3D-printed Components Research Articles

Interfacial characterization of soil-3D printing materials

3D printing has emerged as a revolutionary technique for producing products with specific shapes and mechanical properties tailored to various needs. Its ability to fabricate intricate structures and forms has garnered considerable attention, leading to numerous research efforts exploring its potential benefits in geotechnical applications. These endeavours highlight the possibilities of utilizing 3D printing technology to create innovative and customized materials for soil reinforcement, such as geosynthetics, and fibres, as well as replicating soil particles, physical models of soil structures, and drainage systems in geo-structures. Additionally, beyond its role in geotechnical engineering, the interaction between geo-structures (foundations, retaining walls, embankments, tunnels, piles, infrastructures, etc.) and the surrounding soil under different loading and environmental conditions is of paramount importance. The interface between these structures and the soil plays a critical role in load transfer and overall stability. Therefore, this study focuses on investigating the interface between soil and 3D printed components through direct shear testing. The experimental campaign aims to examine how different factors, including the type of 3D printing materials, material rigidity, and surface texture of the printed components, influence the shear behaviour of the soil-3D printing material interface. The findings suggest that Young’s modulus of the 3D printed materials plays a crucial role in determining the response of the soil-3D printed parts interface. Furthermore, an optimized design is proposed to achieve the desired shearing resistance at the interface. The insights gained from this investigation have practical implications for optimizing the design of 3D-printed components in geotechnical engineering applications.

Theory of Critical Distances and notched filament-based 3D-printed components: lessons learned from polymers and concrete

The present paper reviews the work we did in recent years (Ahmed and Susmel, 2018, 2019; Alanzi et al., 2022) – to use the Theory of Critical Distances to model the detrimental effect of manufacturing defects and voids in 3D-printed concrete/polymers subjected to static loading. The validity and robustness of the proposed approach is assessed against a large number of experimental results that were generated by testing 3D-printed specimens of both concrete and polylactide (PLA) containing manufacturing defects/voids. The sound agreement between experiments and predictive model makes it evident that the Theory of Critical Distances (TCD) is not only a reliable design approach, but also a powerful tool suitable for guiding and informing effectively the additive manufacturing process.

Progress in materials for 3D printing

The realm of 3D printing is rapidly evolving, offering a wide range of options from typical thermoplastics to advanced graphene-based composites. This technology improves production efficiency and gives consumers more control over customizing products and specifications. However, alongside its transformative potential, 3D printing also presents challenges, such as potential impacts on manufacturing jobs and security issues. Since its modest beginnings in developing visualization models, 3D printing has evolved to transform the manufacturing of distinct devices, implants, tissue engineering scaffolds, and drug delivery systems. This paper explores the most recent progress in 3D printing materials, including smart materials, ceramics, electronics, biomaterials, and composites, emphasizing the significance of adapting to changing materials and product requirements. It delves into the complex connection between printing parameters and the characteristics of printed composite parts, providing new opportunities to improve the strength and functionality of 3D-printed components. This review highlights how 3D printing can be utilized in various industries, such as medical devices and explosives research, using materials such as titanium, aluminum, carbon fiber, and thermoplastic polyurethanes. With the continuous growth of the 3D printing field, it is essential to adopt new methods and materials to fully realize its impact on the future of manufacturing and product development.

Mechanical Characterisation of Bond Formation during Overprinting of PEEK Laminates.

The latest generation of high-temperature 3D printers enables the production of complex structural components from aerospace-grade thermoplastics such as PEEK (polyether ether ketone). However, adding long or continuous fibres is currently limited, and thermal stresses introduced during the process restrict the maximum part dimensions. Combining 3D-printed components with continuous fibre-reinforced components into one hybrid structure has the potential to overcome such limitations. This work aims to determine whether in situ bonding between PEEK laminates and PEEK 3D printing during overprinting is feasible and which process parameters are significantly responsible for the bonding quality. To this end, the bonding is analysed experimentally in two steps. Firstly, the influence of the process parameters on the thermal history and the strength of the bond is investigated. In the second step, a detailed investigation of the most critical parameters is carried out. The investigation showed the feasibility of overprinting with bonding strengths of up to 15 MPa. It was shown that the bonding strength depends primarily on the temperature in the interface. Additionally, the critical parameters to control the process were identified. The process influences that were displayed form the basis for future hybrid component and process designs.

Intercalary Prosthetic Reconstruction with Three-Dimensional-Printed Custom-Made Porous Component for Defects of Long Bones with Short Residual Bone Segments After Tumor Resection.

Intercalary reconstruction for patients with short residual bone segments remains challenging. Three-dimensional (3D)-printed custom-made porous implants are a promising technique for short-segment fixation in these patients. This study aims to evaluate the efficiency of 3D-printed custom-made porous components (3DCPCs) for short-segment fixation, focusing on prosthesis survivorship, radiographic results, and potential complications. This retrospective study involved 39 patients who underwent intercalary prosthetic reconstruction with 3DCPCs after tumor resection of the femur, tibia, or humerus from June 2015 to October 2020. Segment bone loss involved the femur (n = 15), tibia (n = 16), and humerus (n = 8), leaving 78 residual bone segments. There were 46 short segments requiring 46 3DCPCs and 32 segments with the ability to accommodate 32 off-the-shelf standard uncemented stems for prosthesis fixation. Clinical and functional outcomes were evaluated. Prosthesis-overall survivorship and prosthesis-specific survivorship were analyzed using Kaplan-Meier survival analysis. Radiographic results and modes of failure of using this technique were also examined. The mean follow-up was 41 months. The prosthesis-overall survivorship was 87.2% and 84.6% at 2 and 5 years, respectively. The prosthesis-specific survivorship was 92.1% and 89.5% at 2 and 5 years, respectively. There was not a substantial difference in prosthesis survivorship among the femur, tibia, and humerus. The average MSTS score was 26.2, ranging from 22 to 28. The radiographic evaluation results revealed excellent or good interface (38/46) in most of the 46 porous components. A total of 38 of 46 bone segments' remolding demonstrated no change. In total, seven patients (16.3%) had complications requiring further surgery. The prosthesis survivorship of using 3DCPCs for short-segment fixation is similar or better compared to other studies involving intercalary prosthetic reconstruction with short-segment fixation. Radiographic evaluation revealed good osteointegration and avoidance of stress shielding. Overall, intercalary prosthetic reconstruction with 3DCPC is a feasible modality for patients with short residual bone segments after tumor resection.

An Open-Source 3D-Printed Hindlimb Stabilization Apparatus for Reliable Measurement of Stimulation-Evoked Ankle Flexion in Rat.

Currently there are numerous methods to evaluate peripheral nerve stimulation interfaces in rats, with stimulation-evoked ankle torque being one of the most prominent. Commercial rat ankle torque measurement systems and custom one-off solutions have been published in the literature. However, commercial systems are proprietary and costly and do not allow for customization. One-off lab-built systems have required specialized machining expertise, and building plans have previously not been made easily accessible. Here, detailed building plans are provided for a low-cost, open-source, and basic ankle torque measurement system from which additional customization can be made. A hindlimb stabilization apparatus was developed to secure and stabilize a rat's hindlimb, while allowing for simultaneous ankle-isometric torque and lower limb muscle electromyography (EMG). The design was composed mainly of adjustable 3D-printed components to accommodate anatomical differences between rat hindlimbs. Additionally, construction and calibration procedures of the rat hindlimb stabilization apparatus were demonstrated in this study. In vivo torque measurements were reliably acquired and corresponded to increasing stimulation amplitudes. Furthermore, implanted leads used for intramuscular EMG recordings complemented torque measurements and were used as an additional functional measurement in evaluating the performance of a peripheral nerve stimulation interface.In conclusion, an open-source and noninvasive platform, made primarily with 3D-printed components, was constructed for reliable data acquisition of evoked motor activity in rat models. The purpose of this apparatus is to provide researchers a versatile system with adjustable components that can be tailored to meet user-defined experimental requirements when evaluating motor function of the rat hindlimbs.

A Survey on Extraterrestrial Habitation Structures with a Focus on Energy-Saving 3D Printing Techniques

In the past two decades, various space agencies have shown great enthusiasm for constructing habitable structures on lunar and Martian surfaces. Consequently, several extraterrestrial structures have been proposed by different researchers. Nevertheless, only a small number of those structures are energy-efficient and cost-effective. In this research, a comprehensive review of the proposed extraterrestrial structures has been conducted. The objective is to evaluate different habitat construction techniques from technical, economic, and energy-consumption perspectives. To carry this out, different proposed structures are elaborated, and their advantages and limitations are discussed. The primary focus is on the 3D printing technique, which has demonstrated significant potential in automated manufacturing tasks. From the conducted research, it was found that the combination of 3D-printed components along with an internal breathable inflatable module is the most promising technique for habitat development on the Moon and Mars. Moreover, the microwave sintering method was identified as the most energy-saving and reliable approach for melting the on-site regolith for use in the 3D printing process. This survey has applied a multidisciplinary approach to evaluate the most energy-saving planetary construction techniques that are economically crucial for different private or government-funded space agencies.

Poke And Delayed Drink Intertemporal Choice Task (POKE-ADDICT): An open-source behavioral apparatus for intertemporal choice testing in rodents.

Advancements in neuroscience research present opportunities and challenges, requiring substantial resources and funding. To address this, we describe here "Poke And Delayed Drink Intertemporal Choice Task (POKE-ADDICT)", an open-source, versatile, and cost-effective apparatus for intertemporal choice testing in rodents. This allows quantification of delay discounting (DD), a cross-species phenomenon observed in decision making which provides valuable insights into higher-order cognitive functioning. In DD, the subjective value of a delayed reward is reduced as a function of the delay for its receipt. Using our apparatus, we implemented an effective intertemporal choice paradigm for the quantification of DD based on an adjusting delayed amount (ADA) algorithm using mango juice as a reward. Our paradigm requires limited training, a few 3D-printed parts and inexpensive electrical components, including a Raspberry Pi control unit. Furthermore, it is compatible with several invivo procedures and the use of nose pokes instead of levers allows for faster task learning. Besides the main application described here, the apparatus can be further extended to implement other behavioral tests and protocols, including standard operant conditioning. In conclusion, we describe a versatile and cost-effective design based on Raspberry Pi that can support research in animal behavior, decision making and, more specifically, delay discounting.

Open material database for tensile test properties of additive manufacturing materials

In recent years, the investigation of material properties within additive manufacturing, also known as 3D printing, has gained significant research attention. The intricate interplay between numerous fabrication parameters and the resultant material properties of 3D-printed components has become crucial, particularly for enabling effective topology optimization. Considering this, we propose the establishment of an accessible open database. This repository stores a comprehensive collection of fabrication files corresponding to each distinct material and printer combination, accompanied by the outcomes of meticulous tensile testing. To support the research community, our initiative extends to the inclusion of material provider datasheets, facilitating comprehensive result comparisons. A standardized approach utilizing consistently applied strain rates is recommended, focusing on a compact dog bone specimen design. This pioneering attempt encompasses an expansive array of data derived from 25 distinct materials and 9 diverse printers, meticulously capturing the inherent variability within the samples. The database catalogues the complete spectrum of tensile test data, encompassing various essential measurements such as mass, and crucial material properties including Young’s modulus, yield stress, fracture strain, and absorbed energy. These recorded metrics can be seamlessly correlated against density, manufacturing time, or cost parameters, enabling the generation of insightful plots and analysis. Through this collaborative effort, we aim to provide researchers with a robust foundation for informed decision-making and advancements in additive manufacturing.

Intrawound navigation for custom-made acetabular component in revision total hip arthroplasty: Does it improve implant positioning?

BackgroundThe number of hip revisions makes up over 12 % of all hip arthroplasty cases. For large acetabular defects custom-made acetabular component (CMAC) are required. Rates of malposition of CMACs are highly variable. Our study aims to develop a readily available, reliable and easily reproducible method for positioning of the CMAC. We tried to answer the following questions: 1) how often does the postoperative position of the implant corresponds to the planned one; 2) is the use of intrawound navigation improve the precision of acetabular implant position. MethodsThis was a single-center observational cohort study and included two groups: the experimental group (use of 3D navigation for implant positioning) and the control group (no navigation use). All the patients were scheduled for acetabular revision surgery with custom-made 3D-printed acetabular components. All surgeries took place between 2016 and 2020. Results25 % freehand group, 85 % implants in the navigation group matched accuracy positioning criteria. The relative risk of malposition was significantly higher without the intraoperative navigation, with 5 times greater risk of malpositioning in the freehand group versus the navigation group. ConclusionNavigation method allows planning of the implant and reamer sizes for optimal bone preparation and preservation. It provides easier implantation of the complex implant with reliable, stable primary fixation in massive bone defects. It reliably decreases malposition rate, allowing for implant placement in a proper position with sufficient bone-implant contact. Further research is needed to determine the relationship between CMAC position accuracy and long-term clinical and radiographic outcomes.

A review of the performance of polymer parts printed on fused deposition modelling under cyclic loading

Fused deposition modelling (FDM) is one of the most promising and widely used additive manufacturing (AM) technologies. FDM is commonly used to fabricate simple to complex 3D parts from polymeric materials. Different 3D-printed polymeric components manufactured using FDM technology exhibit various mechanical and load-bearing properties. They are utilized in various industries, particularly the medical industry, for load-bearing applications in bio-implants. Therefore, it is crucial to understand the mechanical characteristics, especially the fatigue behaviour, of these 3D-printed parts under cyclic loadings. This paper focuses on the dynamic behaviour of 3D-printed polymeric parts produced through the FDM process and under different loading modes. First, the FDM mechanism, the various polymeric materials used in FDM, and the effective FDM parameters are briefly introduced. Then, the paper comprehensively covers one of the most important mechanical characteristics of 3D-printed parts for load-bearing applications: their fatigue life under different printing conditions and cyclic loadings. The most influential factors on the fatigue behaviour of polymers include the type of polymeric material, surrounding environmental conditions, cyclic loading conditions, the type of testing specimen, and the FDM printing parameters (such as raster angle, infill density, nozzle diameter, and nozzle temperature). In addition to the anisotropic behaviour reported by various studies on 3D-printed parts using FDM, it has been concluded that the layered structure (with a large number of interfaces between the raster) and the presence of microholes are two factors that weaken the fatigue strength of 3D-printed structures compared to other fabrication processes. These conditions can be exacerbated by choosing inappropriate printing parameters, and often, the failure mechanism in 3D-printed parts fabricated with FDM is delamination.

Driving Sustainability: Carbon Footprint, 3D Printing, and Legislation concerning Electric and Autonomous Vehicles.

In recent years, there has been a remarkable development in the technology and legislation related to electric and autonomous vehicles (i.e., EVs/AVs). This technological advancement requires the deployment of the most up-to-date supporting infrastructure to achieve safe operation. Further infrastructure is needed for Level 5 vehicles, namely the introduction of super-fast wireless 5G technology. To achieve harmony between the rapid technological advancement of EVs/AVs and environmental preservation, enacting legislation related to their sustainable use is vital. Thus, this manuscript provides a review of the technological development of EVs/AVs, with a special focus on carbon footprints and the implementation of additive manufacturing using recycled materials. While EVs have a 12.13% increased carbon footprint compared to conventional vehicles, AVs with basic and advanced intelligence features have an increased carbon footprint of 41.43% and 99.65%, respectively. This article emphasizes that the integration of 3D-printed components has the potential to offset this impact with a substantial 60% reduction. As a result, custom-made solutions involving 3D printing are explored, leading to greater speed, customization, and cost-effectiveness for EVs/AVs. This article also lists the advantages and disadvantages of the existing legislation in Spain, the United Kingdom, and the western Balkans, demonstrating various approaches to promoting electric mobility and the development of autonomous vehicles. In Spain, initiatives like the MOVES program incentivize EV adoption, while the UK focuses on expanding the EV market and addressing concerns about EVs' quiet operation. In the western Balkans, the adoption of legislation lags behind, with limited incentives and infrastructure for EVs. To boost sales, legal mechanisms are necessary to reduce costs and improve accessibility, in addition to offering subsidies for the purchase of EVs. To this end, an analysis of the incentive measures proposed for the development and use of renewable power sources for the supply of energy for EVs/AVs is presented.

Towards 3D-printed alumina-based multi-material components with enhanced thermal shock resistance

A novel architectural design is introduced which utilizes the layer-by-layer capabilities of the vat photopolymerization 3D printing process to fabricate multi-material ceramic components with improved thermal shock resistance. The combination of 3D-printed alumina-zirconia (ZTA) with alumina (A) layers generates compressive residual stresses in the embedded alumina regions during cooling down from sintering. Thermal shock tests in water are performed on samples at different maximum temperatures and the strength degradation of the multi-material design is investigated and compared to the reference monoliths. Experimental results show that the retained strength of the multi-material ceramic after thermal shock is twice as high as that of the monoliths, associated with the crack arrest capability of the embedded layers. The concept is demonstrated on 3D-printed multi-ceramic blades for potential high temperature applications, showing enhanced “damage-tolerance” against thermal shock cracks. These findings open the path for fabricating reliable ceramic components using the vat photopolymerization process.

Three-Dimensional Printing, an Emerging Advanced Technique in Electrochemical Energy Storage and Conversion

Three-dimensional (3D) printing, as an advanced additive manufacturing technique, is emerging as a promising material-processing approach in the electrical energy storage and conversion field, e.g., electrocatalysis, secondary batteries and supercapacitors. Compared to traditional manufacturing techniques, 3D printing allows for more the precise control of electrochemical energy storage behaviors in delicately printed structures and reasonably designed porosity. Through 3D printing, it is possible to deeply analyze charge migration and catalytic behavior in electrocatalysis, enhance the energy density, cycle stability and safety of battery components, and revolutionize the way we design high-performance supercapacitors. Over the past few years, a significant amount of work has been completed on 3D printing to explore various high-performance energy-related materials. Although impressive strides have been made, challenges still exist and need to be overcome in order to meet the ever-increasing demand. In this review, the recent research progress and applications of 3D-printed electrocatalysis materials, battery components and supercapacitors are systematically presented. Perspectives on the prospects for this exciting field are also proposed with applicable discussion and analysis.

Combined RVE-Cohesive elements approach to the multi-scale modelling of FDM 3D-printed components

Mechanical strength of 3D-printed components dramatically depends on printing process parameters. These can be usually set over a relatively wide range, in combinations that determine the microstructure morphology and the resulting mechanical behaviour. The present investigation focuses on the relationship between revealed structure and resulting mechanical properties of FDM-printed ABS specimens. The peculiar structures, examined at the meso- and microscale, are modelled by a finite-element Representative Volume Element (RVE) approach, in conjunction with cohesive elements to reproduce the sealing efficiency between fused filaments. The simulation of the tensile response up to failure falls within the 95% of confidence with experiments. Also, homogenized response of RVE determines spatial material constants useful for the effective numerical simulations of functional components, and intra- and inter-layer damage mechanisms are distinguished providing hints for the structural optimization.

Effects of post-processing techniques on the mechanical characterization of additively manufactured parts

Additive manufacturing (AM) has been used for manufacturing of components with complex geometries. AM also known as three-dimensional (3D) printing, is a topic of high growth in recent years, requiring improved mechanical performance of 3D-printed parts. In this context, much progress is being made to improve the reliability of 3D printing and mechanical behavior of AMed parts. Indeed, post-processing techniques can highly improve the microstructure, and consequently the mechanical behavior of the functional end-use products. Since accuracy and mechanical behavior of 3D-printed components are influenced by heat and surface treatment techniques, a better understanding of these effects can lead to improvement in performance of printed parts. In this context, the current study presents a review on the effects of post-processing on the mechanical characterization of 3D-printed parts. To this aim, 3D printing techniques on both metal and polymer materials are considered. Here, we have reviewed how post-processes can relieve residual stresses, provide smooth surfaces, restore a minimum material ductility, and prevent distortions. The summarized information can be utilized not only for comparison and the improvement of 3D-printed components, but also can be beneficial in the development of new post-processing techniques.

Improving the Impact Resistance through Annealing in PLA 3D Printed Parts

This study conducts an experimental exploration and thorough analysis of the influence of annealing on the impact resistance of PLA 3D-printed components. The investigation extends its scope to encompass the influence of printing parameters, specifically layer thickness and infill percentage. The research highlights that the impact resistance of annealed 3D printed PLA components is predominantly influenced by the infill percentage, with the highest impact energy observed at a full 100% infill. It is noticeable that the application of annealing post-processing heat treatment results in a remarkable, up to threefold, increase of the impact energy highlighting its potential efficacy as a viable technique for enhancing the mechanical integrity of PLA 3D printed products. Consequently, this study establishes annealing as a promising methodology, particularly for PLA 3D printing applications that encounter significant mechanical loads.

Clinical and radiologic outcomes of Lima ProMade custom 3D-printed glenoid components in primary and revision reverse total shoulder arthroplasty with severe glenoid bone loss: a minimum 2-year follow-up.

The purpose of this study is to report the clinical and radiologic outcomes of patients undergoing primary or revision reverse total shoulder arthroplasty using custom 3D-printed components to manage severe glenoid bone loss with a minimum of 2-year follow-up. Following ethical approval, patients were identified and invited to participate. Inclusion criteria were (1) severe glenoid bone loss necessitating the need for custom implants and (2) patients with definitive glenoid and humeral components implanted more than 2 years prior. Included patients underwent clinical assessment using the Oxford Shoulder Score (OSS), Constant-Murley score, American Shoulder and Elbow Surgeons Standardized Shoulder Assessment Form (ASES), and the quick Disabilities of the Arm, Shoulder, and Hand questionnaire (QuickDASH). Radiographic assessment included anteroposterior and axial projections. Patients were invited to attend a computed tomography (CT) scan to confirm osseointegration. Statistical analysis used descriptive statistics (mean and standard deviation [SD]) and paired t test for parametric data. Eleven patients declined to participate. Five patients were deceased prior to study commencement, leaving 42 remaining patients in this analysis. Three patients had revision surgery before the 2-year follow-up; of these, 2 retained their custom glenoid components. Mean follow-up was 31.6 months from surgery (range 24-52 months). All 4 scores improved: OSS from a mean 15 (SD8.4) to 36 (SD12) (P<.001), Constant-Murley score from a mean 15 (SD11.2) to 52 (SD20.1) (P<.001), QuickDASH from a mean 70 (SD21) to 31 (SD24.8) (P=.004), and the ASES score from a mean 22 (SD17.8) to 71 (SD23.3) (P=.007). Radiologic evaluation demonstrated good osseointegration in all but 1 included patient. The utility of custom 3D-printed components for managing severe glenoid bone loss in primary and revision reverse total shoulder arthroplasty yields significant clinical improvements in this complex cohort. Large complex glenoid bone defects can be managed successfully with custom 3D-printed glenoid components.

A literature review to determine the availability of materials for application in 3D printing processes within the Brazilian construction industry

In the present day, the civil construction industry grapples with various challenges, including low productivity, a shortage of skilled labour, resistance to technological innovations, and significant environmental impacts. Extensive literature underscores the urgency of modernizing the sector by embracing new technologies such as digital prototyping and advanced manufacturing processes. In light of these considerations, this article aims to assess the range of materials available for 3D printing to determine the feasibility of integrating this technology into the Brazilian civil construction industry (BCI). Through a comprehensive analysis of materials currently in use, drawn from scientific research, it becomes evident that mortar-based materials are emerging as a preferred choice for 3D printing components within civil construction. Considering that the Brazilian construction sector already heavily relies on cement as its primary material for constructing the built environment, a promising landscape unfolds for the gradual adoption and integration of three-dimensional printing technology into the industry. This alignment with existing practices and materials positions the BCI favourably for embracing the potential of 3D printing.

Investigations on friction stir spot welding to overcome bed size limits of material extrusion (MEX) 3D printers

PurposeMaterial extrusion (MEX) 3D printers suffer from an intrinsic limitation of small size of the prints due to its restricted bed dimension. On the other hand, friction stir spot welding (FSSW) is gaining wide interest from automobile, airplane, off-road equipment manufacturers and even consumer electronics. This paper aims to explore the possibility of FSSW on Acrylonitrile Butadiene Styrene/Polylactic acid 3D-printed components to overcome the bed size limitation of MEX 3D printers.Design/methodology/approachFour different tool geometries (tapered cylindrical pin with/without concavity, pinless with/without concavity) were used to produce the joints. Three critical process parameters related to FSSW (tool rotational speed, plunge depth and dwell time) and two related to 3D printing (material combination and infill percentages) were investigated and optimized using the Taguchi L27 design of experiments. The influence of each welding parameter on the shear strength was evaluated by analysis of variance.FindingsResults revealed that the infill percentage, a 3D printing parameter, had the maximum effect on the joint strength. The joints displayed pull nugget, cross nugget and substrate failure morphologies. The outcome resulted in the joint efficiency reaching up to 100.3%, better than that obtained by other competitive processes for 3D-printed thermoplastics. The results, when applied to weld a UAV wing, showed good strength and integrity. Further, grafting the joints with nylon micro-particles was also investigated, resulting in a detrimental effect on the strength.Originality/valueTo the best of the authors’ knowledge, this is the first study to demonstrate that the welding of dissimilar 3D-printed thermoplastics with/without microparticles is possible by FSSW, whilst the process parameters have a considerable consequence on the bond strength.