces via fused filament fabrication (FFF) 3D printing with polylactic acid (PLA). Three geometric patterns—triangular-based prisms (TG), truncated pyramids (TP), and truncated ellipsoidal cones (CET)—were developed to modify the surface wettability. Morphological analysis revealed that the printer resolution limits the accurate reproduction of sharp CAD-defined features. Despite this, TG structures exhibited superhydrophobic behavior evaluated through static water contact angles (WCAs), reaching up to 164° along the structured direction and so representing a 100% increase relative to flat PLA surfaces (WCA = 82°). To improve print fidelity, TP and CET geometries with enlarged features were introduced, resulting in contact angles up to 128°, corresponding to a 56% increase in hydrophobicity. The truncated shapes enable the fabrication of the smallest features achievable via the FFF technique, while maintaining good resolution and obtaining higher contact angles. In addition, surface functionalization with fluoropolymer-coated SiO2 nanoparticles, confirmed by SEM and Raman spectroscopy, led to a further slight enhancement in wettability up to 18% on the structured surfaces. These findings highlight the potential of FFF-based microstructuring, combined with surface treatments, for tailoring the wetting properties of 3D-printed polymeric parts with promising applications in self-cleaning, de-icing, and anti-wetting surfaces. Full article
(This article belongs to the Special Issue Latest Research on 3D Printing of Polymer and Polymer Composites)
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Graphical abstract

19 pages, 4844 KB  
Article
Electrochemical Oxidation Degradation of Methylene Blue Dye on 3D-Printed Anode Electrodes
by Claudia Cirillo, Mariagrazia Iuliano, Muhammad Shahzad, Emanuela Grazia Di Martino, Luca Gallucci, Nicola Funicello, Gerardo Iannone, Salvatore De Pasquale and Maria Sarno
Polymers 2025, 17(18), 2499; https://doi.org/10.3390/polym17182499 - 16 Sep 2025
Viewed by 714
Abstract
This study presents an innovative strategy for the electrochemical degradation of methylene blue (MB) using 3D-printed helical anode electrodes fabricated from commercially available conductive Polylactic acid/carbon black (PLA/CB) filaments. The choice of PLA/CB is particularly significant, since the amorphous PLA matrix combined with [...] Read more.
This study presents an innovative strategy for the electrochemical degradation of methylene blue (MB) using 3D-printed helical anode electrodes fabricated from commercially available conductive Polylactic acid/carbon black (PLA/CB) filaments. The choice of PLA/CB is particularly significant, since the amorphous PLA matrix combined with a percolating carbon black network provides a biodegradable, low-cost, and chemically versatile polymer composite that can be transformed from a simple prototyping filament into a functional electrochemical platform. Through a combination of chemical/electrochemical activation and electrodeposition of copper nanoparticles (Cu NPs), the polymer electrodes were successfully converted into highly efficient catalytic platforms. Beyond material functionalization, the influence of electrode geometry was systematically investigated, comparing single-, double-, and triple-spiral helical configurations. The double-spiral geometry proved the most effective, offering the best balance between active surface area and electrolyte flow dynamics. Under mild conditions (2 V, pH 6, 0.1 M NaCl), the system achieved up to 97% MB removal, while also demonstrating remarkable stability and reusability over at least ten consecutive cycles. These results highlight the synergistic role of polymer chemistry, arrangement, and metal decoration, demonstrating how 3D printing can be a useful platform for the easy production of electrodes with different geometries, even starting from simple conductive filaments reused in sustainable and scalable functional materials for advanced wastewater treatment. Full article
(This article belongs to the Special Issue Latest Research on 3D Printing of Polymer and Polymer Composites)
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Graphical abstract

21 pages, 13165 KB  
Article
Experimental Study of Photopolymer Resin Composition for AlN Ceramic 3D Printing via Digital Light Processing
by Ning Kuang, Yifan Liu, Wenjie Zhao and Junfei Wu
Polymers 2025, 17(17), 2344; https://doi.org/10.3390/polym17172344 - 29 Aug 2025
Cited by 1 | Viewed by 942
Abstract
Aluminum nitride (AlN) ceramics exhibit exceptional properties that render them highly valuable for diverse industrial applications. However, conventional manufacturing techniques encounter significant challenges in fabricating complex AlN components with precise geometries. To address these limitations, digital light processing (DLP) has emerged as a [...] Read more.
Aluminum nitride (AlN) ceramics exhibit exceptional properties that render them highly valuable for diverse industrial applications. However, conventional manufacturing techniques encounter significant challenges in fabricating complex AlN components with precise geometries. To address these limitations, digital light processing (DLP) has emerged as a promising additive manufacturing approach for AlN ceramics. This study presents a systematic investigation of the monomer composition in the photopolymer resin system through a comprehensive experimental evaluation. The results demonstrate that an optimized mixture of monomers ACMO (56.7 wt%), DEGDA (2.7 wt%), and TMPTA (40.6 wt%) yields photopolymer resin with superior comprehensive performance. Utilizing this optimized formulation, a 50 vol% solid loading AlN ceramic slurry was successfully prepared, and subsequently, dense AlN ceramic components were fabricated through DLP. This provides an important basis for optimizing the slurry preparation of AlN ceramic fabrication based on DLP 3D printing. Full article
(This article belongs to the Special Issue Latest Research on 3D Printing of Polymer and Polymer Composites)
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24 pages, 1844 KB  
Article
Strategic Framework for Additive Manufacturing with Smart Polymer Composites: A Pathway to Net-Zero Manufacturing
by Alok Yadav, Rajiv Kumar Garg, Anish Sachdeva, Karishma M. Qureshi and Mohamed Rafik Noor Mohamed Qureshi
Polymers 2025, 17(10), 1336; https://doi.org/10.3390/polym17101336 - 14 May 2025
Cited by 3 | Viewed by 1014
Abstract
Despite manufacturing firms recognizing the potential benefits of polymer-based smart materials (PBSM) in additive manufacturing (AM), their large-scale integration remains limited. As manufacturing firms strive toward net-zero emissions (NZE) and sustainable manufacturing, integrating PBSM into AM could be pivotal for manufacturing firms striving [...] Read more.
Despite manufacturing firms recognizing the potential benefits of polymer-based smart materials (PBSM) in additive manufacturing (AM), their large-scale integration remains limited. As manufacturing firms strive toward net-zero emissions (NZE) and sustainable manufacturing, integrating PBSM into AM could be pivotal for manufacturing firms striving to achieve NZE and more sustainable production. In this regard, this study uses a mixed-method approach: a systematic literature review (SLR) to address the current trends and critical challenges associated with the “development, processing, and scalability” of PBSM adoption for AM. Further, the study analyzes 100 responses from Indian manufacturing firms, employing exploratory factor analysis (EFA) to develop a framework. This framework is further validated by determining the priority order of challenges using the Combined Compromise Solution (CoCoSo) through a case study. The outcome highlights that end-of-life management and lack of standardization are the most critical challenges for manufacturing firms, restricting the adoption of PBSM for AM. This research provides valuable insights for industry professionals and academia, guiding a strategic roadmap toward net-zero manufacturing. With this transformation, industries can align with global net-zero targets and contribute to India’s net-zero economy (NZE) goal by 2070. Full article
(This article belongs to the Special Issue Latest Research on 3D Printing of Polymer and Polymer Composites)
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