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Powder bed-based additive manufacturing (AM) is a promising family of technologies for industrial applications. The purpose of this study is to provide a new metrics based on the analysis of the compaction behavior for the evaluation of flowability of AM powders.

In this work, a novel qualification methodology based on a camera mounted onto a commercially available tap density meter allowed to assess the compaction behavior of a selection of AM materials, both polymers and metals. This methodology automatizes the reading of the powder height and obtains more information compared to ASTM B527. A novel property is introduced, the “tapping modulus,” which describes the packing speed of a powdered material and is related to a compression/vibration powder flow.

The compaction behavior was successfully correlated with the dynamic angle of repose for polymers, but interestingly not for metals, shedding more light to the different flow behavior of these materials.

Because of the chosen materials, the results may lack generalizability. For example, the application of this methodology outside of AM would be interesting.

This paper suggests a new methodology for assessing the flowing behavior of AM materials when subjected to compression. The device is inexpensive and easy to implement in a quality assurance environment, being thus interesting for industrial applications.

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.

The paper aims to promote the development of intelligent materials and the 4D printing technology by introducing recent advances and applications of additive layered manufacturing (ALM) technology of intelligent materials and the development of the 4D printing technology. Also, an arm-type ALM technology of shape memory polymer (SMP) with thermosetting polyurethane is briefly introduced.

This paper begins with an overview of the development and applications of intelligent materials around the world and the 4D printing technology. Then, the authors provide a brief outline of their research on arm-type ALM technology of SMP with thermosetting polyurethane.

The paper provides the recent developments and applications of intelligent materials and 4D printing technology. Then, it is suggested that intelligent materials mixed with different functional materials will be developed, and these types of materials will be more suitable for 4D printing.

This paper overviews the current developments and applications of intelligent materials and its use in 4D printing technology, and briefly states the authors’ research on arm-type ALM technology of SMP with thermosetting polyurethane.

Polymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing the fabrication of gears without the aid of support structures and subsequent assembly. However, there are constraints in the process that negatively affect its adoption compared to other additive technologies such as material extrusion to produce gears. This study aims to demonstrate that it is possible to overcome the problems due to the physics of the process to produce accurate mechanism.

Technological aspects such as orientation, wheel-shaft thicknesses and degree of powder recycling were examined. Furthermore, the evolving tooth profile was considered as a design parameter to provide a manufacturability map of gear-based mechanisms.

Results show that there are some differences in the functioning of the gear depending on the type of powder used, 100% virgin or 50% virgin and 50% recycled for five cycles. The application of a groove on a gear produced with 100% virgin powder allows the mechanism to be easily unlocked regardless of the orientation and wheel-shaft thicknesses. The application of a specific evolutionary profile independent of the diameter of the reference circle on vertically oriented gears guarantees rotation continuity while preserving the functionality of the assembled mechanism.

In the literature, there are various studies on material aging and reuse in the PBF-LB/P process, mainly focused on the powder deterioration mechanism, powder fluidity, microstructure and mechanical properties of the parts and process parameters. This study, instead, was focused on the functioning of gears, which represent one of the applications in which this technology can have great success, by analyzing the two main effects that can compromise it: recycled powder and vertical orientation during construction.

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 study aims to investigate the potential of using polymer multi-material additive manufacturing (MMAM) to produce miniature hydraulic piston actuators combining rigid structures and flexible seals. Such actuators offer great potential for medical robots in X-ray and magnetic resonance environments, where conventional piston actuators cannot be used because of safety issues caused by metal components.

Hydraulic pistons with two different integrated flexible seal shapes are designed and manufactured using MMAM. Design 1 features a ring-shaped seal made from a flexible material that is printed on the surface of the rigid piston shaft. Design 2 appears identical from the outside, yet an axial opening in the piston shaft is added to enable self-reinforced sealing as fluid pressure increases. For both designs, samples with three different outer diameters are fabricated leading to a total of six different piston versions. The pistons are then evaluated regarding leakage, friction and durability.

Measurement results show that the friction force for Design 2 is lower than that of Design 1, making Design 2 more suitable for the intended application. None of the versions of Design 2 shows leakage for pressures up to 1.5 MPa. For Design 1, leak-tightness varies with the outer diameter, yet none of the versions is consistently leak-tight at 1.5 MPa. Furthermore, the results show that prolonged exposure to water decreases the durability of the flexible material significantly. The durability the authors observe may, however, be sufficient for short-term or single-use devices.

The authors investigate a novel design approach for hydraulic piston actuators based on MMAM. These actuators are of particular interest for patient-specific medical devices used in radiological interventions, where metal-free components are required to safely operate in X-ray and magnetic resonance environments. This study may serve as a basis for the development of new actuators, as it shows a feasible solution, yet pointing out critical aspects such as the influence of small geometry changes or material performance changes caused by water absorption.

The aim of this paper is presenting a new application of material obtained from the acrylonitrile butadiene styrene (ABS) recycling process from electronic equipment housings. Elements of computer monitors were used to prepare re-granulate, which in turn was used to manufacture a filament for fused filament fabrication (FFF) additive manufacturing technology.

The geometry of test samples (i.e. dumbbell and bar) was obtained in accordance with the PN-EN standards. Samples made with the FFF technology were used to determine selected mechanical properties and to compare the results obtained with the properties of ABS re-granulate mould pieces made with the injection moulding technology. The GATE device manufactured by 3Novatica was used to make the prototypes with the FFF technology. Processing parameters were tested with the use of an Aflow extrusion plastometer manufactured by Zwick/Roell and other original testing facilities. Tests of mechanical properties were performed with a Z030 universal testing machine, a HIT 50P pendulum impact tester and a Z3106 hardness tester manufactured by Zwick/Roell.

The paper presents results of tests performed on a filament obtained from the ABS re-granulate and indicates characteristic processing properties of that material. The properties of the new secondary material were compared with the available original ABS materials that are commonly used in the additive technology of manufacturing geometrical objects. The study also presents selected results of tests of functional properties of ABS products made in the FFF technology.

The test results allowed authors to assess the possibility of a secondary application of used elements of electronic equipment housings in the FFF technology and to compare the strength properties of products obtained with similar products made with the standard injection moulding technology.

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.

The purpose of this paper is to review possibilities of implementing ceramic additive manufacturing (AM) into electronic device production, which can enable great new possibilities.

A short introduction into additive techniques is included, as well as primary characterization of structuring capabilities, dielectric performance and applicability in the electronic manufacturing process.

Ceramic stereolithography (SLA) is suitable for microchannel manufacturing, even using a relatively inexpensive system. This method is suitable for implementation into the electronic manufacturing process; however, a search for better materials is desired, especially for improved dielectric parameters, lowered sintering temperature and decreased porosity.

Relatively inexpensive ceramic SLA, which is now available, could make ceramic electronics, currently restricted to specific applications, more available.

Ceramic AM is in the beginning phase of implementation in electronic technology, and only a few reports are currently available, the most significant of which is mentioned in this paper.

This paper aims to describe the influence of maleinized linseed oil (MLO), when used as a lubricant, on the thermal and rheological properties of PLA/MWCNTs (polylactic acid/multi-walled carbon nanotubes) and PLA/HNT (halloysite nanotubes) nanocomposites, as a reference for application in 3D printing processes.

Nanocomposites were obtained by melting in a twin-screw extruder, mixing PLA with MWCNTs and HNTs in different percentages of 0.5, 0.75 and 1 Wt.% for subsequent mixing by the same process with 5 phr MLO, for application in additive manufacturing, as analyzed by means of differential scanning calorimetry (DSC), capillary rheometry, melt flow rate (MFL) and field emission scanning electron microscopy (FESEM).

The results obtained for thermal characterization by using DSC indicate the non-variation of glass transition temperature Tg = 62 ± 2°C and a melting temperature (Tm) around 170°C. Crystallization temperature dropped by approximately 12°C, which should be kept in mind during the transformation processes. The values obtained by capillary rheometry indicate that the material’s viscosity is reduced by the influence of the MLO plasticizer’s lubricant effect on the PLA’s molecular structure. The melt flow index values confirm a rise of approximately 46% in the flow index and back up the capillary rheometry results. The values obtained were as follows: PLA/0.5 Wt.% MWCNT/MLO 5 phr 54.07, PLA/0.75 Wt.% MWCNT/MLO 5 phr 53.46, PLA/1 Wt.% MWCNT/MLO 5 phr 51.84y PLA/0.5 Wt.% HNT/MLO 5 phr 61.8, PLA/0.75 Wt.% HNT/MLO 5 phr 68.3 and PLA/1 Wt.% HNT/MLO 5 phr 71.2 g/10 min. Apart from the nanocharge distribution, the information obtained from the FESEM shows the existence of a cluster, which could have been avoided by more energetic stirring during the nanocompound manufacturing process.

This paper presents an analysis of the insertion of plasticizer in nanocomposites for the application in additive manufacturing processes in fusion deposition modelling (FDM) system.

This is a novel original research work.