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.

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments.

Current status and future directions of fused filament fabrication

3D printing of polyether-ether-ketone for biomedical applications

Additive manufacturing (AM) is rapidly evolving as the most comprehensive tool to manufacture products ranging from prototypes to various end-user applications. Fused filament fabrication (FFF) is the most widely used AM technique due to its ability to manufacture complex and relatively high strength parts from many low-cost materials. Generally, the high strength of the printed parts in FFF is attributed to the research in materials and respective process factors (process variables, physical setup, and ambient temperature). However, these factors have not been rigorously reviewed for analyzing their effects on the strength and ductility of different classes of materials. This review systematically elaborates the relationship between materials and the corresponding process factors. The main focus is on the strength and ductility. A hierarchical approach is used to analyze the materials, process parameters, and void control before identifying existing research gaps and future research directions.

https://www.mdpi.com/1996-1944/12/10/1664/pdf

Effect of Material and Process Specific Factors on the Strength of Printed Parts in Fused Filament Fabrication: A Review of Recent Developments.

/pdf/a-review-on-the-fused-deposition-modeling-fdm-3d-printing-stu4vuyk9r.pdf

A review on the fused deposition modeling (FDM) 3D printing: Filament processing, materials, and printing parameters

Effects of extrusion speed and printing speed on the 3D printing stability of extruded PEEK filament

Biodegradable stents offer the potential to reduce the in-stent restenosis by providing support long enough for the vessel to heal. The polylactic acid (PLA) vascular stents with negative Poisson's ratio (NPR) structure were manufactured by fused deposition modeling (FDM) 3D printing in this study. The effects of stent diameter, wall thickness and geometric parameters of arrowhead NPR structure on radial compressive property of 3D-printed PLA vascular stent were studied. The results showed that the decrease of stent diameter, the increase of wall thickness and the increase of the surface coverage could enhance the radial force (per unit length) of PLA stent. The radial and longitudinal size of PLA stent with NPR structure decreased simultaneously when the stent was crimped under deformation temperature. The PLA stent could expand in both radial and longitudinal direction under recovery temperature. When the deformation temperature and recovery temperature were both 65 °C, the diameter recovery ratio of stent was more than 95% and the maximum could reach 98%. The length recovery ratio was above 97%. This indicated the feasibility of utilizing the shape memory effect (SME) of PLA to realize the expansion of 3D-printed PLA vascular stent under temperature excitation.

Radial Compressive Property and the Proof-of-Concept Study for Realizing Self-expansion of 3D Printing Polylactic Acid Vascular Stents With Negative Poisson's Ratio Structure

Fe-based metallic glasses are amorphous alloys with high strength, high hardness, and excellent corrosion resistance; however, the immaturity of processing methods has prevented their wide application in industrial production. Fe-based metallic glass parts were manufactured employing pneumatic injection additive manufacturing in this study. An evenly dispersed and stable Fe-based metallic glass powder slurry with a solids content of 50% was prepared firstly. Then the Fe-based metallic glass parts were printed. The printed parts were dried, debinded, and sintered for strengthening. The deformations of the printed parts and sintered parts relative to the original model were then analyzed by a 3D scanning reconstruction method. The slightly average bulging and sunken deformation of the printed parts and sintered parts confirmed the good printing accuracy of the pneumatic injection manufacture system. The effects of the sintering temperature and holding time on the properties of the sintered parts were studied. For a sintering temperature of 580 °C and holding time of 1 h, the surface quality of the sintered parts was better. The sintering of 3D-printed Fe-based metallic glass parts was preliminarily realized in this study, and the feasibility of preparing Fe-based metallic glass using pneumatic injection additive manufacture was verified.

Shuo Zhang

Papers

Effects of extrusion speed and printing speed on the 3D printing stability of extruded PEEK filament

Radial Compressive Property and the Proof-of-Concept Study for Realizing Self-expansion of 3D Printing Polylactic Acid Vascular Stents With Negative Poisson's Ratio Structure

Optimization of Sintering Time and Holding Time for 3D Printing of Fe-Based Metallic Glasses