Mechanical and cytotoxicity properties of hybrid ceramics filled polyamide 12 filament feedstock for craniofacial bone reconstruction via fused deposition modelling
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.
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.
“…The latest research into composites has successfully shown the promising in vivo behaviour of composites although not manufactured using AM but with conventional techniques, as listed in Table 4. For instance, Yu et al and Ma et al tested the moulded composites of PEEK and HA hPdLF cells viability higher on composites than unfilled PA12 [192] HA/PEEK Extrusion of HA, sintering and compression moulding with…”
Section: Printed Composite Materials For Craniofacial Implantsmentioning
Millions of craniofacial surgeries are performed annually worldwide for craniofacial bones’ replacement and augmentation. This represents a significant economic burden as well as aesthetic expectations. Autografts and allografts are the first choice for treatment of craniofacial defects; however, their limited availability and difficulty to shape have led to investigation for alternative strategies. Biomaterial-based approaches have been used for implantation as they have ample supply but their processing through conventional technologies present several drawbacks; the major one relates to the poor versatility towards the production of patient-specific implants. Additive manufacturing has gained considerable attention during the last decade, as it allows the manufacturing of implants according to patient need. Biomaterial implants can be additively manufactured but have one or more limitations of stress shielding, radiopacity, high strength to weight ratio and limited bone integration. Over the last few decades, composites are investigated to surmount the limitations with traditional implants and also improve their bone integration. This review provides an overview of the most recent polymeric composite-based biomaterials that have been used in combination with 3D printing technology for the development of patient-specific craniofacial implants. Starting with the conventional treatments, biomaterials available for the craniofacial implants, the additive manufacturing rationale are discussed. Also, the main challenges still associated with 3D printing of polymer-based composites are critically reviewed and the future perspective presented.
“…There are three main methods that allow the use of materials reinforced with the FDM. One such method is the addition of a filament of short fibers or metallic particles at the molding level to the screw extruder [5,6]. Extruded composite materials with a reinforcement content between 1% to 10% were subjected to a tensile strength test, resulting in an 18% increase in strength [7].…”
Polymer composites with increased utility properties are becoming competition for conventional materials, in conjunction with additive manufacturing techniques. The aim of this study was to evaluate tribological characteristics of fibrous composites produced in fused deposition modeling (FDM) with the use of an innovative head with symmetrical feeding of the matrix material. Analysis of the influence of composite-forming temperature on their tribological properties allowed the determining of the optimal printing process parameters for this group of composites. Significant differences in the friction process of the same reinforced materials were observed in dry and wet environments. Fibrous composites showed 10 times lower wear intensity as well as two times lower friction value in water than in air. Research shows friction in the water environment ensures more even wear of the surface of the composites involved in the work. The article contains 3D microscopic imaging of the friction plane of the tested composites and a description of a typical course of material wear is described.
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