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Go to Editorial ManagerOver the last several years, additive manufacturing (AM), sometimes known as "3D printing", has seen remarkable expansion due to mechatronics and materials science advancements. Fused filament deposition (FDM) production is the predominant technology in additive manufacturing (AM) because of its cost-effectiveness in operational and material expenses. Nevertheless, the materials often used for this technique are pristine thermoplastics. Unsuccessful printing and throwaway prototypes generate a significant quantity of trash. Utilizing green and sustainable products is crucial to minimize the environmental effects. Recycled, bio-based, and mixed recycled materials provide a promising solution for 3D printing. The absence of comprehension about the interlayer adhesion process and material degradation in FDM printing has presented a significant obstacle for these environmentally friendly materials. This study comprehensively examines many materials used for FDM three-dimensional printing filaments, including recycled, bio-based, and mixed materials. The merits and drawbacks of thermoplastics and their composites were deliberated over. This evaluation is a comprehensive guide for engineers and researchers in selecting appropriate materials for three-dimensional printing. Three-dimensional printed objects have worse mechanical characteristics in comparison to injection molded materials.
Specimens with the structure of a face-centered cubic were produced using several sets of printing conditions. An experimental testing is conducted to carefully evaluate the microstructural analysis and compressive strength of this structure. The results include the measurement of mechanical properties, such as the peak stress. Fused deposition modeling is employed for the additive manufacturing of experimental specimens made from shape memory polymer thermoplastic polyurethane (MM-3520). We take into account the impact of printing factors on lattice structures, such as layer thickness, printing temperature, and printing speed. Analyzing the microstructure of the printed specimens exhibits that the specimens with highest printing temperature, lowest printing speed and thinner printing layer have better layers adhesion and lower porosities. All the mechanical tests are performed on specimens with the same structure and at a relatively constant density. Among the tested printing parameters, using a layer height of 0.1 mm, a printing temperature of 230 °C, and a printing speed of 20 mm/s yields the highest strength in the specimens. However, specimens printed with a layer height of 0.2 mm, a printing temperature of 220 °C, and a printing speed of 30 mm/s also exhibit good strength, albeit slightly lower than the maximum values. Additionally, when using these specific settings (0.3 mm – 210 °C – 40 mm/s), the mechanical qualities are minimized, yet the stress-strain curves exhibit characteristics similar to elastomers.
Functionally graded materials were created using laser-directed energy deposition technology. This work examines how different mixing ratios of Stainless Steel 316L and Inconel 625 affect the relative density and porosity of these materials. Twelve samples were created using a constant laser power of 600 W, three different laser scan speeds (20, 25, and 30 mm/s), and four different SS316L/IN625 transition ratios (85%/15%, 60%/40%, 40%/60%, and 15%/85%). To determine the volumetric distribution across the compositional gradients, the porosity and relative density measurements were taken. Optical and scanning electron microscopy were used for microstructural analytical characterization to differentiate between compositional gradients in grain shape and phase distribution. The mechanical performance was examined using microhardness measures, namely the Vickers method. This study applied to prove the process parameters and compositional transformations to the resulting microstructural features and mechanical properties, providing insight into optimizing the laser-directed energy deposition-manufactured functionally graded materials for advanced performance. The best graded composition was found that gives the best overall performance based on experimental data.