Commercial 3D Printer Research Articles

Evaluation of metal additive manufacturing for high-field modular-stellarator radial plates and conductors

The utilization of metal additively manufactured radial plates and conductors for high-field modular-stellarator coils is assessed, particularly, for resistive coils having turns of variable cross-section (additively manufactured aluminium or copper turns). This concept of radial plates might also be applicable to superconducting wire and resistive conductors of constant cross-section.Modular coils and their winding packs for (high-field) stellarators require high precision, durability under high internal Lorentz forces and thermal stresses, stiffness and strength, in rather contorted components. Radial plates have been utilized in tokamaks (i.e. ITER) and are proposed for tokamak and stellarator reactors (i.e. FFHR), particularly when the high Lorentz forces may compromise the mechanical integrity of the insulation and winding pack. Radial plates for tokamaks have been produced by milling steel plate, and welding different segments if the size requires it. However, the contorted shape of stellarator modular coils makes the manufacturing of radial plates more challenging. This suggests the possible use of additive manufacturing, which is particularly appropriate for short series of geometrically complex parts.In relation to those matters, this work investigates whether metal additive manufacturing of contorted radial plates and metallic conductor turns (windings, to be introduced in the radial plates) of variable cross-section and proper insulation, may be satisfactory for small or middle size high-field stellarators. The emphasis is placed on the accuracy, mechanical properties and cost of those parts. The feasibility, advantages and weakness of the additive manufacturing process and the assembling procedure are tested and studied. With the present commercial metal 3D printers, metal additively manufactured radial plates will require final milling to achieve enough accuracy. Coil casings appear feasible without final milling, and windings of variable cross-section, produced from brazing modified flexible copper wire, are promising.

Xanthate-Based Photoiniferter RAFT Polymerization toward Oxygen-Tolerant and Rapid Living 3D Printing

Three-dimensional (3D) printing based on photoinduced reversible addition–fragmentation chain transfer (RAFT) polymerization is emerging as a versatile and powerful method to prepare “living” 3D objects, which can be postmodified with various functionalities. However, an additional photoinitiator or photocatalyst is necessary in these systems, which is toxic and will cause negative effects on the properties of the prepared materials. Here, we report oxygen-tolerant and rapid living 3D printing based on photoiniferter RAFT polymerization, which does not need additional photoinitiators or photocatalysts. A xanthate, O-ethyl-S-2-ethyl propionate, was chosen as both the photoinitiator and RAFT agent in this process. Various monomers and RAFT agents were screened in this system. Materials with different properties were prepared utilizing the postfunctionalization of the printed living objects. Furthermore, a polymer welding method was proposed by painting fresh monomers between two living objects for post-photocuring. This photoiniferter RAFT polymerization-based living 3D printing method was also successfully applied to a commercial digital light processing technique-based 3D printer, offering a facile method to fabricate living 3D materials with different shapes.

3D-printed electrochemical pestle and mortar for identification of falsified pharmaceutical tablets.

Falsified medicines and healthcare supplements provide a major risk to public health and thus early identification is critical. Although a host of analytical approaches have been used to date, they are limited, as they require extensive sample preparation, are semi-quantitative and/or are inaccessible to low- and middle-income countries. Therefore, for the first time, we report a simple total analysis system which can rapidly and accurately detect falsified medicines and healthcare supplements. We fabricated a poly-lactic acid (PLA) pestle and mortar and using a commercial 3D printer, then made carbon black/PLA (CB/PLA) electrodes in the base of the mortar using a 3D printing pen to make an electrochemical cell. The pestle and mortar were able to crush and grind the tablets into a fine powder to the same consistency as a standard laboratory pestle and mortar. Using melatonin tablets to characterise the device, the 3D-printed pestle and mortar was able to detect the concentration of melatonin in the presence of insoluble excipients. The calibration plot showed a linear response from 37.5 to 300µg/mL, where the limit of detection was 7µg/mL. Electrochemical treatment was able to regenerate the CB/PLA working electrode allowing for repeated use of the device. In a blinded study, the device was able to accurately determine falsified melatonin tablets with recovery percentages between 101% and 105%. This was comparable to HPLC measurements. Overall, these findings highlight that our 3D-printed electrochemical pestle and mortar is an accessible and effective total analysis system that can have the ability to identify falsified medicines and healthcare supplements in remote locations.

Poly(acrylic acid)-Based Hydrogel Actuators Fabricated via Digital Light Projection Additive Manufacturing

Electroactive polymers that exhibit controlled deformation under an applied electric field, either in liquid or air, have great potential as soft robotic actuators. However, materials for soft robotics currently face challenges, including slow response, high actuation potential, and a lack of underlying mechanistic understanding. Additionally, fabrication of soft robotic actuators with complex design features has historically been restricted by two-dimensional fabrication methods. In this work, we investigate cross-linked poly(acrylic acid)-based actuators prepared utilizing digital light projection (DLP), an additive manufacturing technique that enables fabrication of actuators with complex geometries. A series of photopolymerizable inks are prepared incorporating acrylic acid (monomer), trimethylolpropane trimethacrylate (cross-linker), and phenylbis(2,4,6-trimethylbenzoyl)phosphine oxide (photoinitiator). Soft actuators are 3D-printed utilizing a commercial DLP 3D printer operating under 405 nm UV light. These 3D-printed actuators exhibit large deformation (up to 43°), high actuation speed (up to 1.08°/s), and stable actuation performance for bending cycles under relatively low actuation voltage (4–6 V). Factors such as acrylic acid content, cross-linker concentration, actuator thicknesses, and electric field strength are varied, and their impact on the 3D-printed actuators are evaluated and discussed. Lastly, a membrane valve actuator is fabricated, and its ability to open and close under applied potential is demonstrated.

Scanning Strategy Investigation for Direct Powder Bed Selective Laser Processing of Silicon Carbide Ceramic

Direct-Powder Bed Selective Laser Processing (D-PBSLP) is considered a promising technique for the Additive Manufacturing (AM) of Silicon Carbide (SiC). For the successful D-PBSLP of SiC, it is necessary to understand the effects of process parameters. The process parameters are the laser power, scanning speed, hatching distance, and scanning strategies. This study investigates the effect of scanning strategies on the D-PBSLP of SiC and ensures that other process parameters are appropriately selected to achieve this. A numerical model was developed to obtain the proper process parameters for the investigation of scanning strategies in this work. Different scanning strategies available in the commercial Phoenix 3D printer manufactured by 3D Systems, such as concentric in–out, linear, inclined zigzag, and hexagonal, have been investigated. It was concluded that the zigzag strategy is the best scanning strategy, as it was seen that SiC samples could be printed at a high relative density of above 80% without a characteristic pattern on the layer’s top surface. SiC samples were successfully printed using different laser powers and scanning speeds obtained from the numerical model and zigzag strategy. Additionally, complex geometry in the form of triple periodic minimum surface (gyroid) was also successfully printed.

Photonic waveguide bundles using 3D laser writing and deep neural network image reconstruction.

In recent years, three-dimensional (3D) printing with multi-photon laser writing has become an essential tool for the manufacturing of three-dimensional optical elements. Single-mode optical waveguides are one of the fundamental photonic components, and are the building block for compact multicore fiber bundles, where thousands of single-mode elements are closely packed, acting as individual pixels and delivering the local information to a sensor. In this work, we present the fabrication of polymer rectangular step-index (STIN) optical waveguide bundles in the IP-Dip photoresist, using a commercial 3D printer. Moreover, we reduce the core-to-core spacing of the imaging bundles by means of a deep neural network (DNN) which has been trained with a large synthetic dataset, demonstrating that the scrambling of information due to diffraction and cross-talk between fiber cores can be undone. The DNN-based approach can be adopted in applications such as on-chip platforms and microfluidic systems where accurate imaging from in-situ printed fiber bundles suffer cross-talk. In this respect, we provide a design and fabrication guideline for such scenarios by employing the DNN not only as a post-processing technique but also as a design optimization tool.

Evaluation of Stereolithography-Based Additive Manufacturing Technology for BaTiO3 Ceramics at 465 nm

A piezoceramic BaTiO3 material that is difficult for 3D printing was tested with a homemade laser-based stereolithography (SLA) setup. The high light absorbance of BaTiO3 in the spectral range of 350–410 nm makes this material hardly usable with most commercial SLA 3D printers. The typical polymerization depth of BaTiO3 ceramic pastes in this spectral range hardly reaches 30–50 µm for 40 vol % powder loading. A spectral change to 465 nm was realized in this work via a robot-based experimental SLA setup to improve the 3D printing efficiency. The ceramic paste was prepared from a preconditioned commercial BaTiO3 powder and used for 3D printing. The paste’s polymerization was investigated with variation of powder fraction (10–55 vol %), speed of a laser beam (1–10 mm/s, at constant laser power), and a hatching spacing (100–1000 µm). The polymerization depths of over 100 µm were routinely reached with the 465 nm SLA for pastes having 55 vol % powder loading. The spectral shift from 350–410 nm spectral region to 465 nm reduced the light absorption by BaTiO3 and remedied the photopolymerization process, emphasizing the importance of comprehensive optical analysis of prospective powders in SLA technology. Two multi-layered objects were 3D-printed to demonstrate the positive effect of the spectral shift.

Polydopamine surface functionalization of 3D printed resin material for enhanced polystyrene adhesion towards insulation layers for 3D microelectrode arrays (3D MEAs).

3D printing involves the use of photopolymerizable resins, which are toxic and typically have incompatible properties with materials such as polystyrene (PS), which present limitations for biomedical applications. We present a method to dramatically improve the poor adhesion between the PS insulative layer on 3D printed Microelectrode Array (MEA) substrates by functionalizing the resin surface with polydopamine (PDA), a mussel-inspired surface chemistry derivative. A commercial 3D printing prepolymer resin, FormLabs Clear (FLC), was printed using a digital light processing (DLP) printer and then surface functionalized with PDA by alkali-induced aqueous immersion deposition and self-polymerization. It was observed that the adhesion of the PS to FLC was improved due to the precision emanating from the DLP method and further improved after the functionalization of DLP printed substrates with PDA at 1, 12, and 24 h time intervals. The adhesion of PS was evaluated through scotch tape peel testing and instron measurements of planar substrates and incubation testing with qualitative analysis of printed culture wells. The composition and topology of the samples were studied to understand how the properties of the surface change after PDA functionalization and how this contributes to the overall improvement in PS adhesion. Furthermore, the surface energies at each PDA deposition time were calculated from contact angle studies as it related to adhesion. Finally, biocompatibility assays of the newly modified surfaces were performed using mouse cardiac cells (HL-1) to demonstrate the biocompatibility of the PDA functionalization process. PDA surface functionalization of 3D DLP printed FLC resin resulted in a dramatic improvement of thin film PS adhesion and proved to be a biocompatible solution for improving additive manufacturing processes to realize biosensors such as in vitro MEAs.

Aluminum concentration range for the extrudability of ceramic pastes

With the goal of developing refractory pastes to replace metal alloys used in turbine blades for Deep Space exploration, the French Space Agency, CNES, in collaboration with the Institute of Research for Ceramics, IRCER, has developed a preliminary research where dense alumina ceramics were formulated, printed and tested. This preliminary research will be the prelude to substituting by materials with more interesting creep properties at high temperature, for example, yttrium aluminum garnet, YAG. Since alumina is less expensive than YAG, preliminary tests were performed with alumina. These alumina pastes were 3D-printed by robocasting from very high solid loaded alumina pastes (>75 wt%), in the presence of organic additives, namely glycerol, PVA and ISOBAM 104. Several formulations of pastes were prepared, with the aim to obtain dense ceramic pieces. After, the alumina and the organic additives were mechanically mixed and the pastes were extruded with a commercial 3D printer. The best sample was obtained with a paste presenting an Al2O3 solid load of 79.37 wt% (63.5 vol%). A debinding step was performed afterwards to eliminate their organic content and the consolidation of the shaped pieces was finally achieved by sintering at 1700 °C. A % shrinkage of 8, 6.8 and 13.8 in the X, Y and Z-axes was measured, being one of the lowest values at 1700 °C compared to those in the literature.

A simple and convenient 3D printed temporal bone model for drilling simulating surgery

Background It is still far away from most of us in that it requires complex 3D modeling. Aims/objectives To investigate a more precision, simple, convenient and economical three-dimensional (3D) printed temporal bone model printed by a commercial desktop 3D printer, which can be widely promoted and applied in the training of beginners in otology. Material and Methods The CT data of the temporal bone were imported into Mimics to construct a 3D digital model of the temporal bone. After loaded into a high-precision 3D printer, a high-precision temporal bone model was printed at a scale of 1:1. Then, the model was evaluated by 5 senior attending physicians, including its morphological accuracy, simulation about surgery, advantages and educational value, using the 7-point Likert scale. Results A life-like temporal bone model was successfully printed out. Five senior attending physicians all thought that the printed model was similar to the natural temporal bone in physical properties and the haptic sensation of bone drilling, and was accurate, simple, convenient and effective. In addition, the model was considered to be of high application value in the teaching of temporal bone anatomy and surgery simulation, which had a material cost of only 3 dollars. Conclusions The high-precision 3D printed temporal bone model is highly similar to the natural temporal bone, and can be conveniently and effectively used in the training of simulating temporal bone surgery for beginners in otology. Its production is simple and economical, so it can be popularized on a large scale.

Binder-jetting 3D printer capable of voxel-based control over deposited ink volume, adaptive layer thickness, and selective multi-pass printing

The limited control over the printing process in commercial powder bed 3D printers hinders the exploration of novel materials and applications. In this study, a custom binder-jetting 3D printer was developed. The resulting fine-grained control over the printing process enables features such as voxel-based control over the printed ink volume, adaptive layer thickness, and selective multi-pass printing. A protocol was developed to optimize the 3D printing process for new build materials and binders, in which resolution tests were used as a guideline for improving the dimensional accuracy. As a demonstration of the voxel-based control over the printing process, a functionally graded object was printed.

Accuracy of commercial 3D printers for the fabrication of surgical guides in dental implantology

Objectives: To evaluate the accuracy of two different surgical guides (small extent = single implant and large extent = full arch) fabricated by five additive manufacturing technologies (SLA=Stereolithography, DLP= Digital Light Processing, FDM=Fused Deposition Modeling, SLS=Selective Laser Sintering, Inkjet).Methods: Overall, 72 guides (6 per type) were obtained with the different machines (SLA=Form2; DLP=Rapid Shape D40 and Cara Print 4.0; FDM=Raise 3D Pro2; SLS=Prodways P1000; Polyjet®=Stratasys J750). The guides were surface-scanned with an optical dental scanner, and the resulting files were compared with the initial design files using a surface matching software. Root Mean Square (RMS) and standard deviation were calculated, representing respectively trueness and precision. Kruskall-Wallis non-parametric test was used to compare trueness and precision between small-extent and large-extent guides and 3D printer by pairs. The threshold for significance was α=0.05, except for the comparison of printers by pairs where a Bonferroni-corrected level of 0.0033 was used.Results: Significant differences were observed for trueness and precision between small-extent and large-extent guides, regardless the printer except for DLP (trueness and precision) and SLS (precision). SLA, DLP and Polyjet® technologies showed similar results in terms of trueness and precision for both small-extend and large-extend guides (P>0.05).Conclusions: The size affected the accuracy of CAD-CAM surgical guides. The different additive manufacturing technologies had a limited impact on the accuracy.Clinical Significance: This study is of clinical interest as it shows that the 3D printing technology (SLA/DLP) has a limited impact on 3D printed surgical guides accuracy. However, the size of the guide can have a significant impact, as small-extent guides were more accurate than large-extent guides.

3D printing of soft thermoplastic elastomers: Effect of the deposit angle on mechanical and thermo-mechanical properties

This work presents the first experimental characterization of the mechanical and thermomechanical properties of a soft 3D printed thermoplastic styrenic elastomer. The tested specimens were obtained by Fused Deposition Modeling with a modified commercial 3D printer. Three different deposit strategies (deposit angle of 0°, 45° and ±45°) have been tested. Scanning electronic Microscopy was used for analyzing the microstructure of the printed specimens. The specimens were tested under two different uniaxial tensile loadings. The first one consists in applying several sets of load–unload cycles at three increasing strain levels. The second one corresponds to one load–unload cycle at different loading rates. For both tests, the temperature variations were characterized by means of infrared thermography. Results showed that the printing strategy does not have a significant effect on the mechanical response, including the softening, the hysteresis loop and the permanent set, but has an effect on its thermal response. Differences found in terms of self-heating due to intrinsic dissipation clearly show that the deposit angle influences the viscosity of the specimens.

In Situ Printing and Functionalization of Hybrid Polymer-Ceramic Composites Using a Commercial 3D Printer and Dielectrophoresis-A Novel Conceptual Design.

Three-dimensional printing-based additive manufacturing has emerged as a new frontier in materials science, with applications in the production of functionalized polymeric-based hybrid composites for various applications. In this work, a novel conceptual design was conceived in which an AC electric field was integrated into a commercial 3D printer (-based fused filament fabrication (FFF) working principle) to in situ manufacture hybrid composites having aligned ceramic filler particles. For this work, the thermoplastic poly lactic acid (PLA) was used as a polymer matrix while 10 vol% KNLN (K0.485Na0.485Li0.03NbO3) ceramic particles were chosen as a filler material. The degree of alignment of the ceramic powders depended upon print speed, printing temperature and distance between electrodes. At 210 °C and a 1 kV/mm applied electric field, printed samples showed nearly complete alignment of ceramic particles in the PLA matrix. This research shows that incorporating electric field sources into 3D printing processes would result in in situ ceramic particle alignment while preserving the other benefits of 3D printing.

One-step production of 3D printed ferroelectric polymer forms using fused deposition modeling

This Letter presents the possibility of 3D print polymer forms with a ferroelectric crystal structure in a one-step process by using the fused deposition modeling method. The approach does not require any additional equipment, other than an extruder for filament production and a commercial 3D printer to fabricate ferroelectric polymer forms. By using the copolymer of vinylidene fluoride and tetrafluoroethylene as a filament for 3D printing, complex spatial structures, such as the gyroid form, are accessible. Compared to polyvinylidene fluoride, the copolymer of vinylidene fluoride and tetrafluoroethylene retains its ferroelectric properties even after melting in the 3D printing process and soldification. The x-ray diffraction investigation shows that the 3D forms are having a planar zigzag conformation on macromolecule scales, which relates to a crystal structure with ferroelectric properties. Annealing the 3D forms at a temperature of 110 °C for 12 h does not cause any changes to the spatial polymer structures but leads to an increase in the degree of crystallinity by more than 20%. This result contributes to an increase in the ferroelectric crystalline phase content by ∼17% and the Curie temperature by ∼7 °C in contrast to non-annealed 3D forms.

Analysis and optimization of geometry of 3D printer part cooling fan duct

Part cooling fans are used in FDM 3D printers to control the deposition quality and warping issues. However, the fan ducts used for the purpose are often non-optimized, and therefore, the performance of such ducts can be improved by analyzing the geometry and adopting necessary modifications. This work looks into the geometry of the part cooling fan duct of a common commercial 3D printer, and studies the influence of a convergent-divergent type duct opening on the flow behavior. The inlet and outlet angles and the throat length have been analyzed numerically to identify the most suitable geometry. Results indicate that there are optimum values for all of these three geometrical parameters to obtain the highest air flow velocity at the outlet, and the flow behavior deteriorates beyond such optimum parameters. From the numerical analysis, the optimized convergent-divergent duct having 20° outlet angle, 3 mm throat length, and 40° inlet angle can increase the average air flow velocity by approximately 23% over the air flow velocity of a standard part cooling fan without the convergent- divergent section.

Combining Materials Obtained by 3D-Printing and Electrospinning from Commercial Polylactide Filament to Produce Biocompatible Composites

The design of scaffolds to reach similar three-dimensional structures mimicking the natural and fibrous environment of some cells is a challenge for tissue engineering, and 3D-printing and electrospinning highlights from other techniques in the production of scaffolds. The former is a well-known additive manufacturing technique devoted to the production of custom-made structures with mechanical properties similar to tissues and bones found in the human body, but lacks the resolution to produce small and interconnected structures. The latter is a well-studied technique to produce materials possessing a fibrillar structure, having the advantage of producing materials with tuned composition compared with a 3D-print. Taking the advantage that commercial 3D-printers work with polylactide (PLA) based filaments, a biocompatible and biodegradable polymer, in this work we produce PLA-based composites by blending materials obtained by 3D-printing and electrospinning. Porous PLA fibers have been obtained by the electrospinning of recovered PLA from 3D-printer filaments, tuning the mechanical properties by blending PLA with small amounts of polyethylene glycol and hydroxyapatite. A composite has been obtained by blending two layers of 3D-printed pieces with a central mat of PLA fibers. The composite presented a reduced storage modulus as compared with a single 3D-print piece and possessing similar mechanical properties to bone tissues. Furthermore, the biocompatibility of the composites is assessed by a simulated body fluid assay and by culturing composites with 3T3 fibroblasts. We observed that all these composites induce the growing and attaching of fibroblast over the surface of a 3D-printed layer and in the fibrous layer, showing the potential of commercial 3D-printers and filaments to produce scaffolds to be used in bone tissue engineering.

3D printed continuous glass fibre-reinforced polyamide composites: Fabrication and mechanical characterisation

Fused Filament Fabrication is a very common additive manufacturing technology and several manufacturers have developed commercial 3D-printers that enable the use of fibre-reinforced filaments in order to improve the mechanical properties of the printed parts. The obtained material is a composite that exhibits complex mechanical properties. The aim of this study is to characterize the mechanical behaviour of 3D-printed continuous glass fibre-reinforced polyamide composites. In a first step, we focus on the reinforced filament: the heterogeneity of its microstructure is evidenced as well as its brittle elastic tensile behaviour. In a second step, parts of different fibre orientations and fibre volume contents are manufactured using a Mark Two 3D-printer (MarkForged®), their microstructure is analysed and tensile, flexural and short beam bending tests are performed. As expected, the results show a significant influence of fibre volume content and fibre orientation. Standard homogenization methods are used to compare the predicted mechanical behaviour to the experimental results. Regarding the elastic stiffness, a good correlation is observed when the material is loaded in the direction of the fibres. Regarding the tensile strength, the results show that no benefit is obtained above a fibre volume content of about 11%. These results highlight the importance of choosing an optimised stacking sequence prior to the printing process, in order to obtain composites with the desired mechanical properties. The mechanical results are analysed in the light of Scanning Electron Microscopy observations of specimen cross-sections before and after testing.

Mechanical characterization and neutrophil NETs response of a novel hybrid geometry polydioxanone near-field electrospun scaffold

Near-field electrospinning (NFES) is a direct fiber writing sub-technique derived from traditional electrospinning (TES) by reducing the air gap distance to the magnitude of millimeters. In this paper, we demonstrate a NFES device designed from a commercial 3D printer to semi-stably write polydioxanone (PDO) microfibers. The print head was then programmed to translate in a stacking grid pattern, which resulted in a scaffold with highly aligned grid fibers that were intercalated with low density, random fibers. As the switching process can be considered random, increasing the grid size results in both a lower density of fibers in the center of each grid cell as well as a lower density of ‘rebar-like’ stacked fibers. These scaffolds resulted in tailorable as well as greater surface pore sizes as given by scanning electron micrographs and 3D permeability as indicated by fluorescent microsphere filtration compared to TES scaffolds of the same fiber diameter. Furthermore, ultimate tensile strength, percent elongation, yield stress, yield elongation, and Young’s modulus were all tailorable compared to the static TES scaffold characterization. Lastly, the innate immune response of neutrophil extracellular traps was attenuated on NFES scaffolds compared to TES scaffolds. These results suggest that this novel NFES scaffold architecture of PDO can be highly tailored as a function of programming for a variety of biomedical and tissue engineering applications.

3D printing of continuous carbon fiber reinforced thermoset composites using UV curable resin

AbstractAdditive manufacturing is trending toward functional applications beyond the scope of rapid prototyping. This requires the development of high‐performance, lightweight, and complex structures resulting from additive manufacturing. One of the biggest challenges for fulfilling these requirements is the limitation of material properties. The introduction of reinforcement allows for the expansion of current polymer‐based 3D printing technologies to achieve increased material properties while maintaining complex geometries. Commercial 3D printers able to print thermoplastic composites have recently been demonstrated with good repeatability. However, limitations of these thermoplastic composites include low fiber volume fraction and susceptibility to high temperatures. In contrast, thermoset‐based composites offer greater thermal stability and higher mechanical performance due to the cross‐linked structure of the polymer. Moreover, using continuous reinforcement instead of short fiber reinforcement offers higher performance opportunities. Therefore, the challenge of 3D printing with continuous fiber‐reinforced thermoset composite is addressed in this study. A 3D printer capable of printing a UV curable resin system reinforced with continuous carbon fiber was constructed. Variations of printed composites' mechanical properties depending on the fiber tow characteristic were investigated. Two different carbon fiber types and their associated tow twist count and sizing were evaluated in this study. Burn‐off tests were used to determine the printed composites' final fiber volume fraction. Using a rule of mixtures approach, strength and modulus were predicted for each composite and compared against their experimental values. Predicted modulus values were found within 2%–5% of experimental, while strength values were significantly less than predicted.