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This study aims to evaluate the low energy impact characteristics of 3D printed carbon fiber thermoplastic and thermoset polymer composite using the Izod impact test. The effects of infill density are examined on the Izod impact properties of 3D printed thermoset polymer and thermoplastic composite specimens. Furthermore, a thorough investigation is conducted into the effect of heat treatment using a hot-air oven on both types of 3D printed composite specimens. To characterize the impact characteristics of each specimen, the fracture surfaces caused by impact load are inspected, and the fracture mechanism is studied using scanning electron micrographs.

Izod Impact specimens of thermoset (epoxy resin) and thermoplastic carbon fiber of different infill density (70, 75, 80, 85, 90 and 100%) are fabricated using the different fiber impregnation 3D printing process. To carry out the heat treatment process, printing of composites is done for each infill design from both thermoset and thermoplastic composites and the impact characteristics of specimens are evaluated on a pendulum test-rig using the ASTM D-256 standard. Using a scanning electron microscope, each fracture zone underwent four separate scanning processes, ranging in size from 2 µm to 100 µm.

The impact resistance of the 3D printed thermoset and thermoplastic composite material is significantly influenced by the type of fiber placement and infill density in the matrix substrate. Because of the weak interfacial strength between the layers of fiber and polyamide 6, the specimen printed with continuous fiber implanted at the part exhibited reduced impact resistance. At 75% infill density, the impact specimen printed with coextruded fiber showed the highest impact resistance with a 367.02% greater magnitude than the continuous fiber specimen with the same infill density.

This work presents a novel approach to analyze the low energy impact characteristics and three-dimensional printing of carbon fiber reinforced thermoplastic and carbon fiber reinforced thermoset and thermoplastic composite material.

This study aims to improve the mechanical properties of an object produced by fused deposition modelling with high-grade polymer.

The study uses an ensembled surrogate-assisted evolutionary algorithm (SAEA) to optimize the process parameters for example, layer height, print speed, print direction and nozzle temperature for enhancing the mechanical properties of temperature-sensitive high-grade polymer poly-ether-ether-ketone (PEEK) in fused deposition modelling (FDM) 3D printing while considering print time as one of the important parameter. These models are integrated with an evolutionary algorithm to efficiently explore parameter space. The optimized parameters from the SAEA approach are compared with those obtained using the Gray Relational Analysis (GRA) Taguchi method serving as a benchmark. Later, the study also highlights the significant role of print direction in optimizing the mechanical properties of FDM 3D printed PEEK.

With the use of ensemble learning-based SAEA, one can successfully maximize the ultimate stress and percentage elongation with minimum print time. SAEA-based solution has 28.86% higher ultimate stress, 66.95% lower percentage of elongation and 7.14% lower print time in comparison to the benchmark result (GRA Taguchi method). Also, the results from the experimental investigation indicate that the print direction has a greater role in deciding the optimum value of mechanical properties for FDM 3D printed high-grade thermoplastic PEEK polymer.

This study is valid for the parameter ranges, which are defined to conduct the experimentation.

This study has been conducted on the basis of taking only a few important process parameters as per the literatures and available scope of the study; however, there are many other parameters, e.g. wall thickness, road width, print orientation, fill pattern, roller speed, retraction, etc. which can be included to make a more comprehensive investigation and accuracy of the results for practical implementation.

This study deploys a novel meta-model-based optimization approach for enhancing the mechanical properties of high-grade thermoplastic polymers, which is rarely available in the published literature in the research domain.

Additive manufacturing (AM) is a layer-by-layer technique that helps to create physical objects from a three-dimensional data set. Fused deposition modeling is a widely used material extrusion (MEX)-based AM technique that melts thermoplastic filaments and selectively deposits them over a build platform. Despite its simplicity and affordability, it suffers from various printing defects, with partial warping being a prevalent issue. Warpage is a physical deformation caused by thermal strain incompatibility that results in the bending of the printed part away from the build platform. This study aims to investigate the warpage characteristics of printed parts based on geometrical parameters and build orientations to reduce the warpage extent.

Cuboidal samples of thermoplastic acrylonitrile butadiene styrene ranging from 5 to 80 mm were printed using a commercial MEX system. A Taguchi method-based design of experiment trial was performed to optimize the placement and orientation of the part for minimal warpage.

It was found that a lower value of the “in-plane” aspect ratio and a more prominent part thickness are favorable for minimal warpage. The part should always be placed near the region with the highest temperature (least thermal gradient) to minimize the warpage.

A novel dimensionless parameter (Y) is proposed that should be set to a minimum value to achieve minimal warpage. The results of this study can help improve the design and part placement for the MEX technique, thus elevating the print quality.

Herein, the authors report the effects of printing parameters, joining method, and annealing conditions on the structural performance of fusion-joined short-beam sections produced by additive manufacturing.

The authors first identified appropriate printing parameters for joining segmented short beams and then used those parameters to print and fusion-join segments with different configurations of stiffeners to form a longer section of a wing or small wind turbine blade structure.

It was found that the beams with three lateral and three base stiffening ribs give the highest flexural strength among the three beams investigated. Results on joined beams annealed at different conditions showed that annealing at 70 °C for 0.5 h yields higher performance than annealing at the same temperature for longer times. It is also found that in the case of the hot-plate-welded three-dimensional (3D)-printed structures, no annealing is needed for reaching a high strength-to-weight ratio, but annealing is helpful for maximizing the modulus-to-weight ratio. Both thermal buckling and edge wrapping were observed under annealing at 70°C for 0.5 h for 3D-printed beams comprising two lateral and four base stiffening plates.

Fusion-joining of additively manufactured segments is needed owing to the constraint in building volume of a typical commercial 3D-printer. However, study of the effect of process parameters is needed to quantify their effect on mechanical performance. This investigation has therefore identified key printing parameters and annealing conditions for fusion-joining short segments to form larger structures, from multiple 3D-printed sections, such as wind blade structures.

Additive manufacturing (AM), also known as three-dimensional (3D) printing technology, has been used in the health-care industry for over two decades. It is in high demand in the health-care industry due to its strength to manufacture custom-designed and personalized 3D constructs. Recently, AM technologies are being explored to develop personalized drug delivery systems, such as personalized oral dosages, implants and others due to their potential to design and develop systems with complex geometry and programmed controlled release profile. Furthermore, in 2015, the US Food and Drug Administration approved the first AM medication, Spritam® (Apprecia Pharmaceuticals) which has led to tremendous interest in exploring this technology as a bespoke solution for patient-specific drug delivery systems. The purpose of this study is to provide a comprehensive overview of AM technologies applied to the development of personalized drug delivery systems, including an analysis of the commercial status of AM based drugs and delivery devices.

This review paper provides a detailed understanding of how AM technologies are used to develop personalized drug delivery systems. Different AM technologies and how these technologies can be chosen for a specific drug delivery system are discussed. Different types of materials used to manufacture personalized drug delivery systems are also discussed here. Furthermore, recent preclinical and clinical trials are discussed. The challenges and future perceptions of personalized medicine and the clinical use of these systems are also discussed.

Substantial works are ongoing to develop personalized medicine using AM technologies. Understanding the regulatory requirements is needed to establish this area as a point-of-care solution for patients. Furthermore, scientists, engineers and regulatory agencies need to work closely to successfully translate the research efforts to clinics.

This review paper highlights the recent efforts of AM-based technologies in the field of personalized drug delivery systems with an insight into the possible future direction.

This study aims to evaluate the development of composites made of epoxy (E) resin with different weight percentages of polypropylene (PP) and graphene oxide (Go) to form nanocomposite plates.

A hand lay-up process was used to develop 21 different composites, with varying concentrations of PP (5%–35%) and Go (5%–35%). A ternary composite of E matrix was produced by combining binary fillers PP and Go (5%–35%) in a 1:1 ratio to a (95%–5%) solution. With the help of adopting the melt condensation deal to extract Go, the modified Hummers method was used to make Go platelets.

Through field emission scanning electron microscopy (FESEM) and X-ray diffraction investigations, the particulate’s size and structural characteristics were identified. Based on the FESEM analysis of the collapsed zones of the composites, a warp-and-weft-like structure is evident, which endorses the growth yield strength, flexural modulus and impact strength of the composites.

The developed nanocomposites have exceptional mechanical capabilities compared to plain E resin, with E resin exhibiting better tensile strength, modulus and flexural strength when combined with 10% PP and 10% Go. When compared to neat E resin, materials formed from composites have exceptional mechanical properties. When mixed with 10% PP and 10% Go, E resin in particular displays improved tensile strength (23 MPa), tensile modulus (4.15 GPa), flexural strength (75.6 MPa) and other attributes. Engineering implications include automobile side door panels, spacecraft applications, brake pads and flexible battery guards.

Cracking, deformation and rutting are the most prevalent types of pavement distress, and these deformations and flow characteristics greatly distress the pavement features while also limiting its use. In India, on the other hand, more than 300 million scrap tyres are generated each year, and their disposal has become a severe environmental issue. Furthermore, the scrap generated by the used tyre must be disposed of properly. Hence, this study presents the experimental investigations of bitumen incorporating with Crumb rubber as main additive along with SBS polymer, to enhance the engineering property.

Crumb rubber (CR) was used as an additive along with styrene–butadiene–styrene (SBS) polymer to enrich the engineering qualities of the bitumen to reduce the disposal problem of scrap tyres and reduce the risk of environmental pollution. Because SBS polymer is expensive, response surface methodology modelling's central composite design (CCD) was used to optimise the number of tests. CCD modelling's input factors (process variables) were the inclusion rates of SBS and CR, which ranged from 2% to 5% and 4% to 10%, respectively, by total weight. Furthermore, the influence of SBS polymer and CR on the characteristics of modified bitumen was prioritised.

The addition of SBS and CR enhanced the bitumen's penetration resistance at service temperatures. Furthermore, increasing the SBS and CR concentration affected the flow characteristics of the modified bitumen and enhanced its viscosity. The addition of SBS and CR as bitumen modifiers increased penetration resistance by 24.06%. The Dynamic Shear Rheometer test demonstrated that the complex modulus of virgin bitumen increases with increasing SBS and CR content, which is consistent with the shifting softening point trend. The dosing rate of up to 3.5% SBS and 11% CR considerably contributed to the creation of polymer link networks, which increased the complex modulus of the bitumen by 16.5%. The CCD model's analysis of variance and Pareto bar chart demonstrated that the dose of CR is significant in improving the engineering features of the virgin bitumen rather than the SBS.

The utilisation of CR as a bitumen modifier may solve the problem of waste tyre disposal while also lowering the risk of environmental damage. Furthermore, because the presence of CR increased the engineering properties, particularly the complex modulus of virgin bitumen, the use of CR in combination with SBS polymer can be an efficient and cost-effective strategy to improving bitumen qualities.

This paper aims to present a predictive model approach to estimate the tensile behavior of polylactic acid (PLA) under uncertainty using the fused deposition modeling (FDM) and American Society for Testing and Materials (ASTM) D638’s Types I and II test standards.

The prediction approach combines artificial neural network (ANN) and finite element analysis (FEA), Monte Carlo simulation (MCS) and experimental testing for estimating tensile behavior for FDM considering uncertainties of input parameters. FEA with variance-based sensitivity analysis is used to quantify the impacts of uncertain variables, resulting in determining the significant variables for use in the ANN model. ANN surrogates FEA models of ASTM D638’s Types I and II standards to assess their prediction capabilities using MCS. The developed model is applied for testing the tensile behavior of PLA given probabilistic variables of geometry and material properties.

The results demonstrate that Type I is more appropriate than Type II for predicting tensile behavior under uncertainty. With a training accuracy of 98% and proven presence of overfitting, the tensile behavior can be successfully modeled using predictive methods that consider the probabilistic nature of input parameters. The proposed approach is generic and can be used for other testing standards, input parameters, materials and response variables.

Using the proposed predictive approach, to the best of the authors’ knowledge, the tensile behavior of PLA is predicted for the first time considering uncertainties of input parameters. Also, incorporating global sensitivity analysis for determining the most contributing parameters influencing the tensile behavior has not yet been studied for FDM. The use of only significant variables for FEA, ANN and MCS minimizes the computational effort, allowing to simulate more runs with reduced number of variables within acceptable time.

Snap fits are crucial in automotive applications for rapid assembly and disassembly of mating components, eliminating the need for fasteners. This study aims to focus on designing and analyzing serviceable cantilever fit snap connections used in automobile plastic components. Snap fits are classified into permanent and semi-permanent fittings, with permanent fittings having a snap clipping angle between 0° and 5° and semi-permanent fittings having a clipping angle between 15° and 45°. Polypropylene random copolymer is chosen for its exceptional fatigue resistance and elasticity.

The design process includes determining dimensions, computing assembly, disassembly pressures and creating three-dimensional computer-aided design models. Finite element analysis (FEA) is used to evaluate the snap-fit mechanism’s stress, deformation and general functionality in operational scenarios.

The study develops a modified snap-fit mechanism with decreased bending stress and enhanced mating force optimization. The maximum bending stress during assembly is 16.80 MPa, requiring a mating force of 7.58 N, while during disassembly, it is 37.3 MPa, requiring a mating force of 16.85 N. The optimized parameters significantly improve the performance and dependability of the snap-fit mechanism. The results emphasize the need of taking into account both the assembly and disassembly processes in snap-fit design, because the research demonstrates greater forces during disassembly. The approach developed integrates FEA and design for assembly (DFA) concepts to provide a solution for improving the efficiency and reliability of snap-fit connectors in automotive applications.

The research paper’s distinctiveness comes from the fact that it presents a thorough and realistic viewpoint on snap-fit design, emphasizes material selection, incorporates DFA principles and emphasizes the specific requirements of both assembly and disassembly operations. These discoveries may enhance the efficiency, reliability and sustainability of snap-fit connections in plastic automobile parts and beyond. In conclusion, the idea that disassembly needs to be done with a lot more force than installation in a snap-fit design can have a good effect on buzz, squeak and rattle and noise, vibration and harshness characteristics in automobiles.

The manufacture of polymer composites with a lower environmental footprint requires incorporation of sustainably sourced components. In addition, the incorporation of novel components should not compromise the material properties. The purpose of this paper is to demonstrate the use of a synthetic amine functional toluidine acetaldehyde condensate (AFTAC) as a modifier for fiber-reinforced epoxy composites. One of the fiber components was sourced from agricultural byproducts, and glass fiber was used as the fiber component for comparison.

The AFTAC condensate was synthesized via an acid-catalyzed reaction between o-toluidine and acetaldehyde. To demonstrate its efficacy as a toughening agent for diglycidyl ether bisphenol A resin composites and for the comparison of reinforcing materials of interest, composites were fabricated using a natural fiber (mat stick) and a synthetic glass fiber as the reinforcing material. A matched metal die technique was used to fabricate the composites. Composites were prepared and their mechanical and thermal properties were evaluated.

The inclusion of AFTAC led to an improvement in the mechanical strengths of these composites without any significant deterioration of the thermal stability. It was also observed that the fracture strengths for mat stick fiber-reinforced composites were lower than that of glass fiber-reinforced composites.

To the best of the authors’ knowledge, the use of the AFTAC modifier as well as incorporation of mat stick fibers in epoxy composites has not been demonstrated previously.