Improving the material extrusion processing of thermoplastic olefin/graphene nanoplatelet composites through control of the morphology.

The aim of this research is to develop thermoplastic olefin (TPO) composites containing polypropylene (PP), an elastomeric ethylene-octene copolymer (EOC) and graphene nanoplatelets (GNPs), suitable for material extrusion (MEX). A PP functionalized with amino-pyridine (PP-g-Py) was used as a compatibilizer. The composite blends had droplet-matrix morphology at compositions as high as 40 wt% EOC. Imaging by Transmission Electron Microscopy showed that the GNPs resided at the interface between the blend components. This microstructure promoted higher thermal conductivity of the TPO/GNP composite blends, as compared to the PP/GNP composite (1.54 W/m K, vs 1.3 W/m K respectively). PP/GNP composites processed by MEX exhibited inadequate interfacial fusion between the deposited strands, which resulted in severe delamination during tensile and flexural testing, and consequently poor mechanical properties. In the TPO/GNP composites containing 40 wt% EOC, the slower crystallization of the elongated EOC domains promoted interfacial adhesion between the strands, resulting in better part consolidation, more consistent mechanical properties and improved ductility compared to the PP/GNP composites.

Spark Plasma Sintering of Complex Metal and Ceramic Structures Produced by Material Extrusion.

Alternative approaches to laser fusion for the additive manufacturing (AM) of metals are often hampered by the need for long sintering cycles. Typical sintering cycles require heating at temperatures above 80% of the melting point for several hours. The process is time- and energy-consuming, particularly when high-melting materials are involved. Applying pressure can drastically reduce the time and temperature required for densification. Recently, a particular kind of pressure-assisted sintering process known as spark plasma sintering (SPS) or field-assisted sintering (FAST) received considerable attention in academia and industry due to its ability to enhance densification. However, conventional SPS/FAST techniques cannot be directly applied to the densification of objects presenting a complex geometry. This work shows how a modified SPS/FAST setup, operating in a pseudoisostatic mode, can be used for debinding and sinter objects produced by material extrusion. This approach can be applied to metals and metal-based and ceramic-based composites when their geometry does not include closed cavities. Depending on the characteristics of the pressure-transfer medium, some level of anisotropy in the volume reduction associated with the densification can be observed. Still, it can easily be corrected by appropriately compensating sintering deformation during printing. Using this approach, the time required for the debinding and sintering can be reduced considerably. It represents an alternative approach to the AM of a wide range of inorganic materials characterized by a relatively low-cost, high material flexibility, and low environmental impact.

A Review of Non-Powder-Bed Metal Additive Manufacturing: Techniques and Challenges.

Metal additive manufacturing has significantly evolved since the 1990s, achieving a market valuation of USD 6.36 billion in 2022, with an anticipated compound annual growth rate of 24.2% from 2023 to 2030. While powder-bed-based methods like powder bed fusion and binder jetting dominate the market due to their high accuracy and resolution, they face challenges such as lengthy build times, excessive costs, and safety concerns. Non-powder-bed-based techniques, including direct energy deposition, material extrusion, and sheet lamination, offer advantages such as larger build sizes and lower energy consumption but also encounter issues like residual stress and poor surface finish. The existing reviews of non-powder-bed-based metal additive manufacturing are restricted to one technical branch or one specific material. This survey investigates and analyzes each non-powder-bed-based technique in terms of its manufacturing method, materials, product quality, and summary for easy understanding and comparison. Innovative designs and research status are included.

Evaluation of Additives on the Cell Metabolic Activity of New PHB/PLA-Based Formulations by Means of Material Extrusion 3D Printing for Scaffold Applications.

In this study, specific additives were incorporated in polyhydroxyalcanoate (PHB) and polylactic acid (PLA) blend to improve its compatibility, and so enhance the cell metabolic activity of scaffolds for tissue engineering. The formulations were manufactured through material extrusion (MEX) additive manufacturing (AM) technology. As additives, petroleum-based poly(ethylene) with glicidyl metacrylate (EGM) and methyl acrylate-co-glycidyl methacrylate (EMAG); poly(styrene-co-maleic anhydride) copolymer (Xibond); and bio-based epoxidized linseed oil (ELO) were used. On one hand, standard geometries manufactured were assessed to evaluate the compatibilizing effect. The additives improved the compatibility of PHB/PLA blend, highlighting the effect of EMAG and ELO in ductile properties. The processability was also enhanced for the decrease in melt temperature as well as the improvement of thermal stability. On the other hand, manufactured scaffolds were evaluated for the purpose of bone regeneration. The mean pore size and porosity exhibited values between 675 and 718 µm and 50 and 53%, respectively. According to the results, the compression stress was higher (11-13 MPa) than the required for trabecular bones (5-10 MPa). The best results in cell metabolic activity were obtained by incorporating ELO and Xibond due to the decrease in water contact angle, showing a stable cell attachment after 7 days of culture as observed in SEM.

Printability Metrics and Engineering Response of HDPE/Si3N4 Nanocomposites in MEX Additive Manufacturing.

Herein, silicon nitride (Si3N4) was the selected additive to be examined for its reinforcing properties on high-density polyethylene (HDPE) by exploiting techniques of the popular material extrusion (MEX) 3D printing method. Six different HDPE/Si3N4 composites with filler percentages ranging between 0.0-10.0 wt. %, having a 2.0 step, were produced initially in compounds, then in filaments, and later in the form of specimens, to be examined by a series of tests. Thermal, rheological, mechanical, structural, and morphological analyses were also performed. For comprehensive mechanical characterization, tensile, flexural, microhardness (M-H), and Charpy impacts were included. Scanning electron microscopy (SME) was used for morphological assessments and microcomputed tomography (µ-CT). Raman spectroscopy was conducted, and the elemental composition was assessed using energy-dispersive spectroscopy (EDS). The HDPE/Si3N4 composite with 6.0 wt. % was the one with an enhancing performance higher than the rest of the composites, in the majority of the mechanical metrics (more than 20% in the tensile and flexural experiment), showing a strong potential for Si3N4 as a reinforcement additive in 3D printing. This method can be easily industrialized by further exploiting the MEX 3D printing method.

Characterization of the Anisotropic Electrical Properties of Additively Manufactured Structures Made from Electrically Conductive Composites by Material Extrusion.

Additive manufacturing (AM) of components using material extrusion (MEX) offers the potential for the integration of functions through the use of multi-material design, such as sensors, actuators, energy storage, and electrical connections. However, there is a significant gap in the availability of electrical composite properties, which is essential for informed design of electrical functional structures in the product development process. This study addresses this gap by systematically evaluating the resistivity (DC, direct current) of 14 commercially available filaments as unprocessed filament feedstock, extruded fibers, and fabricated MEX-structures. The analysis of the MEX-structures considers the influence of anisotropic electrical properties induced by the selective material deposition inherent to MEX. The results demonstrate that composites containing fillers with a high aspect ratio, such as carbon nanotubes (CNT) and graphene, significantly enhance conductivity and improve the reproducibility of MEX structures. Notably, the extrusion of filaments into MEX structures generally leads to an increase in resistivity; however, composites with CNT or graphene exhibit less reduction in conductivity and lower variability compared to those containing only carbon black (CB) or graphite. These findings underscore the importance of filler selection and composition in optimizing the electrical performance of MEX structures.

Effect of Material Extrusion Process Parameters to Enhance Water Vapour Adsorption Capacity of PLA/Wood Composite Printed Parts.

This study aims to optimise the water vapour adsorption capacity of polylactic acid (PLA) and wood composite materials for application in dehumidification systems through material extrusion additive manufacturing. By analysing key process parameters, including nozzle diameter, layer height, and temperature, the research evaluates their impact on the porosity and adsorption performance of the composite. Additionally, the influence of different infill densities on moisture absorption is investigated. The results show that increasing wood content significantly enhances water vapour adsorption, with nozzle diameter and layer height identified as the most critical factors. These findings confirm that composite materials, especially those with higher wood content and optimised printing parameters, offer promising solutions for improving dehumidification efficiency. Potential applications include heating, ventilation, and air conditioning systems or environmental control. This work introduces an innovative approach to using composite materials in desiccant-based dehumidification and provides a solid foundation for future research. Further studies could focus on optimising material formulations and scaling this approach for broader industrial applications.

Investigating mechanical properties of 3D printed polylactic acid / poly-3-hydroxybutyrate composites. Compressive and fatigue performance.

The 3D printing technique known as Material Extrusion (MEX) was initially employed for prototyping, but it has evolved to fit applications in mechanical and biomedical industries. Polylactic acid (PLA) stands out as a commonly used polymer for manufacture pieces by MEX, due to its good properties and organic origins. Pursuing renewable and biodegradable thermoplastics has led to the development materials such as composite of PLA with wood fibers and blends with poly-3-hydroxybutyrate (PHB). This study aims to characterize the effect of the most relevant printing parameters on the mechanical properties of a PLA/PHB blend, motivated by the interest to facilitate the use of this type of materials in industrial applications. To achieve it, compressive and fatigue tests were carried out, comparing the results with those obtained in previous studies for pure PLA and PLA-wood composite. Results show that the compressive behavior of PLA/PHB is influenced by the layer height, nozzle diameter and fill density. Its fatigue behavior is mainly determined by the nozzle diameter and the fill density. Moreover, the mechanical performance of PLA/PHB (Young's Modulus of 1.67 GPa, yield Strength of 33.8 MPa and maximum fatigue life of 9711 cycles) is inferior compared to pure PLA and PLA-wood composite. Despite the increase in the biodegradability that PHB introduces into PLA, the findings of this study reveal that there is statistically evidence that it can also hinder the mechanical performance of the base material.

Determination of the Optimum Architecture of Additively Manufactured Magnetic Bioactive Glass Scaffolds for Bone Tissue Engineering and Drug-Delivery Applications.

For better bone regeneration, precise control over the architecture of the scaffolds is necessary. Because the shape of the pore may affect the bone regeneration, therefore, additive manufacturing has been used in this study to fabricate magnetic bioactive glass (MBG) scaffolds with three different architectures, namely, grid, gyroid, and Schwarz D surface with 15 × 15 × 15 mm3 dimensions and 70% porosity. These scaffolds have been fabricated using an in-house-developed material-extrusion-based additive manufacturing system. The composition of bioactive glass was selected as 45% SiO2, 20% Na2O, 23% CaO, 6% P2O5, 2.5% B2O3, 1% ZnO, 2% MgO, and 0.5% CaF2 (wt %), and additionally 0.4 wt % of iron carbide nanoparticles were incorporated. Afterward, MBG powder was mixed with a 25% (w/v) Pluronic F-127 solution to prepare a slurry for fabricating scaffolds at 23% relative humidity. The morphological characterization using microcomputed tomography revealed the appropriate pore size distribution and interconnectivity of the scaffolds. The compressive strengths of the fabricated grid, gyroid, and Schwarz D scaffolds were found to be 14.01 ± 1.01, 10.78 ± 1.5, and 12.57 ± 1.2 MPa, respectively. The in vitro study was done by immersing the MBG scaffolds in simulated body fluid for 1, 3, 7, and 14 days. Darcy's law, which describes the flow through porous media, was used to evaluate the permeability of the scaffolds. Furthermore, an anticancer drug (Mitomycin C) was loaded onto these scaffolds, wherein these scaffolds depicted good release behavior. Overall, gyroid-structured scaffolds were found to be the most suitable among the three scaffolds considered in this study for bone tissue engineering and drug-delivery applications.

4D Printing of Multifunctional and Biodegradable PLA-PBAT-Fe3O4 Nanocomposites with Supreme Mechanical and Shape Memory Properties.

4D printing magneto-responsive shape memory polymers (SMPs) using biodegradable nanocomposites can overcome their low toughness and thermal resistance, and produce smart materials that can be controlled remotely without contact. This study presented the development of 3D/4D printable nanocomposites based on poly (lactic acid) (PLA)-poly (butylene adipate-co-terephthalate) (PBAT) blends and magnetite (Fe3O4) nanoparticles. The nanocomposites are prepared by melt mixing PLA-PBAT blends with different Fe3O4 contents (10, 15, and 20 wt%) and extruded into granules for material extrusion 3D printing. The morphology, dynamic mechanical thermal analysis (DMTA), mechanical properties, and shape memory behavior of the nanocomposites are investigated. The results indicated that the Fe3O4 nanoparticles are preferentially distributed in the PBAT phases, enhancing the storage modulus, thermal stability, strength, elongation, toughness, shape fixity, and recovery of the nanocomposites. The optimal Fe3O4 loading is found to be 10 wt%, as higher loadings led to nanoparticle agglomeration and reduced performance. The nanocomposites also exhibited fast shape memory response under thermal and magnetic activation due to the presence of Fe3O4 nanoparticles. The 3D/4D printable nanocomposites demonstrated multifunctional multi-trigger shape-memory capabilities and potential applications in contactless and safe actuation.

Enhancing Fatigue Resistance of Polylactic Acid through Natural Reinforcement in Material Extrusion.

This research paper aims to enhance the fatigue resistance of polylactic acid (PLA) in Material Extrusion (ME) by incorporating natural reinforcement, focusing on rotational bending fatigue. The study investigates the fatigue behavior of PLA in ME, using various natural fibers such as cellulose, coffee, and flax as potential reinforcements. It explores the optimization of printing parameters to address challenges like warping and shrinkage, which can affect dimensional accuracy and fatigue performance, particularly under the rotational bending conditions analyzed. Cellulose emerges as the most promising natural fiber reinforcement for PLA in ME, exhibiting superior resistance to warping and shrinkage. It also demonstrates minimal geometrical deviations, enabling the production of components with tighter dimensional tolerances. Additionally, the study highlights the significant influence of natural fiber reinforcement on the dimensional deviations and rotational fatigue behavior of printed components. The fatigue resistance of PLA was significantly improved with natural fiber reinforcements. Specifically, PLA reinforced with cellulose showed an increase in fatigue life, achieving up to 13.7 MPa stress at 70,000 cycles compared to unreinforced PLA. PLA with coffee and flax fibers also demonstrated enhanced performance, with stress values reaching 13.6 MPa and 13.5 MPa, respectively, at similar cycle counts. These results suggest that natural fiber reinforcements can effectively improve the fatigue resistance and dimensional stability of PLA components produced by ME. This paper contributes to the advancement of additive manufacturing by introducing natural fiber reinforcement as a sustainable solution to enhance PLA performance under rotational bending fatigue conditions. It offers insights into the comparative effectiveness of natural fibers and synthetic counterparts, particularly emphasizing the superior performance of cellulose.

Material Characterization of Silicones for Additive Manufacturing.

Three-dimensional printing is ideally suited to produce unique and complex shapes. In this study, the material properties of polysiloxanes, commonly named silicones, produced additively by two different methods, namely, multi-jet fusion (MJF) and material extrusion (ME) with liquid printing heads, are investigated. The chemical composition was compared via Fourier-transform infrared spectroscopy, evolved gas analysis mass spectrometry, pyrolysis gas chromatography coupled to mass spectrometry, and thermogravimetry (TGA). Density and low-temperature flexibility, mechanical properties and crosslink distance via freezing point depression were measured before and after post-treatment at elevated temperatures. The results show significant differences in the chemical composition, material properties, as well as surface quality of the tested products produced by the two manufacturing routes. Chemical analysis indicates that the investigated MJF materials contain acrylate moieties, possibly isobornyl acrylate linking branches. The hardness of the MJF samples is associated with crosslinking density. In the ashes after TGA, traces of phosphorus were found, which could originate from initiators or catalysts of the curing process. The ME materials contain fillers, most probably silica, that differ in their amount. It is possible that silica also plays a role in the processing to stabilize the extrusion strand. For the harder material, a higher crosslink density was found, which was supported also by the other tested properties. The MJF samples have smooth surfaces, while the ME samples show grooved surface structures typical for the material extrusion process. Post-treatment did not improve the material properties. In the MJF samples, significant color changes were observed.

Influence of Infill Patterns on the Shape Memory Effect of Cold-Programmed Additively Manufactured PLA.

In four-dimensional additive manufacturing (4DAM), specific external stimuli are applied in conjunction with additive manufacturing technologies. This combination allows the development of tailored stimuli-responsive properties in various materials, structures, or components. For shape-changing functionalities, the programming step plays a crucial role in recovery after exposure to a stimulus. Furthermore, precise tuning of the 4DAM process parameters is essential to achieve shape-change specifications. Within this context, this study investigated how the structural arrangement of infill patterns (criss-cross and concentric) affects the shape memory effect (SME) of compression cold-programmed PLA under a thermal stimulus. The stress-strain curves reveal a higher yield stress for the criss-cross infill pattern. Interestingly, the shape recovery ratio shows a similar trend across both patterns at different displacements with shallower slopes compared to a higher shape fixity ratio. This suggests that the infill pattern primarily affects the mechanical strength (yield stress) and not the recovery. Finally, the recovery force increases proportionally with displacement. These findings suggest a consistent SME under the explored interval (15-45% compression) despite the infill pattern; however, the variations in the mechanical properties shown by the stress-strain curves appear more pronounced, particularly the yield stress.

Modelling of Bond Formation during Overprinting of PEEK Laminates.

The rapid technological progress of large-scale CNC (computer numerical control) systems for Screw Extrusion Additive Manufacturing (SEAM) has made the overprinting of composite laminates a much-discussed topic. It offers the potential to efficiently produce functionalised high-performance structures. However, bonding the 3D-printed structure to the laminate has proven to be a critical point. In particular, the bonding mechanisms must be precisely understood and controlled to ensure in situ bonding. This work investigates the applicability of healing models from 3D printing to the overprinting of thermoplastic laminates using semi-crystalline, high-performance material like PEEK (polyether ether ketone). For this purpose, a simulation methodology for predicting the bonding behaviour is developed and tested using experimental data from a previous study. The simulation consists of a transient heat analysis and a diffusion healing model. Using this model, a qualitative prediction of the bond strength could be made by considering the influence of wetting. It was shown that the thermal history of the interface and, in particular, the tolerance of the deposition of the first layer are decisive for in situ bonding. The results show basic requirements for future process and component developments and should further advance the maturation of overprinting.

Design and Manufacturing of Dielectric Resonators via 3D Printing of Composite Polymer/Ceramic Filaments.

Rapid technological advancements in recent years have opened the door to innovative solutions in the field of telecommunications and wireless systems; thus, new materials and manufacturing methods have been explored to satisfy this demand. This paper aims to explore the application of low-cost, commercially available 3D-printed ceramic/polymer composite filaments to design dielectric resonators (DRs) and check their suitability for use in high-frequency applications. Three-dimensional printing was used to fabricate the three-dimensional dielectric resonant prototypes. The filaments were characterized in terms of their thermal and mechanical properties and quality of printability. Additionally, the filaments' dielectric properties were analyzed, and the prototypes were designed and simulated for a target frequency of ~2.45 GHz. Afterward, the DRs were successfully manufactured using the 3D printing technique, and no post-processing techniques were used in this study. A simple and efficient feeding method was used to finalize the devices, while the printed DRs' reflection coefficient (S11) was measured. Results on prototype size, manufacture ease, printability, cost per volume, and bandwidth (BW) were used to evaluate the materials' suitability for high-frequency applications. This research presents an easy and low-cost manufacturing process for DRs, opening a wide range of new applications and revolutionizing the manufacturing of 3D-printed high-frequency devices.

Enhanced Feedstock Processability for the Indirect Additive Manufacturing of Metals by Material Extrusion through Ethylene-Propylene Copolymer Modification.

Filament-based material extrusion (MEX) represents one of the most commonly used additive manufacturing techniques for polymer materials. In a special variation of this process, highly filled polymer filaments are used to create metal parts via a multi-step process. The challenges associated with creating a dense final part are versatile due to the different and partly contrary requirements of the individual processing steps. Especially for processing in MEX, the compound must show sufficiently low viscosity, which is often achieved by the addition of wax. However, wax addition also leads to a significant reduction in ductility. This can cause filaments to break, which leads to failure of the MEX process. Therefore, the present study investigates the influence of different ethylene-propylene copolymers (EPCs) with varying ethylene contents as a ductility-enhancing component within the feedstock to improve filament processing behavior. The resulting feedstock materials are evaluated regarding their mechanical, thermal and debinding behavior. In addition, the processability in MEX is assessed. This study shows that a rising ethylene content within the EPC leads to a higher ductility and an enhanced filament flexibility while also influencing the crystallization behavior of the feedstock. For the MEX process, an ethylene fraction of 12% within the EPC was found to be the optimum regarding processability for the highly filled filaments in MEX and the additional processing steps to create sintered metal parts.

Systematic Evaluation of Adhesion and Fracture Toughness in Multi-Material Fused Deposition Material Extrusion.

Material extrusion (MEX) additive manufacturing has successfully fabricated assembly-free structures composed of different materials processed in the same manufacturing cycle. Materials with different mechanical properties can be employed for the fabrication of bio-inspired structures (i.e., stiff materials connected to soft materials), which are appealing for many fields, such as bio-medical and soft robotics. In the present paper, process parameters and 3D printing strategies are presented to improve the interfacial adhesion between carbon fiber-reinforced nylon (CFPA) and thermoplastic polyurethane (TPU), which are extruded in the same manufacturing cycle using a multi-material MEX setup. To achieve our goal, a double cantilever beam (DCB) test was used to evaluate the mode I fracture toughness. The results show that the application of a heating gun (assembled near the nozzle) provides a statistically significant increase in mean fracture toughness energy from 12.3 kJ/m2 to 33.4 kJ/m2. The underlying mechanism driving this finding was further investigated by quantifying porosity at the multi-material interface using an X-ray computed tomography (CT) system, in addition to quantifying thermal history. The results show that using both bead ironing and the hot air gun during the printing process leads to a reduction of 24% in the average void volume fraction. The findings from the DCB test and X-ray CT analysis agree well with the polymer healing theory, in which an increased thermal history led to an increased fracture toughness at the multi-material interface. Moreover, this study considers the thermal history of each printed layer to correlate the measured debonding energy with results obtained using the reptation theory.

Strength and Electrostatic Discharge Resistance Analysis of Additively Manufactured Polyethylene Terephthalate Glycol (PET-G) Parts for Potential Electronic Application.

Optoelectronic components are crucial across various industries. They benefit greatly from advancements in 3D printing techniques that enable the fabrication of intricate parts. Among these techniques, Material Extrusion (MEX) stands out for its simplicity and cost-effectiveness. Integrating 3D printing into production processes offers the potential to create components with enhanced electrostatic discharge (ESD) resistance, a critical factor for ensuring the reliability and safety of optoelectronic devices. Polyethylene terephthalate glycol-modified (PET-G) is an amorphous copolymer renowned for its high transparency, excellent mechanical properties, and chemical resistance, which make it particularly suitable for 3D printing applications. This study focuses on analyzing the mechanical, structural, and electrostatic properties of pure PET-G as well as PET-G doped with additives to evaluate the effects of doping on its final properties. The findings highlight that pure PET-G exhibits superior mechanical strength compared to doped variants. Conversely, doped PET-G demonstrates enhanced resistance to electrostatic discharge, which is advantageous for applications requiring ESD mitigation. This research underscores the importance of material selection and optimization in 3D printing processes to achieve desired mechanical and electrical properties in optoelectronic components. By leveraging 3D printing technologies like MEX and exploring material modifications, industries can further innovate and enhance the production of optoelectronic devices, fostering their widespread adoption in specialized fields.

Investigation into Influence of Tensile Properties When Varying Print Settings of 3D-Printed Polylactic Acid Parts: Numerical Model and Validation.

Material Extrusion (MEX), particularly Fused Filament Fabrication (FFF), is the most widespread among the additive manufacturing (AM) technologies. To further its development, understanding the influence of the various printing parameters on the manufactured parts is required. The effects of varying the infill percentage, the number of layers of the top and bottom surfaces and the number of layers of the side surfaces on the tensile properties of the printed parts were studied by using a full factorial design. The tensile test results allowed a direct comparison of each of the three parameters' influence on the tensile properties of the parts to be conducted. Yield strength appears to be the most affected by the number of layers of the top and bottom surfaces, which has twice the impact of the number of layers of the side surfaces, which is already twice as impactful as the infill percentage. Young's modulus is the most influenced by the number of layers of the top and bottom surfaces, then by the infill percentage and finally by the number of layers of the side surfaces. Two mathematical models were considered in this work. The first one was a polynomial model, which allowed the yield strength to be calculated as a function of the three parameters mentioned previously. The coefficients of this model were obtained by performing tensile tests on nine groups of printed samples, each with different printing parameters. Each group consisted of three samples. A second simplified model was devised, replacing the numbers of layers on the side and top/bottom surfaces with their fractions of the cross-section surface area of the specimen. This model provided results with a better correlation with the experimental results. Further tests inside and outside the parameter ranges initially chosen for the model were performed. The experimental results aligned well with the predictions and made it possible to assess the accuracy of the model, indicating the latter to be sufficient and reliable. The accuracy of the model was assessed through the R2 value obtained, R2 = 92.47%. This was improved to R2 = 97.32% when discarding material infill as an input parameter.

Testing Protocol Development for the Fracture Toughness of Parts Built with Big Area Additive Manufacturing.

The mechanical testing of additively manufactured parts has largely relied on the existing standards developed for traditional manufacturing. While this approach leverages the investment made in current standards development, it inaccurately assumes that the mechanical response of additive manufacturing (AM) parts is identical to that of parts manufactured through traditional processes. When considering thermoplastic, material extrusion AM, the differences in response can be attributed to an AM part's inherent inhomogeneity caused by porosity, interlayer zones, and surface texture. Additionally, the interlayer bonding of parts printed with large-scale AM is difficult to adequately assess, as much testing is performed such that stress is distributed across many layer interfaces; therefore, the lack of AM-specific standards to assess interlayer bonding is a significant research gap. To quantify interlayer bonding via fracture toughness, double cantilever beam (DCB) testing has been used for some AM materials, and DCB has been generally used for a variety of materials including metal, wood, and laminates. Mode I DCB testing was performed on thermoplastic matrix composites printed with Big Area Additive Manufacturing (BAAM). Of particular interest was the notch shape and deflection speed during testing. The results examine the differences when using two notch types and three deflection speeds. The testing method introduced by the following paper differentiates itself from the ones described in the standards used by modernizing the methodology. This was conducted with the introduction of Digital Image Correlation (DIC) to gather displacement and load data simultaneously without human intervention.