Effects of raster angle on the mechanical properties of PLA and Al/PLA composite part produced by fused deposition modeling

This paper studies the mechanical properties of polylactic acid (PLA) and aluminum fiber–reinforced PLA composite (Al/PLA) specimens fabricated by fused deposition modeling (FDM) process. The effect of raster angle (0°, 90°, 45°, 0°/90°, and ± 45°) on dynamic mechanical thermal property and tensile property of FDM‐printed PLA and Al/PLA has been studied. The results show reduced tensile strength and Young's modulus in Al/PLA composite specimen in comparison with pure PLA specimen. However, the elongation‐at‐break increases, which is due to Al fiber with the higher elasticity and lower tensile strength than PLA. The addition of Al fibers improves the dynamic mechanical thermal property of pure PLA because of the good interaction of the PLA matrix with the surrounding Al fibers. Raster angle plays an important role in FDM process. All specimens printed with 0° raster angle show highest tensile strength and dynamic mechanical properties, while specimens printed with 90° raster angle have the lowest values. Fractured surfaces indicate that the failure of the specimen with 0° raster angle is due to breaking of individual layers, while for 90° raster angle, specimen fails under separation of the adjacent raster layers.     

Three‐dimensional printing of poly(lactic acid) bio‐based composites with sugarcane bagasse fiber: Effect of printing orientation on tensile performance

The cellulose fiber was extracted from the abandoned crop sugarcane bagasse (SCB) by means of chemical treatment methods. Poly(lactic acid) (PLA) bio‐based composites with SCB were prepared through fused deposition modeling (FDM) 3D‐printing technology, and the morphologies, mechanical properties, crystallization properties, and thermal stability of 3D‐printed composites were investigated. Compared with the neat PLA, the incorporation of SCB into PLA reduces the tensile strength and flexural strength of 3D‐printed samples but increases the flexural modulus. The difference in tensile performance and bending performance is that the tensile strength of 3D‐printed samples is best when the SCB content is 6 wt%, while the flexural modulus continuously decreases as the SCB content increases. Furthermore, the effects of various printing methods on the tensile performance of 3D‐printed samples were explored via modifying G‐code of 3D models. The results indicate that the optimum SCB fiber content is identical for all printing methods except method “vertical.” Due to the fibers and molecular chains are oriented to varying degrees with altering raster angle in 3D‐printed samples, the fully oriented sample printed by method “parallel” has a better tensile strength. Besides, SCB exhibits enough high thermal decomposition temperature to meet requirements for melt extrusion processing of PLA composites, and SCB fiber is capable of promoting the crystallization of PLA.     

Influence of the molding angle on tensile properties of FDM parts with orthogonal layering

Fused deposition molding (FDM) is one of the most widely used three‐dimensional (3D) printing technologies. This paper explores the influence of the forming angle on the tensile properties of FDM specimens. Orthogonal layering details were studied through experiments, theory, and finite element simulations. The stiffness and strength of the specimens were analyzed using the classical laminated plate theory and the Tsai–Wu failure criterion. The experimental process was simulated using finite element simulations. Results show that it is feasible to predict the stiffness and strength of FDM specimens using classical laminated plate theory and the Tsai–Wu failure criterion. A molding angle of 45° leads to specimens with maximized tensile properties. Numerical simulations show that changing the molding angle changes the internal stress and deformation fields inside samples, leading to FDM samples with different mechanical properties due to the orthogonal layers at different molding angles.     

Enhanced mechanical properties of MWCNT reinforced ABS nanocomposites fabricated through additive manufacturing process

Multiwall carbon nanotubes (MWCNTs) can be spread out in acrylonitrile butadiene styrene (ABS) using a twin-screw micro-compounding extruder. It can significantly improve the mechanical properties of 3D-printed objects. Dispersed MWCNTs in pure ABS to develop the nanocomposites through a two-time micro compounding extruding process. 3D printed filaments with a diameter of 1.75 mm have been prepared by processing the acquired composite structure through a filament extruder. The mechanical and other properties of 3D printed pure ABS and 1, 2, and 3 wt.% of the fused deposition modeling (FDM) process were studied for MWCNTs/ABS composites. Compared with pure ABS, the tensile and thermal properties were significant for 1, 2, and 3 wt.% of MWCNTs/ABS composites. Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), thermogravimetric analysis (TGA), and scanning electron microscopy (SEM) were also analyzed for 0, 1, 2, and 3 wt.% MWCNTs/ABS composites. Additive manufacturing (AM) processes have recently been emphasized for their applications in electronics, aerospace, biomedical, and automobile engineering.     

3D printed PCL scaffold reinforced with continuous biodegradable fiber yarn: A study on mechanical and cell viability properties

In this study, poly (ε‐caprolactone) (PCL) scaffolds were printed and reinforced, simultaneously, with biodegradable poly glycolic acid (PGA) suture yarn, as a continuous reinforcing fiber, in the Fused Deposition Modeling (FDM) 3D printing process. Albeit PCL is a suitable material for biomedical applications, its low mechanical properties, and low degradation rate have limited its usage. A biocompatible suture yarn was used as the reinforcing material to enhance the mechanical properties and biodegradation characteristics, via an innovative method of continuous fiber embedding in the FDM process. The reinforced PCL samples were 3D printed with the setting porosity value of 60% and 0°/60°/120° lay-down pattern. The mechanical and biological properties of the scaffolds were tested to prove the effectiveness of the produced scaffolds for bone substitute purposes. Mechanical properties assessments showed that with a 22 vol.% suture yarn content in the 3D printed PCL scaffolds, the tensile strength, and elastic modulus remarkably increased up to 374% and 775%, respectively. The degradation of the reinforced PCL was 20 times higher than that of the non-reinforced PCL samples, after ten weeks, dominated by the fiber degradation phenomenon. After three days of cell culture, the proliferation assay of the built scaffovd the non-toxicity of the reinforced PCL.     

Effects of laser scanning speed on surface roughness and mechanical properties of aluminum/Polylactic Acid (Al/PLA) composites parts fabricated by fused deposition modeling

Although fused deposition modeling (FDM) has gradually become one of the popular additive manufacturing technologies in different industries, high surface roughness has always been an inevitable disadvantage of FDM parts. Laser polishing represents a recent and novel application of laser surface irradiation that can be used for precise, post-process smoothing of the rough surfaces commonly encountered on FDM parts. The influence of laser polishing on surface modification and mechanical properties of aluminum/Polylactic Acid (Al/PLA) composites has been investigated. Laser scanning speed was varied to evaluate its effect on the surface quality and mechanical properties of the experimental samples. The results indicated that laser polishing could enable reductions in surface roughness of over 86.6% (from 23.27 μm to 3.11 μm Sa). The tensile strength of specimen also increased from 41.01 MPa to 51.31 MPa with increasement of 25.1%. The dynamic mechanical analysis (DMA) results showed that there was a remarkable improvement in the storage modulus and glass transition temperature of Al/PLA composite specimens after laser polishing, which suggested that the laser polishing treatment could play a role in decreasing the porosity inside the FDM parts and improve interfacial adhesion between the PLA matrix and Al fibers. Moreover, the fracture morphologies were observed to investigate the possible strengthening mechanism. These results demonstrate how laser polishing can simultaneously smooth and modify the surface characteristics of a FDM part surface.     

Influence of fused deposition modeling parameters on the mechanical properties of ABS parts

This work aims to determine the influence of fused deposition modeling (FDM) printing parameters on the mechanical properties of parts fabricated on an Ultimaker2 printer with acrylonitrile butadiene styrene (ABS). The effect of several parameters such as interlayer cooling time (ILCT), nozzle diameter, infill density, raster angle and layer thickness on the ultimate tensile strength, yield strength, and elastic modulus of produced parts was evaluated. Two independent studies were conducted: a first study dedicated to the ILCT and a second study where the influence of other parameters was evaluated through a design of experiments (DoE) approach. Both studies were carried out through the execution of standard tensile tests. The statistical analysis of tensile tests results was processed with the ANOVA methodology. The obtained results indicate that a reduced ILCT improves the tensile strength of parts. It is shown that nozzle diameter and infill density are the parameters that most influence the mechanical properties of ABS, with the upper range selected values improving the studied mechanical properties. The raster angle configuration of (?45^o/45^o) benefits UTS and yield strength of ABS samples. Interactions of nozzle diameter on layer thickness were detected. It was observed that smaller layer thickness promotes a higher elastic modulus and UTS; however, for thinner layers (0.06‐0.10 mm), no significant differences were found on strength of samples due to potential high distortion levels.     

Additive manufacturing of continuous carbon fiber reinforced poly-ether-ether-ketone with ultrahigh mechanical properties

Continuous carbon fiber reinforced poly-ether-ether-ketone (CCF/PEEK) composites have attracted significant interests in mission-critical applications for their exceptional mechanical properties and high thermal resistance. In this study, we additively manufactured CCF/PEEK laminates by the Laser-assisted Laminated Object Manufacturing technique, which was recently reported by the authors. The effects of laser power and consolidation speed on the flexural strength of the CCF/PEEK composites were studied to obtain the optimal process parameters. Hot press postprocessing was performed to further improve the mechanical properties of the composites. Various fiber alignment laminates were prepared, and the flexural and tensile properties were characterized. The hot press postprocessing 3D printed unidirectional CCF/PEEK composites exhibited ultrahigh flexural modulus and strength of 125.7 GPa and 1901.1 MPa, respectively. In addition, the tensile modulus and strength of the composites reached 133.1 GPa and 1513.8 MPa. The results showed that the fabricated CCF/PEEK exhibited superior mechanical performance compare to fused filament fabrication (FFF) printed carbon fiber reinforced thermoplastics (CFRTP).     

Epoxy shape memory polymer (SMP): Material preparation,uniaxial tensile tests and dynamic mechanical analysis

The utilization of epoxy shape memory polymers (SMPs) as engineering materials for deployable structures has attracted considerable attention due to their excellent thermo-mechanical endurance and satisfactory processability. Knowledge of static and dynamic mechanical properties is essential for analyzing structural behavior and recovery, especially for new epoxy SMPs. In this paper, a new epoxy SMP was prepared with epoxy and aromatic amine curing agent. Uniaxial tensile tests and digital image correlation were used to obtain static mechanical properties. Dynamic mechanical analysis was carried out to evaluate glass transition temperatures that corresponded to the heat in the recovery process.It was found that elastic modulus, Poisson’s ratio and shear modulus are 1413 MPa, 0.35 and 591 MPa, respectively. The beginning of glass transition temperature of 37.4 °C could be effectively achieved by electrical heaters, validating the shape memory properties of epoxy SMPs. In general, this study could provide useful observations and basic mechanical properties of epoxy SMPs.     

Evaluation of Mechanical Properties of Epoxy/Nanoclay/Multi-Walled Carbon Nanotube Nanocomposites using Taguchi Method

This paper reports the improvement of the mechanical properties of epoxy/nanoclay/multi-walled carbon nanotube (MWNT) nanocomposites prepared by the solution casting method for a range of pre-cure temperatures (room temperature, 50, and 70 °C), cure temperature (120, 130, and 140 °C), nanoclay content (0.5, 1.0, 1.5 wt%) and content of MWNT (0.2, 0.6, 1.0 wt%) for three levels. The influence of these parameters on the mechanical properties of epoxy/nanoclay/MWNT has been investigated using Taguchi's experimental design. The output measured responses are the tensile properties (tensile modulus, tensile strength and strain at break), impact strength and fracture toughness. From the Analysis of Mean (ANOM) and Analysis of Variance (ANOVA), MWNT content, pre-cure temperature and cure temperature had the most significant effects for the impact strength with contribution percentages of 38%, 28% and 23% respectively. However, for the fracture toughness and strain at break, the enhancements of properties come from the nanoclay content (59%), MWNT content (18%) and pre-cure temperature (23%). While the improvement in tensile strength was influenced by nanoclay and MWNT content, the cure temperature has a stronger effect on the tensile modulus. In this respect, Taguchi method points to the Taguchi method, in this way, points to the dominant parameters and gives the optimum parameter settings for each mechanical property. Confirmation experiments were performed with the optimum parameter settings and the mechanical properties were measured compared with the predicted results.     

Effects of Wood Flour (WF) Pretreatment and the Addition of a Toughening Agent on the Properties of FDM 3D-Printed WF/Poly(lactic acid) Biocomposites

In order to improve the properties of wood flour (WF)/poly(lactic acid) (PLA) 3D-printed composites, WF was treated with a silane coupling agent (KH550) and acetic anhydride (Ac₂O), respectively. The effects of WF modification and the addition of acrylicester resin (ACR) as a toughening agent on the flowability of WF/PLA composite filament and the mechanical, thermal, dynamic mechanical thermal and water absorption properties of fused deposition modeling (FDM) 3D-printed WF/PLA specimens were investigated. The results indicated that the melt index (MI) of the specimens decreased after WF pretreatment or the addition of ACR, while the die swell ratio increased; KH550-modified WF/PLA had greater tensile strength, tensile modulus and impact strength, while Ac₂O-modified WF/PLA had greater tensile modulus, flexural strength, flexural modulus and impact strength than unmodified WF/PLA; after the addition of ACR, all the strengths and moduli of WF/PLA could be improved; after WF pretreatment or the addition of ACR, the thermal decomposition temperature, storage modulus and glass transition temperature of WF/PLA were all increased, and water absorption was reduced.     

Oligomeric bisphenol A‐based PEEK‐like phthalonitrile‐cure and polymer properties

The cure behavior and properties of oligomeric bisphenol A‐based PEEK‐like phthalonitrile (PN) are thoroughly examined in this article. The resin is easily processed from the melt at a relatively low temperature (150–200 °C) and the monomer cure occurs in a controlled manner as a function of the amine content and processing thermal conditions. Dynamic mechanical measurements and thermogravimetric analysis show that the polymer properties improve as the maximum PN postcure temperature is increased to 415 °C. The effects of the amine and polymer postcure conditions on the flexural and tensile properties of the PN polymer are investigated. The mechanical properties of the polymer are maximized after postcuring to moderate temperatures (330–350 °C). The polymer exhibits an average flexural strength and tensile strength at break of 117 and 71 MPa, respectively. After oxidative aging at 302 °C for 100 h, the polymer retains excellent mechanical properties. The average flexural and tensile strength retention of the polymers are 81 and 75%, respectively. Microscale calorimetric measurements reveal that the flammability parameters of the oligomeric PN are low compared to other thermosets. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2016 , 54, 3769–3777     

Multiscale characterization and constitutive parameters identification of polyamide (PA12) processed via selective laser sintering

This study is focused on multiscale characterization and constitutive parameters identification of selectively laser sintered PA12 specimens. The process parameters and change in crystallinity due to 3D printing were identified via differential scanning calorimetry (DSC). Tension, compression, shear, flexural and fracture tests performed on samples fabricated, both in 0° and 90° directions reveal that the tensile toughness of samples printed in 0° orientation, outperform samples printed in 90° orientation by an average of 24%. Cryogenically fractured samples were analyzed via SEM and micro-computed tomography to analyze 2D/3D defects and correlate the microstructure with macroscopic properties. The constitutive parameters for a strain-rate and temperature-dependent Three Network (TN) material model were identified using the measured mechanical properties. Furthermore, mechanical response of micro-architected Kelvin lattice structure was analyzed by Finite Element Method employing the TN constitutive model and the predictions were corroborated with measurements.     

Uniaxial tensile tests and dynamic mechanical analysis of satin weave reinforced epoxy shape memory polymer composite

The utilization of epoxy shape memory polymer composite (SMPCs) as engineering materials for deployable structures has attracted considerable attention in recent decades due to high strength and satisfactory stiffness in comparison with shape memory polymers (SMPs). Knowledge of static and dynamic mechanical properties is essential for analyzing structural behavior and recovery properties, especially for new epoxy SMPCs. In this paper, a new weave reinforced epoxy shape memory polymer composite was prepared with satin weave technique and resin transfer molding technique. Uniaxial tensile tests and dynamic mechanical analysis were carried out to obtain basic mechanical properties and glass transition temperatures, respectively.The tensile strength and breaking elongation of warp specimens were comparable with those of weft specimens. The increment of elastic modulus and hysteresis loop areas became smaller with loading cycles, meaning that cyclic tests could obtain approximate stable mechanical properties. For dynamic mechanical properties, glass transition temperature (T_g) obtained from storage modulus curves was lower than that determined from tan delta curves and T_gs in the warp and weft directions were similar (29.4 °C vs 29.7 °C). Moreover, the storage modulus in response to T_g was two orders of magnitude less than that with respect to low temperature, which demonstrated the easy processibility of epoxy SMPCs near glass transition temperature. In general, this study could provide useful observations and basic mechanical properties of new epoxy SMPCs.     

Wheat gluten films obtained by compression molding

Edible films based on plasticized wheat gluten protein were prepared by intensive mixing followed by compression molding. The effects of water and glycerol, which were selected as plasticizers for the wheat gluten, as well as the processing conditions (mixing time and molding temperature) on the physical and mechanical properties of the films were evaluated. The resulting films were characterized in terms of moisture sorption, total soluble matter, water vapor permeability, dynamic mechanical and tensile properties. It was found that plasticizer type and concentration had a dominating effect on mechanical properties and WVP, while other physical properties remain almost non-affected. Moreover, the effect of the added plasticizer (glycerol) on the film properties strongly depends on natural presence of water in commercial gluten (9% as is). On the other hand, the pressing temperature affected the final properties of the films more than the mixing time because the former influences the final cross-linking degree of the protein network. Processing temperatures higher than 100 °C led to darker films that would be discarded by consumers if they were used as food packaging.     

Optimization of tensile properties of injection molded α-nucleated polypropylene using response surface methodology

Tensile properties are among the significant properties of isotactic polypropylene (iPP). The mechanical properties including the tensile properties are fairly dependent on the overall crystallinity and crystallite size and their distribution in molded product, type of crystal structure and testing conditions. In presence of α-nucleating agents, the crystallization rate and onset temperature of isotactic PP increase. In this paper, the role of externally added commercial α-nucleating agent HPN-20E (Milliken Inc.) on tensile properties was investigated with respect to tensile properties of pure iPP. The experimental part includes the use of design of experiment (DoE) - response surface methodology (RSM) with central composite design (CCD) having three factors namely mold temperature, melt temperature and injection rate. Two levels of each factor with six centre points and five numbers of replicates were selected. The nucleating agent, HPN-20E, was added 1.0% by wt. in iPP (mfr 11.0 g/10min) using a lab scale co-rotating twin screw extruder. The compounded pellets were dried at 85 °C in a circulating hot air oven for 24 h. The tensile samples (ASTM-638D, type-I) were molded on a micro-injection molding machine (make BabyPlast, Italy). The samples were tested for tensile properties on a universal testing machine (make Lloyds, USA). The measured responses were tensile strength (MPa), Young's modulus (MPa) and work to break (N.mm). The same experimental procedure was also followed for pure iPP and same responses were measured to set the baseline of experiment. The analysis of variance (ANOVA) tests unearth that mold and melt temperatures are highly interacting in nature. That is why previous attempts based on traditional way of varying one parameter at a time were not so successful to relate tensile properties with injection molding variables. The RSM tests resulted into useful quantitative relationship between the tensile properties and injection molding process variables.     

Hierarchical crystalline structures and dynamic mechanical properties of injection‐molded bars of HDPE: attributes of temperature field

The relationship among the processing parameters, crystalline morphologies and mechanical properties of injected‐molded bar becomes much complicated primarily due to the existence of temperature gradient coupled with the shear gradient along the sample thickness. The effect of thermal gradient field on the microstructural evolution, hierarchical structures and dynamic mechanical properties of high‐density polyethylene parts molded via gas‐assisted injection molding (GAIM) were investigated using scanning electron microscope, differential scanning calorimetry, dynamic mechanical analysis and two‐dimensional wide‐angle X‐ray diffraction. The three‐dimensional temperature profiles during the cooling stage under different melt temperatures of GAIM process were obtained by using a transient heat transfer model of the enthalpy transformation approach, and the phase‐change plateaus were clearly observed in the cooling curves. It was found that a variety of melt temperatures could induce considerable variations of the hierarchical structures, orientation behavior and dynamic mechanical properties of the injection‐molded bars. With reduced melt temperature, GAIM samples with higher molecular orientation and improved dynamic mechanical properties were obtained. Copyright © 2013 John Wiley & Sons, Ltd.     

Wavelength Orthogonal Photodynamic Networks

The ability of light to remotely control the properties of soft matter materials in a dynamic fashion has fascinated material scientists and photochemists for decades. However, only recently has our ability to map photochemical reactivity in a finely wavelength resolved fashion allowed for different colors of light to independently control the material properties of polymer networks with high precision, driven by monochromatic irradiation enabling orthogonal reaction control. The current concept article highlights the progress in visible light-induced photochemistry and explores how it has enabled the design of polymer networks with dynamically adjustable properties. We will explore current applications ranging from dynamic hydrogel design to the light-driven adaptation of 3D printed structures on the macro- and micro-scale. While the alternation of mechanical properties via remote control is largely reality for soft matter materials, we herein propose the next frontiers for adaptive properties, including remote switching between conductive and non-conductive properties, hydrophobic and hydrophilic surfaces, fluorescent or non-fluorescent, and cell adhesive vs. cell repellent properties.     

Fabrication of open‐porous PCL/PLA tissue engineering scaffolds and the relationship of foaming process,morphology, and mechanical behavior

Tissue engineering scaffolds should provide a suitable porous structure and proper mechanical strength, which is beneficial for the delivery of growth factor and regulation of cells. In this study, the open‐porous polycaprolactone (PCL)/poly (lactic acid) (PLA) tissue engineering scaffolds with suitable porous scale were fabricated using different ratios of PCL/PLA blends. At the same time, the relationship of foaming process, morphology, and mechanical behavior in the optimized batch microcellular foaming process were studied based on the single‐factor experiment method. The porous structures and mechanical strength of the scaffolds were optimized by adjusting foaming parameters, including the temperature, pressure, and CO₂ dissolution time. The results indicated that the foaming parameters influence the cell morphology, further determine the mechanical behavior of PCL/PLA blends. When the PCL content is high, with the increase of temperature and time, the cell diameter and the elastic modulus increased, and the tensile strength and elastic modulus increased with the increase of the average cell size, and decreased as the increase of the cell density. While when the PLA content was high, the cell diameter showed the same trend, and the tensile strength and elastic modulus were higher, and the elongation at break was lower, and tensile strength and elastic modulus decreased with the increase of the average cell size and increased with the increase of cell density. This work successfully fabricated optimized porous PCL/PLA scaffolds with excellent suitable mechanical properties, pore sizes, and high interconnectivity, indicating the effectiveness of modulating the batch foaming process parameters.     

Electrospun polymer nanofibers: Mechanical and thermodynamic perspectives

This article reviews and discusses some open problems concerning polymer materials of reduced sizes and dimensions. Such objects exhibit exceptional physical properties when compared with their macroscopic counterparts. More specifically, abrupt increases in polymer nanofiber elastic modulus have been observed when diameters drop below a certain value. In addition, temperature dependence of elastic modulus is highly influenced by fiber diameter. Mechanical (macroscopic) analyses have failed to provide satisfactory explanations for the mechanisms ruling such features, calling for detailed microscopic examination of the systems in question. A hypothesis bridging the current knowledge gaps is presented. The key element of this hypothesis is based on confinement of the supermolecular microstructure of polymer nanofibers and its dominant role in the deformation process. This suggestion challenges the commonly held view suggesting that surface effects are the most significant parameters impacting mechanical and thermodynamic nanofiber behaviors. The review will focus on the mechanical and thermodynamic properties of electrospun polymer nanofibers, selected as representatives of nanoscale polymer objects. © 2011 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys, 2011