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Additive manufacturing (AM) methods such as material extrusion (ME) are becoming widely used by engineers, designers and hobbyists alike for a wide variety of applications. Successfully manufacturing objects using ME three-dimensional printers can often require numerous iterations to attain predictable performance because the exact mechanical behavior of parts fabricated via additive processes are difficult to predict. One of that factors that contributes to this difficulty is the wide variety of ME feed stock materials currently available in the marketplace. These build materials are often sold based on their base polymer material such as acrylonitrile butadiene styrene or polylactic acid (PLA), but are produced by numerous different commercial suppliers in a wide variety of colors using typically undisclosed additive feed stocks and base polymer formulations. This paper aims to present the results from an experimental study concerned with quantifying how these sources of polymer variability can affect the mechanical behavior of three-dimensional printed objects. Specifically, the set of experiments conducted in this study focused on following: several different colors of PLA filament from a single commercial supplier to explore the effect of color additives and three filaments of the same color but produced by three different suppliers to account for potential variations in polymer formulation.

A set of five common mechanical and material characterization tests were performed on 11 commercially available PLA filaments in an effort to gain insight into the variations in mechanical response that stem from variances in filament manufacturer, feed stock polymer, additives and processing. Three black PLA filaments were purchased from three different commercial suppliers to consider the variations introduced by use of different feed stock polymers and filament processing by different manufacturers. An additional eight PLA filaments in varying colors were purchased from one of the three suppliers to focus on how color additives lead to property variations. Some tests were performed on unprocessed filament samples, while others were performed on objects three-dimensional printed from the various filaments. This study looked specifically at four mechanical properties (Young’s modulus, storage modulus, yield strength and toughness) as a function of numerous material properties (e.g. additive loading, molecular weight, molecular weight dispersity, enthalpy of melting and crystallinity).

For the 11 filaments tested the following mean values and standard deviations were observed for the material properties considered: p_a = 1.3 ± 0.9% (percent additives), M_w = 98.6 ± 16.4 kDa (molecular weight), Ð = 1.33 ± 0.1 (molecular weight dispersity), H_m = 37.4 ± 7.2 J/g (enthalpy of melting) and = 19.6 ± 2.1% (crystallinity). The corresponding mean values and standard deviations for the resulting mechanical behaviors were: E = 2,790 ± 145 MPa (Young’s modulus), E’ = 1,050 ± 125 MPa (storage modulus), S_y = 49.6 ± 4.93 MPa (yield strength) and U_t = 1.87 ± 0.354 MJ/m^³ (toughness). These variations were observed in filaments that were all manufactured from the same base polymer (e.g. PLA) and are only different in terms of the additives used by the manufacturers to produce different colors or different three-dimensional printing performance. Unfortunately, while the observed variations were significant, no definitive strong correlations were found between these observed variations in the mechanical behavior of the filaments studied and the considered material properties.

These variations in mechanical behavior and material properties could not be ascribed to any specific factor, but rather show that the mechanical of three-dimensional printed parts are potentially affected by variations in base polymer properties, additive usage and filament processing choices in complex ways that can be difficult to predict.

These results emphasize the need to take processing and thereby even filament color, into account when using ME printers, they emphasize the need for designers to use AM with caution when the mechanical behavior of a printed part is critical and they highlight the need for continued research in this important area. While all filaments used were marked as PLA, the feedstock materials, additives and processing conditions created significant differences in the mechanical behavior of the printed objects evaluated, but these differences could not be accurately and reliably predicted as function of the observed material properties that were the focus of this study.

The testing methods used in the study can be used by engineers and creators alike to better analyze the material properties of their filament printed objects, to increase success in print and mechanical design. Furthermore, the results clearly show that as AM continues to evolve and grow as a manufacturing method, standardization of feedstock processing conditions and additives would enable more reliable and repeatable printed objects and would better assist designers in effectively implementing AM methods.

The purpose of this study is to understand how printing parameters and subsequent annealing impacts porosity and crystallinity of 3D printed polylactic acid (PLA) and how these structural characteristics impact the printed material’s tensile strength in various build directions.

Two experimental studies were used, and samples with a flat vs upright print orientation were compared. The first experiment investigates a scan of printing parameters and annealing times and temperatures above the cold crystallization temperature (T_cc) for PLA. The second experiment investigates annealing above and below T_cc at multiple points over 12 h.

Annealing above T_cc does not significantly impact the porosity but it does increase crystallinity. The increase in crystallinity does not contribute to an increase in strength, suggesting that co-crystallization across the weld does not occur. Atomic force microscopy (AFM) images show that weld interfaces between printed fibers are still visible after annealing above T_cc, confirming the lack of co-crystallization. Annealing below T_cc does not significantly impact porosity or crystallinity. However, there is an increase in tensile strength. AFM images show that annealing below T_cc reduces thermal stresses that form at the interfaces during printing and slightly “heals” the as-printed interface resulting in an increase in tensile strength.

While annealing has been explored in the literature, it is unclear how it affects porosity, crystallinity and thermal stresses in fused filament fabrication PLA and how those factors contribute to mechanical properties. This study explains how co-crystallization across weld interfaces is necessary for crystallinity to increase strength and uses AFM as a technique to observe morphology at the weld.

This paper aims to provide an overview of the recent findings of the mechanical properties of parts manufactured by fused deposition modeling (FDM). FDM has become a widely used technique for the manufacturing of thermoplastic parts. The mechanical performance of these parts under service conditions is difficult to predict due to the large number of process parameters involved. The review summarizes the current knowledge about the process-property relationships for FDM-based three-dimensional printing.

The review first discusses the effect of material selection, including pure thermoplastics and polymer-matrix composites. Second, process parameters such as nozzle temperature, raster orientation and infill ratio are discussed. Mechanisms that these parameters affect the specimen morphology are explained, and the effect of each parameter on the strength of printed parts are systematically presented.

Mechanical properties of FDM-produced parts strongly depend on process parameters and are usually lower than injection-molded counterparts. There is a need to understand the effect of each parameter and any synergistic effects involved better.

Through the optimization of process parameters, FDM has the potential to produce parts with strength values matching those produced by conventional methods. Further work in the field will make the FDM process more suitable for the manufacturing of load-bearing components.

This paper presents a critical assessment of the current knowledge about the mechanical properties of FDM-produced parts and suggests future research directions.

The emergence of tissue engineering has led to the development of three‐dimensional cellular scaffolds that reconstruct the tissue structure. Research into the use of biodegradable materials in scaffolds has grown; the aim is that when tissue growth is complete, the scaffold degrades completely. This research aims to design novel scaffolds and investigates biodegradable polylactide (PLA) yarns; in particular, poly(l‐lactide) (PLLA) yarns extruded in‐house. To study degradation and determine the effect on the biodegradable yarns/textiles, they were immersed in phosphate buffer solution (PBS, pH=7.4) for various durations at 37°C. Mechanical properties were evaluated on tensile testing rigs and they were observed, before and after the immersion period. Cells were then cultured (37°C, 5 per cent carbon dioxide in air) on the textiles for 1 week. As expected, after immersion, the yarns exhibit a decrease in elongation and tenacity. Initial results indicate that the yarn properties influence cell attachment and spreading.

In this study, a three‐dimensional (3D) flow model is used to approximate the crystallinity gradients of slowly crystallizing polymers developed in the injection molding process. A generalized second order parallel splitting formula is constructed to achieve both the accuracy and efficiency of the computation. Calculated values of flow‐wise (flow‐thickness plane) and width‐wise (width‐thickness plane) crystallinity distributions are obtained and compared with experimental results. The structure‐oriented simulation method developed is not only capable of describing moldability parameters, but is also able to predict the characteristics of ultimate properties of the final products.

The purpose of this paper is to explore the synthesis, preparation and investigation of micro structural, optical and mechanical studies of polyvinyl alcohol (PVA) doped with tungsten oxide (WO₃) nanocomposites films. These films were prepared by simple solvent casting method is further characterized using Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), UV-visible spectroscopy, universal testing machine (UTM), scanning electron microscope (SEM), energy-dispersive analysis of X-rays (EDAX) and atomic force microscope (AFM) techniques to determine the enhancement in structural, optical and mechanical properties with increase in dopant concentration.

The present paper deals with the synthesis of WO₃ nanoparticles using precipitation method and doping into PVA matrix to prepare a polymer nanocomposite film using coagulation and solvent casting method. The FTIR explores the interaction of dopants with PVA matrix. The XRD spectra investigate the variation of crystallinity. The UV/Vis-spectra reveals the information of optical energy band gap and the Urbach Energy for different doping concentrations. The mechanical properties of the nanocomposites were exposed using UTM. The phase homogeneity, film topography, chemical composition of nanocomposites is analyzed using SEM, EDAX and AFM techniques supporting the above results.

The films characterized by FTIR spectroscopy explores the irregular shift in the bands of pure and doped PVA can be understood on the basis of intra/inter molecular hydrogen bonding with the adjacent OH group of PVA backbone. The XRD result reconnoiters that the particle size and crystallinity increases whereas microstructural strain and dislocation density decreases with increase in dopant concentration. Further the drastic decrease in optical energy band gap E _g =0.94 eV for doping concentration x=15 wt% and the increase in values of Urbach Energy (E _u ) with doping concentrations were investigated by UV/Vis spectra. Also the extinction coefficient was high in the wavelength range of 250-400 nm and low in the wavelength range of 400-1,200 nm. The mechanical studies indicates that the addition of the WO₃ with weight percentage concentration x=15 percent increases the tensile strength and Young’s modulus. The phase homogeneity, the particle size of the dopants and chemical composition of nanocomposites is analyzed using SEM and EDAX. The film topography of the nanocomposites is analyzed using AFM techniques supporting the above results.

The investigation of synthesis, preparation and investigation of micro structural, optical and mechanical studies of PVA doped with WO₃ nanocomposites films as been done. The results prove that these nanocomposites having good mechanical strength with crystalline nature and also very low optical energy gap value that could find possible applications in industries.

The purpose of this paper is to investigate the effect of different heating approaches during thermal rounding of polymer powders on powder bulk properties such as particle size, shape and flowability, as well as on the yield of process.

This study focuses on the rounding of commercial high-density polyethylene polymer particles in two different downer reactor designs using heated walls (indirect heating) and preheated carrier gas (direct heating). Powder bulk properties of the product obtained from both designs are characterized and compared.

Particle rounding with direct heating leads to a considerable increase in process yield and a reduction in powder agglomeration compared to the design with indirect heating. This subsequently leads to higher powder flowability. In terms of shape, indirect heating yields not only particles with higher sphericity but also entails substantial agglomeration of the rounded particles.

Shape modification via thermal rounding is the decisive step for the success of a top-down process chain for selective laser sintering powders with excellent flowability, starting with polymer particles from comminution. This report provides new information on the influence of the heating mode (direct/indirect) on the performance of the rounding process and particle properties.

Process parameters in Fused Filament Fabrication (FFF) can affect mechanical and surface properties of printed parts. Numerous studies have reported parametric studies of various materials using full factorial and Taguchi design of experiments (DoEs). However, a comparison between the two are not well-established in literature. The purpose of this study is to compare full factorial and Taguchi DoEs to determine the effects of FFF process parameters on mechanical and surface properties of Nylon 6/66 copolymer. In addition, perform in-depth failure mechanism analysis to understand why the process parameters affect the responses.

A full factorial DoE was used to determine the effects of FFF process parameters, such as infill density, infill pattern, layer height and raster angle on responses, such as compressive strength, impact strength, surface roughness and manufacturing time of Nylon 6/66. Micro-computed tomography was used to analyse the impact test samples before and after impact and scanning electron microscope was used to understand the failure mechanism of infill and top layers. Differential scanning calorimetry (DSC) scans of infill and top layers were then taken to determine if a variation in crystallinity existed in different regions of the build.

Analysis of variance and main effects plots reveal that infill density has the greatest effect on mechanical and surface properties while manufacturing time is most affected by layer height for the polymer used. A 20% reduction in infill increased impact strength by 19% on average, X-ray images of some of the samples before and after impact tests are presented to understand the reason behind the difference. Moreover, DSC revealed a difference in the degree of crystallinity between the infill and top layers for 80% infill density samples. In addition, Taguchi DoE is realized to be a more efficient technique to determine optimum process parameters for responses that vary linearly as it reduces experimental effort significantly while providing mostly accurate results.

To the author’s knowledge, no published paper has reported a comparison between predictive DoE method with full factorial DoE to verify their accuracy in determining the effects of FFF process parameters on properties of printed parts. Also, a theory was developed based on DSC results that as the infill is printed faster, it cools slowly compared to the top layers, and hence the infill is in a less crystalline state when compared to the top layers. This increased the ductility of the infill (of 80% infill samples) and thus improved impact absorption.

This study aims to demonstrate for the first time that the cheap, commodity polymer, poly(propylene), can be successfully processed using high speed sintering, and that it can be recycled several times through the process, with little to no detriment to either the polymer itself or the parts obtained. This is significant as a step towards the realisation of high speed sintering as a technology for high-volume manufacturing.

A poly(propylene) powder designed for laser sintering was used to build parts on a high speed sintering machine. The unsintered powder was then collected and reused. Repeating this process allowed creation of seven generations of aged powder. A variety of characterisation techniques were then used to measure polymer, powder and part properties for each generation to discern any effects arising from ageing in the machine.

It was found that poly(propylene) could be used successfully in high speed sintering, albeit with a low build success rate. Increased powder age was found to correlate to an increase in the build success rate, changes in microscopic and bulk powder properties and improvement to the dimensional accuracy of the parts obtained. By contrast, no discernible correlations were seen between powder age and polymer molecular weight, or between powder age and the tensile properties of parts.

This is the first report of the use of poly(propylene) in high speed sintering. It is also first study regarding powder recyclability in high speed sintering, both in general and using poly(propylene) specifically.

Polyethylene terephthalate (PET) as a fiber molding polymer is widely used in aerospace, electrical and electronic, clothing and other fields. The purpose of this study is to improve the thermal insulation performance of polyethylene terephthalate (PET), the SiO₂ aerogel/PET composites slices and fibers were prepared, and the effects of the SiO₂ aerogel on the morphology, structure, crystallization property and thermal conductivity of the SiO₂ aerogel/PET composites slices and their fibers were systematically investigated.

The mass ratio of purified terephthalic acid and ethylene glycol was selected as 1:1.5, which was premixed with Sb₂O₃ and the corresponding mass of SiO₂ aerogel, and SiO₂ aerogel/PET composites were prepared by direct esterification and in-situ polymerization. The SiO₂ aerogel/PET composite fibers were prepared by melt-spinning method.

The results showed that the SiO₂ aerogel was uniformly dispersed in the PET matrix. The thermal insulation coefficient of PET was significantly reduced by the addition of SiO₂ aerogel, and the thermal conductivity of the 1.0 Wt.% SiO₂ aerogel/PET composites was reduced by 75.74 mW/(m · K) compared to the pure PET. The thermal conductivity of the 0.8 Wt.% SiO₂ aerogel/PET composite fiber was reduced by 46.06% compared to the pure PET fiber. The crystallinity and flame-retardant coefficient of the SiO₂ aerogel/PET composite fibers showed an increasing trend with the addition of SiO₂ aerogel.

The SiO₂ aerogel/PET composite slices and their fibers have good thermal insulation properties and exhibit good potential for application in the field of thermal insulation, such as warm clothes. In today’s society where the energy crisis is becoming increasingly serious, improving the thermal insulation performance of PET to reduce energy loss will be of great significance to alleviate the energy crisis.

In this study, SiO₂ aerogel/PET composite slices and their fibers were prepared by an in situ polymerization process, which solved the problem of difficult dispersion of nanoparticles in the matrix and the thermal conductivity of PET significantly reduced.