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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 purpose of this paper is to report on the developments in manufacturing soft magnetic materials using laser powder bed fusion (L-PBF).

Ternary soft magnetic Fe-49Co-2V powder was produced by gas atomization and used in an L-PBF machine to produce samples for material characterization. The L-PBF process parameters were optimized for the material, using a design of experiments approach. The printed samples were exposed to different heat treatment cycles to improve the magnetic properties. The magnetic properties were measured with quasi-static direct current and alternating current measurements at different frequencies and magnetic flux densities. The mechanical properties were characterized with tensile tests. Electrical resistivity of the material was measured.

The optimized L-PBF process parameters resulted in very low porosity. The magnetic properties improved greatly after the heat treatments because of changes in microstructure. Based on the quasi-static DC measurement results, one of the heat treatment cycles led to magnetic saturation, permeability and coercivity values comparable to a commercial Fe-Co-V alloy. The other heat treatments resulted in abnormal grain growth and poor magnetic performance. The AC measurement results showed that the magnetic losses were relatively high in the samples owing to formation of eddy currents.

The influence of L-PBF process parameters on the microstructure was not investigated; hence, understanding the relationship between process parameters, heat treatments and magnetic properties would require more research.

The relationship between microstructure, chemical composition, heat treatments, resistivity and magnetic/mechanical properties of L-PBF processed Fe-Co-V alloy has not been reported previously.

Numerous metals can be processed using the additive manufacturing process laser-based powder bed fusion of metals (PBF-LB/M, ISO/ASTM 52900). The main advantages of additive manufacturing technologies are the high degree of design freedom and the cost-effective implementation of lightweight structures. This could be profitable for gears with increased power density, combining reduced mass with considerable material strength. Current research on additively manufactured gears is focused on developing lightweight structures but is seldom accompanied by simulations and even less by mechanical testing. There has been very little research into the mechanical and material properties of additively manufactured gears. The purpose of this study is to investigate the behavior of lightweight structures in additively manufactured gears under static loads.

This research identifies the static load-carrying capacity of helical gears with different lightweight structures produced by PBF-LB/M with the case hardening steel 16MnCr5. A static gear loading test rig with a maximum torque at the pinion of T₁ = 1200 Nm is used. Further focus is set on analyzing material properties such as the relative density, microstructure, hardness depth profile and chemical composition.

All additively manufactured gear variants show no failure or plastic deformation at the maximum test load. The shaft hub connection, the lightweight hub designs and the gearing itself are stable and intact regarding their form and function. The identified material characteristics are comparable to conventionally manufactured gears (wrought and machined), but also some particularities were observed.

This research demonstrates the mechanical strength of lightweight structures in gears. Future research needs to consider the dynamic load-carrying capacity of additively manufactured gears.

While aiming to create methods for fibre recycling, the question of colours in waste textiles is also in focus; whether the colour should be kept or should be removed while recycling textile fibre. More knowledge is needed for colour management in a circular economy approach.

The research included the use of different dye types in a cotton dyeing process, the process for decolourizing and the results. Two reactive dyes, two direct dyes and one vat dye were used in the study. Four chemical treatment sequences were used to evaluate colour removal from the dyed cotton fabrics, namely, HCE-A, HCE-P-A, HCE-Z-P-A and HCE-Y-A.

The objective was to evaluate how different chemical refining sequences remove colour from direct, reactive and vat dyed cotton fabrics, and how they influence the specific cellulose properties. Dyeing methods and the used refining sequences influence the degree of colour removal. The highest achieved final brightness of refined cotton materials were between 71 and 91 per cent ISO brightness, depending on the dyeing method used.

Only cotton fibre and three different colour types were tested.

With cotton waste, it appears to be easier to remove the colour than to retain it, especially if the textile contains polyester residues, which are desired to be removed in the textile refining stage.

Colour management in the CE context is an important new track to study in the context of the increasing amount of textile waste used as a raw material.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

Fabrics with photothermal conversion functions were developed based on the introduction of shape stable composite phase change materials (CPCMs).

Acidified single-walled carbon nanotubes (SWCNTs) were selected as support material to prepare CPCMs with n-octadecane to improve the thermal conductivity and shape stability. The CPCMs were finished onto the surface of cotton fabric through the coating and screen-printing method. The chemical properties of CPCMs were characterized by Fourier transform infrared spectrometer, XRD and differential scanning calorimetry (DSC). The shape stability and thermal conductivity were also evaluated. In addition, the photothermal conversion and temperature-regulating performance of the finished fabrics were analyzed.

When the addition amount of acidified SWCNTs are 14% to the mass of n-octadecane, the best shape stability of CPCMs is obtained. DSC analysis shows that the latent heat energy storage of CPCMs is as high as 183.1 J/g. The thermal conductivity is increased by 84.4% compared with that of n-octadecane. The temperature-regulating fabrics coated with CPCMs have good photothermal conversion properties.

CPCMs with high latent heat properties are applied to the fabric surface through screen printing technology, which not only gives the fabric the photothermal conversion performance but also reflects the design of personalized patterns.

CPCMs and polydimethylsiloxane (PDMS) are mixed to make printing paste and printed cotton fabric with temperature-regulating functional is developed.

SWCNTs and n-octadecane are composited to prepare CPCMs with excellent thermal properties, which can be mixed with PDMS to make printing paste without adding other pastes. The fabric is screen-printed to obtain a personalized pattern and can be given a thermoregulatory function.

Purpose – This purpose of the research is to investigate the process of manufacturing LDPE recycle thermoplastic composites with reinforcement oil palm empty fruit bunch (OPEFB) biomass microfillers.

Design/Methodology/Approach – Methods of physical and chemical modification of OPEFB fibers into the LDPE matrix and the addition of some compatibilizer such as MAPE and xylene process through melt blending can improve mechanical properties, electrical properties, biodegradability, and improve the morphology of composites.

Research Limitations/Implications – These composites are prepared by the following matrix ratio: filler (70:30)% and filler size (63, 75, 90, and 106) μm. The LDPE plastic is crushed to a size of 0.5–1 cm, then pressed with hot press free heating for 5 min and with a pressure of 10 min at 145 °C. Based on the characterization obtained, the tensile strength and the high impact on the use of 106 μm filler is 13.86 MPa and 3,542.6 J/m², and thermal stability indicates the degradation temperature (T₀) 497.83 °C. FT-IR analysis shows the presence of functional groups of cellulose and lignin molecules derived from TKKS collected in the composite.

Practical Implications – Based on the characterization obtained, this composite can be applied as furniture material and vehicle dashboard.

Originality/Value – Composites obtained from recycle of LDPPE plastics waste has some advantages such as good compatibility and high tensile strength. This composite used the OPEFB filler whose size is in micrometer, and so this product is different from other products.

The purpose of this paper is to present a complex pyrolysis computational fluid dynamics (CFD) model of timber protection exposed to fire in a medium size enclosure. An emphasis is placed on rarely used temperature-dependent thermal material properties effecting the overall simulation outputs. Using the input dataset, a fire test model with oriented strand boards (OSB) in the room corner test facility is created in Fire Dynamics Simulator (FDS).

Seven FDS models comprising different complexity approaches to modelling the burning of wood-based materials, from a simplified model of burning based on a prescribed heat release rate to complex pyrolysis models which can describe the fire spread, are presented. The models are validated by the experimental data measured during a fire test of OSB in the room corner test facility.

The use of complex pyrolysis approach is recommended in real-scale enclosure fire scenarios with timber as a supplementary heat source. However, extra attention should be paid to burning material thermal properties implementation. A commonly used constant specific heat capacity and thermal conductivity provided poor agreement with experimental data. When the fire spread is expected, simplified model results should be processed with great care and the user should be aware of possible significant errors.

This paper brings an innovative and rarely used complex pyrolysis CFD model approach to predict the behaviour of timber protection exposed to fire. A study on different temperature-dependent thermal material properties combined with multi-step pyrolysis in the room corner test scenario has not been sufficiently published and validated yet.

The purpose of this paper is to prepare stabile emulsions with 0–15% of colloidal silica and high monomer/water ratio and to investigate the influence of silica addition and surface modification on the polyacrylate properties.

Improving the properties of the composite can be achieved by optimizing the compatibility between the phases of the composite system with improving the interactions at the matrix/filler interface. Therefore, the silica surface was modified with nonionic emulsifier octylphenol ethoxylate, cationic initiator 2,2'-azobis-(amidinopropane dihydrochloride) and 3-methacryloxypropyltrimethoxysilane and polyacrylate/silica nanocomposites were prepared via in situ emulsion polymerization. Particle size distribution, rheological properties of the emulsions and morphology, thermal properties and mechanical properties of the film prepared from the emulsions were investigated.

Polyacrylate/silica systems with unmodified silica, silica modified with nonionic emulsifier and cationic initiator have micrometer, while pure PA matrix and systems with silica modified with silane have nanometer particle sizes. Addition and surface modification of the filler increased emulsion viscosity. Agglomeration of silica particles in composites was reduced with silica surface modification. Silica filler improves thermal stability and tensile strength of polyacrylate.

This paper provides broad spectrum of information depending on filler surface modification and latex preparation via in situ emulsion polymerization and properties with high amount of filler and monomer/water ratio with the aim that prepared latex is suitable for film formation and final application.

Because of the anisotropy of the process and the variability in the quality of printed parts, finite element analysis is not directly applicable to recycled materials manufactured using fused filament fabrication. The purpose of this study is to investigate the numerical-experimental mechanical behavior modeling of the recycled polymer, that is, recyclable polyethylene terephthalate (rPET), manufactured by a deposition FFF process under compressive stresses for new sustainable designs.

In all, 42 test specimens were manufactured and analyzed according to the ASTM D695-15 standards. Eight numerical analyzes were performed on a real design manufactured with rPET using Young's compression modulus from the experimental tests. Finally, eight additional experimental tests under uniaxial compression loads were performed on the real sustainable design for validating its mechanical behavior versus computational numerical tests.

As a result of the experimental tests, rPET behaves linearly until it reaches the elastic limit, along each manufacturing axis. The results of this study confirmed the design's structural safety by the load scenario and operating boundary conditions. Experimental and numerical results show a difference of 0.001–0.024 mm, allowing for the rPET to be configured as isotropic in numerical simulation software without having to modify its material modeling equations.

The results obtained are of great help to industry, designers and researchers because they validate the use of recycled rPET for the ecological production of real-sustainable products using MEX technology under compressive stress and its configuration for numerical simulations. Major design companies are now using recycled plastic materials in their high-end designs.

Validation results have been presented on test specimens and real items, comparing experimental material configuration values with numerical results. Specifically, to the best of the authors’ knowledge, no industrial or scientific work has been conducted with rPET subjected to uniaxial compression loads for characterizing experimentally and numerically the material using these results for validating a real case of a sustainable industrial product.