Search Results (1,725)

Advances in additive manufacturing have accelerated the development of 3D-printed dental resin composites. These materials contain a higher proportion of organic matrix and less filler than light-cured representatives, which may affect their behavior in the oral environment. This study aimed to evaluate the biological and chemical properties of 3D-printed dental resin composites before and after artificial aging, and to compare them with the light-cured representative. Specimens from a light-cured composite (Omnichroma—OMCR) and two 3D-printed composites (GT Temp PRINT—GTPR; SprintRay CROWN—SPRY) were subjected to aging treatments: unaged (T0) or thermocycled for 5000 (T1) and 10,000 cycles (T2). Biological evaluation was performed using MTT assay and Live/Dead cell fluorescence microscopy using human gingival fibroblasts, whereas Raman spectroscopy analysed materials’ structural changes. Materials exhibited good biocompatibility (>70% cell viability), with OMCR displaying greater variability. OMCR was more susceptible to chemical degradation under thermal stresses than both 3D-printed materials. Tested 3D-printed composites can provide comparable or even superior biological and chemical properties compared to light-cured representative, likely due to optimized resin formulations and post-curing protocols that improve polymer network organization and reduce residual monomer release. These findings support the potential of tested 3D-printed composites for manufacturing dental restorations. Full article

With the increasing demand for high-energy-density lithium batteries, the role of separators has expanded significantly beyond conventional ion conduction and physical isolation. By integrating sensors and introducing functional coatings, separators have gained the ability to monitor internal states in real time and achieve adaptive regulation. This paper systematically reviews the latest research progress on separators modified with functional materials and coatings to achieve information sensing, intelligent response, and multifunctional integration. Notably, an electrochemical sensor based on MXene/MWCNTs-COOH/MOF-808 has been developed for rapid chemical detection; a fully printed ultra-thin flexible multifunctional sensor array has enabled multi-parameter synchronous monitoring; an ion-selective MOF-808-EDTA separator has induced uniform lithium-ion flux; and a PVDF-HFP/LLZTO/PVDF-HFP trilayer separator has maintained structural integrity at 300 °C. These innovative achievements fully demonstrate the enormous potential of intelligent separators in monitoring internal battery states, inhibiting dendrite growth, preventing thermal runaway, and significantly enhancing battery safety, cycle life, and energy density. This points to a transformative development path for the next generation of batteries with higher safety and intelligence. Full article

Brilliant blue, as a pigment food additive, has all the characteristics of printing and dyeing wastewater and belongs to persistent and refractory organic compounds. The photocatalysis–Fenton reaction system consists of two parts: photocatalytic reaction and Fenton reaction. Electrons promote the decomposition of H₂O₂ to produce •OH. In addition, the effective separation of e- and h⁺ by light strengthens the direct oxidation of h⁺, and h⁺ reacts directly with OH⁻ to produce •OH, which can further promote the removal of organic pollutants. In this paper, g-C₃N₄ and Fe/g-C₃N₄ photocatalysts were prepared by the thermal polycondensation method. Fe/g-C₃N₄ of 15 wt% can reach 98.59% under the best degradation environment, and the degradation rate of g-C₃N₄ is only 7.6% under the same conditions. The photocatalytic activity of the catalysts was further studied. Through active species capture experiments, it is known that •OH and •O₂⁻ are the main active species in the system, and the action intensity of •OH is greater than that of •O₂⁻. The degradation reaction mechanism is that H₂O₂ combines with Fe²⁺ in Fe/g-C₃N₄ to generate a large amount of •OH and Fe³⁺, and the combination of Fe-N bonds accelerates the cycle of Fe³⁺/Fe²⁺ and promotes the formation of •OH, thereby accelerating the degradation of target pollutants. •O₂⁻ can reduce Fe³⁺ to Fe²⁺, Fe²⁺ reacts with H₂O₂ to produce •OH, which promotes degradation, and •O₂⁻ itself also plays a role in degradation. In addition, under the optimal experimental conditions obtained by response surface experiments, the fitting degree of first-order reaction kinetics is 0.96642, and the fitting degree of second-order reaction kinetics is 0.57884. Therefore, this reaction is more in line with first-order reaction kinetics. The adsorption rate is only proportional to the concentration of Fe/g-C₃N₄. Full article

Fused filament fabrication of thermoplastic composites, despite its recyclability, increased strength, and efficiency, faces structural limitations under elevated temperatures. The literature on heat treatments for improving the thermal resilience of accessible 3D printed composites is limited. Therefore, this study comprehensively presents the efficacy of annealing on carbon fiber reinforced polyamide (PAHT-CF). The methodology includes uniaxial tensile testing of 200 samples across a wide temperature range (25–150 °C) and five different infill orientations, annealed as per the Technical Data Sheet (80 °C, 12 h). Scanning electron microscopy (SEM) of the fracture surfaces revealed the microstructural changes responsible for the improved properties after annealing. At 25 °C, annealing led to a 50% strength increase (63.88 MPa) and a 70% lower strain (2.65%). At 150 °C, the material maintained a 17.5% strength advantage (23.62 MPa) and a 17.5% reduction in strain (12.67%). The 0°, 90°, and 0/90° orientations exhibited the highest improvements, while the remainder displayed lower strengths and higher deformation beyond the glass transition temperature (70 °C). Overall, annealed PAHT-CF demonstrates high-temperature resilience, comparable to previously analyzed materials like carbon fiber reinforced polyether–ether–ketone (PEEK-CF). This makes it a potentially accessible alternative for the aerospace and automotive sectors. However, practical applications must consider the trade-off between its enhanced mechanical properties and the increased lead time from annealing. Full article

This study develops and validates a weft knitted Mini-Jacquard in Peruvian Pima cotton as a print-free coloration strategy by integrating CAD-based pattern simulation with prototype manufacturing. A three-color design (red, blue, white) was programmed on a flat knitting machine using a 10 × 14 rapport. Color-wise yarn consumption was computed directly from the digital pattern, and the physical sample was characterized through combustion testing and optical micrographs. The prototype exhibited a yarn count of ~20/1 Ne, S-twist (~11.18 TPI), and 100% cellulosic composition. The blue yarn showed the highest consumption (≈73.81%), followed by white (≈19.65%) and red (≈6.55%), consistent with the digital rapport’s color distribution. The CAD stage ensured pattern fidelity and supported raw-material planning; the knitted sample showed a soft hand, dimensional stability, and sharp motif definition upon visual assessment. A sustainability and comparative analysis with chemical printing was conducted, revealing that the Mini-Jacquard achieved the highest design accuracy and tactile comfort, outperforming screen printing and heat transfer in geometric fidelity, chromatic homogeneity, and texture. The Mini-Jacquard optimized operational times (320 min/m²) compared to transfer printing (332 min/m²) and screen printing (740 min/m²), reducing process stages and complexity. Although Jacquard production involves higher energy costs ($34.8) and material expenses ($11.6), it provides greater structural value and durability, positioning it for high-end applications. Moreover, the Mini-Jacquard could reduce water consumption by approximately 90% and thermal energy use by 70%, eliminating chemical residues and extending fabric lifespan, thus offering high sustainability and circular potential. A transparent scenario-based analysis indicates substantial reductions in water and thermal-energy use when omitting printing/fixation/washing stages, along with the elimination of printing-stage effluents. Overall, design-integrated coloration via Mini-Jacquard is technically feasible and potentially eco-efficient for Pima-cotton value chains, with applications in apparel, accessories, and functional textiles. Full article

Large-format additive manufacturing (LFAM) is an enabling manufacturing technology capable of producing large parts with highly complex geometries for a wide variety of applications, including automotive, infrastructure/construction, and aerospace mold and tooling. In the past decade, the LFAM industry has seen widespread use of bio-based, glass, and/or carbon fiber reinforced thermoplastic composites which, when printed, serve as a lower-cost alternative to metallic parts. One of the highest-volume materials utilized by the industry is carbon fiber (CF)-filled polycarbonate (PC), which in out-of-autoclave applications can achieve comparable mechanical performance to metal at a significantly lower cost. Previous work has shown that if this material is recovered at various points throughout the manufacturing process for both the lab and pilot scale, it can be mechanically recycled with minimal impacts on the functional performance and printability of the material while significantly reducing the feedstock costs. End-of-life (EOL) CF-PC components were processed through industrial shredding, melt compounding, and LFAM equipment, followed by evaluation of the second-life material properties. Experimental assessments included quantitative analysis of fiber length attrition, polymer molecular weight degradation using gel permeation chromatography (GPC), density changes via pycnometry, thermal performance using dynamic mechanical analysis (DMA), and mechanical performance (tensile properties) in both the X- and Z-directions. Results demonstrated a 24.6% reduction in average fiber length compared to virgin prints, accompanied by a 21% decrease in X-direction tensile strength and a 39% reduction in tensile modulus. Despite these reductions, Z-direction tensile modulus improved by 4%, density increased by 6.8%, and heat deflection temperature (HDT) under high stress retained over 97% of its original value. These findings underscore the potential for integrating mechanically recycled CF-PC into industrial LFAM applications while highlighting the need for technological innovations to mitigate fiber degradation and enhance material performance for broader adoption. This critical step toward circular material practices in LFAM offers a pathway to reducing feedstock costs and environmental impact while maintaining functional performance in industrial applications. Full article

This study investigates the feasibility of using scrap aerogel (SAG) generated during silica aerogel production as a partial substitute for sand in 3D concrete printing. Through comprehensive experiments and finite element analysis, the printability, thermal insulation properties, and mechanical characteristics (compressive strength and flexural strength) of 3D-printed scrap-aerogel-incorporated concrete (3DP-SAIC) were evaluated at different SAG replacement ratios. The results indicate that the thermal conductivity of the concrete decreases with increasing SAG content. When 30% of the sand is replaced by aerogel, the thermal conductivity perpendicular to the printed layer direction is reduced by 40.90%. The thermal properties of SAIC closely resemble those of aerogel concrete (AIC) while significantly reducing manufacturing costs. Compared to existing 3D-printed aerogel concrete, this study achieves a 73.1% cost reduction. Compared to standard cast specimens (SC-SAIC), 3DP-SAIC exhibits pronounced anisotropic thermal behavior. The study also evaluated the reinforcement effects of four basalt fibers (BF) with different aspect ratios on the mechanical properties of 3DP-SAIC. Although BF provides limited enhancement to compressive strength, it significantly boosts flexural strength. Specifically, BF with a length of 12 mm and a diameter of 17 μm increases flexural strength by 26.97%. These findings highlight the application potential of recycled aerogel in 3D-printed concrete, offering a sustainable thermal insulation solution with suitable mechanical properties for green building technologies. Full article

Additive manufacturing (AM) has significant potential for rapid prototyping of intricate 3-dimensional geometries, yet its adoption in RF and microwave applications remains limited. Key barriers include inadequate material characterization, high dielectric losses, poor thermal stability, and challenges with multi-material integration. This work addresses these issues by developing a high-k, low-loss composite filament with a reduced coefficient of thermal expansion (CTE), specifically formulated for fused deposition modelling (FDM). By varying filler volume fractions (30%, 40%, and 50% v/v) and surfactant content, their impact on thermal stability and CTE was investigated and measured by thermomechanical analysis (TMA). XRD, Pycnometry, and EDS analysis were performed to verify the effect of the calcination process on ceramic microfillers. The B.E.T. method (Brunauer–Emmet–Teller) was utilized to calculate the specific surface area of the samples with N₂ uptake. SEM images of the different composites were presented to visually demonstrate the homogeneous distribution of microfillers in the thermoplastic matrix. Titania was evaluated as the ceramic filler. Titania composites demonstrated decreased CTE values (35.93 ppm/°C at 50% v/v filler coated with surfactant) compared to composites without surfactant. A dielectric waveguide (DWG) printed with the T30S composite achieved an insertion loss of 0.46 dB at 17.23 GHz, significantly outperforming a commercially available ABS450-based DWG (0.95 dB at 16.88 GHz). Measurements aligned closely with 3D electromagnetic simulations, confirming dielectric properties (ε_r = 5.55, tan δ = 0.0009) suitable for advanced RF and microwave devices and advanced packaging applications. Full article

Dynamic covalent bonds within polymer materials have been the subject of ongoing research. These bonds impart polymers, particularly thermosets, with capabilities for self-healing and reprocessing. Concurrently, three-dimensional (3D) printing techniques have undergone rapid advancement and widespread adoption. Since polymers are among the primary materials used in 3D printing, networks featuring dynamic covalent bonds have emerged as a prominent research area. This review outlines approaches for incorporating dynamic covalent bonds into polymers suitable for 3D printing and examines representative studies that leverage these chemistries in material design. Polymers produced using these strategies demonstrate both self-healing and reprocessability, primarily via bond-exchange (metathesis) reactions. In addition, we discuss how the type and amount of dynamic bonds in the network affect the resulting material properties, with particular emphasis on their mechanical, physical, and thermal performance. In particular, the introduction of dynamic covalent bonds seems to significantly improve the degree of anisotropy, which has been the limitation of 3D printing techniques. Finally, we compile recent applications for objects printed from polymers that include dynamic covalent bonds. Full article

This study explores the valorization of chestnut burrs (Castanea sativa), an abundant agro-industrial residue, as a natural filler for polylactic acid (PLA)-based biocomposites with potential applications in additive manufacturing. PLA/chestnut burr composite filaments were prepared by melt extrusion with filler contents of 2.5%, 5%, 10%, and 15% w/w, and their chemical, thermal, morphological, and mechanical properties were systematically characterized. ATR-FTIR confirmed the absence of major chemical modifications of the PLA matrix. Thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC), the latter performed on both the extruded filaments and the material after fused deposition modeling (FDM) 3D printing, revealed a slight decrease in thermal stability with increasing filler content, coupled with enhanced crystallinity. Mechanical properties analysis showed that the addition of chestnut burrs did not negatively impact the viscoelastic behavior of the filaments. Scanning electron microscopy (SEM) highlighted good filler dispersion up to 5% loading, while higher percentages led to increased surface roughness and microvoids. Importantly, antioxidant activity assays (DPPH, ABTS, FRAP, and Folin–Ciocâlteu) demonstrated that the incorporation of chestnut burr significantly enhanced the radical-scavenging capacity, reducing power, and total phenolic content (TPC) of PLA. These functionalities were preserved, and in some cases amplified, after FDM 3D printing, indicating that the processing conditions did not degrade the bioactive constituents. Overall, chestnut burrs are confirmed as an effective multifunctional filler for PLA, improving its antioxidant activity while maintaining structural and thermal performance, supporting the development of sustainable biocomposites for emerging applications. Full article

This article demonstrates that 3D-printed parts can replace metal parts in optomechanics in the correct circumstances. Three examples are shown: a clamping fork for pedestal holders where stability is important, an adjustable mirror holder where the rigidity is the main criterion, and a stray light shield where the transmissivity is critical. By combining carbon-fiber-reinforced polymers (CFRPs) with 3D printing, it is possible to produce components that fill the gap between standard 3D-printed plastics and metal parts in terms of strength and stability. These parts are designed to be lighter, more compact, and easier to modify, while keeping good mechanical properties such as resistance to vibration, shape accuracy, and controlled thermal expansion. The article focuses on the application of composite 3D printing on optomechanical components. It compares different methods of composite 3D printing, including fused filament fabrication (FFF) with either chopped fibers or with continuous fiber reinforcement. Three examples from the HiLASE Centre demonstrate how these parts are used in practice, confirming that it is indeed possible to 3D print components that are lighter and cheaper yet still highly functional compared to their off-the-shelf counterparts—for example, lightweight and stiff mounts, shielding against stray laser light, or flexible elements allowing fine mechanical adjustments. Simulations of the deformations are included to compare the printed and metal versions. The article ends with a summary of the benefits and limitations of using 3D-printed composites in optomechanics. Full article

The rapid growth in electronic waste (e-waste) generation highlights the urgent need for efficient and environmentally sustainable methods for metal recovery. This study focuses on the selective recovery of valuable metals from multilayer ceramic capacitors (MLCCs), commonly found in printed circuit boards (PCBs) of post-consumer electronics. MLCCs were manually recovered from dismantled computer PCBs, thermally treated, pulverized, and characterized using X-ray fluorescence and X-ray diffraction techniques. To evaluate green alternatives to traditional acid leaching, three deep eutectic solvents (DESs) based on choline chloride (ChCl) were prepared: citric acid (CA), glycerol (GLY), and a ternary (GLY-CA) mixture of both (GLY-CA). Leaching experiments were conducted over a 24 h period and analyzed using atomic absorption spectroscopy. The results showed complete recovery (100%) of copper using both CA and the GLY-CA mixture, while nickel recovery reached 100% with CA and moderate levels with GLY-CA. Zinc recovery was also high (99%) with both CA and GLY-CA. Iron showed a maximum recovery of 60%, potentially due to its occurrence in various chemical forms. The ternary DES (GLY-CA) demonstrated lower viscosity, improving handling and operational efficiency. These findings highlight the potential of citric-acid-based and ternary (GLY-CA) DESs as effective, low-toxicity leaching agents for the recovery of critical metals from MLCCs. Full article

Poly(L-lactide) (PLA) is a promising biopolymer for biomedical applications due to its biodegradability and biocompatibility; however, its brittleness restricts its use in fused deposition modeling (FDM). To overcome this limitation, flexible PLA monofilaments with enhanced mechanical performance and printability were developed. In this study, PLA was melt-blended with acetyl triethyl citrate (ATEC, 1.0–5.0 wt%) as a plasticizer and zinc phenyl phosphonate (TMC-200, 0.3 wt%) as a nucleating agent. It was found that the PLA with 3.0 wt% ATEC (PLA/A) exhibited the greatest flexibility, while the addition of TMC-200 further improved tensile strength and ductility. Specifically, the ternary blend of PLA/TMC-200/ATEC (PLA/T/A) exhibited a synergistic effect, achieving superior mechanical properties (tensile strength: 35.0 MPa, elongation at break: 232.0%, compared to 12.1% for pure PLA) and raising the degree of crystallinity (X_c) from 4.7% to 45.0%. Monofilaments (1.70 ± 0.05 mm) fabricated from PLA/T/A exhibited smooth surfaces, balanced mechanical performance, and excellent cytocompatibility (over 99% cell viability in L929 fibroblasts). Moreover, FDM-printed specimens retained enhanced mechanical and thermal performance, demonstrating material stability after processing. Shelf-life testing further confirmed the structural integrity of PLA/T/A monofilament after 8 weeks at 50 °C. Overall, PLA/T/A provides an effective strategy for producing high-performance, medical-grade PLA monofilaments with improved toughness, printability, and biocompatibility, enabling their application in biomedical 3D printing. Full article

This study presents a finite element analysis (FEA)-based numerical homogenization method for evaluating the effective thermo-mechanical properties of a large-area additively manufactured particulate-filled composite using realistic periodic representative volume elements (RVEs) generated from reconstructed X-ray µ-CT image scans of a 3D-printed bead. The numerical results of the predicted effective properties, including the elastic stiffness, coefficient of thermal expansion (CTE) and thermal conductivity, were benchmarked with the Mori–Tanaka–Benveniste analytical estimates, which were found to be comparable. Initial sensitivity analysis using a single region of interest (ROI) extracted from the bead’s volume was performed to determine a suitable RVE size. The impact of inherent micro-porosities on the resulting composite material’s behavior was also quantified in the current investigation and was shown to reduce the composite’s effective properties. Using a suitable RVE size, the effect of anisotropy due to spatial variation in the microstructure across the bead specimen on the computed composite’s effective properties was also assessed. The results show that the regions closer to the exposed surface of the print bead with highly aligned and densely packed fiber particulates have superior properties as compared to inner regions with a more randomly oriented and less densely packed fibrous microstructure. Full article

The high-temperature thermal stability of dexamethasone (DEX) was systematically investigated under nitrogen and air atmospheres using non-isothermal thermogravimetry at heating rates of 0.1–20 °C·min⁻¹. The thermal decomposition was found to initiate below the melting temperature, proceeding via a three-step pathway that generated a complex mixture of volatile and condensed by-products (~10% solid residuum at 550 °C). Kinetic modeling was realized using the single-curve multivariate kinetic analysis (sc-MKA), and was based on the autocatalytic framework with temperature-dependent parameters, combined with consequent reaction mechanisms. An excellent agreement of the theoretical model with the experimental data enabled reliable predictive extrapolations to pharmaceutical processing conditions. Whereas the onset of degradation was observed at ~180–190 °C, significant decomposition rates (>1% mass loss during first 5 min) were only reached above 220 °C, well above the processing windows of most pharmaceutical polymers. Consequently, dexamethasone can be considered thermally stable for hot-melt extrusion and fused deposition modeling, except in high-temperature-processing applications involving polymers such as, e.g., polylactic acid, polyvinyl alcohol, or thermoplastic polyurethanes. Importantly, the study highlights that reliable kinetic predictions require measurements across a broad heating-rate range and in both oxidizing and inert atmospheres, with special emphasis on low heating rates (≤0.2 °C·min⁻¹), which proved critical for capturing early-stage degradation. These findings provide a rigorous kinetic framework for ensuring safe incorporation of DEX into advanced pharmaceutical and medical device formulations. Full article