Architected Materials for Additive Manufacturing: A Comprehensive Review.

One of the main advantages of Additive Manufacturing (AM) is the ability to produce topologically optimized parts with high geometric complexity. In this context, a plethora of architected materials was investigated and utilized in order to optimize the 3D design of existing parts, reducing their mass, topology-controlling their mechanical response, and adding remarkable physical properties, such as high porosity and high surface area to volume ratio. Thus, the current re-view has been focused on providing the definition of architected materials and explaining their main physical properties. Furthermore, an up-to-date classification of cellular materials is presented containing all types of lattice structures. In addition, this research summarized the developed methods that enhance the mechanical performance of architected materials. Then, the effective mechanical behavior of the architected materials was investigated and compared through the existing literature. Moreover, commercial applications and potential uses of the architected materials are presented in various industries, such as the aeronautical, automotive, biomechanical, etc. The objectives of this comprehensive review are to provide a detailed map of the existing architected materials and their mechanical behavior, explore innovative techniques for improving them and highlight the comprehensive advantages of topology optimization in industrial applications utilizing additive manufacturing and novel architected materials.

Temperature Mapping of 3D Printed Polymer Plates: Experimental and Numerical Study.

In Fused Deposition Modeling (FDM), which is a common thermoplastic Additive Manufacturing (AM) method, the polymer model material that is in the form of a flexible filament is heated above its glass transition temperature (Tg) to a semi-molten state in the head's liquefier. The heated material is extruded in a rastering configuration onto the building platform where it rapidly cools and solidifies with the adjoining material. The heating and rapid cooling cycles of the work materials exhibited during the FDM process provoke non-uniform thermal gradients and cause stress build-up that consequently result in part distortions, dimensional inaccuracy and even possible part fabrication failure. Within the purpose of optimizing the FDM technique by eliminating the presence of such undesirable effects, real-time monitoring is essential for the evaluation and control of the final parts' quality. The present work investigates the temperature distributions developed during the FDM building process of multilayered thin plates and on this basis a numerical study is also presented. The recordings of temperature changes were achieved by embedding temperature measuring sensors at various locations into the middle-plane of the printed structures. The experimental results, mapping the temperature variations within the samples, were compared to the corresponding ones obtained by finite element modeling, exhibiting good correlation.

On the effects of the lateral strains on the fiber Bragg grating response.

In this paper, a combined experimental-numerical based work was undertaken to investigate the Bragg wavelength shift response of an embedded FBG sensor when subjected to different conditions of multi-axial loading (deformation). The following cases are examined: (a) when an isotropic host material with no constrains on planes normal to the embedded sensor's axis is biaxially loaded, (b) when the same isotropic host material is subjected to hydrostatic pressure and (c) when the hydrostatically loaded host material is an anisotropic one, as in the case of a composite material, where the optical fiber is embedded along the reinforcing fibers. The comparison of the experimental results and the finite element simulations shows that, when the axial strain on the FBG sensor is the dominant component, the standard wavelength-shift strain relation can be used even if large lateral strains apply on the sensor. However when this is not the case, large errors may be introduced in the conversion of the wavelength to axial strains on the fiber. This situation arises when the FBG is placed parallel to high modulus reinforcing fibers of a polymer composite.

Mechanical characteristics of an Ormocomp(®) biocompatible hybrid photopolymer.

In this work, the mechanical behaviour of a photocured Ormocomp(®) hybrid material is investigated. Its biocompatible nature has attracted a growing interest for microfabrication applications in biomedicine and tissue engineering. Measurements of in situ solidification strain development and achieved degree of curing, as obtained using a fibre optic sensor, are presented. The results show that the solidification strains generated during UV-curing are significant at the maximum achieved degree of curing. The mechanical response (Young's modulus) of the material was investigated by testing of thin-film and regular size specimens. It was found that the measured mean elastic modulus of the thin-film specimens was of the same order of magnitude as that of the larger specimens but noticeably smaller.