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The purpose of this paper is to evaluate and exploit the combination of additive manufacturing polymeric technology and structural adhesives. The main advantage is to expand the maximum dimension of the 3D printed parts, which is typically limited, by joining the parts with structural adhesive, without losing strength and stiffness and keeping the major asset of polymeric 3 D printing: freedom of shape of the system and low cost of parts.

The materials used in the paper are the following. The adhesive considered is a commercial inexpensive acrylic, quite similar to superglue, applicable with almost no surface preparation and fast curing, as time constraint is one of the key problems that affects industrial adhesive applications. The 3D printed parts were in acrylonitrile butadiene styrene (ABS), obtained with a Fortus 250mc FDM machine, from Stratasys. The work first compares flat overlap joint with joints designed to permit mechanical interlocking of the adherends and then to a monolithic component with the same geometry. Single lap, joggle lap and double lap joints are the configurations experimentally characterized following a design of experiment approach.

The results show a failure in the substrate, due to the low strength of the polymeric adherends for the first batch of typical bonded configurations, single lap, joggle lap and double lap. The central bonded area, with an increased global thickness, never does fail, and the adhesive is able to transfer the load both with and without mechanical interlocking. An additional set of scarf joints was also tested to promote adhesive failure as well as to retrieve the adhesive strength in this application. The results shows that bonding of polymeric AM parts is able to express its full potential compared with a monolithic solution even though the joint fails prematurely in the adherend due to the bending stresses and the notches present in the lap joints.

Because of the 3D printed polymeric material adopted, the results may be generalized only when the elastic properties of the adherends and of the adhesive are similar, so it is not possible to extend the findings of the work to metallic additive manufactured components.

The paper shows that the adhesives are feasible way to expand the potentiality of 3 D printed equipment to obtain larger parts with equivalent mechanical properties. The paper also shows that the scarf joint, which fails in the adhesive first, can be used to extract information about the adhesive strength, useful for the designers which have to combine adhesive and additive manufactured polymeric parts.

To the best of the researchers’ knowledge, there are scarce quantitative information in technical literature about the performance of additive manufactured parts in combination with structural adhesives and this work provides an insight on this interesting subject. This manuscript provides a feasible way of using rapid prototyping techniques in combination with adhesive bonding to fully exploit the additive manufacturing capability and to create large and cost-effective 3 D printed parts.

This paper comprehensively addresses the influence of chopped strand mat glass fiber-reinforced polymer (GFRP) patch configurations such as geometry, dimensions, position and the number of layers of patches, whether a single or double patch is used and how well debonding the area under the patch improves the strength of the cracked aluminum plates with different crack lengths.

Single-edge cracked aluminum specimens of 150 mm in length and 50 mm in width were tested using the tensile test. The cracked aluminum specimens were then repaired using GFRP patches with various configurations. A three-dimensional (3D) finite element method (FEM) was adopted to simulate the repaired cracked aluminum plates using composite patches to obtain the stress intensity factor (SIF). The numerical modeling and validation of ABAQUS software and the contour integral method for SIF calculations provide a valuable tool for further investigation and design optimization.

The width of the GFRP patches affected the efficiency of the rehabilitated cracked aluminum plate. Increasing patch width WP from 5 mm to 15 mm increases the peak load by 9.7 and 17.5%, respectively, if compared with the specimen without the patch. The efficiency of the GFRP patch in reducing the SIF increased as the number of layers increased, i.e. the maximum load was enhanced by 5%.

This study assessed repairing metallic structures using the chopped strand mat GFRP. Furthermore, it demonstrated the superiority of rectangular patches over semicircular ones, along with the benefit of using double patches for out-of-plane bending prevention and it emphasizes the detrimental effect of defects in the bonding area between the patch and the cracked component. This underlines the importance of proper surface preparation and bonding techniques for successful repair.

Many additively manufactured parts suffer from reduced interlayer strength. This anisotropy is necessarily tied to the orientation during manufacture. When individual features on a part have conflicting optimal orientations, the part is unavoidably compromised. This paper aims to demonstrate a strategy in which conflicting features can be functionally separated into “co-parts” which are individually aligned in an optimal orientation, selectively reinforced with continuous fiber, printed simultaneously and, finally, assembled into a composite part with substantially improved performance.

Several candidate parts were selected for co-part decomposition. They were printed as standard fused filament fabrication plastic parts, parts reinforced with continuous fiber in one plane and co-part assemblies both with and without continuous fiber reinforcement (CFR). All parts were loaded until failure. Additionally, parts representative of common suboptimally oriented features (“unit tests”) were similarly printed and tested.

CFR delivered substantial improvement over unreinforced plastic-only parts in both standard parts and co-part assemblies, as expected. Reinforced parts held up to 2.5x the ultimate load of equivalent plastic-only parts. The co-part strategy delivered even greater improvement, particularly when also reinforced with continuous fiber. Plastic-only co-part assemblies held up to 3.2x the ultimate load of equivalent plastic only parts. Continuous fiber reinforced co-part assemblies held up to 6.4x the ultimate load of equivalent plastic-only parts. Additionally, the thought process behind general co-part design is explored and a vision of simulation-driven automated co-part implementation is discussed.

This technique is a novel way to overcome one of the most common challenges preventing the functional use of additively manufactured parts. It delivers compelling performance with continuous carbon fiber reinforcement in 3D printed parts. Further study could extend the technique to any anisotropic manufacturing method, additive or otherwise.

Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using fused filament fabrication (FFF) with polylactic acid (PLA) and glycol-modified polyethylene terephthalate (PETG) is proposed as an economical, simpler and faster solution compared to traditional metallic molds or three-dimensional (3D) printing with other difficult-to-print thermoplastics, which are prone to shrinkage and delamination (acrylonitrile butadiene styrene, polypropilene-PP) or high-cost due to both material and printing equipment expenses (PEEK, polyamides or polycarbonate-PC). The purpose of this study has been to evaluate the ease of release of PUR foam on these materials in combination with release agents to facilitate the mulding/demoulding process.

PETG, PLA and hardenable polylactic acid (PLA 3D870) have been evaluated as mold materials in combination with aqueous and solvent-based release agents within a full design of experiments by three consecutive molding/demolding cycles.

PLA 3D870 has shown the best demoldability. A mold expressly designed to manufacture a foam cushion has been printed and the prototyping has been successfully achieved. The demolding of the part has been easier using a solvent-based release agent, meanwhile the quality has been better when using a water-based one.

The combination of PLA 3D870 and FFF, along with solvent-free water-based release agents, presents a compelling low-cost and eco-friendly alternative to traditional metallic molds and other 3D printing thermoplastics. This innovative approach serves as a viable option for rapid tooling in PUR foam molding.

Honeycombs enjoy wide use in various engineering applications. The emergence of additive manufacturing (AM) as a method of customisable of parts has enabled the reinvention of the honeycomb structure. However, research on in-plane compressive performance of both classical and new types of honeycombs fabricated via AM is still ongoing. Several important findings have emerged over the past years, with significance for the AM community and a review is considered necessary and timely. This paper aims to review the in-plane compressive performance of AM honeycomb structures.

This paper provides a state-of-the-art review focussing on the in-plane compressive performance of AM honeycomb structures, covering both polymers and metals. Recently published studies, over the past six years, have been reviewed under the specific theme of in-plane compression properties.

The key factors influencing the AM honeycombs' in-plane compressive performance are identified, namely the geometrical features, such as topology shape, cell wall thickness, cell size and manufacturing parameters. Moreover, the techniques and configurations commonly used for geometry optimisation toward improving mechanical performance are discussed in detail. Current AM limitations applicable to AM honeycomb structures are identified and potential future directions are also discussed in this paper.

This work evaluates critically the primary results and findings from the published research literature associated with the in-plane compressive mechanical performance of AM honeycombs.

This paper highlights a crucial public safety issue due to falling objects from tall residential buildings in Singapore. A systematic façade inspection regime and a system of evaluation of severity for the detection and assessment of potential falling objects from tall buildings are presented.

The research uses qualitative case study approach with 450 tall residential buildings sampled for the study. The common materials, elements, components with high risk of falling objects, the nature and type of the falling, the critical factors affecting the falling, the respective level of severity, and the effectiveness of various diagnostic techniques and protocols, are summarised.

Façade for tall residential buildings in Singapore comprises mainly cementitious materials cast in situ or precast, with fixtures and architectural features, all of which have potential of falling. The common anomalies arising from each material and fixture/features are identified, the causes evaluated and their implications to future design, construction and maintenance analysed.

This study provides original and significant information to a crucial public safety issue, setting design and construction criteria that will serve as a benchmark for new and existing facades, applicable to all cities dominated by tall buildings. The paper presents original figures, checklists and guides as a basis for readers' consideration to use according to their respective unique conditions.

Data has become a factor of production. This occurs when history enters the era of big data, in which technologies such as artificial intelligence, cloud computing and blockchain are used to collect, manipulate, mine and process data. Data is a special product of labor, a sub-derivative of other production factors.

The data factor has a dual attribute: being physical (technical) and social. The social attribute of the data factor can not only materialize the technical attribute but also amplify it. In other words, the data has a multiplication effect on the allocation efficiency of other production factors. The social attribute of the data is brought out via the technical attribute as the medium. From a technical perspective, this medium is strongly adhesive, and after being bonded with other factors of production, it will only lead to a physical reaction and not change the nature of other factors.

However, once these two attributes interact with each other, especially when data is combined with capital, the most adhesive factor in the market economy, a series of new social relations will then be produced based on the technical attribute, resulting in significant adjustments in social relations, involving both positive and negative externalities.

Therefore, to get a scientific understanding of the dual attribute and its interaction effects on the data factor, it is necessary to take the following steps. We should promote institutional design that amplifies the positive externality, with a focus on facilitating public data sharing and improving the value of commercial data development. Also, we need to strengthen institutional arrangements that prevent and control the negative externality by emphasizing data supervision based on data types and levels as well as the rule of law.

Simulations exist for the prediction of the behaviour of building structural systems under fire, including two-way coupled fire-structure interaction. However, these simulations do not include detailed models of the connections, whereas these connections may impact the overall behaviour of the structure. Therefore, this paper proposes a two-scale method to include screw connections.

The two-scale method consists of (a) a global-scale model that models the overall structural system and (b) a small-scale model to describe a screw connection. Components in the global-scale model are connected by a spring element instead of a modelled screw, and the stiffness of this spring element is predicted by the small-scale model, updated at each load step. For computational efficiency, the small-scale model uses a proprietary technique to model the behaviour of the threads, verified by simulations that model the complete thread geometry, and validated by existing pull-out experiments. For four screw failure modes, load-deformation behaviour and failure predictions of the two-scale method are verified by a detailed system model. Additionally, the two-scale method is validated for a combined load case by existing experiments, and demonstrated for different temperatures. Finally, the two-scale method is illustrated as part of a two-way coupled fire-structure simulation.

It was shown that proprietary ”threaded connection interaction” can predict thread relevant failure modes, i.e. thread failure, shank tension failure, and pull-out. For bearing, shear, tension, and pull-out failure, load-deformation behaviour and failure predictions of the two-scale method correspond with the detailed system model and Eurocode predictions. Related to combined load cases, for a variety of experiments a good correlation has been found between experimental and simulation results, however, pull-out simulations were shown to be inconsistent.

More research is needed before the two-scale method can be used under all conditions. This relates to the failure criteria for pull-out, combined load cases, and temperature loads.

The two-scale method bridges the existing very detailed small-scale screw models with present global-scale structural models, that in the best case only use springs. It shows to be insightful, for it contains a functional separation of scales, revealing their relationships, and it is computationally efficient as it allows for distributed computing. Furthermore, local small-scale non-convergence (e.g. a screw failing) can be handled without convergence problems in the global-scale structural model.

Currently on additive manufacturing, extensive research is directed toward mitigating the main challenges associated with multi-material in fused filament fabrication which has a weak bonding strength between dissimilar materials. Low interfacial bonding strength leads to defects, anisotropy and temperature gradient in materials which negatively impact the mechanical performance of the multi-material prints. The purpose of this study was to assess the performance of different interface geometry designs in terms of the mechanical properties of the specimens.

Tensile test specimens were printed using: mono-material without a boundary interface, mono-material with the interface geometries (Face-to-face; U-shape; T-shape; Dovetail; Encapsulation; Mechanical interlocking; and Overlap) and multi-material with the interface geometries. The materials chosen with high and low compatibility were Tough polylactic acid (PLA) and TPU.

The main results of this study indicate that the interface geometries with the mechanical constriction between materials provide better structural integrity to the specimens. Moreover, in the case of the mono-material parts, the most effective interface design was the mechanical interlocking for both Tough PLA and TPU. On the other hand, in the case of multi-material specimens, the encapsulation showed the highest ultimate tensile strength, whereas the overlap and T-shape presented more robust bonding.

This study examines the mechanical performance, particularly tensile strength, strain at break, Young’s modulus and yield strength of different interface designs which were not studied in the previous studies.

The material extrusion (ME) process induces variations in the final part’s microscopic and macroscopic structural characteristics. This viewpoint article aims to uncover the relation between ME fabrication parameters and the microstructural and mesostructural characteristics of the ME BASF Ultrafuse Steel 316L metal parts. These characteristics can affect the structural integrity of the produced parts and components used in various engineering applications.

Recent studies on the ME BASF Ultrafuse Steel 316L are reviewed, with a focus on those which report microstructural and mesostructural characteristics that may affect structural integrity.

A relationship between ME fabrication parameters and subsequent microstructural and mesostructural characteristics is discussed. Common microstructural and mesostructural/macrostructural defects are also highlighted and discussed.

This viewpoint article attempts to bridge the existing gap in the literature, highlighting the influence of ME fabrication parameters on Steel 316L parts fabricated via this additive manufacturing method. Moreover, this article identifies and discusses important considerations for the purposes of selecting and optimising the structural integrity of ME-fabricated Steel 316L parts.