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Polymers
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Progress in 3D Printing II
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Progress in 3D Printing II

A special issue of Polymers (ISSN 2073-4360). This special issue belongs to the section "Polymer Processing and Engineering".

Deadline for manuscript submissions: 25 January 2025 | Viewed by 10308

Special Issue Editor

Dr. Ali Bagheri

E-Mail Website
Guest Editor
School of Science and Technology, The University of New England, Armidale, NSW 2351, Australia
Interests: controlled radical polymerization; 3D printing; drug delivery systems
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Three-dimensional printing, also known as additive manufacturing, rapid prototyping, or layered manufacturing, was introduced in the 1980s with the goal of fabricating customized or complex objects without the use of molds or machining. It has attracted particular attention from polymer chemists, materials scientists, and engineers due to the versatile polymer chemistry-related innovations, and it is widely used in the scientific fields of microfluidics, biomedical devices, soft robotics, surgery, tissue engineering, dentistry, and drug delivery.

Following the success of "Progress in 3D Printing", https://www.mdpi.com/journal/polymers/special_issues/Prog_3D_Print, a previous Special Issue in Polymers, we continue to provide a platform to showcase recent research advances in polymer processing and the development of polymers and advanced polymer systems, specifically for 3D printing.

Dr. Ali Bagheri
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Polymers is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2700 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing
  • 3D printing
  • polymers
  • composites and nanocomposites
  • biomaterials
  • engineering polymer materials

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Published Papers (7 papers)

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Research

13 pages, 2977 KiB  
Article
3D-Printed Phenylboronic Acid-Bearing Hydrogels for Glucose-Triggered Drug Release
by Jérémy Odent, Nicolas Baleine, Serena Maria Torcasio, Sarah Gautier, Olivier Coulembier and Jean-Marie Raquez
Polymers 2024, 16(17), 2502; https://doi.org/10.3390/polym16172502 - 3 Sep 2024
Viewed by 777
Abstract
Diabetes is a major health concern that the next-generation of on-demand insulin releasing implants may overcome via personalized therapy. Therein, 3D-printed phenylboronic acid-containing implants with on-demand glucose-triggered drug release abilities are produced using high resolution stereolithography technology. To that end, the methacrylation of [...] Read more.
Diabetes is a major health concern that the next-generation of on-demand insulin releasing implants may overcome via personalized therapy. Therein, 3D-printed phenylboronic acid-containing implants with on-demand glucose-triggered drug release abilities are produced using high resolution stereolithography technology. To that end, the methacrylation of phenylboronic acid is targeted following a two-step reaction. The resulting photocurable phenylboronic acid derivative is accordingly incorporated within bioinert polyhydroxyethyl methacrylate-based hydrogels at varying loadings. The end result is a sub-centimeter scaled 3D-printed bioinert implant that can be remotely activated with 1,2-diols and 1,3-diols such as glucose for on-demand drug administration such as insulin. As a proof of concept, varying glucose concentration from hypoglycemic to hyperglycemic levels readily allow the release of pinacol, i.e., a 1,2-diol-containing model molecule, at respectively low and high rates. In addition, the results demonstrated that adjusting the geometry and size of the 3D-printed part is a simple and suitable method for tailoring the release behavior and dosage. Full article
(This article belongs to the Special Issue Progress in 3D Printing II)
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21 pages, 6445 KiB  
Article
Influence of Build Orientation and Part Thickness on Tensile Properties of Polyamide 12 Parts Manufactured by Selective Laser Sintering
by Jonathan J. Slager, Brian C. Earp and Ahmed M. Ibrahim
Polymers 2024, 16(16), 2241; https://doi.org/10.3390/polym16162241 - 7 Aug 2024
Cited by 1 | Viewed by 1037
Abstract
The use of additive manufacturing to rapidly test and evaluate solutions to engineering problems has been demonstrated. Selective laser sintering (SLS) is a subset of additive manufacturing that is particularly well suited to producing structural thin wall models and end use parts which [...] Read more.
The use of additive manufacturing to rapidly test and evaluate solutions to engineering problems has been demonstrated. Selective laser sintering (SLS) is a subset of additive manufacturing that is particularly well suited to producing structural thin wall models and end use parts which can improve the ability to prototype and manufacture certain designs at a substantially lower cost and time compared to current methods. However, a more comprehensive understanding of the material properties of these parts is warranted. The presented research investigates the influence of print orientation and sample thickness on the material properties of printed SLS parts. This novel work involves holding a hatch pattern constant across SLS prints using polyamide 12 material to isolate the anisotropic effects of orientation and thickness. An evaluation of ultimate tensile strength, modulus of elasticity, strain at failure, yield strength, and Poisson’s ratio, and scanning electron microscope fractography are conducted. Transverse strain and Poisson’s ratio are a key aspect that provide insight into the feasibility of building numerical orthotropic models. These data are used to calculate the degree of anisotropy due to both thickness and orientation. The results support the future use of SLS printing and modeling of thin-walled structures, such as scaled structural ship modeling. The presented data provide guidance on the impact of print orientation and thickness that will aid in manufacturing structural parts with intentionally tuned material properties. Full article
(This article belongs to the Special Issue Progress in 3D Printing II)
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18 pages, 3356 KiB  
Article
Investigation of Friction Stir Welding of Additively Manufactured Biocompatible Thermoplastics Using Stationary Shoulder and Assisted Heating
by Pedro Rendas, Lígia Figueiredo, Pedro Melo, Carlos Galhano, Catarina Vidal and Bruno A. R. Soares
Polymers 2024, 16(13), 1897; https://doi.org/10.3390/polym16131897 - 2 Jul 2024
Cited by 2 | Viewed by 1024
Abstract
Additive manufacturing (AM), also known as 3D printing, offers many advantages and, particularly in the medical field, it has stood out for its potential for the manufacture of patient-specific implantable devices. Thus, the unique properties of 3D-printed biocompatible polymers such as Polylactic Acid [...] Read more.
Additive manufacturing (AM), also known as 3D printing, offers many advantages and, particularly in the medical field, it has stood out for its potential for the manufacture of patient-specific implantable devices. Thus, the unique properties of 3D-printed biocompatible polymers such as Polylactic Acid (PLA) and Polyetheretherketone (PEEK) have made these materials the focus of recent research where new post-processing and joining techniques need to be investigated. This study investigates the weldability of PLA and PEEK 3D-printed plates through stationary shoulder friction stir welding (SS-FSW) with assisted heating. An SS-FSW apparatus was developed to address the challenges of rotating shoulder FSW of thermoplastics, with assisted heating either through the shoulder or through the backing plate, thus minimizing material removal defects in the welds. Successful welds revealed that SS-FSW improves surface quality in both PLA and PEEK welds compared to rotating shoulder tools. Process parameters for PLA welds are investigated using the Taguchi method, emphasizing the importance of lower travel speeds to achieve higher joint efficiencies. In PEEK welds, the heated backing plate proved effective in increasing process heat input and reducing cooldown rates which were associated with higher crystallinity PEEK. Despite these findings, further research is needed to improve the weld strength of SS-FSW with these materials considering aspects like tool design, process stability, and 3D printing parameters. This investigation emphasizes the potential of SS-FSW in the assembly of thermoplastic materials, offering insights into the weldability of additively manufactured biocompatible polymers like PLA and PEEK. Full article
(This article belongs to the Special Issue Progress in 3D Printing II)
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14 pages, 4995 KiB  
Article
Laser-Sintering of Cyclic Olefine Copolymer for Low Dielectric Loss Applications
by Manuel Romeis, Michael Ehrngruber and Dietmar Drummer
Polymers 2024, 16(12), 1751; https://doi.org/10.3390/polym16121751 - 20 Jun 2024
Viewed by 999
Abstract
With increasing demands for data transfer, the production of components with low dielectric loss is crucial for the development of advanced antennas, which are needed to meet the requirements of next-generation communication technologies. This study investigates the impact of a variation in energy [...] Read more.
With increasing demands for data transfer, the production of components with low dielectric loss is crucial for the development of advanced antennas, which are needed to meet the requirements of next-generation communication technologies. This study investigates the impact of a variation in energy density on the part properties of a low-loss cyclic olefin copolymer (COC) in the SLS process as a way to manufacture complex low-dielectric-loss structures. Through a systematic variation in the laser energy, its impact on the part density, geometric accuracy, surface quality, and dielectric properties of the fabricated parts is assessed. This study demonstrates notable improvements in material handling and the quality of the manufactured parts while also identifying areas for further enhancement, particularly in mitigating thermo-oxidative aging. This research not only underscores the potential of COC in the realm of additive manufacturing but also sets the stage for future studies aimed at optimizing process parameters and enhancing material formulations to overcome current limitations. Full article
(This article belongs to the Special Issue Progress in 3D Printing II)
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21 pages, 9945 KiB  
Article
Optimization of Printing Process Variables and the Effect of Post-Heat Treatments on the Mechanical Properties of Extruded Polylactic Acid–Aluminum Composites
by Sakthi Balan Ganapathy, Aravind Raj Sakthivel, Jayakrishna Kandasamy, Tabrej Khan and Mansour Aloufi
Polymers 2023, 15(24), 4698; https://doi.org/10.3390/polym15244698 - 13 Dec 2023
Cited by 3 | Viewed by 1322
Abstract
Polymer extrusions are employed in the fabrication of crucial parts for automotive, aerospace, and other mechanical applications. The use of fillers and microfibers is contributing to the advancement of material extrusion polymers. In order to enhance their mechanical characteristics, printed materials undergo a [...] Read more.
Polymer extrusions are employed in the fabrication of crucial parts for automotive, aerospace, and other mechanical applications. The use of fillers and microfibers is contributing to the advancement of material extrusion polymers. In order to enhance their mechanical characteristics, printed materials undergo a post-heating process utilizing microwaves. Specimens were fabricated using polylactic acid filaments containing 2 wt% aluminum. Two sets of specimens were fabricated and subjected to testing in order to evaluate the features of extruded specimens and specimens that underwent post-heating. In terms of mechanical performance, specimens subjected to post-heating exhibited superior results compared to specimens merely subjected to extrusion. The tensile, flexural, and Shore D hardness properties of the specimens exhibited improvements of 5.07, 6.16, and 1.32%, respectively, after being subjected to heating. Furthermore, the wear rate decreased by 13.58 percent. The results of the regression analysis indicate that the print angle and the air gap exhibit the greatest influence on the observed responses. The validation test outcomes exhibit a high level of concordance with the predicted findings. The mechanical and surface properties of components extruded with filler-added material are enhanced by subsequent heating. Full article
(This article belongs to the Special Issue Progress in 3D Printing II)
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19 pages, 6905 KiB  
Article
Surface Roughness and Grain Size Variation When 3D Printing Polyamide 11 Parts Using Selective Laser Sintering
by Riccardo Tonello, Knut Conradsen, David Bue Pedersen and Jeppe Revall Frisvad
Polymers 2023, 15(13), 2967; https://doi.org/10.3390/polym15132967 - 6 Jul 2023
Cited by 7 | Viewed by 2539
Abstract
Selective laser sintering (SLS) is a well-established technology that is used for additive manufacturing. Significant efforts have been made to improve SLS by optimizing the powder deposition, laser beam parameters, and temperature settings. The purpose is to ensure homogeneous sintering and prevent geometric [...] Read more.
Selective laser sintering (SLS) is a well-established technology that is used for additive manufacturing. Significant efforts have been made to improve SLS by optimizing the powder deposition, laser beam parameters, and temperature settings. The purpose is to ensure homogeneous sintering and prevent geometric and appearance inaccuracies in the manufactured objects. We evaluated the differences in the surface roughness and grain size of curved objects manufactured by using upcoming SLS technology that features two CO laser sources. Our analysis was carried out on polyamide 11 (PA11), which is a sustainable biobased polymer that has been gaining popularity due to its high-performance properties: its low melting point, high viscosity, and excellent mechanical properties. By using a Taguchi experimental design and analysis of variance (ANOVA), we examined the influence on the surface roughness and grain size of the build setup, the presence of thin walls, and the position of the sample on the powder bed. We found significant differences in some surface roughness and grain size measurements when these parameters were changed. Full article
(This article belongs to the Special Issue Progress in 3D Printing II)
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21 pages, 4555 KiB  
Article
Integrating Exposure Assessment and Process Hazard Analysis: The Nano-Enabled 3D Printing Filament Extrusion Case
by Stratos Saliakas, Spyridon Damilos, Melpo Karamitrou, Aikaterini-Flora Trompeta, Tatjana Kosanovic Milickovic, Costas Charitidis and Elias P. Koumoulos
Polymers 2023, 15(13), 2836; https://doi.org/10.3390/polym15132836 - 27 Jun 2023
Cited by 4 | Viewed by 1972
Abstract
Nanoparticles are being used in novel applications of the thermoplastics industry, including automotive parts, the sports industry and leisure and consumer goods, which can be produced nowadays through additive manufacturing. However, there is limited information on the health and safety aspects during the [...] Read more.
Nanoparticles are being used in novel applications of the thermoplastics industry, including automotive parts, the sports industry and leisure and consumer goods, which can be produced nowadays through additive manufacturing. However, there is limited information on the health and safety aspects during the production of these new materials, mainly from recycled sources. This study covers the exposure assessment to nano- and micro-size particles emitted from the nanocomposites during the production of filaments for 3D printing through a compounding and extrusion pilot line using recycled (post-industrial) thermoplastic polyurethane (TPU) and recycled polyamide 12 (PA12), which have been also upcycled through reinforcement with iron oxide nanoparticles (Fe3O4 NPs), introducing matrix healing properties triggered by induction heating. The assessment protocol included near- and far-field measurements, considering the extruder as the primary emission source, and portable measuring devices for evaluating particulate emissions reaching the inhalable zone of the lab workers. A Failure Modes and Effects Analysis (FMEA) study for the extrusion process line was defined along with a Failure Tree Analysis (FTA) process in which the process deviations, their sources and the relations between them were documented. FTA allowed the identification of events that should take place in parallel (simultaneously) or in series for the failure modes to take place and the respective corrective actions to be proposed (additional to the existing control measures). Full article
(This article belongs to the Special Issue Progress in 3D Printing II)
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