Freedom of design, mass customisation, waste minimisation and the ability to manufacture complex structures, as well as fast prototyping, are the main benefits of additive manufacturing (AM) or 3D printing. A comprehensive review of the main 3D printing methods, materials and their development in trending applications was carried out. In particular, the revolutionary applications of AM in biomedical, aerospace, buildings and protective structures were discussed. The current state of materials development, including metal alloys, polymer composites, ceramics and concrete, was presented. In addition, this paper discussed the main processing challenges with void formation, anisotropic behaviour, the limitation of computer design and layer-by-layer appearance. Overall, this paper gives an overview of 3D printing, including a survey on its benefits and drawbacks as a benchmark for future research and development.

Additive manufacturing (3D printing): A review of materials, methods, applications and challenges

3D printing, more formally known as Additive Manufacturing (AM), is already being adopted for rapid prototyping and soon rapid manufacturing. This review provides a brief discussion about AM and also the most employed AM technologies for polymers. The commonly-used ASTM and ISO mechanical test standards which have been used by various research groups to test the strength of the 3D-printed parts have been reported. Also, a summary of an exhaustive amount of literature regarding the mechanical properties of 3D-printed parts is included, specifically, properties under different loading types such as tensile, bending, compressive, fatigue, impact and others. Properties at low temperatures have also been discussed. Further, the effects of fillers as well as post-processing on the mechanical properties have also been discussed. Lastly, several important questions to consider in the standardization of mechanical test methods have been raised.

Mechanical characterization of 3D-printed polymers

A strain sensor has been fabricated from a polymer nanocomposite with multiwalled carbon nanotube (MWNT) fillers. The piezoresistivity
of this nanocomposite strain sensor has been investigated based on an improved three-dimensional (3D) statistical resistor network
model incorporating the tunneling effect between the neighboring carbon nanotubes (CNTs), and a fiber reorientation model. The
numerical results agree very well with the experimental measurements. As compared with traditional strain gauges, much higher sensitivity
can be obtained in the nanocomposite sensors when the volume fraction of CNT is close to the percolation threshold. For a small
CNT volume fraction, weak nonlinear piezoresistivity is observed both experimentally and from numerical simulation. The tunneling
effect is considered to be the principal mechanism of the sensor under small strains.

Tunneling effect in a polymer/carbon nanotube nanocompositestrain sensor

Bioinspired engineering of honeycomb structure – Using nature to inspire human innovation

The recognition that minimizing an integral function through variational methods (as in the last chapters) leads to the second-order differential equations of Euler-Lagrange for the minimizing function made it natural for mathematicians of the eighteenth century to ask for an integral quantity whose minimization would result in Newton’s equations of motion. With such a quantity, a new principle through which the universe acts would be obtained. The belief that “something” should be minimized was in fact a long-standing conviction of natural philosophers who felt that God had constructed the universe to operate in the most efficient manner—but how that efficiency was to be assessed was subject to interpretation. However, Fermat (1657) had already invoked such a principle successfully in declaring that light travels through a medium along the path of least time of transit. Indeed, it was by recognizing that the brachistochrone should give the least time of transit for light in an appropriate medium that Johann Bernoulli “proved” that it should be a cycloid in 1697. (See Problem 1.1.) And it was Johann Bernoulli who in 1717 suggested that static equilibrium might be characterized through requiring that the work done by the external forces during a small displacement from equilibrium should vanish. This “principle of virtual work” marked a departure from other minimizing principles in that it incorporated stationarity—even local stationarity—(tacitly) in its formulation. Efforts were made by Leibniz, by Euler, and most notably, by Lagrange to define a principle of least action (kinetic energy), but it was not until the last century that a truly satisfactory principle emerged, namely, Hamilton’s principle of stationary action (c. 1835) which was foreshadowed by Poisson (1809) and polished by Jacobi (1848) and his successors into an enduring landmark of human intellect, one, moreover, which has survived transition to both relativity and quantum mechanics. (See [L], [Fu] and Problems 8.11 8.12.)

Variational Principles in Mechanics

Measurements of the mechanical response of unidirectional 3D-printed PLA

The uniaxial compressive responses of two polymeric foams (Divinycell H100 and H250) and balsa wood (ProBalsa LD7) have been measured over a wide range of strain rates, ranging from 10−4 s−1 to 4000 s−1. These materials are widely used as cores for composite sandwich structures. The high strain rate compression tests were performed using a Split-Hopkinson Pressure Bar made from AZM magnesium alloy, with semi-conductor strain gauges used to measure the low levels of stress in the specimens. The experimental data for compressive strength as a function of strain rate are adequately approximated by power-law fits. The compressive yield strength of the H250 PVC foam and balsa wood doubles when the strain rate is increased from quasi-static rates (10−4 s−1) to rates on the order of 103 s−1. In contrast, the H100 PVC foam displays only a small elevation in uniaxial compressive strength (about 30%) for the same increase in strain rate.

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The high strain rate response of PVC foams and end-grain balsa wood

Composite sandwich beams, comprising glass–vinylester face sheets and a PVC foam core, have been manufactured and tested quasi-statically. Clamped and simply supported beams were tested in three-point bending in order to investigate the initial collapse modes, the mechanisms that govern the post-yield deformation and parameters that set the ultimate strength of these beams. Initial collapse is by three competing mechanisms: face microbuckling, core shear and indentation. Simple formulae for the initial collapse loads of clamped and simply supported beams along with analytical expressions for the finite deflection behaviour of clamped beams are presented. The simply supported beams display a softening post-yield response, while the clamped beams exhibit hardening behaviour due to membrane stretching of the face sheets. Good agreement is found between the measured, analytical and finite element predictions of the load versus deflection response of the simply supported and clamped beams. Collapse mechanism maps with contours of initial collapse load and energy absorption are plotted. These maps are used to determine the minimum mass designs of sandwich beams comprising woven glass face sheets and a PVC foam core.

/pdf/collapse-of-clamped-and-simply-supported-composite-sandwich-3krvbxo5c2.pdf

Collapse of clamped and simply supported composite sandwich beams in three-point bending

http://www-mech.eng.cam.ac.uk/profiles/fleck/papers/220.pdf

The dynamic response of composite sandwich beams to transverse impact

We present an application of data analytics and supervised machine learning to allow accurate predictions of the macroscopic stiffness and yield strength of a unidirectional composite loaded in the transverse plane. Predictions are obtained from the analysis of an image of the material microstructure, as well as knowledge of the constitutive models for fibres and matrix, without performing physically-based calculations. The computational framework is based on evaluating the 2-point correlation function of the images of 1800 microstructures, followed by dimensionality reduction via principal component analysis. Finite element (FE) simulations are performed on 1800 corresponding statistical volume elements (SVEs) representing cylindrical fibres in a continuous matrix, loaded in the transverse plane. A supervised machine learning (ML) exercise is performed, employing a gradient-boosted tree regression model with 10-fold cross-validation strategy. The model obtained is able to accurately predict the homogenized properties of arbitrary microstructures.

/pdf/predictions-of-the-mechanical-properties-of-unidirectional-567me7g32d.pdf

Vito L. Tagarielli

Papers

Measurements of the mechanical response of unidirectional 3D-printed PLA

The high strain rate response of PVC foams and end-grain balsa wood

Collapse of clamped and simply supported composite sandwich beams in three-point bending

The dynamic response of composite sandwich beams to transverse impact

Predictions of the mechanical properties of unidirectional fibre composites by supervised machine learning