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1. 3D printing of biofiber-reinforced composites and their mechanical properties: a review

   https://doi.org/10.1108/RPJ-08-2019-0214  

   Jiang, Lai; Peng, Xiaobo; Walczyk, Daniel (June 2020, Rapid Prototyping Journal)

   null (Ed.)

   Purpose This paper aims to summarize the up-to-date research performed on combinations of various biofibers and resin systems used in different three-dimensional (3D) printing technologies, including powder-based, material extrusion, solid-sheet and liquid-based systems. Detailed information about each process, including materials used and process design, are described, with the resultant products’ mechanical properties compared with those of 3D-printed parts produced from pure resin or different material combinations. In most processes introduced in this paper, biofibers are beneficial in improving the mechanical properties of 3D-printed parts and the biodegradability of the parts made using these green materials is also greatly improved. However, research on 3D printing of biofiber-reinforced composites is still far from complete, and there are still many further studies and research areas that could be explored in the future. Design/methodology/approach The paper starts with an overview of the current scenario of the composite manufacturing industry and then the problems of advanced composite materials are pointed out, followed by an introduction of biocomposites. The main body of the paper covers literature reviews of recently emerged 3D printing technologies that were applied to biofiber-reinforced composite materials. This part is classified into subsections based on the form of the starting materials used in the 3D printing process. A comprehensive conclusion is drawn at the end of the paper summarizing the findings by the authors. Findings Most of the biofiber-reinforced 3D-printed products exhibited improved mechanical properties than products printed using pure resin, indicating that biofibers are good replacements for synthetic ones. However, synthetic fibers are far from being completely replaced by biofibers due to several of their disadvantages including higher moisture absorbance, lower thermal stability and mechanical properties. Many studies are being performed to solve these problems, yet there are still some 3D printing technologies in which research concerning biofiber-reinforced composite parts is quite limited. This paper unveils potential research directions that would further develop 3D printing in a sustainable manner. Originality/value This paper is a summary of attempts to use biofibers as reinforcements together with different resin systems as the starting material for 3D printing processes, and most of the currently available 3D printing techniques are included herein. All of these attempts are solutions to some principal problems with current 3D printing processes such as the limit in the variety of materials and the poor mechanical performance of 3D printed parts. Various types of biofibers are involved in these studies. This paper unveils potential research directions that would further widen the use of biofibers in 3D printing in a sustainable manner. 

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2. Examining the mass loss and thermal properties of 3D printed models produced by fused deposition modeling and stereolithography under elevated temperatures

   https://doi.org/10.1108/RPJ-01-2022-0007  

   Hsieh, Shu-An; Anderson, Jared L. (June 2022, Rapid Prototyping Journal)

   Purpose This paper aims to study the mass loss of three-dimensional (3D) printed materials at high temperatures. A preconcentration and analysis technique, static headspace gas chromatography-mass spectrometry (SHS-GC-MS), is demonstrated for the analysis of volatile compounds liberated from fused deposition modeling (FDM) and stereolithography (SLA) 3D printed models under elevated temperatures. Design/methodology/approach A total of seven commercial 3D printing materials were tested using the SHS-GC-MS approach. The printed model mass and mass loss were examined as a function of FDM printing parameters including printcore temperature, model size and printing speed, and the use of SLA postprocessing procedures. A high temperature resin was used to demonstrate that thermal degradation products can be identified when the model is incubated under high temperatures. Findings At higher printing temperatures and larger model sizes, the initial printed model mass increased and showed more significant mass loss after thermal incubation for FDM models. For models produced by SLA, the implementation of a postprocessing procedure reduced the mass loss at elevated temperatures. All FDM models showed severe structural deformation when exposed to high temperatures, while SLA models remained structurally intact. Mass spectra and chromatographic retention times acquired from the high temperature resin facilitated identification of eight compounds (monomers, crosslinkers and several photoinitiators) liberated from the resin. Originality/value The study exploits the high sensitivity of SHS-GC-MS to identify thermal degradation products emitted from 3D printed models under elevated temperatures. The results will aid in choosing appropriate filament/resin materials and printing mechanisms for applications that require elevated temperatures. 

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3. Mechanical Recycling of 3D-Printed Thermosets for Reuse in Vat Photopolymerization

   https://doi.org/10.1021/acsapm.4c00184  

   Maines, Erin M.; Polley, Michaela A.; Haugstad, Greg; Zhao, Brenda; Reineke, Theresa M.; Ellison, Christopher J. (April 2024, ACS Applied Polymer Materials)

   Additive manufacturing, otherwise known as three-dimensional (3D) printing, is a rapidly growing technique that is increasingly used for the production of polymer products, resulting in an associated increase in plastic waste generation. Waste from a particular class of 3D-printing, known as vat photopolymerization, is of particular concern, as these materials are typically thermosets that cannot be recycled or reused. Here, we report a mechanical recycling process that uses cryomilling to generate a thermoset powder from photocured parts that can be recycled back into the neat liquid monomer resin. Mechanical recycling with three different materials is demonstrated: two commercial resins with characteristic brittle and elastic mechanical properties and a third model material formulated in-house. Studies using photocured films showed that up to 30 wt% of the model material could be recycled producing a toughness of 2.01 ± 0.55 MJ/m3, within error of neat analogues (1.65 ± 0.27 MJ/m3). Using dynamic mechanical analysis and atomic force microscopy-based infrared spectroscopy, it was determined that monomers diffuse into the recycled powder particles, creating interpenetrating networks upon ultraviolet (UV) exposure. This process mechanically adheres the particles to the matrix, preventing them from acting as failure sites under a tensile load. Finally, 3D-printing of the commercial brittle material with 10 wt% recycle content produced high quality parts that were visually similar. The maximum stress (46.7 ± 6.2 MPa) and strain at break (11.6 ± 2.3%) of 3D-printed parts with recycle content were within error the same as neat analogues (52.0 ± 1.7 MPa; 13.4 ± 1.8%). Overall, this work demonstrates mechanical recycling of photopolymerized thermosets and shows promise for the reuse of photopolymerized 3D-printing waste. 

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4. 3D-printing nanocrystals with light

   https://doi.org/10.1126/science.add8382  

   Pan, Jia-Ahn; Talapin, Dmitri V. (September 2022, Science)

   The ability to fabricate custom three-dimensional (3D) objects on demand has revolutionized prototyping and small-scale manufacturing processes. From low-cost filament extruders that a hobbyist can use to replace a plastic battery cover, to laser sintering machines for metal spacecraft parts, the reach of 3D printing technologies in low- and high-end markets continues to broaden. A crucial part of this progress has been the expansion of the library of materials that can be 3D-printed. Nanocrystals have many functional properties, but their integration with 3D printing has been limited, mostly relying on the use of polymer material as a scaffolding. On page 1112 of this issue, Liu et al. ( 1 ) demonstrate the 3D printing of nanocrystals using a method known as two-photon lithography. The intense beam of an infrared femtosecond laser induces simultaneous absorption of two photons in a very small volume, triggering photochemical reactions at nanocrystal surfaces. 

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5. Suitability of 3D-Printed devices for low-temperature geochemical T experiments

   https://doi.org/doi.org/10.1016/j.apgeochem.2018.08.012  

   Kletetschka, K; Rimstidt, J Donald; Long, Timothy E; Michel, F Marc (August 2018, Applied geochemistry)

   Desktop 3D printing stereolithography (SLA) is a fabrication technique based on photopolymerization that can be used to efficiently create novel reaction devices for laboratory geochemistry with complex features (e.g. internal channels, small volumes) that are beyond the capabilities of traditional machining methods. However, the stability of 3D printed parts for low-temperature aqueous geochemical conditions has not been carefully evaluated. Furthermore, it is unclear what criteria should be used when attempting to optimize the mechanical and chemical properties during post-processing steps. Addressing these challenges is important for determining the suitability of 3D printed devices for laboratory investigations such as mineral precipitation/dissolution ex- periments. Here, we use thermogravimetric analysis (TGA) profiles, dynamic mechanical analysis (DMA), and chemical extraction of leachables to show how ultraviolet (UV) post-curing can optimize properties of a com- mercial photo-reactive resin (Formlabs Standard Clear). The mechanical and chemical stability of the post-cured material was enhanced and a working temperature of up to 80 °C was determined. We further provide data showing the stability and compatibility of the material in aqueous conditions of pH 0, 5.7 and 12. As SLA 3D printing is still an emerging and rapidly developing technology, the method presented here will provide a fra- mework for assessing how new printer types and materials (i.e. resins) impact the suitability of SLA printed devices for future experimental studies. 

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