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3D Printing of Polymer Composite Materials—Advances in Materials and Processes

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

Deadline for manuscript submissions: 31 October 2026 | Viewed by 6072

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Special Issue Editor

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
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 rapid rate and can be credited with 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;

In recognition of your contributions to these fields, I would like to invite you to support this Special Issue by submitting a paper. This Special Issue will 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
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 250 words) can be sent to the Editorial Office for assessment.

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 (6 papers)

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Research

23 pages, 8253 KB

Open AccessArticle

Mechanical Performance of Novel 3D-Printed Symmetric Corrugated Hierarchical Honeycombs

by Derui Zhang, Junpeng Ma, Long Liu, Yan Zhu, Anfu Guo, Peng Qu, Shuai Guo, Zengrui Song, Yaqin Song and Shaoqing Wang

Polymers 2026, 18(10), 1233; https://doi.org/10.3390/polym18101233 - 18 May 2026

Viewed by 423

Abstract

Symmetric corrugated hierarchical honeycombs (SCHHs) are critical lightweight load-bearing structures, featuring distinctive topological architectures and excellent mechanical performance. However, they are prone to local buckling under out-of-plane compression and shear loading, which degrades their overall load-bearing capacity. To address this limitation, this work proposes an innovative dual-optimization strategy integrating cylindrical support structure introduction and nano-silica (SiO₂) matrix modification to synergistically enhance the compressive and tribological properties of SCHHs. 3D-printed SCHHs and their reinforced variant (SCHH-AC) with embedded cylindrical supports were fabricated, and the effects of nano-SiO₂ modification (0–9 wt.%) on the compressive performance and tribological behavior of the photopolymer resin matrix were systematically investigated. Experimental results demonstrate that the SCHH-AC-7% SiO₂ configuration achieves optimal compressive performance. A critical SiO₂ concentration threshold was identified: agglomeration at 9 wt.% induces severe mechanical degradation. Tribological tests confirm that SiO₂ incorporation effectively reduces the resin matrix’s friction coefficient and wear rate, with the 7 wt.% concentration yielding the lowest wear rate. Additionally, geometric parametric analysis reveals that increasing the corrugation period number and amplitude further enhances SCHH’s compressive strength and energy absorption. This study establishes a theoretical and experimental foundation for the structural design and material modification of lightweight honeycombs, advancing their practical application in high-performance engineering fields demanding lightweight load-bearing and wear resistance. Full article

(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials—Advances in Materials and Processes)

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22 pages, 20929 KB

Open AccessArticle

Production of Green Synthesized Zinc Oxide Nanoparticle-Reinforced PMMA-Based Photopolymer Resins on DLP-Based 3D Printers and Characterization

by Behiç Selman Erdoğdu, Muhammed İhsan Özgün, Emrah Madenci, Mehmet Ali Sayınbatur and Fatih Erci

Polymers 2026, 18(10), 1229; https://doi.org/10.3390/polym18101229 - 18 May 2026

Viewed by 490

Abstract

In this study, the structural, thermal, and mechanical properties of nanocomposites obtained by adding zinc oxide (ZnO) nanoparticles (NPs), produced by phyto-mediated synthesis using Dianthus chinensis plant extract, to a PMMA-based photopolymer resin at different ratios (0.05%, 0.10%, 0.15%, 0.20%, and 0.25%, by weight) were evaluated. The prepared composite resins were produced in different test geometries using a DLP (digital light processing)-based 3D printer (Asiga Ultra). Following the structural characterization of ZnO nanoparticles, tensile, compressive, and flexural mechanical tests were performed on the resulting composites, as well as FTIR, TGA, DSC, and DMA analyses. The FTIR results showed that ZnO NPs were physically integrated into the matrix. TGA and DSC analyses revealed that the addition of ZnO NPs, particularly at an addition rate of 0.15%, increased thermal stability. DMA analyses showed an increase in storage modulus and glass transition temperature as the addition rate increased. In mechanical tests, the highest modulus of elasticity and maximum strength values were obtained at additive ratios of 0.10–0.15%. The highest tensile strength (55.31 MPa) and compressive strength (388.53 MPa) were obtained at ZnO contents of 0.10–0.15 wt%, while the maximum flexural strength reached 125.94 MPa at 0.15 wt% ZnO. In addition, the storage modulus increased from 1.469 × 10⁹ Pa for the control resin to 1.872 × 10⁹ Pa for the composite containing 0.15 wt% ZnO, indicating improved stiffness and thermomechanical stability. The stress–strain curves show that improvements in ductility and deformation capacity of the material are achieved at these additive ratios. The findings demonstrate that green-synthesized ZnO nanoparticles are an effective and sustainable additive material for improving the mechanical and thermal performance of DLP-based photopolymer dental resins. Full article

(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials—Advances in Materials and Processes)

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27 pages, 5493 KB

Open AccessArticle

Machine Learning-Enabled Optimization and Prediction of Mechanical Properties of 3D-Printed PLA Composites Filled with Rice Husk Biochar

by Borhen Louhichi, Joy Djuansjah, P. S. Rama Sreekanth, Sundarasetty Harishbabu, P. V. Subhanjaneyulu, Santosh Kumar Sahu, It Ee Lee and Gwo Chin Chung

Polymers 2026, 18(4), 527; https://doi.org/10.3390/polym18040527 - 21 Feb 2026

Viewed by 779

Abstract

This investigation focuses on rice husk biochar (RHBC) as a sustainable filler in a polylactic acid (PLA) matrix. This study employs optimization techniques, including central composite design (CCD) and analysis of variance (ANOVA), to systematically evaluate the effects of key 3D printing parameters such as filler content (0 wt.%, 10 wt.%, 20 wt.%), nozzle temperature (190 °C, 200 °C, 210 °C), orientation angle (0°, 60°, 120°), and fill pattern (hexagon, triangle, and 3D infill). Furthermore, machine learning models are used to predict the mechanical properties of PLA/RHBC composites from experimental data. The effects of these parameters on tensile strength, Young’s modulus, and hardness were analyzed. The ANOVA results showed that filler content was the most influential factor for tensile strength and Young’s modulus, contributing 36.47% and 73.25%, respectively, compared to pure PLA. For hardness, both filler content and nozzle temperature were key contributors, with a 44.08% improvement over pure PLA. Machine learning models, including multiple linear regression (MLR), K-Nearest Neighbors (KNN), Support Vector Machine (SVM), and Gradient Boosting, were used to predict the mechanical properties. Among these, Gradient Boosting achieved the best performance, with R² values of 97.79% for tensile strength, 98.79% for Young’s modulus, and 96.8% for hardness. This study provides a robust framework that combines experimental analysis, statistical design, and machine learning to optimize RHBC as an eco-friendly filler for the development of PLA composites for adoption in the automotive, sports and aerospace industries. Full article

(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials—Advances in Materials and Processes)

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23 pages, 5287 KB

Open AccessArticle

Development and Characterization of Biodegradable Polymer Filaments for Additive Manufacturing

by Tomáš Balint, Jozef Živčák, Radovan Hudák, Marek Schnitzer, Miroslav Kohan, Maria Danko, Richard Staško, Peter Szedlák, Marek Jałbrzykowski, Katarzyna Leszczyńska, Pavol Alexy, Ivana Bírová, Zuzana Vanovčanová and Martina Culenová

Polymers 2025, 17(24), 3328; https://doi.org/10.3390/polym17243328 - 17 Dec 2025

Viewed by 1084

Abstract

In this study, the authors focus on optimizing the processing parameters for the fabrication of biodegradable polymer filaments intended for subsequent 3D printing of biomedical structures and implants. Following extrusion and additive manufacturing, the produced materials underwent a comprehensive evaluation that included mechanical, microbiological, biofilm formation, and electron microscopy analyses. The complexity of these tests aimed to determine the potential of the developed materials for biomedical applications, particularly in the field of scaffold fabrication. At the initial stage, three types of filaments (technical designations 111, 145, and 146) were produced using Fused Filament Fabrication (FFF) technology. These filaments were based on a PLA/PHB matrix with varying types and concentrations of plasticizers. Standardized destructive tensile and compressive mechanical tests were conducted using an MTS Insight 1 kN testing system equipped with an Instron 2620-601 extensometer. Among the tested samples, the filament labeled 111, composed of PLA/PHB thermoplastic starch and a plasticizer, exhibited the most favorable mechanical performance, with a Young’s modulus of elasticity of 4.63 MPa for 100% infill. The filament labeled 146 had a Young’s modulus of elasticity of 4.53 MPa for 100% infill and the material labeled 145 had a Young’s modulus of elasticity of 1.45 MPa for 100% infill. Microbiological assessments were performed to evaluate the capacity of bacteria and fungi to colonize the material surfaces. During bacterial activity assessment, we observed biofilm formation on the examined sample surfaces of each material from the smooth and rough sides. The colony-forming units (CFUs) increased directly with the exposure time. For all samples from each material, the Log10 (CFU) value reached above 9.41 during 72 h of incubation for the activity of each type of bacteria (Staphylococcus aureus, Pseudomonas aeruginosa, Candida albicans). Scanning electron microscopy provided insight into the surface quality of the material and revealed its local quality and purity. Surface defects were eliminated by this method. Overall, the results indicate that the designed biodegradable filaments, especially formulation 111, have promising properties for the development of scaffolds intended for hard tissue replacement and could also be suitable for regenerative applications in the future after achieving the desired biological properties. Full article

(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials—Advances in Materials and Processes)

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17 pages, 42728 KB

Open AccessArticle

Metamortar Composites Reinforced with Re-Entrant Auxetic Cells: Mechanical Performance and Enhanced Energy Absorption

by Jorge Fernández, César Garrido, Luis Muñoz, Felipe Nuñez, Rodrigo Valle and Víctor Tuninetti

Polymers 2025, 17(23), 3153; https://doi.org/10.3390/polym17233153 - 27 Nov 2025

Cited by 2 | Viewed by 1141

Abstract

This study investigates the mechanical behavior and energy absorption capacity of a novel metamortar composite, developed by embedding re-entrant auxetic cellular structures into a cementitious mortar matrix. Auxetic materials, which exhibit a negative Poisson’s ratio, offer distinct advantages in impact resistance and stress dissipation. Despite their promising properties, their integration into cement-based systems remains limited. In this work, auxetic cells were fabricated using different 3D printing filaments and combined with mortar to form hybrid composites. The specimens were subjected to quasi-static compression tests to evaluate their Young’s modulus, yield strength, and energy absorption capacity. Results indicate that the auxetic inclusions substantially improved the mechanical performance of the mortar, particularly in the case of PLA-based cells, which achieved the highest values across all tested parameters. The enhancements are attributed to the synergistic deformation mechanisms of the auxetic geometry and the surrounding matrix, promoting efficient load distribution and delayed crack propagation. These findings contribute to the advancement of cementitious metamaterials and establish a foundation for scaling toward metaconcrete systems with improved energy dissipation for use in protective, seismic, and infrastructure applications. Full article

(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials—Advances in Materials and Processes)

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25 pages, 7480 KB

Open AccessArticle

Structure—Property—Performance Relationships in Thermoplastic Polyurethane: Influence of Infill Density and Surface Texture

by Patricia Isabela Brăileanu, Marius-Teodor Mocanu, Tiberiu Gabriel Dobrescu, Dan Dobrotă and Nicoleta Elisabeta Pascu

Polymers 2025, 17(19), 2716; https://doi.org/10.3390/polym17192716 - 9 Oct 2025

Cited by 5 | Viewed by 1493

Abstract

This study investigates the structure–property–performance (SPP) relationships of two thermoplastic polyurethanes (TPUs), FILAFLEX FOAMY 70A and SMARTFIL^® FLEX 98A, manufactured by fused filament fabrication (FFF). Disc specimens were produced with varying gyroid infill densities (10–100%) and Archimedean surface textures, and their tribological and surface characteristics were analyzed through Ball-on-Disc tests, profilometry, and optical microscopy. SMARTFIL^® FLEX 98A exhibited a sharp reduction in the coefficient of friction (μ) with increasing infill, from 1.174 at 10% to 0.371 at 100%, linked to improved structural stability at higher densities. In contrast, FILAFLEX FOAMY 70A maintained a stable but generally higher coefficient of friction (0.585–0.729) across densities, reflecting its foamed microstructure and bulk yielding behavior. Surface analysis revealed significantly higher roughness in SMARTFIL^® FLEX 98A, while FILAFLEX FOAMY 70A showed consistent roughness across infill levels. Both TPUs resisted inducing abrasive wear on the steel counterpart, but their stress-accommodation mechanisms diverged. These findings highlight distinct application profiles: SMARTFIL^® FLEX 98A for energy-absorbing, deformable components, and FILAFLEX FOAMY 70A for applications requiring stable surface finish and low adhesive wear. The results advance the design of functionally graded TPU materials through the controlled tuning of infill and surface features. Full article

(This article belongs to the Special Issue 3D Printing of Polymer Composite Materials—Advances in Materials and Processes)

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