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Polymer Materials for Application in Additive Manufacturing
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Polymer Materials for Application in Additive Manufacturing

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

Deadline for manuscript submissions: 20 August 2025 | Viewed by 6414

Special Issue Editor

Dr. Andrzej Rybak

E-Mail Website1 Website2
Guest Editor
ABB Corporate Technology Center, 31-038 Kraków, Poland
Interests: thin films and nanotechnology material characterization; solar cells; thin film deposition advanced materials; conducting polymers hybrid materials; carbon nanomaterials
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) has been a promising technology in various applications such as 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. Further, perspectives and critical reviews about the current limitations as well as the future directions and emerging applications in the field are welcome.

Dr. Andrzej Rybak
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 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
  • fused deposition modeling (FDM)
  • fiber reinforcement
  • filament improvement
  • functional materials
  • three-dimensional printing technologies
  • structural design

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Published Papers (6 papers)

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Research

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16 pages, 4184 KiB  
Article
Low Shrinkage Transparent UV-Cured 3D Printing Hard Silicone Resins
by Haibo Wu, Qili Shen, Zhu Liu, Xiantai Zhou, Yanxiong Fang, Hongping Xiang and Xiaoxuan Liu
Polymers 2025, 17(8), 1123; https://doi.org/10.3390/polym17081123 - 21 Apr 2025
Viewed by 201
Abstract
Acrylated silicone elastomers for UV-curing 3D printing have gathered considerable attention in biomedical applications due to their exceptional mechanical and thermal stability. However, traditional manufacturing methods for these resins often face challenges such as stringent conditions and self-polymerization. In this study, various acrylate [...] Read more.
Acrylated silicone elastomers for UV-curing 3D printing have gathered considerable attention in biomedical applications due to their exceptional mechanical and thermal stability. However, traditional manufacturing methods for these resins often face challenges such as stringent conditions and self-polymerization. In this study, various acrylate silicone resins (LMDT-AE) and silicone oils (PDMS-AE) were synthesized through ring-opening hydrolysis-polycondensation. The structures of LMDT-AE and PDMS-AE, with varying AE contents (molar ratio of organic groups to silicon atoms), were characterized using FTIR, 1H NMR, 13C NMR, and GPC. Additionally, their physical properties, including viscosity, density, refractive index, and transparency, were thoroughly examined. The 3D-AE silicone resin composed of LMDT-AE-2.0 and PDMS-AE-20/1, in a mass ratio of 2:1, demonstrated superior mechanical properties, thermal stability, and curing shrinkage rate compared to other formulations. This curing silicone resin is capable of producing 3D physical entities with smooth surfaces and well-defined contours. It is shown that the successful preparation of transparent and high-strength UV-cured silicone resin based on free radical polymerization can provide a potential path for high-precision biological 3D printing. Full article
(This article belongs to the Special Issue Polymer Materials for Application in Additive Manufacturing)
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16 pages, 5593 KiB  
Article
Geometric Accuracy and Dimensional Precision in 3D Printing-Based Gear Manufacturing: A Study on Interchangeability and Forming Precision
by Xiaofeng Wei, Siwei Zhang, Lingli Sun, Xinyu Zhao, Mengchen Sun, Run Yu, Xingwen Zhou and Yuhang Li
Polymers 2025, 17(3), 416; https://doi.org/10.3390/polym17030416 - 4 Feb 2025
Viewed by 918
Abstract
This paper investigates the geometric interchangeability and dimensional precision of parts fabricated using Fused Deposition Modeling (FDM), with a focus on gear manufacturing. By employing a substrate and two spur gears as test components, critical process parameters, including layer thickness, extrusion speed, and [...] Read more.
This paper investigates the geometric interchangeability and dimensional precision of parts fabricated using Fused Deposition Modeling (FDM), with a focus on gear manufacturing. By employing a substrate and two spur gears as test components, critical process parameters, including layer thickness, extrusion speed, and print temperature, were optimized to achieve enhanced accuracy. Geometric and dimensional tolerances such as straightness, roundness, and surface roughness were systematically evaluated using advanced metrological techniques. The results indicate that larger components demonstrate higher precision, with deviations for large and pinion gears ranging between −0.045 and 0.060 mm, and −0.150 and 0.078 mm, respectively. Analysis reveals that the anisotropic nature of the FDM process and thermal shrinkage significantly impact accuracy, particularly in smaller features. Residual stress analysis reveals that smaller components formed via FDM exhibit higher stress concentrations and dimensional deviations due to voids and uneven thermal contraction, whereas larger components and flat substrates achieve better stress distribution and precision. The findings suggest that reducing material shrinkage coefficients and optimizing process parameters can enhance part quality, achieving dimensional tolerances within ±0.1 mm and geometric consistency suitable for practical applications. This research highlights the potential of FDM for precision manufacturing and provides insights into improving its performance for high-demand industrial applications. Full article
(This article belongs to the Special Issue Polymer Materials for Application in Additive Manufacturing)
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20 pages, 6614 KiB  
Article
3D Printing of Virucidal Polymer Nanocomposites (PLA/Copper Nanoparticles)
by Waldeir Silva Dias, Luana Cristiny da Cruz Demosthenes, João Carlos Martins da Costa, Leandro Aparecido Pocrifka, Nayra Reis do Nascimento, Samantha Coelho Pinheiro, Gilberto Garcia del Pino, José Luis Valin Rivera, Meylí Valin Fernández and José Costa de Macêdo Neto
Polymers 2025, 17(3), 283; https://doi.org/10.3390/polym17030283 - 22 Jan 2025
Viewed by 927
Abstract
Metallic nanoparticles with virucidal properties dispersed in a polymeric matrix have gained prominence in the scientific community as a rapid and effective alternative that employs the additive manufacturing (AM) or 3D printing method. This study aims to produce filaments for 3D printing using [...] Read more.
Metallic nanoparticles with virucidal properties dispersed in a polymeric matrix have gained prominence in the scientific community as a rapid and effective alternative that employs the additive manufacturing (AM) or 3D printing method. This study aims to produce filaments for 3D printing using polymer nanocomposites based on polylactic acid (PLA) and copper nanoparticles (CuNPs) in different proportions. The virucidal activity of various proportions of nanoparticles in PLA was investigated. The composites were produced following a mixture design (DOE) with concentrations ranging from 1% to 2% copper nanoparticles, which were blended with PLA using a single-screw extruder. The samples were characterized by thermogravimetry (TG), differential scanning calorimetry (DSC), tensile strength testing, and fracture analysis using scanning electron microscopy (SEM). A thermal analysis of the composites indicated that the CuNPs contributed to an increase in the degradation temperature and crystallization of the PLA. Sample S7 (1.25% of CuNPs) exhibited a 4% increase in the degradation temperature compared to pure PLA. The best tensile strength results were observed in sample S7 (1.25% of CuNPs), 30% more than sample S3 (1.33% of CuNPs) due to good material cohesion, as evidenced by microscopy analyses. Regarding virucidal analyses, most composites demonstrated virus inhibition activity. Full article
(This article belongs to the Special Issue Polymer Materials for Application in Additive Manufacturing)
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21 pages, 5628 KiB  
Article
Towards Photocrosslinkable Lyotropic Blends of Organosolv Lignin and Hydroxypropyl Cellulose for 3D Printing by Direct Ink Writing
by Mehmet-Talha Yapa, Jacques Lalevée and Marie-Pierre Laborie
Polymers 2024, 16(20), 2869; https://doi.org/10.3390/polym16202869 - 10 Oct 2024
Cited by 1 | Viewed by 1628
Abstract
Polymer blends containing up to 70% organosolv lignin content and lyotropic cellulose derivatives have been established as “lignin inks” for direct ink writing of fully biobased 3D parts. However, a fast-crosslinking mechanism is needed to improve throughput and design space. In this paper, [...] Read more.
Polymer blends containing up to 70% organosolv lignin content and lyotropic cellulose derivatives have been established as “lignin inks” for direct ink writing of fully biobased 3D parts. However, a fast-crosslinking mechanism is needed to improve throughput and design space. In this paper, UV-photocrosslinkable organosolv lignin/hydroxypropyl cellulose inks are formulated through doping with common photocrosslinkers. The most potent photocrosslinkers for neat hydroxypropyl cellulose, lignin and their blends are determined through a series of DOEs. Hydroxypropyl cellulose is significantly more amenable to photocrosslinking than organosolv lignin. The optimal photocrosslinkable ink formulations are printable and exhibit up to 70% gel content, although thermal post-curing remains essential. Chemical, thermal, and mechanical investigations of the photocrosslinked 3D parts evidence efficient crosslinking of HPC through its hydroxyl groups, while lignin appears internally plasticized and/or degraded during inefficient photocrosslinking. Despite this, photocrosslinkable inks exhibit improved tensile properties, shape flexibility, and fidelity. The heterogeneous crosslinking and residual creep highlight the need to further activate lignin for homogeneous photocrosslinking in order to fully exploit the potential of lignin inks in DIW. Full article
(This article belongs to the Special Issue Polymer Materials for Application in Additive Manufacturing)
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20 pages, 6692 KiB  
Article
Three-Dimensionally Printed Ternary Composites of Polyamide: Effect of Gradient Structure on Dimensional Stability and Mechanical Properties
by Qiming Chen, Zewei Cai, Dhandapani Kuzhandaivel, Xianliang Lin, Jianlei Wang and Suyu Chen
Polymers 2024, 16(19), 2697; https://doi.org/10.3390/polym16192697 - 24 Sep 2024
Viewed by 1158
Abstract
Fused deposition modeling (FDM) 3D printing has the advantages of a simple molding principle, convenient operation, and low cost, making it suitable for the production and fabrication of complex structural parts. Moving forward to mass production using 3D printing, the major hurdle to [...] Read more.
Fused deposition modeling (FDM) 3D printing has the advantages of a simple molding principle, convenient operation, and low cost, making it suitable for the production and fabrication of complex structural parts. Moving forward to mass production using 3D printing, the major hurdle to overcome is the achievement of high dimensional stability and adequate mechanical properties. In particular, engineering plastics require precise dimensional accuracy. In this study, we overcame the issues of FDM 3D printing in terms of ternary material compounds for polyamides with gradient structures. Using multi-walled carbon nanotubes (MWCNTs) and boron nitride (BN) as fillers, polyamide 6 (PA6)-based 3D-printed parts with high dimensional stability were prepared using a single-nozzle, two-component composite fused deposition modeling (FDM) 3D printing technology to construct a gradient structure. The ternary composites were characterized via DSC and XRD to determine the optimal crystallinity. The warpage and shrinkage of the printed samples were measured to ensure the dimensional properties. The mechanical properties were analyzed to determine the influence of the gradient structures on the composites. The experimental results show that the warpage of pure polymer 3D-printed parts is as high as 72.64%, and the introduction of a gradient structure can reduce the warpage to 3.40% by offsetting the shrinkage internal stress between layers. In addition, the tensile strength of the gradient material reaches up to 42.91 MPa, and the increasing filler content improves the interlayer bonding of the composites, with the bending strength reaching up to 60.91 MPa and the interlayer shear strength reaching up to 10.23 MPa. Therefore, gradient structure design can be used to produce PA6 3D-printed composites with high dimensional stability without sacrificing the mechanical properties of PA6 composites. Full article
(This article belongs to the Special Issue Polymer Materials for Application in Additive Manufacturing)
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Review

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19 pages, 7063 KiB  
Review
Application of 3D Printing Technology in Dentistry: A Review
by Yangqing Chen and Junchao Wei
Polymers 2025, 17(7), 886; https://doi.org/10.3390/polym17070886 - 26 Mar 2025
Viewed by 1088
Abstract
Three-dimensional (3D) printing is a cutting-edge technology that is widely used in biomedical fields to construct various commercial products or scaffolds for theoretical research. In this review, 3D printing technologies with different principles are briefly introduced, including selective laser melting (SLM), selective laser [...] Read more.
Three-dimensional (3D) printing is a cutting-edge technology that is widely used in biomedical fields to construct various commercial products or scaffolds for theoretical research. In this review, 3D printing technologies with different principles are briefly introduced, including selective laser melting (SLM), selective laser sintering (SLS), fused deposition modeling (FDM), stereolithography (SLA), and digital light processing (DLP). In addition, the applications of 3D printing in dentistry, such as dental implantology, prosthodontics, orthodontics, maxillofacial surgery, and dental tissue regeneration, were summarized. Furthermore, the perspective and challenges of 3D printing were also addressed to help the readers obtain a clear map for the development of 3D printing in dentistry. Full article
(This article belongs to the Special Issue Polymer Materials for Application in Additive Manufacturing)
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