Search Results (12)

This study evaluates the feasibility of 3D-printed polymer composite external fixator (EF) rings as a cost-effective alternative to stainless steel fixators, focusing on hybrid fixators for complex tibial fractures. Mechanical performance was assessed in three stages: (1) evaluating the initial EF–tibia configuration under axial loading and wire pre-tension conditions; (2) analyzing the stiffness evolution and weight-bearing capacity during early healing with progressive callus formation; and (3) optimizing ring designs through numerical analysis to improve structural performance under increased pre-tension. The results showed that, for the metallic EF, the axial displacement under one-leg stance reached 8.41 mm without pre-tension, reducing to 6.83 mm at 500 N pre-tension, though transverse displacement remained significant, suggesting the need for higher wire tension. Callus formation enhanced the load-bearing capacity, as expected. However, excessive displacements persisted under the one-leg stance, indicating that full weight-bearing should be delayed beyond two weeks for a fracture gap of 3 mm. A ring design assessment showed that full-ring configurations with two wires per ring improved performance. The 3D-printed full-ring design made of carbon-fiber-reinforced polylactic acid (PLA-CF) reduced stress by 85% at 500 N pre-tension compared to the initial configuration, remaining within allowable limits. While confirming feasibility, the study highlights the need for geometric refinements to accommodate higher preloads and improve transverse stiffness. Full article

The idea supporting the investigation of the current manuscript was to develop customized filters for air conditioners with different pore percentages and geometry with the additional advantage of presenting antibacterial performance. This property was expected due to the reinforcement of Cu nanoparticles in the polymeric matrix of poly(lactic acid) (PLA) and polyurethane (TPU). The filaments were characterized by their chemical composition, thermal and mechanical properties, and antibacterial behavior before and after processing by fused filament fabrication. An X-ray photoelectron spectroscopy showed that the nanocomposite filaments presented Cu particles at their surface in different valence states, including Cu⁰, Cu⁺, and Cu²⁺. After processing, the metallic particles are almost absent from the surface, a result confirmed by micro-computer tomography (μ-CT) characterization. Antibacterial tests were made using solid-state diffusion tests to mimic the dry environment in air conditioner filters. The tests with the nanocomposite filaments showed that bacteria proliferation was hindered. However, no antibacterial performance could be observed after processing due to the absence of the metallic element on the surface. Nevertheless, antimicrobial performance was observed when evaluated in liquid tests. Therefore, the obtained results provide valuable indications for developing new nanocomposites that must maintain their antimicrobial activity after being processed and tested in the dry conditions of solid-state diffusion. Full article

Polymer additive manufacturing has advanced from prototyping to producing essential parts with improved precision and versatility. Despite challenges like surface finish and wear resistance, new materials and metallic reinforcements in polymers have expanded its applications, enabling stronger, more durable parts for demanding industries like aerospace and structural engineering. This research investigates the tribological behaviour of FFF surfaces by integrating copper and aluminium reinforcement particles into a PLA (polylactic acid) matrix. Pin-on-disc tests were conducted to evaluate friction coefficients and wear rates. Statistical analysis was performed to study the correlation of the main process variables. The results confirmed that reinforced materials offer interesting characteristics despite their complex use, with the roughness of the fabricated parts increasing by more than 300%. This leads to an increase in the coefficient of friction, which is related to the variation in the material’s mechanical properties, as the hardness increases by more than 75% for materials reinforced with Al. Despite this, their performance is more stable, and the volume of material lost due to wear is reduced by half. These results highlight the potential of reinforced polymers to improve the performance and durability of components manufactured through additive processes. Full article

The development of multi-material filaments has enabled fused filament fabrication-based additive manufacturing to address demand for high-performance lightweight multifunctional components. In this study, polylactic acid (PLA) and acrylonitrile butadiene styrene based filaments with metallic reinforcements of magnetic iron (MI), stainless steel (SS), bronze (Br), copper (Cu), Bismuth (Bi), and Tungsten (W) were investigated to elucidate their complex processing–structure–property relationships. The microstructure of 3D-printed materials were characterized by microscopy and analyzed to determine the metal cross-sectional area percentage and the relationship between metal reinforcement, the polymer matrix, and porosity. Compression testing was conducted in directions parallel and perpendicular to the build direction in order to evaluate the effect of orientation and metal reinforcement on the mechanical properties. 3D-printed specimens experienced either fracture through print layers or layer-wise interfacial rupture for loads applied perpendicular and parallel to the print layers, respectively. A dependence of yield strength on loading orientation was observed for Br-PLA, Cu-PLA, SS-PLA, Bi-ABS, and W-ABS; however, MI-PLA and pure ABS specimens did not exhibit this sensitivity. Metal reinforcement also influenced the magnitude of compressive yield strength, with MI-PLA and SS-PLA demonstrating increased strength over Br-PLA and Cu-PLA, while ABS demonstrated increased strength over Bi-ABS and W-ABS. These results demonstrate the importance of considering orientation in printing and applications, the trade-off between various metallic reinforcements for added multifunctionality, and the potential of these tailored polymer composites for novel 3D-printed structures. Full article

This study investigates the feasibility of 3D printing continuous stainless steel fibre-reinforced polymer composites. The printing study was carried out using 316L stainless steel fibre (SSF) bundles with an approximate diameter of 0.15 mm. This bundle was composed of 90 fibres with a 14 μm diameter. This fibre bundle was first coated with polylactic acid (PLA) in order to produce a polymer-coated continuous stainless steel filament, with diameters tailored in the range from 0.5 to 0.9 mm. These filaments were then used to print composite parts using the material extrusion (MEX) technique. The SSF’s volume fraction ($V_f$) was controlled in the printed composite structures in the range from 4 to 30 $V_f$%. This was facilitated by incorporating a novel polymer pressure vent into the printer nozzle, which allowed the removal of excess polymer. This thus enabled the control of the metal fibre content within the printed composites as the print layer height was varied in the range from 0.22 to 0.48 mm. It was demonstrated that a lower layer height yielded a more homogeneous distribution of steel fibres within the PLA polymer matrix. The PLA-SSF composites were assessed to evaluate their mechanical performance, volume fraction, morphology and porosity. Composite porosities in the range of 2–21% were obtained. Mechanical testing demonstrated that the stainless steel composites exhibited a twofold increase in interlaminar shear strength (ILSS) and a fourfold increase in its tensile strength compared with the PLA-only polymer prints. When comparing the 4 and 30 $V_f$% composites, the latter exhibited a significant increase in both the tensile strength and modulus. The ILSS values obtained for the steel composites were up to 28.5 MPa, which is significantly higher than the approximately 13.8 MPa reported for glass fibre-reinforced PLA composites. Full article

The present paper aims to address the crucial concern of pollution induced by growing plastic waste and electromagnetic interference (EMI). Nanocomposites combining poly(lactic acid) (PLA) and organo-modified montmorillonite (OMMT) are synthesized and compression molded into thin films. A first set of samples, referred as virgin, was kept as is, while a second set of samples were photochemically, thermally and hydrolytically aged before mechanical recycling via extruding and second compression molding, resulting in the so-called recycled composite. The electromagnetic (EM) properties with a focus on microwave absorption performances of virgin and recycled samples are compared for various thicknesses and weight concentrations of OMMT in PLA matrix. The EM performances are gauges by Rozanov and Salisbury structures that consist in one- and two-layer stacks of composite films back-coated by a metal foil. Characterization in Rozanov configuration shows an average absorption index over the Ka band of 29.3% and 21.1% for, respectively, virgin and recycled PLA reinforced with 4 wt.% OMMT. An optimization of the film thickness is proposed; up to 61.85% and 80% of absorption with a thickness of 1.4 mm and 3.75 mm, respectively, is reached with a metal back-coated rPLA-4%OMMT film. Characterization in Salisbury configuration gives advantage to the recycled structure with an average absorption of 49.6% for a total thickness of 1.4 mm. The requirements of EMI shielding are met by PLA-OMMT composites with a certain benefit of recycling process on EM performance. Full article

Three-dimensional (3D) printing, or additive manufacturing, is a group of innovative technologies that are increasingly employed for the production of 3D objects in different fields, including pharmaceutics, engineering, agri-food and medicines. The most processed materials by 3D printing techniques (e.g., fused deposition modelling, FDM; selective laser sintering, SLS; stereolithography, SLA) are polymeric materials since they offer chemical resistance, are low cost and have easy processability. However, one main drawback of using these materials alone (e.g., polylactic acid, PLA) in the manufacturing process is related to the poor mechanical and tensile properties of the final product. To overcome these limitations, fillers can be added to the polymeric matrix during the manufacturing to act as reinforcing agents. These include inorganic or organic materials such as glass, carbon fibers, silicon, ceramic or metals. One emerging approach is the employment of natural polymers (polysaccharides and proteins) as reinforcing agents, which are extracted from plants or obtained from biomasses or agricultural/industrial wastes. The advantages of using these natural materials as fillers for 3D printing are related to their availability together with the possibility of producing printed specimens with a smaller environmental impact and higher biodegradability. Therefore, they represent a “green option” for 3D printing processing, and many studies have been published in the last year to evaluate their ability to improve the mechanical properties of 3D printed objects. The present review provides an overview of the recent literature regarding natural polymers as reinforcing agents for 3D printing. Full article

Affordable commercial desktop 3-D printers and filaments have introduced additive manufacturing to all disciplines of science and engineering. With rapid innovations in 3-D printing technology and new filament materials, material vendors are offering specialty multifunctional metal-reinforced polymers with unique properties. Studies are necessary to understand the effects of filament composition, metal reinforcements, and print parameters on microstructure and mechanical behavior. In this study, densities, metal vol%, metal cross-sectional area %, and microstructure of various metal-reinforced Polylactic Acid (PLA) filaments were characterized by multiple methods. Comparisons are made between polymer microstructures before and after printing, and the effect of printing on the metal-polymer interface adhesion has been demonstrated. Tensile response and fracture toughness as a function of metal vol% and print height was determined. Tensile and fracture toughness tests show that PLA filaments containing approximately 36 vol% of bronze or copper particles significantly reduce mechanical properties. The mechanical response of PLA with 12 and 18 vol% of magnetic iron and stainless steel particles, respectively, is similar to that of pure PLA with a slight decrease in ultimate tensile strength and fracture toughness. These results show the potential for tailoring the concentration of metal reinforcements to provide multi-functionality without sacrificing mechanical properties. Full article

In this work, the modification process of poly(lactic acid) (PLA) with metal-based nanoparticle (NPs) additives (Ag, ZnO, TiO₂) at different loading (0.5, 1.0, and 2.5 wt%) and by melt-mix extrusion method followed by film formation as one of the advantageous techniques for industrial application have been investigated. PLA nanoparticle composite films (PLA-NPs) of PLA-Ag, PLA-ZnO, PLA-TiO₂ were fabricated, allowing convenient dispersion of NPs within the PLA matrix to further pursue the challenge of investigating the surface properties of PLA-NPs reinforced plastics (as films) for the final functional properties, such as antimicrobial activity and surface mechanical properties. The main objective was to clarify how the addition of NPs to the PLA during the melt extrusion process affects the chemistry, morphology, and wettability of the surface and its further influence on the antibacterial efficiency and mechanical properties of the PLA-NPs. Therefore, the effect of Ag, ZnO, and TiO₂ NPs incorporation on the morphology (SEM), elemental mapping analysis (SEM-EDX), roughness, surface free energy (SFE) of PLA-NPs measured by goniometry and calculated by OWRK (Owens, Wendt, Rabel, and Kaelble) model was evaluated and correlated with the final functional properties such as antimicrobial activity and surface mechanical properties. The developed PLA-metal-based nanocomposites, with improved mechanical and antimicrobial surface properties, could be used as sustainable and biodegradable materials, offering desirable multifunctionalities not only for food packaging but also for cosmetics and hygiene products, as well as for broader plastic products where antimicrobial activity is desirable. Full article

The utilization of polymer-based materials is quickly expanding. The enterprises of today are progressively seeking techniques to supplant metal parts with polymer-based materials as a result of their light weight, simple support and modest costs. The ceaselessly developing requirement for composite materials with new or enhanced properties brings about the preparation of different polymer mixes with various arrangements, morphologies and properties. Fused filament fabrication processes such as 3D-printing are nowadays shaping the actual pathway to a full pallet of materials, from art–craft to biomaterials. In this study, the structural and mechanical behavior of three types of commercially available filaments comprised of synthetic poly(acrylonitrile-co-butadiene-co-styrene) (ABS), poly(lactic acid) (PLA) and poly(lactic acid)/polyhydroxyalkanoate reinforced with bamboo wood flour composite (PLA/PHA BambooFill) were assessed through mechanical testing and optical microscopy, aiming to understand how the modifications that occur in the printed models with internal architecture are influencing the mechanical properties of the 3D-printed material. It has been determined that the material printed from PLA presents the highest compression strength, three-point bending and shock resistance, while the ABS shows the best tensile strength performance. A probability plot was used to verify the normality hypothesis of data for the tensile strength, in conjunction with the Anderson–Darling statistic test. The results of the statistic indicated that the data were normally distributed and that there is a marked influence of the internal architecture of the 3D-printed models on the mechanical properties of the printed material. Full article

In order to consider 3D objects from suitable Fused Deposition Modelling (FDM) printers as prototypes for the automotive sector, this sample must be able to reproduce textural effects (sparkle or graininess) or metallic or gonio-appearance to reinforce the attractive appeal of these materials. This study worked with two different commercial filaments: grey metallic PLA (poly(lactic acid)) and ABS (acrylonitrile-butadiene-styrene copolymer) with diffractive pigments. For both materials, a statistical design of experiments (DoE) was carried out to find the printing parameters effect on the final 3D-objects gonio-appearance. The selected printing parameters were printing speed (2 levels), layer height (2 levels) and sample thickness (3 levels). Twelve smooth square objects were printed from each material. The ABS-diffractive filaments achieved the most significant flop and higher sparkle values than metallic PLA. Graininess was high when working with PLA filaments instead of ABS. Layer height was the most significant parameter to maximize PLA objects’ flop or sparkle effects. The best result was found when printing at 0.1 mm. For the ABS samples, the stronger flop and sparkle effects were achieved with the 50 mm/s printing speed, the 0.1 mm layer height and the lowest thickness level. This study shows the methodology to study the printing parameters effects and interactions to maximize the FDM-3D-objects gonio-appearance. Full article

Five Poly(lactic acid) (PLA) film samples were analyzed to study the gas barrier behavior, thermal stability and mechanical performance for food packaging application. O₂, CO₂, N₂, N₂O, and C₂H₄ pure gases; Air; and Modified Atmosphere (MA, 79% N₂O/21% O₂) were used to analyze the influence of the chemical structure, storage temperature and crystalline phase on the gas barrier behavior. The kinetic of the permeation process was investigated at different temperatures, ranging from 5 °C to 40 °C. Annealing thermal treatment on the samples led to the crystalline percentage, influencing especially the gas solubility process. Thermal properties such as T_g and χ_c, and mechanical properties such as tensile strength and modulus were remarkably improved with surface PLA modification. A more pronounced reinforcing effect was noted in the case of metallization, as well as improved gas barrier performance. Tensile testing and tensile cycling tests confirmed the rigidity of the films, with about a 20% loss of elasticity after 25 cycles loading. Full article