The Influence of Microstructural Arrangement on the Failure Characteristics of 3D-Printed Polymers: Exploring Damage Behaviour in Acrylonitrile Butadiene Styrene.

This study investigated how printing conditions influence the fracture behaviour of 3D-printed acrylonitrile butadiene styrene (ABS) under tensile loading. Dog-bone-shaped ABS specimens were produced using the fusion filament fabrication technique, with varying printing angles. Tensile tests were conducted on pre-notched specimens with consistent pre-notch lengths but different orientations. Optical and scanning electron microscopies were employed to analyse crack propagation in the pre-notched specimens. In order to support experimental evidence, finite element computation was implemented to study the damage induced by the microstructural rearrangement of the filaments when subject to tensile loading. The findings revealed the simple linear correlation between the failure properties including elongation at break and maximum stress in relation to the printing angle for different pre-notch lengths. A more progressive damage was found to support the ultimate performance of the studied material. This experiment evidence was used to build a damage model of 3D-printed ABS that accounts for the onset, growth, and damage saturation. This damage modelling is able to capture the failure properties as a function of the printing angle using a sigmoid-like damage function and a modulation of the stiffness within the raster. The numerical results demonstrated that damage pattern develops as a result of the filament arrangement and weak adhesion between adjacent filaments and explains the diffuse damage kinetics observed experimentally. This study concludes with a topological law relating the notch size and orientation to the rupture properties of 3D-printed ABS. This study supports the idea of tailoring the microstructural arrangement to control and mitigate the mechanical instabilities that lead to the failure of 3D-printed polymers.

Digital Light Processing Route for 3D Printing of Acrylate-Modified PLA/Lignin Blends: Microstructure and Mechanical Performance.

In this study, digital light processing (DLP) was utilized to generate 3D-printed blends composed of photosensitive acrylate-modified polylactic acid (PLA) resin mixed with varying weight ratios of lignin extracted from softwood, typically ranging from 5 wt% to 30 wt%. The microstructure of these 3D-printed blends was examined through X-ray microtomography. Additionally, the tensile mechanical properties of all blends were assessed in relation to the weight ratio and post-curing treatment. The results suggest that post-curing significantly influences the tensile properties of the 3D-printed composites, especially in modulating the brittleness of the prints. Furthermore, an optimal weight ratio was identified to be around 5 wt%, beyond which UV light photopolymerization experiences compromises. These findings regarding acrylate-modified PLA/lignin blends offer a cost-effective alternative for producing 3D-printed bio-sourced components, maintaining technical performance in reasonable-cost, low-temperature 3D printing, and with a low environmental footprint.

The Thermal and Mechanical Behaviour of Wood-PLA Composites Processed by Additive Manufacturing for Building Insulation.

This study was aimed at considering the potential of wood-based composites processed using additive manufacturing as insulators in the building sector. A polylactic acid blend with 30% wood particles was used as a feedstock material in fused filament technology. Its thermal and mechanical properties were determined for various processing conditions, including printing temperature and infill rate. The results showed a minor contraction in its tensile performance as a result of the printing process. The printing temperature had a negligible effect on its stiffness and a limited influence on the other engineering constants, such as the tensile strength and ultimate stress. The thermal properties of printed structures have been found to significantly depend on the infill rate. Although the tested 3D printed wood-PLA material exhibited good thermal properties, which were tuneable using the printing conditions, its performance was still 38% to 57% lower compared to insulators such as the glass wool of the synthetic foams used in the building sector.

Digital Image Correlation and Finite Element Computation to Reveal Mechanical Anisotropy in 3D Printing of Polymers.

In this study, we propose to revisit the mechanical anisotropy inferred to printed ABS polymers using fused deposition modelling by combining digital image correlation (DIC), mechanical testing and finite element computation. Tensile specimens are printed using different design orientations and raster angles. Monitoring of deformed samples is performed, and strain fields are derived for each configuration. Finite element modelling of the 3D-printed material behaviour is considered to shed more light on deformation mechanisms. Experimental results show that a heterogeneous strain field develops, leading to more significant strain localisation for samples printed with the main dimension aligned with the building direction. The optimal printing angle allowing the filament to be crossed at -45°/+45° shows the best behaviour with even larger elongation at break compared to the raw material. However, digital image correlation based on optical imaging shows that a limiting scale exists for revealing the effect of filament orientation on strain localisation. Finite element results reveal the nature of the strain localisation as related presence of porosity close to the frame and the development of asymmetrical filling within the printed structure.

Infill Strategy in 3D Printed PLA Carbon Composites: Effect on Tensile Performance.

Tuning the infill pattern is one of the key features in additive manufacturing to optimise part weight. In this work, the effect of the infill strategy, including rate and pattern type, is studied on the mechanical performance of polylactic acid (PLA)-carbon composite. In particular, three types of patterns and four filling levels are combined. These combinations are evaluated by tensile loading applied on dogbone specimens. In addition, the underlined deformation mechanisms are further explored using filament-based finite element model. The numerical simulation is built from sliced models and converted into 3D meshes to predict tensile performance. The results show that the infill rate has a nonlinear effect on the density of PLA-carbon composites, and its magnitude depends on the complexity of the generated pattern. In addition, tensile loading is found to activate varied modes of shearing and uniaxial deformations depending on the pattern type. This leads to different profiles and rankings of the tensile performance and allows the infill strategy to significantly affect the part performance, along with its density.

Synthesis of a Starchy Photosensitive Material for Additive Manufacturing of Composites Using Digital Light Processing.

In this study, digital light processing (DLP) was used to achieve 3D-printed composite materials containing photosensitive resin blended with starch and hemp fibers. The synthesis of 3D-printed composites was performed without heating, according to various material combinations ranging from pure photosensitive resin to a mixture of three phases, including resin, starch, and hemp fibers, with the weight content for each reinforcing phase reaching up to a third of the formulation. The morphology, composition, and structure of the 3D-printed composites were assessed using infrared spectroscopy, laser granulometry, X-ray diffraction, and optical and scanning electron microscopy. In addition, thermal behavior and mechanical performance were studied using calorimetry, differential scanning calorimetry, and tensile testing combined with high-speed optical imaging. The results showed that the post-curing step is a leading factor for improving the mechanical performance of the 3D-printed composites. In addition, hemp fiber or starch did not alter the tensile strength. However, the largest reinforcing effect in terms of stiffness improvement was obtained with starch. Additionally, starchy composites demonstrated the strongest dependence of heat capacity on operating temperature.

On the Mechanical Performance of Polylactic Material Reinforced by Ceramic in Fused Filament Fabrication.

This study addresses the potential of using ceramics-based filaments as a feedstock material in an additive manufacturing process. Tensile specimens of PLA-ceramic (PLC) material are manufactured using a fused deposition modelling process, applying various printing parameters including printing angle and part orientation. Mechanical testing is performed on both the filaments and 3D-printed parts, and the related engineering quantities are derived. The experimental results show that PLC wire properties are substantially restored for the horizontal and lateral printing orientations, with only a 9% reduction in stiffness. In addition, a typical elastic-plastic response is achieved with these orientations, allowing the PLC to achieve excellent stiffness and elongation-at-break performance. The mechanical performance of the PLC is explained by the large proportion of continuous filaments along the loading direction. In addition, the printing angle is found to be a secondary factor allowing for layups at -45°/+45° and 0°/90°, resulting in the best tensile performance. The downside of using PLC is the lack of mechanical transfer, which is associated with weak interfacial behaviour and the inability to achieve high tensile strength.

Interfacial Behaviour in Polymer Composites Processed Using Droplet-Based Additive Manufacturing.

In this study, we show the extent of interfacial behaviour in the mechanical performance of thermoplastic polyurethane elastomer (TPU)/acrylonitrile butadiene styrene (ABS) composite material manufactured using droplet-based additive manufacturing. Both the interface orientation and the interface strength are varied during the processing. Prior to tensile experiments, X-ray micro-tomography imaging is undertaken to obtain the microstructural arrangement of polymer droplets in the part. Tensile loading is performed simultaneously with digital image acquisition to reveal the extent of strain localization using a digital image correlation approach. The experiments are performed up to the failure of the specimens. Finite element computation based on 3D imaging of the ABS/TPU composite is considered to predict the role of the interface as well as the defect influence on the tensile performance. The experimental results show a major connectivity of the process-generated porosity and a distinct morphology of the ABS/TPU interface. The predictions demonstrate that, despite the limited amount of porosity, their connectivity plays a significant role in triggering damage initiation and growth up to the failure of the composite material.

Effect of Printing Parameters on Mechanical Behaviour of PLA-Flax Printed Structures by Fused Deposition Modelling.

Few studies have reported the performance of Polylactic acid (PLA) flax feedstock composite for additive manufacturing. In this work, we report a set of experiments conducted by fused filament technology on PLA and PLA-flax with the aim of drawing a clear picture of the potential of PLA-flax as a feedstock material. Nozzle and bed temperatures are both combined with the printing angle to investigate their influence on structural and mechanical properties. The study shows a low sensitivity of PLA-flax to process parameters compared to PLA. A varied balance between shearing and uniaxial deformation is found consistent with tensile results where filament crossing at -45/+45° provides the optimal load-bearing capabilities. However, Scanning Electron Microscopy (SEM) and high-speed camera recording shows a limiting reinforcing effect of flax fibre due to the presence of intra-filament porosity and a significant amount of fibre pull-out resulting from the tensile loading. These results suggest that the quality of the bond between PLA matrix and flax fibre, intra-filament porosity, and surface roughness should receive more attention as well as the need for more continuous fibre reinforcement in PLA filaments to optimise the performance of PLA-flax printed materials.

On the Mechanical Behaviour of Biosourced Cellular Polymer Manufactured Using Fused Deposition Modelling.

The aim of this study is to investigate on the compression performance of cellular Polylactic Acid (PLA) manufacturing while using Fused Deposition Modelling. Computer Aided Design (CAD) models of cellular structures are designed using the sequential addition of spherical voids with porosity content varying from 10% to 60%. The three-dimensional (3D) microstructures of cellular PLA are characterised using X-ray micro-tomography to retrieve the correlation between the process-induced defects and the cellular geometrical properties. Mechanical testing is performed under severe compression conditions allowing for the reduction in sample height up to 80%. Finite element computation that is based on real microstructures is used in order to evaluate the effect of defects on the compression performance. The results show a significant drop of the process-induced defects thanks to the use of small layer thickness. Both mechanical anisotropy and performance loss are reduced due to vanishing process-induced defects more significantly when the amount of intended porosities is large. The compression behaviour of 3D printed PLA cellular structures is then found to be only guided by the amount and distribution of the intended porosity.

On the Tensile Behaviour of Bio-sourced 3D-Printed Structures from a Microstructural Perspective.

The influence of the microstructural arrangement of 3D-printed polylactic acid (PLA) on its mechanical properties is studied using both numerical and experimental approaches. Thermal cycling during the laying down of PLA filament is investigated through infra-red measurements for different printing conditions. The microstructure induced by 3D printing is determined using X-ray micro-tomography. The mechanical properties are measured under tensile testing conditions. Finite element computation is considered to predict the mechanical performance of 3D-printed PLA by converting the acquired 3D images into structural meshes. The results confirm the leading role of the printing temperature on thermal cycling during the laying down process. In addition, the weak influence of the printing temperature on the stiffness of 3D-printed PLA is explained by the relatively small change in porosity content. However, the influence of the printing temperature on the ultimate properties is found to be substantial. This major influence is explained from finite element predictions as an effect of pore connectivity which is found to be the control factor for tensile strength.

Microstructure and Mechanical Performance of 3D Printed Wood-PLA/PHA Using Fused Deposition Modelling: Effect of Printing Temperature.

The microstructure and mechanical performance of wood-based filament is investigated in the case of Fused Deposition Modelling (FDM) technique using experimental and numerical approaches. The printing process of wood-PLA/PHA is conducted by varying the printing temperature, typically from 210 °C to 250 °C. The filament temperature during the laying down is measured using infra-red camera to study the thermal cycling. In addition, X-ray micro-tomography is used to evaluate the material arrangement of printed wood-PLA/PHA at different length scales. Tensile experiments are performed to rank the loss in mechanical performance with respect to the filament properties. Finally, finite element computation is considered to predict the tensile behaviour based on the implementation of the real 3D microstructure issued from X-ray micro-tomography. The results show that the wood-based filament is printable over a wide range of temperatures and exhibits a marked heat accumulation tendency at high printing temperatures. However, the limited gain in tensile performance at these temperatures makes 220 °C an optimal choice for printing wood-based filament. The elongation at break of 3D-printed wood-PLA/PHA is remarkably similar to the results observed for the filament. Finite element computation reveals that despite this apparent similarity, the associated deformation mechanisms are different.

Printability and Tensile Performance of 3D Printed Polyethylene Terephthalate Glycol Using Fused Deposition Modelling.

Polyethylene terephthalate glycol (PETG) is a thermoplastic formed by polyethylene terephthalate (PET) and ethylene glycol and known for his high impact resistance and ductility. The printability of PETG for fused deposition modelling (FDM) is studied by monitoring the filament temperature using an infra-red camera. The microstructural arrangement of 3D printed PETG is analysed by means of X-ray micro-tomography and tensile performance is investigated in a wide range of printing temperatures from 210 °C to 255 °C. A finite element model is implemented based on 3D microstructure of the printed material to reveal the deformation mechanisms and the role of the microstructural defects on the mechanical performance. The results show that PETG can be printed within a limited range of printing temperatures. The results suggest a significant loss of the mechanical performance due to the FDM processing and particularly a substantial reduction of the elongation at break is observed. The loss of this property is explained by the inhomogeneous deformation of the PETG filament. X-ray micro-tomography results reveal a limited amount of process-induced porosity, which only extends through the sample thickness. The FE predictions point out the combination of local shearing and inhomogeneous stretching that are correlated to the filament arrangement within the plane of construction.

On the representative elementary size concept to evaluate the compatibilisation of a plasticised biopolymer blend.

This study combines experimental and numerical approaches to investigate the microstructure and mechanical behaviour of non-miscible plasticised starch/zein blends. The concept of Representative Elementary Size (RES) is used to rank the effect of five different plasticisers (cholinium acetate, glycerol, butyl methyl imidazolium chloride, glycerol-choline chloride, urea-choline chloride) inducing microstructural and mechanical changes in the blends. Microstructural and mechanical RESs are derived from microscopy image analysis and Finite Element Modelling of elasticity behaviour of studied blends. Compared to the usual consideration of ultimate mechanical properties (elongation and stress at break), the RES-based approach allows detecting the presence of perfect or imperfect interface between starch and zein particles depending on the nature of plasticiser.

Microstructural design of biopolymer blends and related elasticity with imperfect interfacial bonding.

The underlined microstructure of biopolymer blends reflects complexity of mass and heat transfer during processing. In the present work, such complexity is apprehended using simple and intuitive way to generate typical microstructures resulting from thermomoulding processing. The starting point is a simple generation scheme of the feed powder approximated as circular heat sources. Finite element computation of a transient thermal analysis is performed and the resulting nodal fields are again converted into 2D microstructures. The final microstructures prove to be similar in all geometrical characteristics starch-zein blends. Elasticity response of these blends is explored using finite element computation. Sensitivity analysis is performed to derive the effect of perfect and imperfect interface properties on the mechanical performance of the biopolymer blend. Predictions show a significant role of interfaces which trigger the elasticity properties of the biopolymer blends much larger than the contrast in phase properties. This study demonstrates that nonlinear interface effect on elasticity behaviour is related to geometrical percolation that occurs at specific phase content.