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

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

Deadline for manuscript submissions: 31 March 2026 | Viewed by 620

Special Issue Editor


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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 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 (1 paper)

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Research

25 pages, 7480 KB  
Article
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
Viewed by 488
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 [...] Read more.
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
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