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Polymers
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3D Printing of Polymer Composite Materials
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3D Printing of Polymer Composite Materials

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

Deadline for manuscript submissions: 25 August 2025 | Viewed by 6849

Special Issue Editors

Prof. Dr. Fazeel Khan

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Guest Editor
Department of Mechanical and Manufacturing Engineering, Miami University, Oxford, OH, USA
Interests: 3D printing; additive manufacturing; polymer processing; biocompatible polymers; computational modeling
Prof. Dr. Richard (Chunhui) Yang

E-Mail Website
Guest Editor
School of Engineering, Design and Built Environment, Western Sydney University, Penrith, NSW 2751, Australia
Interests: additive manufacturing; advanced manufacturing; multiscale modeling and simulations of advanced engineering materials and structures; engineering numerical methods and their applications; digital material representation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing technologies for polymeric materials are continuing to evolve at a very rapid rate and can be credited for new product functionality, improved performance, reduced cost, and higher levels of sustainability. It can also be said that new additive methods have democratized manufacturing and bolstered generative design processes by enabling the table-top manufacturing of specialized components by companies of any size. A collective examination of the state of the art can, therefore, be extremely beneficial in tracking advances in additive manufacturing across a myriad of industries.

This Special Issue will assemble studies focusing on experimental and computational research pertaining to the 3D printing of polymeric materials. Relevant topics include, but are not limited to, the following:

  • Material development including composites and 4D printing using shape memory polymers;
  • Process optimization in filament, liquid, and powder-based techniques;
  • The design of target properties;
  • Processing-property effects;
  • Creation of functionally graded materials;
  • Machine learning;
  • Novel post-processing methods.

Recognition your contributions to these fields, I would like to invite you to support this Special Issue by submitting a paper. This would serve the scientific and industrial communities by presenting up-to-date research in an area of vital scientific, industrial, and environmental importance.

I look forward to receiving your contributions.

Prof. Dr. Fazeel Khan
Prof. Dr. Richard (Chunhui) Yang
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

  • 3D printing
  • additive manufacturing
  • polymer processing
  • biocompatible polymers
  • computational modeling
  • shape memory polymers

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Published Papers (5 papers)

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Research

28 pages, 8366 KiB  
Article
Artificial Neural Network Modeling of Mechanical Properties of 3D-Printed Polyamide 12 and Its Fiber-Reinforced Composites
by Catalin Fetecau, Felicia Stan and Doina Boazu
Polymers 2025, 17(5), 677; https://doi.org/10.3390/polym17050677 - 3 Mar 2025
Viewed by 767
Abstract
Fused filament fabrication (FFF) has recently emerged as a sustainable digital manufacturing technology to fabricate polymer composite parts with complex structures and minimal waste. However, FFF-printed composite parts frequently exhibit heterogeneous structures with low mechanical properties. To manufacture high-end parts with good mechanical [...] Read more.
Fused filament fabrication (FFF) has recently emerged as a sustainable digital manufacturing technology to fabricate polymer composite parts with complex structures and minimal waste. However, FFF-printed composite parts frequently exhibit heterogeneous structures with low mechanical properties. To manufacture high-end parts with good mechanical properties, advanced predictive tools are required. In this paper, Artificial Neural Network (ANN) models were developed to evaluate the mechanical properties of 3D-printed polyamide 12 (PA) and carbon fiber (CF) and glass fiber (GF) reinforced PA composites. Tensile samples were fabricated by FFF, considering two input parameters, such as printing orientation and infill density, and tested to determine the mechanical properties. Then, single- and multi-target ANN models were trained using the forward propagation Levenberg–Marquardt algorithm. Post-training performance analysis indicated that the ANN models work efficiently and accurately in predicting Young’s modulus and tensile strength of the 3D-printed PA and fiber-reinforced PA composites, with most relative errors being far less than 5%. In terms of mechanical properties, such as Young’s modulus and tensile strength, the 3D-printed composites outperform the unreinforced PA. Printing PA composites with 0° orientation and 100% infill density results in a maximum increase in Young’s modulus (up to 98% for CF/PA and 32% for GF/PA) and tensile strength (up to 36% for CF/PA and 18% for GF/PA) compared to the unreinforced PA. This study underscores the potential of the ANN models to predict the mechanical properties of 3D-printed parts, enhancing the use of 3D-printed PA composite components in structural applications. Full article
(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials)
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13 pages, 4415 KiB  
Article
Vibration Behavior of 3D-Printed Graded Composites: Fabrication and Testing
by Fazeel Khan, Kumar Singh and Justin Carter
Polymers 2024, 16(23), 3428; https://doi.org/10.3390/polym16233428 - 6 Dec 2024
Viewed by 902
Abstract
Multi-head 3D printers afford the ability to create composite structures with significant differences in properties compared to those created through traditional molding techniques. In addition to the usage of different viscoelastic polymeric materials, the selective spatial placement of the build materials enables the [...] Read more.
Multi-head 3D printers afford the ability to create composite structures with significant differences in properties compared to those created through traditional molding techniques. In addition to the usage of different viscoelastic polymeric materials, the selective spatial placement of the build materials enables the creation of layered and graded geometries to achieve specific mechanical and/or vibrational characteristics. This paper describes how the mechanical properties of the individual materials can be used to predict the damping and natural frequencies of a 3D-printed graded structure. Such structures can find usage in rotating machinery, beams, etc., where vibrational characteristics must be controlled. The simulation and experimental results are presented and two forms of the storage and loss modulus are considered: fixed and variable. For the latter condition, E′ and E″ are established as functions of temperature and frequency. Modal vibration testing of the graded samples shows a good match between the simulation and experimental trials, thereby supporting the proposed model as a useful tool for prescribing the structure of a printed part with tailored dynamic properties. Full article
(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials)
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23 pages, 10289 KiB  
Article
Optimization of Production Parameters for Impact Strength of 3D-Printed Carbon/Glass Fiber-Reinforced Nylon Composite in Critical ZX Printing Orientation
by Selim Hartomacioğlu
Polymers 2024, 16(21), 3006; https://doi.org/10.3390/polym16213006 - 26 Oct 2024
Cited by 2 | Viewed by 1726
Abstract
Additive manufacturing (AM) methods are increasingly being adopted as an alternative for mass production. In particular, Fused Deposition Modeling (FDM) technology is leading the way in this field. However, the adhesion of the layers in products produced using FDM technology is an important [...] Read more.
Additive manufacturing (AM) methods are increasingly being adopted as an alternative for mass production. In particular, Fused Deposition Modeling (FDM) technology is leading the way in this field. However, the adhesion of the layers in products produced using FDM technology is an important issue. These products are particularly vulnerable to forces acting parallel to the layers and especially to impact strength. Most products used in the industry have complex geometries and thin walls. Therefore, solid infill is often required in production, and this production must take place in the ZX orientation. This study aims to optimize the impact strength against loads acting parallel to the layers (ZX orientation) of PA6, one of the most widely used materials in the industry. This orientation is critical in terms of mechanical properties, and the mechanical characteristics are significantly lower compared to other orientations. In this study, filaments containing pure PA6 with 15% short carbon fiber and 30% glass fiber were utilized. Additionally, the printing temperature, layer thickness and heat treatment duration were used as independent variables. An L9 orthogonal array was employed for experimental design and then each experiment was repeated three times to conduct impact strength tests. Characterization, Taguchi optimization, and factor analyses were performed, followed by fracture surface characterization by SEM. As a result, the highest impact strength was achieved with pure PA6 at 8.9 kJ/m2, followed by PA6 GF30 at 8.1 kJ/m2, and the lowest impact strength was obtained with PA6 CF15 at 6.258 kJ/m2. Compared to the literature and manufacturer datasheets, it was concluded that the impact strength values had significantly increased and the chosen experimental factors and their levels, particularly nozzle temperature, were effective. Full article
(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials)
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16 pages, 16695 KiB  
Article
Characterization of PLA/LW-PLA Composite Materials Manufactured by Dual-Nozzle FDM 3D-Printing Processes
by Ye-Eun Park and Sunhee Lee
Polymers 2024, 16(20), 2852; https://doi.org/10.3390/polym16202852 - 10 Oct 2024
Cited by 2 | Viewed by 1575
Abstract
This study investigates the properties of 3D-printed composite structures made from polylactic acid (PLA) and lightweight-polylactic acid (LW-PLA) filaments using dual-nozzle fused-deposition modeling (FDM) 3D printing. Composite structures were modeled by creating three types of cubes: (i) ST4—built with a total of four [...] Read more.
This study investigates the properties of 3D-printed composite structures made from polylactic acid (PLA) and lightweight-polylactic acid (LW-PLA) filaments using dual-nozzle fused-deposition modeling (FDM) 3D printing. Composite structures were modeled by creating three types of cubes: (i) ST4—built with a total of four alternating layers of the two filaments in the z-axis, (ii) ST8—eight alternating layers of the two filaments, and (iii) CH4—a checkered pattern with four alternating divisions along the x, y, and z axes. Each composite structure was analyzed for printing time and weight, morphology, and compressive properties under varying nozzle temperatures and infill densities. Results indicated that higher nozzle temperatures (230 °C and 240 °C) activate foaming, particularly in ST4 and ST8 at 100% infill density. These structures were 103.5% larger on one side than the modeled dimensions and up to 9.25% lighter. The 100% infill density of ST4-Com-PLA/LW-PLA-240 improved toughness by 246.5% due to better pore compression. The ST4 and ST8 cubes exhibited decreased stiffness with increasing temperatures, while CH4 maintained consistent compressive properties across different conditions. This study confirmed that the characteristics of LW-PLA become more pronounced as the material is printed continuously, with ST4 showing the strongest effect, followed by ST8 and CH4. It highlights the importance of adjusting nozzle temperature and infill density to control foaming, density, and mechanical properties. Overall optimal conditions are 230 °C and 50% infill density, which provide a balance of strength and toughness for applications. Full article
(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials)
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13 pages, 5236 KiB  
Article
Three-Dimensionally Printed K-Band Radar Stealth Lightweight Material with Lotus Leaf Structure
by Chuangji Liu, Yingjie Xu, Beiqing Huang, Wan Zhang and Yuxin Wang
Polymers 2024, 16(18), 2677; https://doi.org/10.3390/polym16182677 - 23 Sep 2024
Viewed by 1251
Abstract
K-band radar waves have high penetration and low attenuation coefficients. However, the wavelength of this radar wave is relatively short; thus, designing and preparing both broadband and wide-angle radar wave absorbers in this band presents considerable challenges. In this study, a resin-based K-band [...] Read more.
K-band radar waves have high penetration and low attenuation coefficients. However, the wavelength of this radar wave is relatively short; thus, designing and preparing both broadband and wide-angle radar wave absorbers in this band presents considerable challenges. In this study, a resin-based K-band radar wave absorber with a biomimetic lotus leaf structure was designed and formed by UV curing. Here, microscale lotus leaf papillae and antireflection structures were prepared using a DLP 3D printer, and the contact angle between the material and water droplets was increased from 56° to 130°. In addition, the influence of the geometric parameters of the lotus leaf antireflection structure on the electromagnetic absorption performance and mechanical strength was investigated. After simulation optimization, the maximum electromagnetic loss of the lotus leaf structure 3D-printed sample was −32.3 dB, and the electromagnetic loss was below −10 dB in the 20.8–26.5 GHz frequency range. When the radar incidence angle was 60°, the maximum electromagnetic loss was still less than −10 dB. The designed lotus leaf structure has a higher mechanical energy absorption per unit volume (337.22 KJ/m3) and per unit mass (0.55 KJ/Kg) than commonly used honeycomb lightweight structures during the elastic deformation stage, and we expect that the designed structure can be used as an effective lightweight material for K-band radar stealth. Full article
(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials)
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