Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.
Plastics are one of the most commonly used materials for fabricating microfluidic devices. While various methods exist for fabricating plastic microdevices, hot embossing offers several unique advantages including high throughput, excellent compatibility with most thermoplastics and low start-up costs. However, hot embossing requires metal or silicon molds that are fabricated using CNC milling or microfabrication techniques which are time consuming, expensive and required skilled technicians. Here, we demonstrate for the first time the fabrication of plastic microchannels using 3D printed metal molds. Through optimization of the powder composition and processing parameters, we were able to generate stainless steel molds with superior material properties (density and surface finish) than previously reported 3D printed metal parts. Molds were used to fabricate poly(methyl methacrylate) (PMMA) replicas which exhibited good feature integrity and replication quality. Microchannels fabricated using these replicas exhibited leak-free operation and comparable flow performance as those fabricated from CNC milled molds. The speed and simplicity of this approach can greatly facilitate the development (i.e. prototyping) and manufacture of plastic microfluidic devices for research and commercial applications.
A conventional approach to making miniature or microscale gas chromatography (GC) components relies on silicon as a base material and MEMS fabrication as manufacturing processes. However, these devices often fail in medium-to-high temperature applications due to a lack of robust fluidic interconnects and a high-yield bonding process. This paper explores the feasibility of using metal additive manufacturing (AM), which is also known as metal 3D printing, as an alternative platform to produce small-scale microfluidic devices that can operate at a temperature higher than that which polymers can withstand. Binder jet printing (BJP), one of the metal AM processes, was utilized to make stainless steel (SS) preconcentrators (PCs) with submillimeter internal features. PCs can increase the concentration of gaseous analytes or serve as an inline injector for GC or gas sensor applications. Normally, parts printed by BJP are highly porous and thus often infiltrated with low melting point metal. By adding to SS316 powder sintering additives such as boron nitride (BN), which reduces the liquidus line temperature, we produce near full-density SS PCs at sintering temperatures much lower than the SS melting temperature, and importantly without any measurable shape distortion. Conversely, the SS PC without BN remains porous after the sintering process and unsuitable for fluidic applications. Since the SS parts, unlike Si, are compatible with machining, they can be modified to work with commercial compression fitting. The PC structures as well as the connection with the fitting are leak-free with relatively high operating pressures. A flexible membrane heater along with a resistance-temperature detector is integrated with the SS PCs for thermal desorption. The proof-of-concept experiment demonstrates that the SS PC can preconcentrate and inject 0.6% headspace toluene to enhance the detector’s response.
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