Enhancing 3D Printing Copper-PLA Composite Fabrication via Fused Deposition Modeling through Statistical Process Parameter Study.

The rapid advancement of additive manufacturing (AM) technologies has provided new avenues for creating three-dimensional (3D) parts with intricate geometries. Fused Deposition Modeling (FDM) is a prominent technology in this domain, involving the layer-by-layer fabrication of objects by extruding a filament comprising a blend of polymer and metal powder. This study focuses on the FDM process using a filament of Copper-Polylactic Acid (Cu-PLA) composite, which capitalizes on the advantageous properties of copper (high electrical and thermal conductivity, corrosion resistance) combined with the easily processable thermoplastic PLA material. The research delves into the impact of FDM process parameters, specifically, infill percentage (IP), infill pattern (P), and layer thickness (LT) on the maximum failure load (N), percentage of elongation at break, and weight of Cu-PLA composite filament-based parts. The study employs the response surface method (RSM) with Design-Expert V11 software. The selected parameters include infill percentage at five levels (10, 20, 30, 40, and 50%), fill patterns at five levels (Grid, Triangle, Tri-Hexagonal, Cubic-Subdivision, and Lines), and layer thickness at five levels (0.1, 0.2, 0.3, 0.4, and 0.5 mm). Also, the optimal factor values were obtained. The findings highlight that layer thickness and infill percentage significantly influence the weight of the samples, with an observed increase as these parameters are raised. Additionally, an increase in layer thickness and infill percentage corresponds to a higher maximum failure load in the specimens. The peak maximum failure load (230 N) is achieved at a 0.5 mm layer thickness and Tri-Hexagonal pattern. As the infill percentage changes from 10% to 50%, the percentage of elongation at break decreases. The maximum percentage of elongation at break is attained with a 20% infill percentage, 0.2 mm layer thickness, and 0.5 Cubic-Subdivision pattern. Using a multi-objective response optimization, the layer thickness of 0.152 mm, an infill percentage of 32.909%, and a Grid infill pattern was found to be the best configuration.

Preparation of straw/PLA composites with excellent flame retardancy based on deep eutectic solvent sulfonation.

There have been numerous studies on flame retardant modification of natural fiber/PLA composite materials due to the demand for applications. However, the existing flame retardant modification methods mostly involve adding flame retardants, which have a negative impact on the mechanical properties. Based on this, this study aims to introduce sulfonic groups into the cellulose of straw fibers via modification with a sulfamic acid-based deep eutectic solvent (SDES), thereby achieving flame retardance without affecting the inherent mechanical properties of the composite material. The performance enhancement of DS/PLA is manifested in the following specific aspects: the LOI reaches 36.53 %, the thermal stability is improved from 7.8 % of the residual carbon of PS/PLA to 38.4 %, and the tensile modulus is increased by 69.5 %. The preparation scheme for straw/PLA composite materials in this study is simple, economical, and efficient, and the flame retardant performance of the composite material is excellent, providing valuable references for flame retardant modification of natural fiber/plastic composite materials.

Implementation of microcontroller board on a sustainable and degradable PLA/flax composite substrate: a case study.

In this paper, we present a novel polylactic-acid/flax-composite substrate and the implementation of a demonstrator: a microcontroller board based on commercial design. The substrate is developed for printed circuit board (PCB) applications. The pre-preg is biodegradable, reinforced, and flame-retarded. The novel material was developed to counter the increasing amount of e-waste and to improve the sustainability of the microelectronics sector. The motivation was to present a working circuit in commercial complexity that can be implemented on a rigid substrate made of natural, bio-based materials with a structure very similar to the widely used Flame Retardant Class 4 (FR4) substrate at an early technological readiness level (2-3). The circuit design is based on the Arduino Nano open-source microcontroller board design so that the demonstration could be programmable and easy to fit into education, IoT applications, and embedded designs. During the work, the design was optimized at the level of layout. The copper-clad pre-preg was then prepared and processed with subtractive printed wiring technology and through hole plating. The traditional surface mounting methodology was applied for assembly. The resulting yield of PCB production was around 50%. Signal analysis was successful with analogue data acquisition (voltage) and low-frequency (4 kHz) tests, indistinguishable from sample FR4 boards. Eventually, the samples were subjected to highly accelerated stress test (HAST). HAST tests revealed limitations compared to traditional FR4 printed circuit materials. After six cycles, the weight loss was around 30% in the case of PLA/Flax, and as three-point bending tests showed, the possible ultimate strength (25 MPa at a flexural state) was reduced by 80%. Finally, the sustainability aspect was assessed, where we found that ∼95 vol% and ∼90 wt% of the traditional substrate can be substituted, significantly easing the load of waste on the environment.

Prediction Models of Mechanical Properties of Jute/PLA Composite Based on X-ray Computed Tomography.

The tensile strength and modulus of elasticity of a jute/polylactic acid (PLA) composite were found to vary nonlinearly with the loading angle of the specimen through the tensile test. The variation in these properties was related to the fiber orientation distribution (FOD) and fiber length distribution (FLD). In order to study the effects of the FOD and FLD of short fibers on the mechanical properties and to better predict the mechanical properties of short-fiber composites, the true distribution of short fibers in the composite was accurately obtained using X-ray computed tomography (XCT), in which about 70% of the jute fibers were less than 300 µm in length and the fibers were mainly distributed along the direction of mold flow. The probability density functions of the FOD and FLD were obtained by further analyzing the XCT data. Strength and elastic modulus prediction models applicable to short-fiber-reinforced polymer (SFRP) composites were created by modifying the laminate theory and the rule of mixtures using the probability density functions of the FOD and FLD. The experimental measurements were in good agreement with the model predictions.

Properties of Heat-Treated Wood Fiber-Polylactic Acid Composite Filaments and 3D-Printed Parts Using Fused Filament Fabrication.

Wood fibers (WFs) were treated at a fixed heat temperature (180 °C) for 2-6 h and added to a polylactic acid (PLA) matrix to produce wood-PLA composite (WPC) filaments. Additionally, the effects of the heat-treated WFs on the physicomechanical properties and impact strength of the WPC filaments and 3D-printed WPC parts using fused filament fabrication (FFF) were examined. The results revealed that heat-treated WFs caused an increase in crystallinity and a significant reduction in the number of pores on the failure cross section of the WPC filament, resulting in a higher tensile modulus and lower elongation at break. Additionally, the printed WPC parts with heat-treated WFs had higher tensile strength and lower water absorption compared to untreated WPC parts. However, most of the mechanical properties and impact strength of 3D-printed WPC parts were not significantly influenced by adding heat-treated WFs. As described above, at the fixed fiber addition amount, adding heat-treated WFs improved the dimensional stability of the WPC parts and it enabled a high retention ratio of mechanical properties and impact strength of the WPC parts.

Fused Filament Fabricated Poly(lactic acid) Parts Reinforced with Short Carbon Fiber and Graphene Nanoparticles with Improved Tribological Properties.

This study investigated the mechanical and tribological properties of 3D-printed Poly (lactic acid) (PLA) composites reinforced with different concentrations of carbon fibers (SCF) and graphene nanoparticles (GNP) (0.5 to 5 wt.% of each filler). The samples were produced using FFF (fused filament fabrication) 3D printing. The results showed a good dispersion of the fillers in the composites. SCF and GNP promoted the crystallization of the PLA filaments. The hardness, elastic modulus, and specific wear resistance grew with the increase in the filler concentration. A hardness improvement of about 30% was observed for the composite with 5 wt.% of SCF + 5 wt.% GNP (PSG-5) compared to PLA. The same trend was observed for the elastic modulus with an increase of 220%. All the composites presented lower coefficients of friction (0.49 to 0.6) than PLA (0.71). The composite PSG-5 sample showed the lowest value of specific wear rate (4.04 × 10-4 mm3/N.m), corresponding to about a five times reduction compared to PLA. Therefore, it was concluded that the addition of GNP and SCF to PLA made it possible to obtain composites with better mechanical and tribological behavior.

Evaluating the Mechanical and Tribological Properties of 3D Printed Polylactic-Acid (PLA) Green-Composite for Artificial Implant: Hip Joint Case Study.

Artificial implants are very essential for the disabled as they are utilized for bone and joint function in orthopedics. However, materials used in such implants suffer from restricted mechanical and tribological properties besides the difficulty of using such materials with complex structures. The current study works on developing a new polymer green composite that can be used for artificial implants and allow design flexibility through its usage with 3D printing technology. Therefore, a natural filler extracted from corn cob (CC) was prepared, mixed homogeneously with the Polylactic-acid (PLA), and passed through a complete process to produce a green composite filament suit 3D printer. The corn cob particles were incorporated with PLA with different weight fractions zero, 5%, 10%, 15%, and 20%. The physical, mechanical, and tribological properties of the PLA-CC composites were evaluated. 3D finite element models were constructed to evaluate the PLA-CC composites performance on a real condition implant, hip joints, and through the frictional process. Incorporating corn cob inside PLA revealed an enhancement in the hardness (10%), stiffness (6%), compression ultimate strength (12%), and wear resistance (150%) of the proposed PLA-CC composite. The finite element results of both models proved an enhancement in the load-carrying capacity of the composite. The finite element results came in line with the experimental results.

Optimization of 3D Printing Technology for Fabrication of Dental Crown Prototype Using Plastic Powder and Zirconia Materials.

This research was aimed at developing a dental prototype from 3D printing technology using a synthetic filament of polylactic acid (PLA) and zirconium dioxide (ZrO2) with glycerol and silane coupling agent as a binder. A face-centered central composite design was used to study the effects of the filament extrusion parameters and the 3D printing parameters. Tensile and compressive testing was conducted to determine the stress-strain relationship of the filaments. The yield strength, elongation percentage and Young's modulus were also calculated. Results showed the melting temperature of 193 °C, ZrO2 ratio of 17 wt.% and 25 rpm screw speed contributed to the highest ultimate tensile strength of the synthetic filament. A Nozzle temperature of 210 °C and an infill density of 100% had the most effect on the ultimate compressive strength whilst the printing speed had no significant effects. Differential scanning calorimetry (DSC) was used to study the thermal properties and percentage of crystallinity of PLA filaments. The addition of glycerol and a silane coupling agent increased the tensile strength and filament size. The ZrO2 particles induced the crystallization of the PLA matrix. A higher crystallization was also obtained from the annealing treatment resulting in the greater thermal resistance performance of the dental crown prototype.

Evaluating the Performance of 3D-Printed PLA Reinforced with Date Pit Particles for Its Suitability as an Acetabular Liner in Artificial Hip Joints.

Off-the-shelf hip joints are considered essential parts in rehabilitation medicine that can help the disabled. However, the failure of the materials used in such joints can cause individual discomfort. In support of the various motor conditions of the influenced individuals, the aim of the current research is to develop a new composite that can be used as an acetabular liner inside the hip joint. Polylactic acid (PLA) can provide the advantage of design flexibility owing to its well-known applicability as a 3D printed material. However, using PLA as an acetabular liner is subject to limitations concerning mechanical properties. We developed a complete production process of a natural filler, i.e., date pits. Then, the PLA and date pit particles were extruded for homogenous mixing, producing a composite filament that can be used in 3D printing. Date pit particles with loading fractions of 0, 2, 4, 6, 8, and 10 wt.% are dispersed in the PLA. The thermal, physical, and mechanical properties of the PLA-date pit composites were estimated experimentally. The incorporation of date pit particles into PLA enhanced the compressive strength and stiffness but resulted in a reduction in the elongation and toughness. A finite element model (FEM) for hip joints was constructed, and the contact stresses on the surface of the acetabular liner were evaluated. The FEM results showed an enhancement in the composite load carrying capacity, in agreement with the experimental results.

Applications of Nisin and EDTA in Food Packaging for Improving Fabricated Chitosan-Polylactate Plastic Film Performance and Fish Fillet Preservation.

This study aimed to increase the antibacterial activity of chitosan-polylactic acid (PLA) composite film by adding nisin and ethylenediaminetetraacetic acid (EDTA). We evaluated the mechanical, physicochemical, and antibacterial properties of various PLA composite films, as well as the enhancement effect of PLA composite films with EDTA + nisin on the preservation of grouper fillets. Films of PLA alone, PLA plus chitosan (C5), PLA plus nisin + EDTA (EN2), and PLA plus chitosan plus nisin + EDTA (C5EN1 and C5EN2) were prepared. The addition of EDTA + nisin to the chitosan-PLA matrix significantly improved the antibacterial activity of the PLA composite film, with C5EN1 and C5EN2 films showing the highest antibacterial activity among the five films. Compared with the fish samples covered by C5, the counts of several microbial categories (i.e., mesophilic bacteria, psychrotrophic bacteria, coliforms, Aeromonas, Pseudomonas, and Vibrio) and total volatile basic nitrogen content in fish were significantly reduced in the samples covered by C5EN1. In addition, the counts of samples covered by C5EN1 or C5 were significantly lower compared to the uncovered and PLA film-covered samples.

Regulated Surface Morphology of Polyaniline/Polylactic Acid Composite Nanofibers via Various Inorganic Acids Doping for Enhancing Biocompatibility in Tissue Engineering.

Conductive and degradable nanofibrous scaffolds have great potential in promoting cell growth, proliferation, and differentiation under an external electric field. Although the issue of inferior electrical conductivity in body fluids still exists, polyaniline (PANI)-based degradable nanofibers can promote cell adhesion, growth, and proliferation. To investigate whether the effect is caused by the PANI morphology, we selected three inorganic acids as dopants in the process of PANI in situ oxidative polymerization: hydrochloric acid, sulfuric acid, and perchloric acid. The obtained polyaniline/polylactic acid (PANI/PLA) composite nanofibers were characterized via SEM, FTIR, and XPS analysis, and we confirmed that the PLA nanofibers were successfully coated by PANI without any change to the porous structure of the PLA nanofibers. The in vitro mechanical properties and degradability indicated that the oxidation of acid dopants should be considered and that it was likely to have a higher oxidation degradation effect on PLA nanofibers. The contact angle test demonstrated that PANI/PLA composite nanofibers with different surface morphologies have good wettability, implying that they meet the requirements of bone tissue engineering scaffolds. The surface roughness and cell viability demonstrated that different PANI morphologies on the surface can promote cell proliferation. The higher the surface roughness of the PANI, the better the biocompatibility. Consequently, the regulated surface morphology of PANI/PLA composite nanofibers via different acids doping has positive effect on biocompatibility in tissue engineering.

Characteristics of Unidirectional Green Wood Fiber/Polylactic Acid Composite Parts Printed with Various Layer Thicknesses by Fused Filament Fabrication.

In this study, the effect of layer thickness on the physicomechanical properties of the wood fiber-polylactic acid composite (WPC) part obtained by fused filament fabrication (FFF) was investigated. The results showed that most of the characteristics of the FFF-printed WPC part significantly depended on the printing layer thickness. As the layer thickness increased, the density of the printed WPC part decreased significantly, while the dimensional stability of the water-immersed WPC part decreased. In addition, specific tensile properties increased and the other specific mechanical properties (flexural, compressive, and shear properties) decreased with increasing layer thickness. Furthermore, scanning electronic microscopy micrographs illustrated that the number of voids and defects was more often observed on the surface of the WPC part printed with higher layer thickness. Therefore, these results indicated that the different layer thicknesses in FFF manufacturing have a substantial impact on the dimensional stability and specific mechanical properties of the FFF-printed WPC part.

Mechanical and Thermal Properties of Polylactide (PLA) Composites Modified with Mg, Fe, and Polyethylene (PE) Additives.

In this article, polylactic acid-based composites reinforced with 5% of polyethylene, iron, and magnesium powders were prepared by extrusion and compressed under the pressure of about 10 MPa and characterized. These composites were mechanically, thermally, and morphologically evaluated. It was found, compared to the pure polylactic acid (PLA), an improvement in tensile strength (both σ and YS0.2) was obtained for the composite with the iron powder addition, while the magnesium powder slightly improved the ductility of the composite material (from 2.0 to 2.5%). Degradation studies of these composites in the 0.9% saline solution over a period of 180 days revealed changes in the pH of the solution from acidic to alkaline, in all samples. The most varied mass loss was observed in the case of the PLA-5%Mg sample, where initially the sample mass increased (first 30 days) then decreased, and after 120 days, the mass increased again. In the context of degradation phenomenon of the tested materials, it turns out that the most stable is the PLA composite with the Fe addition (PLA-5%Fe), with highest tensile strength and hardness.

A study on Mg wires/poly-lactic acid composite degradation under dynamic compression and bending load for implant applications.

A novel and economic device is developed for simulating the physiological mechanochemical conditions. The degradation behaviors of poly-lactic acid (PLA) based composite reinforced with magnesium alloy wires (Mg wires/PLA) under dynamic compression and bending loads are investigated. The results denote the dynamic loads significantly influence the degradation behaviors of the composite. The dynamic bending load would profoundly promote the degradation of Mg wires in the composite and then accelerate the mechanical properties loss of the composite. The bending strength retention of the composite under consistent dynamic bending load at a magnitude of 5.6 N (about 5.6 MPa for the maximum stress at the middle surface) after 21 days immersion is about 53.3%, comparing to 69.7% for the dynamic compression load at a magnitude of 12 N (0.5 MPa for the compression stress). Furthermore, a numerical model is successfully postulated to elucidate the bending strength evolution of the composite under different dynamic loading conditions.

Flame Retardancy and Toughness of Poly(Lactic Acid)/GNR/SiAHP Composites.

A novel flame-retardant and toughened bio-based poly(lactic acid) (PLA)/glycidyl methacrylate-grafted natural rubber (GNR) composite was fabricated by sequentially dynamical vulcanizing and reactive melt-blending. The surface modification of aluminum hypophosphite (AHP) enhanced the interfacial compatibility between the modified aluminum hypophosphite by silane (SiAHP) and PLA/GNR matrix and the charring ability of the PLA/GNR/SiAHP composites to a certain extent, and the toughness and flame retardancy of the PLA/GNR/SiAHP composites were slightly higher than those of PLA/GNR/AHP composites, respectively. The notched impact strength and elongation of the PLA composite with 20 wt. %GNR and 18 wt.% SiAHP were 13.1 kJ/m2 and 72%, approximately 385% and 17 fold higher than those of PLA, respectively, and its limiting oxygen index increased to 26.5% and a UL-94 V-0 rating was achieved. Notedly, the very serious melt-dripping characteristics of PLA during combustion was completely suppressed. The peak heat release rate and total heat release values of the PLA/GNR/SiAHP composites dramatically reduced, and the char yield obviously increased with an increasing SiAHP content in the cone calorimeter test. The good flame retardancy of the PLA/GNR/SiAHP composites was suggested to be the result of a synergistic effect involving gaseous and condensed phase flame-retardant mechanisms. The high-performance flame-retardant PLA/GNR/SiAHP composites have great potential application as replacements for petroleum-based polymers in the automotive interior and building fields.

Bio-responsive chitin-poly(L-lactic acid) composite nanogels for liver cancer.

Hepatic carcinoma (HCC) is one of the most common cancer and its treatment has been considered a therapeutic challenge. Doxorubicin (Dox) is one of the most important chemotherapeutic agents used in the treatment for liver cancer. However, the efficacy of Dox therapy is restricted by the dose-dependent toxic side effects. To overcome the cardiotoxicity of Dox as well as the current problems of conventional modality treatment of HCC, we developed a locally injectable, biodegradable, and pH sensitive composite nanogels for site specific delivery. Both control and Dox loaded composite nanogel systems were analyzed by DLS, SEM, FTIR and TG/DTA. The size ranges of the control composite nanogels and their drug loaded counterparts were found to be 90±20 and 270±20 nm, respectively. The control chitin-PLA CNGs and Dox-chitin-PLA CNGs showed higher swelling and degradation in acidic pH. Drug entrapment efficiency and in vitro drug release studies were carried out and showed a higher drug release at acidic pH compared to neutral pH. Cellular internalization of the nanogel systems was confirmed by fluorescent microscopy. The cytotoxicity of the composite nanogels was analyzed toward HepG2 (human liver cancer) cell lines. Furthermore, the results of in vitro hemolytic assay and coagulation assay substantiate the blood compatibility of the system. Overall Dox-chitin-PLA CNGs system could be a promising anticancer drug delivery system for liver cancer therapy.