Fused Deposition Modeling Research Articles

Comparison of FDM and SLA printing on woven fabrics

Possibilities to perform 3D printing directly on textile fabrics have been investigated intensively during the last decade. Usually, fused deposition modeling (FDM) printing with often inexpensive 3D printers is applied in these experiments. Several studies revealed the influence of textile fabrics, FDM polymers and printing parameters, indicating that not all combinations of fabrics and printing materials are suitable for this task. Recently, first approaches to use stereolithography (SLA) or PolyJet Modeling (PJM) directly on textile fabrics have been reported. Here, the first comparison of the adhesion forces reached by FDM and SLA printing on different woven fabrics is shown, revealing significantly better adhesion for SLA printing.

Comprehensive Study of Mechanical, Electrical and Biological Properties of Conductive Polymer Composites for Medical Applications through Additive Manufacturing.

Conductive polymer composites are commonly present in flexible electrodes for neural interfaces, implantable sensors, and aerospace applications. Fused filament fabrication (FFF) is a widely used additive manufacturing technology, where conductive filaments frequently contain carbon-based fillers. In this study, the static and dynamic mechanical properties and the electrical properties (resistance, signal transmission, resistance measurements during cyclic tensile, bending and temperature tests) were investigated for polylactic acid (PLA)-based, acrylonitrile butadiene styrene (ABS)-based, thermoplastic polyurethane (TPU)-based, and polyamide (PA)-based conductive filaments with carbon-based additives. Scanning electron microscopy (SEM) was implemented to evaluate the results. Cytotoxicity measurements were performed. The conductive ABS specimens have a high gauge factor between 0.2% and 1.0% strain. All tested materials, except the PA-based conductive composite, are suitable for low-voltage applications such as 3D-printed EEG and EMG sensors. ABS-based and TPU-based conductive composites are promising raw materials suitable for temperature measuring and medical applications.

Novel auxetic metamaterials inspired from geometry patterns of an Iranian Mosque with improved energy absorption capability

Recent developments in auxetic metamaterials have positioned them as highly effective energy absorbers, offering superior energy absorption and specific energy absorption (SEA) properties. Meanwhile, the fascinating geometric patterns and motifs found in historical arts have emerged as a valuable source of inspiration for designing innovative auxetic unit cells. This research proposes a novel auxetic unit cell inspired by the geometric patterns exhibited in the Isfahan Jameh Mosque in Iran. Two distinct auxetic structures are designed with different arrangements of the proposed unit cell and fabricated via the fused deposition modeling (FDM) additive manufacturing technology. Their negative Poisson’s ratio (NPR), energy absorption capability, and SEA are evaluated through both experimental testing and finite element method (FEM). The comparative analysis of the results shows that the designed structures exhibit significantly enhanced energy absorption compared to the other two different re-entrant auxetic structures. Consequently, these novel auxetic structures hold great promise in replacing conventional re-entrant structures as highly efficient energy absorber devices.

Multi-objective optimization of 3D printing parameters to fabricate TPU for tribological applications

Nowadays, polymers frequently replace metals in several applications where comparable properties are desired due to the convenience of processing them as per the requirement. The present work intends to fabricate a thermoplastic polyurethane suitable for journal bearing application using fused deposition modelling (FDM) additive manufacturing method. The cylindrical samples were prepared for experiments using central composite design to examine the effect of FDM machine parameters (such as layer thickness, infill density, and printing speed) on response such as specific wear rate (SWR), coefficient of friction (COF) and hardness. Layer thickness was noticed to be the most significant parameter for the selected responses with a percentage contribution of ∼34% to 72%. Further, as observed from interaction plots the COF and SWR are lowest, and hardness is highest at highest infill density and lowest printing speed. To obtain an optimized set of FDM machine parameters for minimum SWR, COF and maximum hardness, genetic algorithm based multi-objective optimization is performed. The optimized values are SWR of 4.97 × 10−5 mm3/N-m, COF of 0.37 and hardness value of 37.

Three-Dimensional Printing by Vat Photopolymerization on Textile Fabrics: Method and Mechanical Properties of the Textile/Polymer Composites

Composites of textile fabrics and 3D-printed layers have been investigated thoroughly during the last decade. Usually, material extrusion such as the fused deposition modeling (FDM) technique is used to build such composites, revealing challenges in preparing form-locking connections between both materials due to the highly viscous polymer melt, which can hardly be pressed into textile fabrics. Resins used for 3D printing by vat photopolymerization, i.e., for stereolithography (SLA), are less viscous and can thus penetrate deeper into textile fabrics; however, fixing a textile on the printing bed that is fully dipped into the resin is more complicated. Here, we present one possible solution to easily fix textile fabrics for SLA printing with consumer printers according to the digital light processing (DLP) sub-method. Also, we show the results of a study of the mechanical properties of the resulting textile/polymer composites, as revealed by three-point bending tests.

Behavior of sandwich structures with 3D-printed auxetic and non-auxetic cores under low velocity impact: Experimental and computational analysis

In recent years, impact-resistant structures are highly sought after in various fields such automotive and aerospace applications as they proved notable performances, garnering significant success. The aim of this study is to assess the behavior of the 3D-printable honeycombs subjected to low velocity impact, for providing insights into absorbed energy for different core designs: hexagonal, auxetic, and rectangular, considering an equal number of cells across all designs. This work reports the computational and experimental studies conducted for sandwich structures under different impact loading. The experimental impact tests are carried out using a drop weight impact-testing machine. The examined specimen comprises two face-sheets and architected cell core fabricated through the Fused Filament Fabrication (FFF) process made of polylactic acid (PLA). Variations in the geometric design of the cells result in the formation of cores with auxetic and non-auxetic topologies. Uniaxial tensile tests are performed to identify the mechanical properties of the involved biopolymer. The second attempt consists on comparing three architectural core structures under impact test using experimental and computational methods. Our findings highlight the specific influence of core topology on energy absorption in 3D-printed sandwich structures. Results indicate that while all three configurations (hexagonal, re-entrant, and rectangular) demonstrate comparable energy absorption values, the specific mechanisms and efficiencies vary, with re-entrant cores exhibiting distinct behaviors under impact.

A novel systematically optimized tabular neural network (TabNet) algorithm for predicting the tensile modulus of additively manufactured PLA parts

Assessing the elastic modulus of 3D-printed polylactic acid (PLA) components is essential for understanding their stiffness and load capacity, which are crucial for predicting product performance and durability. In this study, the predictive accuracy of a Tabular Neural Network (TabNet) algorithm for determining the elastic modulus of 3D-printed PLA components via fused deposition modeling (FDM) was investigated. Utilizing a comprehensive dataset of 128 literature-sourced data points, divided into 80 % for training and 20 % for validation, the study proposed a new Taguchi-based method for efficient hyperparameter optimization of the TabNet algorithm. This optimization revealed that a configuration of 8 decision blocks, 16 attention blocks, and 5 decision steps, along with the "Adam" optimizer, a gamma of 1, learning rate of 0.1, and lambda-sparse of 0.01, yielded the highest prediction accuracy for the elastic modulus of PLA parts. The performance of the optimized TabNet model was evaluated using R-squared (R²), Mean Absolute Error (MAE), Mean Squared Error (MSE), and Root Mean Squared Error (RMSE) measures. The findings highlighted an R² of 96.855 %, an MAE of 0.158, an MSE of 0.037, and an RMSE of 0.193 in the validation dataset, demonstrating substantial predictive reliability. To further test the model’s robustness, fourteen unseen data points were analyzed. The observed discrepancies between predicted and actual values were under 10 %, affirming the Taguchi-optimized TabNet algorithm’s effectiveness in forecasting the elastic modulus of FDM 3D-printed PLA components. This investigation provides a significant advancement in additive manufacturing, introducing a precise and reliable method for predicting the mechanical properties of 3D-printed materials.

Advancing laser transmission welding for additive manufacturing: A study of glass fiber reinforced polypropylene parts

Laser transmission welding (LTW) is a well-established technique for joining high-volume thermoplastic parts, such as automotive injection molded parts. For low-volume, prototype, and custom production, additive manufacturing is an emerging technology for producing complex thermoplastic parts. When compared to injection molding, the additive manufacturing process fused filament fabrication (FFF) results in an inhomogeneous structure with entrapped air within the volume. Additionally, the presence of short glass fibers in the polymer matrix leads to higher radiation scattering during the welding process. This paper presents a fundamental study of the weldability of additively manufactured fiber-reinforced parts. The specimens were fabricated using a FFF process with glass fiber-reinforced polypropylene (GF-PP). The study investigates the influence of layer thickness and line width of the FFF process on the optical transmittance. LTW-experiments were conducted using additively manufactured uncolored and black GF-PP samples. Lap shear test specimens were welded with a different energy per unit length. This research presents a process for welding additively manufactured GF-PP parts that can be used with optimized FFF-parameters to produce high-strength and durable prototypes or spare parts for the automotive industry. This research provides valuable insights into the process parameters and considerations required to achieve robust welds in additively manufactured thermoplastic parts, facilitating broader adoption of LTW in additive manufacturing contexts.

Multichannel 3D-printed bionanoparticles-loaded tablet (M3DPBT): designing, development, and in vitro functionality assessment

BackgroundThe intersubject variability which was related to the genetic makeup was the major cause of change in pharmacological and pharmacokinetic behavior of same dosage form in varied human being. 3D printing technology will help therapy evolve and eliminate the limitations of conventional technologies. Nebivolol's (NBL)-limited oral bioavailability is mainly due to its poor aqueous solubility. The research aims to combine advanced 3D printing technology and nanotechnology to design customized therapy and enhance the functionality of NBL using a statistical approach.Results and discussionThe results of the phase solubility indicated that NBL was a poorly aqueous soluble drug. Its solubility was increased by employing nanoparticle drug delivery, which is a promising solubility enhancement technique. The 32 full factorial design was employed to develop and optimize bionanoparticles (BNPs) by solvent evaporation technique using poly (lactic-co-glycolic acid 50:50) (PLGA 50:50) and poloxamer-407 as a surfactant. The BNPs were characterized by % encapsulation efficiency (% EE), Fourier transform infrared spectroscopy (FTIR) and differential scanning calorimeter (DSC), transmission electron microscope (TEM), zeta potential, polydispersity index (PDI), particle size, in vitro drug release, etc. The BNPs loaded of NBL were further incorporated into the multichannel 3D-controlled release tablets made by PVA filaments employing fused deposition modeling (FDM) technology optimized by central composite design (CCD). Multichannel 3D-printed bionanoparticles-loaded tablet (M3DPBT) was optimized using CCD. All designed M3DPBTs were evaluated for post-fabrication parameters. The optimized M3DPBT could release more than 85% NBL within 10 h.ConclusionsThe newly fabricated M3DPBT was found stable. The amount of PLGA 50:50 and Polaxomer was significant for developing BNPs. % infill and layer height were observed as critical for the designing M3DPBT. The combined novel 3D printing and nanotechnology technology will open a new direction for patient compliance and better therapeutic effects.Graphical abstractDesigning and developing of M3DPBT is substantially improve the patient compliance and therapeutic effectiveness of Nebivolol.

Exploring the dynamic mechanical properties of fused filament fabrication printed polyetheretherketone with various infill patterns

Exploring the dynamic mechanical properties of fused filament fabrication printed polyetheretherketone with various infill patterns

Effects of Infill Density and Printing Speed on The Tensile Behaviour of Fused Deposition Modelling 3D Printed PLA Specimens

The mechanical properties such as tensile behavior of a 3D printed object can be influenced by various printing parameters, including printing temperature, orientation, infill density, and printing speed. This study focuses on investigating the effects of infill density and printing speed. Thirty dog-bone specimens were 3D printed using Fused Deposition Modelling (FDM) technique with Polylactic Acid (PLA) filament. Three different infill density settings (40%, 60%, and 80%) and three printing speed settings (30 mm/s, 60 mm/s, and 90 mm/s) were used. Tensile tests were performed on each specimen using a Universal Testing Machine. The experimental results indicate a clear trend of tensile behaviour with infill density. Increasing the infill density leads to improved tensile behaviour in the specimen. The highest Young’s Modulus and ultimate tensile strength (UTS) were achieved at 541.67 MPa and 24.3 MPa, respectively, with an infill density of 80%. On the other hand, printing speed showed an inverse relationship with tensile behaviour. As the printing speed increased, the Young’s Modulus and UTS decreased. However, the effect of printing speed on the mechanical properties was not as significant as that of infill density. When increasing the printing speed from 30 mm/s to 90 mm/s, the UTS only decreased by 5.61%. In contrast, increasing the infill density from 40% to 80% resulted in a UTS increase of 35.23%.

Investigating Additive Manufacturing Possibilities for an Unmanned Aerial Vehicle with Polymeric Materials.

Fused filament fabrication, also known as fused deposition modeling and 3D printing, is the most common additive manufacturing technology due to its cost-effectiveness and customization flexibility compared to existing alternatives. It may revolutionize unmanned aerial vehicle (UAV) design and fabrication. Therefore, this study hypothesizes the 3D printing possibility of UAV using a simple desktop printer and polymeric material. The extensive literature analysis identified the acceptable prototyping object and polymeric material. Thus, the research focuses on applying polylactic acid (PLA) in manufacturing the flying wing-type UAV and develops a fabrication concept to replicate arial vehicles initially produced from a mixture of expanded polystyrene and polyethylene. The material choice stems from PLA's non-toxicity, ease of fabrication, and cost-effectiveness. Alongside ordinary PLA, this study includes lightweight PLA to investigate the mechanical performance of this advanced material, which changes its density depending on the printing temperature. This proof-of-concept study explores the mechanical properties of printed parts of the wing prototype. It also considers the possibility of fragmentation in fabricated objects because of the limitations of printing space. The simplified bending tests identified significant reserves in the mechanical performance regarding the theoretical resistance of the material in the wing prototype, which proves the raised hypothesis and delivers the object for further optimization. Focusing on the mechanical resistance, this study ignored rheology and durability issues, which require additional investigations. Fabricating the wing of the exact geometry reveals acceptable precision of the 3D printing processes but highlights the problematic technology issues requiring further resolution.

Optimising Additive Manufacturing to Produce PLA Sandwich Structures by Varying Cell Type and Infill: Effect on Flexural Properties

The objective of this research is to optimize additive manufacturing processes, specifically Fused Filament Fabrication (FFF) techniques, to produce sandwich structures. Mono-material specimens made of polylactic acid (PLA) were produced, where both the skin and core were fabricated in a single print. To optimize the process, variations were made in both the base cell geometry of the core (Tri-Hexagon and Gyroid) and the core infill (5%, 25%, 50%, and 75%), evaluating their effects on static three-point bending behavior. Optical microscopy was employed to assess both the structure generated by additive manufacturing and the fracture modes. The findings reveal that increasing the infill, and thus the core density, enhances the mechanical properties of the structure, although the improvement is such that samples with 50% infill already demonstrate excellent performance. The difference between hexagonal and Gyroid structures is not significant. Based on microscopic analyses, it is believed that the evolution of 3D printers, from open to closed chamber designs, could significantly improve the deposition of the various layers.

Numerical Simulation Study on Rotary Air Preheater Considering the Influences of Steam Soot Blowing

The ash deposition is a general problem that needs to be solved effectively for the rotary air preheater of the coal-fired boiler. Taking the rotary air preheater of a 600 MW power station as the object, the mesh model of the flue gas side of the air preheater, considering the influences of steam soot blowing, is established using the Gambit 2.4.6 software. Based on the SIMPLE algorithm, the velocity field and the temperature field in the air preheater under varied working conditions are simulated using the software of Ansys Fluent 2021R1, and the influences of the boiler load, the operation parameters of the steam soot blower, and the running and outage of the soot blower on the flue gas velocity distribution in the depth direction of the corrugated plates, the soot-blowing coverage area, the inlet flue gas velocity, and the inlet flue gas temperature of the corrugated plates are analyzed. Under the base working condition, the flue gas velocity on the axis of the steam nozzle first decreases rapidly with increasing the corrugated plate depth (Z < 1.0 m), and then it decreases slowly with an almost equal slope. The longitudinal flue gas velocity has a positive correlation with the boiler load. The longitudinal flue gas velocity obviously decreases when the boiler load is decreased, and its reduction increases as the corrugated plate depth increases. It is one reason that the ash deposition is prone to occur on the cold end surface of corrugated plates under the condition of low boiler load. The longitudinal flue gas velocity increases with the soot-blowing steam velocity increasing when the corrugated plate depth is less than 1.5 m, but after that, it is almost not affected by the change in soot-blowing steam velocity. The soot-blowing coverage area has a negative correlation with the boiler load but a slight positive correlation with the steam velocity of the soot blower on the whole. The inlet flue gas velocity of the corrugated plates has a positive correlation with the boiler load and the inlet steam velocity of the soot blower. The average inlet flue gas velocity decreases by 21.7% when the boiler load is reduced by 50%. For every 5 m/s variation in the inlet steam velocity, the inlet flue gas velocity changes by about 10–14% whether the steam soot blower is put into operation or not, which has an obvious effect on the inlet gas velocity of the corrugated plates. The inlet flue gas temperature of the corrugated plates is, respectively, positively correlated with the boiler load and the inlet steam temperature of the soot blower. When the boiler load is reduced from 100% BMCR to 50% BMCR, the average inlet flue gas temperature of the corrugated plates is reduced by 44.2 K; however, when the soot-blowing steam temperature varies by 20 K, the average inlet flue gas temperature of the corrugated plates varies by only about 1.8 K. It means that it is difficult to enhance the cold end flue gas temperature of the corrugated plates only by raising the soot-blowing steam temperature at low boiler load. Adding a soot blower using high-temperature steam or hot air at the outlet of the corrugated plates may be an option to solve the ash deposition of the corrugated plates.

Direct printing of carbon fiber reinforced thermoplastic plastic on metal sheets via fused deposition modeling assisted by laser texturing

AbstractPrinting polymers on metal surfaces using fused deposition modeling could enhance the versatility of hybrid structures. However, the differences between metals and plastics prevented the effective spreading of molten plastic on metal surfaces, challenging reliable plastic printing on metal substrates. This study employed a nanosecond laser to fabricate laser‐textured grids of varying widths (0.2–0.5 mm) on a 6061 aluminum alloy (6061Al) surface. Carbon fiber reinforced thermoplastic plastic (CFRTP) was printed on 6061Al surface in different printing directions (0°, 45°, and 90°). The influence of laser texturing and printing direction on joint performance was evaluated. The findings indicated the laser‐texturing increased 6061Al surface roughness, enhancing wettability of CFRTP on 6061Al surface. The 45° printing direction provided the best wetting, resulting in a tensile‐shear force of 1631.7 N, 218% higher than at 90°. Optimal performance was achieved with a 0.5‐mm texture width, increasing tensile‐shear force by 180% compared to 0.2 mm and 67% compared to 0.6 mm. Interfacial stress concentration decreased and then increased with the increase of laser‐textured width and the 45° printing direction provided the longest print path and best resin spreading. This research presented a novel approach to metal‐polymer joining, with significant implications for advanced lightweight hybrid structures.Highlights Printing carbon fiber reinforced thermoplastic plastic (CFRTP) on 6061 aluminum alloy (6061Al) surface was achieved by fused deposition modeling via laser texturing. The print direction affected the wetting and spreading space of the molten resin. Pinning effect of printed CFRTP/6061Al by laser texturing was studied. The spreading and wetting of resin determined the mechanical properties.

Three‐Dimensional Printed Integrated Electrochemical Devices for Various Applications–A Review

AbstractThree‐dimensional Printing (3DP) and computer‐assisted design (CAD) are a boon for producing high‐quality analytical and electrochemical devices using low‐cost components. This review briefly explains various 3D printing techniques. The focus is on the fabrication of integrated miniature devices developed through the 3DP process, mainly by the Fused deposition modelling (FDM) technique. Examples of integrated electrochemical devices are presented to highlight the potential of 3DP. Special emphasis is given to surface activation of 3D printed electrodes to enhance their electrochemical activity and various activation methods. This paper discusses the opportunities and future applications in developing all‐in‐one miniature electrochemical devices that might lead to on‐site environmental measurements, point‐of‐care tests, and the development of portable instruments with reduced sample volume.

Investigation of compressive strength of primitive geometries printed through the fused deposition modeling technique with different path patterns

Fused Deposition Modeling (FDM) is a material-extrusion-based technique used primarily for rapid prototyping and sometimes for an actual servicing part. In the FDM technique, input parent materials are commercial polymers. FDM also has some manufacturing parameters, and the raster pattern significantly affects the mechanical performance of the FDM products. Due to its intrinsic nature, Acrylonitrile Butadiene Styrene (ABS) is widely used in many industries, such as automobiles, medicine, etc. Producing the primitive geometry and selecting the proper infill pattern is challenging. Therefore, the current research paper investigates the effects of various infill patterns on the compressive performance of the three geometries (sphere, 3-side, and 4-side pyramids) printed through the FDM technique out of ABS material. The compressive experiments were conducted on the printed samples and load-displacement curves were evaluated. The results reveal that the concentrate path pattern in the sphere samples has the highest compressive failure load (40127 N). Also, the compressive failure loads in the 3-side and 4-side pyramids fabricated with a 45°/−45° raster pattern are 30444 N and 44396 N, respectively. Finally, comprehensive discussions about the obtained results are stated.

Transformative Potential and Healthcare Applications of 3D Printing.

Additive manufacturing, sometimes referred to as 3D printing or AM, has numerous applications in industries like manufacturing, aviation, aerospace, vehicles, and education. It has recently made considerable inroads into the healthcare industry, backed by technology breakthroughs such as fused deposition modeling, binder jetting, and inkjet printing. A variety of biomaterials, such as polycaprolactone, polycarbonate, polypropylene, and polylactic acid, have contributed to this increase. This essay delves into the revolutionary possibilities of 3D printing in healthcare, to shed light on the idea of customized medications via the improvement of efficiency and cost. Researchers are using polymers and additive manufacturing to make customized medical devices. However, obstacles including bureaucratic hurdles, technological developments, and the choice of appropriate materials and printers stand in the way of widespread implementation. To fully realize the promise of 3D printing in healthcare, these challenges must be overcome. The article highlights the revolutionary potential of 3D printing in healthcare by following its development from art and construction to customized drugs and patient-specific medical equipment. In addition to addressing issues like quality control and technological limitations, it emphasizes its wide range of applications in surgical planning, dentistry, and anatomical models. The necessity of adapting regulations and instructional programs is highlighted by discussing future trends like bioprinting and FDA-approved innovations. In order to properly utilize 3D printing in healthcare, this adaption is essential. Personalized prescriptions and increased efficacy from the incorporation of 3D printing could revolutionize the healthcare industry. But even with these advances, problems like choosing the right materials and getting over administrative roadblocks prevent widespread implementation. These challenges need to be successfully overcome for 3D printing in healthcare to reach its full potential.

Multi-material fused deposition modelling of structural–functional integrated absorber with multi-scale structure possessing tunable broadband microwave absorption

Designing and manufacturing advanced structural microwave absorbers is one of the most feasible methods to address the growing electromagnetic stealth and protection challenges in both military and civilian domains. To this end, under the application context of structural–functional integration, a series of nanocomposites with varying ratios were prepared using multi-walled carbon nanotubes (MWCNTs) and inexpensive thermoplastic polypropylene as raw materials. The dispersion of nanofillers, rheological properties, thermal properties, and mechanical properties were evaluated. The research found that the impedance matching factor of the electromagnetic wave absorbers plays a more critical role in determining the material’s absorption capacity compared to the loss factor. Simple structural layering by changing the composition and design can effectively increase the effective absorption bandwidth (EAB) of the absorbers, with microwave attenuation primarily arising from conductive loss, interfacial polarization, dipole polarization, and multiple reflections. Finally, a multi-scale quasi-honeycomb absorber was fabricated using multi-material 3D printing with a structured design. Both simulation and experimental results showed consistent trends, demonstrating low sensitivity to the incident azimuth angle. This research features simplicity, low cost, and strong design capability, providing a new strategy for the preparation of functionally graded materials with potential applications in electromagnetic wave absorption.

Recycling catfish bone for additive manufacturing of silicone composite structures

As a notable commercial aquaculture species, channel catfish ( Ictalurus punctatus) in US faces challenges including the global market competition and enhanced feed costs. Since fish bone waste is a major source of calcium and hydroxyapatite, re-utilization gives birth to several advanced products in the development of animal feed, fertilizers, and nutrition supplements. Recent research findings introduce fish bone powder (FBP) reinforcement in Fused Deposition Modeling (FDM) of plastic composites. However, FBP so far has not been widely utilized for Direct Ink Writing (DIW) 3D printing of silicone composite. In this paper, catfish bone waste has been recycled and processed with a thermal procedure. FBP reinforced silicone composite structures have been developed and manufactured using low-viscosity DIW 3D printing. Morphological and chemical structures of FBPs were analyzed and compared before and after calcination. The rheological and mechanical characterization have indicated the potential of calcinated FBP in advancing the silicone composites. With 0%–50% weight percentages of FBP, composite samples can be designed to get any specified mechanical response (0.5–1.4 MPa in 50% tension strain and 150–550 N in 30% compression strain). The shape holding, overhang, and dimensional accuracy of FBP reinforced silicone composites in single (DIW) and dual (FDM + DIW) 3D printing processes have been demonstrated and summarized. With appropriate adjustments, this FBP-based 3D printing technology can be applied to byproduct recycling of all the US food-fish species, poultry, and livestock.