3D-printed Composites Research Articles

Experimental Investigations of the Influence of Spent Coffee Grounds Content on PLA Based Composite for 3D Printing

Nowadays Fused Deposition Modeling, a widely utilized additive manufacturing technology, is significantly transforming as modern production processes. Beyond basic uses to it role in sustainability, Fused Deposition Modeling offers processing potential for implanting circular economy by reducing virgin materials consumption and enhance the integration of waste food for sustainable 3D printing. This research paper investigated the production of new composite materials based on spent coffee grounds. In addition, PLA and SCG at various contents (0, 3, 5, 10, and 15 wt%) were dried and premixed, then processed into PLA/SCG composite pellets using twin-screw extrusion. These pellets were successfully converted into filaments and subsequently used for 3D printing. The effect of spent coffee grounds in PLA composites was investigated via physical and mechanical analysis of 3D printed samples. Regarding density measurements, results revealed that adding up to 5 wt% of spent coffee grounds increased the density while further additions led to a decrease which due to the printing parameters such as extrusion temperature and nozzle diameter. Considering the mechanical properties, the Young’s modulus increased once the spent coffee grounds content reached 3 wt% and then decreased. In the other hand, there was no enhancement in tensile strength and elongation at break which corroborating with density measurements. This mainly contributed to the changes in mechanical properties caused by printing parameters. This study demonstrates that coffee waste can be used as a filler in environmentally friendly composites for 3D printing, with a maximum SCG content of 15 wt%. This approach not only promotes the reuse of coffee waste but also reduces the cost of traditional PLA filaments.

Tensile strength and durability performances-based evaluation of 3D-printed and mold-cast fibrous geopolymer composites produced at various alkaline activator combinations

This study aimed to investigate the effects of the sodium silicate-to-sodium hydroxide ratio, SH molarity, and carbon fiber volume fraction on the tensile strength and durability properties of mold-cast and 3D-printed geopolymer composites, including flexural and splitting tensile strengths, ultrasonic pulse velocity, water absorption, sorptivity index, and chloride penetration properties. For that purpose, the ground-granulated blast furnace slag and fly ash were employed as alumino-silicate-rich raw material. In order to activate the alumino-silicate-rich raw material, two sodium silicate/sodium hydroxide ratios of 1 and 2 and three sodium hydroxide molarities of 8M, 10M, and 12M were designated. Furthermore, carbon fiber was incorporated into the geopolymer composites at three volume fractions: 0%, 0.3%, and 0.6%. In total, 18 nonfibrous and fibrous geopolymer composites were manufactured in two different ways: mold-cast and 3D-printed. The findings demonstrated that the strength and durability characteristics of 3D-printed specimens were inferior to those of mold-cast specimens, attributed to the presence of weak interfacial bonds between layers. It has been observed that the incorporation of carbon fiber has the effect of improving tensile strength performance. Nevertheless, the addition of carbon fiber led to a slight decrease in UPV values, and an increase in water absorption and sorptivity index values. Also, it adversely influenced the chloride penetration of geopolymer composites. The findings of the study also indicated that increasing the sodium hydroxide molarity had a positive impact on the strength and durability properties of the composites. Nevertheless, it was observed that increasing the sodium silicate-to-sodium hydroxide ratio led to a decrease in both tensile strength and durability performances. Additionally, the microstructure of the geopolymer composites was analyzed using scanning electron microscope (SEM) images.

Characterization of 3D printed composite for final dental restorations.

This study evaluated the mechanical, optical, microstructural, surface, and adhesive behavior of a 3D printing resin comparing it with a machinable resin composite. Specimens of different sizes and shapes were either printed (Vitality, Smart Dent) or machinable (Grandio Blocs, Voco GmbH) resin composites with similar composition were prepared. Surface and mechanical characterization were performed with Knoop hardness, flexural strength (three-point-bending), and elastic modulus tests. The wear of the tested materials was evaluated against steatite antagonists. The optical properties stability (color change, ΔE00, and translucency, TP00) were observed after staining in red wine. In addition, the bond strength of the resin composites to two resin cement protocols were investigated with microshear bond strength tests at baseline and after thermocycling. Scanning electron microscope (SEM) coupled with Energy-Dispersive X-ray Spectroscopy (EDS) was used for microstructural and chemical characterization. Statistical analyses were performed with t- and ANOVA tests. Hardness values (132.76 (16.32) KH- Machinable and 35.87 (2.78) KH - Printed), flexural strength (172.17 (26.99) MPa - Machinable and 88.69 (8.39) MPa - Printed), color and translucency change (1.86 (0.31)/0.06 - Machinable and 3.73 (0.36)/9,16- Printed), and wear depth (24.97mm (3.60)- Machinable and 7.16mm (2.84) - Printed) were statistically different. Average Regarding bond strength, mean values (MPa) for non-aged and aged groups were respectively 21.76 (6.64) / 31.9 (12.66) for Bifix cement (Voco GmbH, Cuxhaven, Germany) and 26.75 (5.14) / 24.36 (6.85) for Variolink cement (Ivoclar Vivadent, Schaan, Liechtenstein) in Printed and 17.79 (3.89) / 9.01 (3.36) ) for Bifix cement and 22.09 (6.55) / 11.01 (3.77) for Variolink cement in Machinable materials. The material and aging factors did affect bond strength but the cement factor did not (p = 0.202). No statistical differences were observed for mean roughness (Ra) between materials. The better dispersion and larger size of the inorganic particles in the Machinable resin were contrasted with the clustered smaller particles of printed resin, under SEM. The mechanical properties and color stability of the machinable resin were superior to those of the printed resin, probably due to the greater amount and dispersion of inorganic particles in the Mach resin, but bond strength after aging was stronger and more stable in the printed resin. 3D-printed resin composites with similar compositions to machinable resin composites do not necessarily exhibit the same properties, which can impact clinical performance. Understanding these differences can assist manufacturers in improving their materials and help clinicians distinguish between materials appropriate for provisional and final restorations.

Thermal-responsive soil-hydrogel composite for additive construction

To improve the formability and bonding strength of 3D printing soil, a temperature-stimulating responsive intelligent soil-hydrogel 3D printing formula was innovatively developed by combining soil and gelatin. Varied soil-gelatin composites, featuring different gelatin content by weight of soil (0 %, 0.5 %, 1 %, and 1.5 %), were prepared and cured at 5 °C to facilitate the crosslinking of gelatin. An array of tests, including rheological assessments, compressive tests, and scanning electron microscopy analysis. Were conducted to thoroughly characterize the performance of gelatin-soil composites for 3D printing. Our findings unveiled that, following the cross-linking of gelatin at 5 °C, the gelatin-soil composites exhibited superior formability and bond strength compared to the reference. Furthermore, the soil-gelatin composites demonstrated not only comparable compressive strength to the reference but also enhanced interlayer bond strength. This innovative soil-hydrogel 3D printing formula, combining the versatility of soil and the responsive characteristics of gelatin, presents a promising avenue for advancing the capabilities of 3D printed soil.

Recyclable hemp hurd fibre-reinforced PLA composites for 3D printing

In this study, 3D printing filaments were produced from hemp hurd fibre-reinforced polylactide (PLA) composites. Hemp hurd microfibres were obtained through alkaline digestion followed by a bleaching treatment and were used to produce PLA-based composites with 20–40 wt% fibre content for fused deposition modelling. Tensile testing of 3D printed composites revealed a gradual increase of Young's modulus with the addition of fibres, reaching a maximum of 7.1 GPa for the 40 wt% composite - a two-fold increase to neat PLA. However, tensile strength was only improved for the 20 wt% formulation, with an increase of 8% in comparison with neat PLA. Nevertheless, the thermo-mechanical properties of the composites were significantly enhanced with the addition of fibres. In addition, physical objects were printed from the recycled filaments to assess their recyclability and printability. It was found that the recycled filaments maintained comparable mechanical properties and printability after three recycling cycles.

A Comparative Study of Non-Destructive Testing Techniques: Active Thermography versus Shearography for 3D-Printed Thermoplastic Composites Reinforced with Continuous Carbon Fiber

This study investigates the feasibility and effectiveness of two non-destructive testing methods, active thermography and shearography, on 3D-printed thermoplastic (TP) composites reinforced with continuous carbon fiber. Artificial defects were introduced into the composite plate to benchmark the detection capabilities of these non-destructive testing techniques (NDT). Active thermography produced a thermogram that highlighted defects through variations in surface temperature. Although effective for identifying defects ranging from 3 to 10 mm in size at four different depths, specifically 1 mm, 1.25 mm, 1.5 mm, and 1.75 mm, through the thickness of a 2.8 mm plate, the method encountered some limitations. It faced challenges in detecting deeper defects and accurately determining their shapes. Shearography, which utilizes fringe pattern distortions to detect surface displacement anomalies, successfully identified near-surface defects within the same size range. However, it required more expertise for accurate interpretation and struggled with detecting smaller and deeper defects. The complementary strengths and limitations of these methods suggest that employing both could offer a more comprehensive solution for defect detection in 3D-printed TP composites.

Development of a Composite Filament Based on Polypropylene and Garlic Husk Particles for 3D Printing Applications

Lignocellulosic waste materials are among the most abundant raw materials on Earth, and they have been widely studied as natural additives in materials, especially for polymer composites, with interesting results when it comes to improving physiochemical properties. The main components of these materials are cellulose, hemicellulose, and lignin, as well as small amounts of other polysaccharides, proteins, and other extractives. Several kinds of lignocellulosic materials, mainly fibers, have been evaluated in polymer matrices, and recently, the use of particles has increased due to their high surface area. Garlic is a spice seed that generates a waste husk that does not have applications, and there are no reports of industrial use of this kind of lignocellulosic material. Additive manufacturing, also known as 3D printing, is a polymer processing technique that allows for obtaining complex shapes that are hard to obtain with ordinary techniques. The use of composites based on synthetic polymers and lignocellulosic materials is a growing field of research. In the present work, the elaboration and evaluation of 3D-printed polypropylene–garlic husk particle (PP-GHP) composites are reported. First, the process of obtaining a filament by means of a single extrusion was carried out, using different GHP contents in the composites. Once the filament was obtained, it was taken to a 3D printer to obtain probes that were characterized using differential scanning calorimetry (DSC), and thermogravimetric analysis (TGA) was performed with the aim of evaluating the thermal behavior of the 3D-printed PP-GHP composites. According to the obtained results, the crystallization process and thermal stability of the PP-GHP composites were modified with the presence of GHP compared with pristine PP. Dynamic mechanical analysis (DMA) showed that the addition of GHP decreased the storage modulus of the printed composites and that the Tan δ peak width increased, which was associated with an increase in toughness and a more complex structure of the 3D-printed composites. X-ray diffraction (XRD) showed that the addition of GHP favored the presence of the β-phase of PP in the printed composites.

Simulation and mechanical testing of 3D printing shin guard composite materials

ABSTRACT This study critically examines the composite material's mechanical properties and performance for 3D-printed shin guards. It contains a thermoplastic polymer matrix with short carbon fibre reinforcement. Shin guard stress and deformation under impact loading were modelled using FEA models. The composite material was 3D-printed and tested for tensile, flexural, and impact properties. The entire cycle of FEA models and careful mechanical testing allows for the development and evaluation of new composite materials and designs. The finite element analysis, such as maximum von Mises stress, is 2890.5 MPa. The carbon fibre-reinforced composite's mechanical properties, including tensile strength, flexural strength, and impact resistance, showed a considerable improvement over those of the unreinforced polymer. The solid design could be heavier and less adaptable than the pattern. Compared to unreinforced polymers, carbon fibre improves strength, stiffness, and impact resistance for the 3D-printed composite. This result thus proves that 3D-printed carbon fibre-reinforced composites could make superior sports protective equipment like shin guards. The FEA calculations and extensive mechanical testing provide a dependable framework for creating and testing these new composite materials and systems.

Three-Dimensional Printing Limitations of Polymers Reinforced with Continuous Stainless Steel Fibres and Curvature Stiffness

This study investigates the printability limitations of 3D-printed continuous 316L stainless steel fibre-reinforced polymer composites obtained using the Materials Extrusion (MEX) technique. The objective was to better understand the geometric printing limitations of composites fabricated using continuous steel fibres, based on a combination of bending stiffness testing and piezoresistive property studies. The 0.5 mm composite filaments used in this study were obtained by co-extruding polylactic acid (PLA), with a 316 L stainless steel fibre (SSF) bundle. The composite printability limitations were evaluated by the printing of a series of ’teardrop’ shaped geometries with angles in the range from 5° to 90° and radii between 2 and 20 mm. The morphology and dimensional measurements of the resulting PLA-SSF prints were evaluated using μCT scanning, optical microscopy, and calliper measurements. Sample sets were compared and statistically examined to evaluate the repeatability, turning ability, and geometrical print limitations, along with dimensional fluctuations between designed and as-printed structures. Comparisons of the curvature bending stiffness were made with the PLA-only polymer and with 3D-printed nylon-reinforced short and long carbon fibre composites. It was demonstrated that the stainless steel composites exhibited an increase in bending stiffness at smaller radii. The change in piezoresistance response of the PLA-SSF with load applied during the curvature bending stiffness testing demonstrated that the 3D-printed composites may have the potential for use as structural health monitoring sensors.

Preparation of continuous carbon fiber reinforced PA6 prepreg filaments with high fiber volume fraction

High-performance continuous carbon fiber prepreg filaments have been a research hotspot in the field of additive manufacturing in recent years, and are considered to be an effective option for improving the mechanical strength of thermoplastic composite parts. However, the effect of fiber volume fraction on the microstructure and tensile properties of 3D printed prepreg filaments remains miss. Therefore, this study selected suitable impregnation processes and materials to prepare prepreg filaments with different fiber volume fraction and investigated their mechanical properties and microscopic morphologies. The results show that the increase of fiber volume fraction effectively promoted the interface bonding between fiber and resin, and increased capacity for load transfer. When the fiber volume fraction was 54.0 %, the tensile strength of the prepreg filaments and specimens reached 1977 MPa and 334 MPa, respectively. This study can provide a process optimization strategy for the preparation of more types of continuous fiber prepreg filaments with high fiber volume fraction, as well as a data reference for the preparation of high-performance 3D-printed thermoplastic composites.

Process-structure–property study of 3D-printed continuous fiber reinforced composites

3D-printed fiber-reinforced composites hold many advantages compared to conventional composites in terms of individualization, mass customization, design freedom, and tailoring the composite geometry to load-bearing specifications. Among candidate continuous fibers for reinforcement, basalt fibers (BFs) serve as an eco-friendly alternative with excellent physical and thermal properties. However, the applicability of continuous BFs to be used for 3D-printed polymer composites was rarely addressed in existing literature. Especially, the effects of impregnation density during manufacturing and the influence of local fiber distribution on the fracture behavior of BF-reinforced composites remain unclear. In this study, a solution coating process was employed as a fiber pre-treatment to improve the packing density of BF in a polylactide (PLA) matrix. The effects of the resulting fiber volume fraction (8–31 %) and the local fiber distribution on the tensile fracture mechanisms of 3D printed BF/PLA samples are thoroughly analyzed using three-dimensional X-ray tomography. It was found that at a concentration of 3 wt-%, the coating solution uniformly dispersed optimally between the fibers, resulting in improved impregnation densities of the BF in the PLA matrix. Thus, the resulting composite exhibited a tensile strength of 175 MPa and a Young’s modulus of 6.2 GPa, respectively. A viscoelastic constitutive model incorporating damage is used for property prediction within a composite design framework to be applied to 3D-printed BF/PLA structures. The model is validated with experimental data from tensile tests. The obtained results demonstrate the applicability of eco-friendly BF/PLA composites for 3D printing of industrial high-performance applications with an individualized property profile.

Design and performance of 3D-Printed ABS@rGO/CF/CeO2 composites for microwave absorption and mechanical strength

Traditional microwave absorbing materials struggle to balance wideband absorption with mechanical properties, particularly in multifunctional applications. This study explores the effects of short carbon fibers (CF), cerium dioxide (CeO2), and reduced graphene oxide (rGO) on the electromagnetic and mechanical properties of 3D-printed composites. The ABS@CF/CeO2/rGO composite with a thickness of 2.2 mm exhibited exceptional microwave absorption, achieving an effective absorption bandwidth (EAB) of 6.6 GHz and a minimum reflection loss (RLmin) of −40.9 dB. The Whale Optimization Algorithm (WOA) was employed to design a load-bearing, microwave-absorbing superstructure, which significantly improved wideband absorption. Experimental results confirmed the superstructure’s isotropy and wide-angle absorption capabilities. The calculated electromagnetic parameters were applied to evaluate the radar cross-section (RCS) of large targets, demonstrating enhanced stealth performance for unmanned aerial vehicles (UAVs). Mechanical tests revealed that rGO improved interlayer bonding strength, while CF negatively impacted bending performance. The superstructure also showed excellent mechanical stability in load-bearing tests, underscoring its potential for practical engineering applications. This study offers insights into designing advanced composite materials with balanced electromagnetic and mechanical properties, guiding future multifunctional material development.

Three-Dimensionally Printed Ternary Composites of Polyamide: Effect of Gradient Structure on Dimensional Stability and Mechanical Properties

Fused deposition modeling (FDM) 3D printing has the advantages of a simple molding principle, convenient operation, and low cost, making it suitable for the production and fabrication of complex structural parts. Moving forward to mass production using 3D printing, the major hurdle to overcome is the achievement of high dimensional stability and adequate mechanical properties. In particular, engineering plastics require precise dimensional accuracy. In this study, we overcame the issues of FDM 3D printing in terms of ternary material compounds for polyamides with gradient structures. Using multi-walled carbon nanotubes (MWCNTs) and boron nitride (BN) as fillers, polyamide 6 (PA6)-based 3D-printed parts with high dimensional stability were prepared using a single-nozzle, two-component composite fused deposition modeling (FDM) 3D printing technology to construct a gradient structure. The ternary composites were characterized via DSC and XRD to determine the optimal crystallinity. The warpage and shrinkage of the printed samples were measured to ensure the dimensional properties. The mechanical properties were analyzed to determine the influence of the gradient structures on the composites. The experimental results show that the warpage of pure polymer 3D-printed parts is as high as 72.64%, and the introduction of a gradient structure can reduce the warpage to 3.40% by offsetting the shrinkage internal stress between layers. In addition, the tensile strength of the gradient material reaches up to 42.91 MPa, and the increasing filler content improves the interlayer bonding of the composites, with the bending strength reaching up to 60.91 MPa and the interlayer shear strength reaching up to 10.23 MPa. Therefore, gradient structure design can be used to produce PA6 3D-printed composites with high dimensional stability without sacrificing the mechanical properties of PA6 composites.

Enhancing flame retardancy in 3D printed polyamide composites using directionally arranged recycled carbon fiber

Combining recycled carbon fiber (rCF) and 3D printing technology has shown great potential for fabricating functional prototypes and production parts used in the aerospace and automotive industries. However, it is still a challenge to design flame-retardant 3D printed parts with high mechanical properties and flame-retardant rating. In the work, a flame-retardant polyamide (PA)-based composite for material extrusion 3D printing was prepared by utilization of rCF, polyhedral oligomeric silsesquioxanes (POSS), and 9,10-Dihydro-9-oxa-10-phosphaphenanthrene (DOPO)-based flame retardant. The 3D-printed composites have high thermal stability, mechanical properties, and excellent flame retardancy with a V-0 rating. With the benefits of material extrusion 3D printing, directionally arranged rCF in 3D printed composites could effectively inhibit the fire spread, extend the time to ignition (TTI), reduce the total heat release (THR) and total smoke release (TSR) of 3D printed composites. The directional flame-retardant mechanism is mainly the thermal conductivity mechanism of the condensed phase and the promotion of stable ordered carbon layer formation. It provides a promising path for designing high-performance flame-retardant materials.

Comparative Strength Study of Indirect Permanent Restorations: 3D-Printed, Milled, and Conventional Dental Composites.

Background/Objectives: Limited research has been performed to assess the strength of resin-bonded 3D-printed restorations. Based on that, this study investigates the impact of different manufacturing methods on the fracture load of indirect composite restorations (ICRs) following an aging process. Methods: Three manufacturing techniques-conventional (CRC), milled (MRC), and printed (PRC)-were evaluated using 60 specimens, each with a diameter of 10 mm and a thickness of 1.0 mm. Sandblasting with Al2O3 particles was employed to optimize the bonding process, significantly influencing surface roughness parameters (Ra, Rz, RSm). All specimens were bonded to the dentin analog using composite resin cement and subjected to either 10,000 thermocycles (TC) or storage (ST) at 37 °C in distilled water. Fracture load assessments were performed using a universal testing machine. A finite element analysis was conducted to assess stress distribution. Results: Two-way ANOVA results indicated that the manufacturing method significantly affected mean fracture load values (p < 0.001), with PRC showing the highest mean fracture load (4185 ± 914 N), followed by MRC (2495 ± 941 N) and CRC (599 ± 292 N). The aging protocol did not have a significant impact on fracture load. Conclusions: This study revealed that 3D-printed resin composite exhibited comparable strength to milled resin composite when adhesively cemented, suggesting it is a promising option for indirect composite restorations based on its mechanical performance. However, further research is needed to evaluate its bond strength and optimal surface treatment methods to prevent early debonding.

Development of acrylonitrile–butadiene–styrene (ABS)/natural fiber composite filaments for innovative 3D and 4D printing

AbstractFruit wastes from the agro‐industry may be used in the preparation of polymer/natural fiber composites. In the current scenario, there is a growing need for sustainable materials that can reduce environmental impact while maintaining or enhancing material properties. One promising approach is the incorporation of natural fibers derived from fruit waste into polymers, which aligns with the global push toward eco‐friendly and circular economy solutions. This work was aimed at the development of filaments of acrylonitrile–butadiene–styrene (ABS)/natural fiber composites for 3D and 4D printing. The fibers used were banana (BAN) peel, orange (ORG) peel, cinnamon (CIN), and neem (NEEM) leaf fibers. The rheological, mechanical, and shape memory properties of the ABS/BAN and ABS/ORG composites were compared with those of the ABS/CIN and ABS/NEEM composites. A slight decrease in viscosity was observed with the addition of the natural fibers to ABS. The ABS/ORG composites showed the highest mechanical properties and good adhesion between the printed layers. The particulate eco‐friendly natural fibers can also be used as pigments, where different types of colors can be obtained. The ABS/natural fiber composites can be processed at the same processing conditions as ABS. The incorporation of natural fibers significantly increased the shape memory result. The use of ABS/natural fiber composites proved to be feasible for preparing the filaments and 3D/4D printing of objects.Highlights The properties of 3D/4D‐printed ABS/natural fiber composites were investigated. Banana and orange peel, cinnamon, and neem leaf fibers were used. Filaments of ABS/natural fiber composites were successfully obtained. The addition of the fibers to ABS decreased the viscosity and increased shape memory. Among the composites, ABS/orange peel showed the highest mechanical properties.

The effect of using surface functionalized granite powder waste on fresh properties of 3D-printed cementitious composites

The production of low-emission additive manufactured cementitious composites using functionalized rock powders offers promising mechanical properties and significantly reduces cement consumption. The effect of powder functionalization on the rheological properties of the mixture remains unclear, so this study investigated how mechanical and chemical functionalization of granite powder waste affects the viscoelastic properties of a cementitious mixture for additive manufacturing. Compression tests were used to track stress-strain changes over time, while Vane and slug tests measured yield stress in mixes with 20 % and 40 % cement replaced by natural (NGP), sieved (SGP), and carbonated granite powder (CGP). The results showed that all three powders (NGP, SGP, and CGP) increased yield stress compared to the reference mix, with CGP having the smallest effect. The functionalization of granite powder may enable the creation of desirable viscoelastic mixtures using sustainable materials. We observed that functionalizing granite powder (SGP and CGP) accelerated changes in the mixture rheological properties, with yield stress increasing by up to 33 %, while NGP showed minimal impact, similar to the reference mix. Differences between the Vane and Slug test results were also identified and their limitations described.

NIR-Responsive Deployable and Self-Fitting 4D-Printed Bone Tissue Scaffold.

The treatment of irregular-shaped and critical-sized bone defects poses a clinical challenge. Deployable, self-fitting tissue scaffolds that can be implanted by minimally invasive procedures are a promising solution. Toward this, we fabricated NIR-responsive and programmable polylactide-co-trimethylene carbonate (PLMC) scaffolds nanoengineered with polydopamine nanoparticles (PDA) by extrusion-based three-dimensional (3D) printing. The 3D-printed scaffolds demonstrated excellent (>99%), fast (under 30 s), and tunable shape recovery under NIR irradiation. PLMC-PDA composites demonstrated significantly higher osteogenic potential in vitro as revealed by the significantly enhanced alkaline phosphatase (ALP) secretion and mineral deposition in contrast to neat PLMC. Intraoperative deployability and in vivo bone regeneration ability of PLMC-PDA composites were demonstrated, using self-fitting scaffolds in critical-sized cranial bone defects in rabbits. The 3D-printed scaffolds were deformed into compact shapes that could self-fit into the defect shape intraoperatively under low power intensity (0.76 W cm-2) NIR. At 6 and 12 weeks postsurgical implantation, near-complete bone regeneration was observed in PLMC-PDA composites, unlike neat PLMC through microcomputed tomography (micro-CT) analysis. The potential clinical utility of the 3D-printed composites to secure complex defects was confirmed through self-fitting of the scaffolds into irregular defects in ex vivo models of rabbit tibia, mandible, and tooth models. Taken together, the composite scaffolds fabricated here offer an innovative strategy for minimally invasive deployment to fit irregular and complex tissue defects for bone tissue regeneration.

A behavior three-way decision approach under interval-valued triangular fuzzy numbers with application to the selection of additive manufacturing composites

Additive manufacturing composites, also recognized as three-dimensional (3D) printing composites, are highly anticipated for their potential to replace industrial materials due to the availability of multiple printing processes and optional materials. However, research gaps exist in cognitive deficiencies and psychological behaviors of decision-makers, as well as experimental error effects caused by material testing, resulting in material selection as a challenging issue. Therefore, this study proposes a novel behavior three-way decision model under the interval-valued triangular fuzzy number (IVTFN) to settle the selection issue of 3D printing composites. The research contributions are summarized as follows. First, the IVTFN is presented to account for the impacts of cognitive deficiency and experimental errors, based on which the concepts of information entropy and fuzzy measure are further developed to conduct the criterion weights. In addition, by integrating the prospect theory and regret theory, a framework for constructing the behavioral decision matrix is presented. Moreover, a novel behavior three-way decision model with the perspectives of objective and preference is proposed to classify the decision region. This study presents a comprehensive methodology integrating the three-way decision model and multi-criteria decision-making method to achieve both alternative ranking and alternative classifying. Finally, a research case of 3D printing composites reinforced by continuous hybrid fibers is adopted to illustrate the validity of the methodology. Comparative analysis and sensitivity analysis are also performed. This study offers valuable insights and tools for systematically tackling the 3D printing composite material selection issues.

Tribology Behavior of In-Situ FDM 3D Printed Glass Fibre-Reinforced Thermoplastic Composites

Fused deposition modeling (FDM) 3D-printed parts are generally weaker compared to injection-moulded parts. Fibre reinforcement is one of the techniques used to enhance the mechanical strength and the tribological behavior of the FDM-printed parts. Recently, a new method for creating FDM 3D-printed composites was developed. Current work focuses on the tribological behavior of the glass fibre-reinforced PLA, manufactured using this new composite manufacturing method. Experiments were conducted to investigate the effect of Glass Fibre (GF) reinforcement on FDM 3D-printed thermoplastic composites, specifically polylactic acid (PLA) under different linear sliding speed and directions. All 3D printed glass fibre-reinforced PLA (PLA-GF) composites exhibited a lower wear rate and a higher friction coefficient compared to 3D printed PLA. Increasing in disc’s linear speed or sliding speed of the pins resulted in a lower coefficient of friction and wear rate. In addition, a perpendicular raster direction towards the disc rotation or pin motion experienced greater friction and greater wear.