-In this work, an extrusion-based 3D printing technique was employed for processing of biobased blends of Poly(Lactic Acid) (PLA) with low-cost kraft lignin. In Fused Filament Fabrication (FFF) 3D printing process, objects are built in a layer-by-layer fashion by melting, extruding and selectively depositing thermoplastic fibers on a platform. These fibers are used as building blocks for more complex structures with defined microarchitecture, in an automated, cost-effective process, with minimum material waste. A sustainable material consisting of lignin biopolymer blended with poly(lactic acid) was examined for its physical properties and for its melt processability during the FFF process. Samples with different PLA/lignin weight ratios were prepared and their mechanical (tensile testing), thermal (Differential Scanning Calorimetry analysis) and morphological (optical and scanning electron microscopy, SEM) properties were studied. The composition with optimum properties was selected for the production of 3D-printing filament. Three process parameters, which contribute to shear rate and stress imposed on the melt, were examined: extrusion temperature, printing speed and fiber's width varied and their effect on extrudates' morphology was evaluated. The mechanical properties of 3D printed specimens were assessed with tensile testing and SEM fractography.

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Abstract. Additive manufacturing (AM) is identified to cost-effectively lower manufacturing inputs and outputs in small batch production, widely employed in customized and high-value manufacturing chains, such as aerospace and medical component manufacturing. Additive manufacturing has the potential to significantly lower life cycle energy demands of products and their CO 2 emissions. Moreover, AM holds promise of overturning many aspects of the economics of manufacturing, as it pays no heed to unit labour costs or traditional economies of scale. Advances in AM technology are yielding faster production times and enabling objects to be printed in multiple combinations of materials, colours and surface finishes. A significant portion of these advances lie on the development of advanced materials for AM processes, which is undeniably one of the main driving forces of the transition from Rapid Prototyping to the Direct Digital Manufacturing era. Industries are nowadays at the inflection point for AM technologies, which have moved from a much-hyped but largely unproven manufacturing processes, to a mature technological solution, with numerous competitive advantages and the ability to produce real, innovative, complex and robust products.

A polyamide (PA) 12-based thermoplastic composite was modified with carbon nanotubes (CNTs), CNTs grafted onto chopped carbon fibers (CFs), and graphene nanoplatelets (GNPs) with CNTs to improve its thermal conductivity for application as a heat sink in electronic components. The carbon-based nanofillers were examined by SEM and Raman. The laser flash method was used to measure the thermal diffusivity in order to calculate the thermal conductivity. Electrical conductivity measurements were made using a Keithley 6517B electrometer in the 2-point mode. The composite structure was examined by SEM and micro-CT. PA12 with 15 wt% of GNPs and 1 wt% CNTs demonstrated the highest thermal conductivity, and its processability was investigated, utilizing sequential interdependence tests to evaluate the composite material behavior during fused filament fabrication (FFF) 3D printing processing. Through this assessment, selected printing parameters were investigated to determine the optimum parametric combination and processability window for the composite material, revealing that the selected composition meets the necessary criteria to be processable with FFF.

Bioinspired scaffolds mimicking natural bone-tissue properties holds great promise in tissue engineering applications towards bone regeneration. Within this work, a way to reinforce mechanical behavior of bioinspired bone scaffolds was examined by applying a physical crosslinking method. Scaffolds consisted of hydroxyapatite nanocrystals, biomimetically synthesized in the presence of collagen and l-arginine. Scaffolds were characterized by X-ray diffraction, Fourier transform infrared spectroscopy, scanning electron microscopy (SEM), microcomputed tomography, and nanoindentation. Results revealed scaffolds with bone-like nanostructure and composition, thus an inherent enhanced cytocompatibility. Evaluation of porosity proved the development of interconnected porous network with bimodal pore size distribution. Mechanical reinforcement was achieved through physical crosslinking with riboflavin irradiation, and nanoindentation tests indicated that within the experimental conditions of 45% humidity and 37 °C, photo-crosslinking led to an increase in the scaffold’s mechanical properties. Elastic modulus and hardness were augmented, and specifically elastic modulus values were doubled, approaching equivalent values of trabecular bone. Cytocompatibility of the scaffolds was assessed using MG63 human osteosarcoma cells. Cell viability was evaluated by double staining and MTT assay, while attachment and morphology were investigated by SEM. The results suggested that scaffolds provided a cell friendly environment with high levels of viability, thus supporting cell attachment, spreading and proliferation.