Recent advances in fused deposition modeling based additive manufacturing of thermoplastic composite structures: A review

Mishra, Vishal; Negi, Sushant; Kar, S.; Sharma, Anup; Rajbahadur, Yadav Narendra Kumar; Kumar, Avinash

doi:10.1177/08927057221102857

Cited by 40 publications

(21 citation statements)

References 113 publications

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“…A heated liquefier melts the plastic at the heart of the extrusion system. This melt is then extruded through the nozzle, and the semi-solid plastic gets deposited in a layer-by-layer pattern in a predetermined thickness on the partially constructed part [ 26 – 28 ]. Figure 5 presents the recommended nozzle temperature for the FDM extrusion of common thermoplastics [ 29 ].…”

Section: Fabrication Methodsmentioning

confidence: 99%

FDM-based additive manufacturing of recycled thermoplastics and associated composites

Mishra

Negi

Kar

2023

J Mater Cycles Waste Manag

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Hailed since the fourth industrial revolution, three-dimensional (3D) printing or additive manufacturing (AM) has been extensively implemented in various manufacturing sectors. This process is popular for generating regular products and incorporating innovative designs into the components like auxetic structures, such as fabrication of engineering products, customized implants and sophisticated biomedical devices. Over the years, one of the interesting outputs of this emerging technology is the reuse of waste thermoplastic materials to produce competent products through the fused deposition modeling (FDM) technique. The strength of FDM components produced from thermoplastic waste is lower than that of virgin plastic FDM counterparts. So, there is a need to understand the significant changes in the recycled thermoplastic material during subsequent extrusions, which are chain scission, change in viscosity and breaking strength. The use of additives has been a promising solution to improve the performance of recycled material for 3D printing applications. Hence, this study aims to provide an overview of reusing plastic waste through FDM-based 3D printing. This review summarizes the current knowledge about the effect of processing on thermo-mechanical properties of recycled plastic FDM parts and the use of various additives to improve the overall quality. In addition, two case studies from open literature have been demonstrated to explain the use of FDM and associated technology for plastic recycling.

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Section: Fabrication Methodsmentioning

confidence: 99%

FDM-based additive manufacturing of recycled thermoplastics and associated composites

Mishra

Negi

Kar

2023

J Mater Cycles Waste Manag

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“…Here, such reviews for hydrogels [182] and polymer/composites are given. [183][184][185] The printing parameters can influence the stiffness of the structure. Hence, understanding their influence is the key to make sure the stiffness measured is representative of the one the material provides to the hygromorph.…”

Section: Measurementmentioning

confidence: 99%

The Design of 4D‐Printed Hygromorphs: State‐of‐the‐Art and Future Challenges

Kergariou

Demoly

Perriman

et al. 2022

Adv Funct Materials

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In recent years, 4D printing has allowed the rapid development of new concepts of multifunctional/adaptive structures. The 4D printing technology makes it possible to generate new shapes and/or property-changing capabilities by combining smart materials, multiphysics stimuli, and additive manufacturing. Hygromorphs constitute a specific class of new smart materials where their properties and morphing capabilities are dependent on the surrounding humidity, which drives actuation. Although multiple efforts have been made to fabricate hygromorph demonstrators, a comprehensive design process to produce hygromorphs by multiple 4D printing techniques is not yet available. The broad aim of this review and concept paper is to i) highlight existing scientific and technology gaps in the field of 4D-printed hygromorphs, ii) identify tools existing in other research fields for filling those gaps, and iii) discuss a series of guidelines for tackling future challenges and opportunities to develop 4D-printed composite hygromorph materials and related manufacturing processes. Accordingly, this review describes the materials and additive manufacturing techniques used for hygromorph composite fabrication. Moreover, the relevant parameters that control actuation, the models selection and performance, the design methods and the actuation measurements for customized 4D-printed hygromorph materials, are discussed.

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“…Additive manufacturing (AM) was developed to produce parts of arbitrary shape quickly, without the need for standard processing and assembly, and at lower costs than previous prototyping techniques. The most common technologies used for AM of polymeric materials comprise fused deposition modeling (FDM), stereolithography (SLA), and related techniques such as digital light processing (DLP) and continuous liquid interface production (CLIP) . Inkjet printing was first introduced to AM in the “drop on powder” variant (binder jetting), in which the inkjet ink is used as a binder for a variety of fillers provided in the form of a powder bed.…”

Section: Introductionmentioning

confidence: 99%

Additive Printing of Thermally Cured Two-Component Epoxy: A Route to Mesoscale Structuring for Improved Ductility

Krawczyk

Wheeldon

Kamble

et al. 2023

ACS Appl. Polym. Mater.

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Epoxies are important thermoset materials with a broad range of applications. They are nominally homogeneous, have high strength and stiffness, but are brittle. In this work, we develop heterogeneous epoxies via additive printing with the goal of improving ductility, without compromising the strength and stiffness. To this end, we develop a reactive inkjet printing technology in which the resin and hardener components are printed successively using multinozzle printheads and which provides control of the local stoichiometric ratio. This allows creating epoxies with both in-plane and out-of-plane local compositional and mechanical heterogeneity. We print and test heterogeneous materials with several microstructural designs and demonstrate significant improvement of ductility, with retention of strength and stiffness. Furthermore, the properties of printed nominally homogeneous samples are close to isotropic and identical to those of the cast material of the same composition. The technology developed makes use of commercially available inks (resin and hardener); it is fully automated and provides sufficient flexibility and productivity to print complex macroscopic samples with 50 μm resolution of microstructural composition control.

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Recent advances in fused deposition modeling based additive manufacturing of thermoplastic composite structures: A review

Cited by 40 publications

References 113 publications

FDM-based additive manufacturing of recycled thermoplastics and associated composites

FDM-based additive manufacturing of recycled thermoplastics and associated composites

The Design of 4D‐Printed Hygromorphs: State‐of‐the‐Art and Future Challenges

Additive Printing of Thermally Cured Two-Component Epoxy: A Route to Mesoscale Structuring for Improved Ductility

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