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Tensile performance of carbon fibre-reinforced 3D-printed polymers: Effect of printing parameters

ENGINEERING FAILURE ANALYSIS 2025年 175卷

作者： Burnett, Clare Graninger, Georg Eren, Zana Falzon, Brian G. Kazanci, Zafer Queens Univ Belfast Sch Mech & Aerosp Engn Adv Composites Res Grp Belfast BT9 5AH North Ireland Kocaeli Univ Fac Aeronaut & Astronaut Dept Aerosp Engn Kartepe Kocaeli Turkiye Western Sydney Univ Sch Engn Design & Built Environm Engn Innovat Hub Parramatta City Campus Precinct Parramatta NSW 2150 Australia

The mechanical performance of fibre-reinforced 3D-printed composites is highly dependent on slicing and processing parameters, yet a systematic understanding of these effects remains limited. This study aims to systematically evaluate the influence of infill pattern, infill density, bed orientation, and layer thickness on the tensile properties of short carbon fibre-reinforced Nylon (Onyx) and unreinforced Nylon fabricated using Markforged 3D printers. Tensile testing was conducted to assess tensile modulus, ultimate tensile strength, elongation at break, and Poisson's ratio across varying slicing parameters. Various raster angles (0 degrees, 90 degrees, 45 degrees and - 45 degrees relative to the x-axis), three infill patterns (rectangular, triangular, hexagonal), and multiple densities (17 %-92 %) were examined to assess their influence on mechanical behaviour. Scanning electron microscopy (SEM) and fibre volume fraction ignition testing were used to quantify void content and fibre distribution in Onyx composites. Furthermore, the Rule of Mixtures (ROM) was applied and demonstrated strong agreement with experimental results, providing a predictive framework for tensile performance across different infill densities. The findings of this study contribute to the optimisation of fibre-reinforced additive manufacturing by identifying key parameters that enhance mechanical properties, supporting structural applications in aerospace, automotive, and lightweight engineering systems.

关键词： Additive manufacturing Material charaacterization 3-D printing printing parameters

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Improved Forming Efficiency Through the Adjustment of Inkjet-Bonded 3D printing parameters and Sand Mold Structure

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INTERNATIONAL JOURNAL OF METALCASTING 2025年 1-25页

作者： Zheng, Jun Qiu, Xiran Zhu, Jun Jia, Rundong Xu, Bojie Xia, Zhushun Wang, Wei Ling, Wei Tang, Bin Guan, Aizhi Zhang, Zhiyi Duan, Fubin Zhejiang Univ Sci & Technol Sch Mech & Energy Engn Hangzhou 310023 Peoples R China Zhejiang Prov Key Lab Food Logist Equipment & Tech Hangzhou 310023 Peoples R China Tongxiang Allied Machinery Co Ltd Tongxiang 314500 Peoples R China

Inkjet-bonded 3D sand printing technology is becoming a more mature technology. The forming efficiency in the casting is especially important, and the forming efficiency includes printing efficiency, sand mold post-treatment efficiency, and casting forming efficiency. This study investigates the impact of inkjet-based 3D sand printing technology on the productivity of castings. By optimizing the printing parameters-layer thickness, recoating speed, X-resolution, and printhead jetting rate-the efficiency of the printing stage was improved, and predictive models were established for the printing stage, post-processing stage, and casting stage. The study found that layer thickness and recoating speed had a significant influence on printing time, while X-resolution and printhead jetting rate played a secondary role. Additionally, two sand mold designs, truss support structures and honeycomb structures, were introduced to enhance forming efficiency during the casting stage. The model was validated through an engine cylinder block case study, where the optimized parameters improved forming efficiency during the printing stage by 20.17%. The truss and honeycomb sand mold designs improved casting efficiency by 6.96% and 14.18%, respectively. Verification experiments conducted on sixteen printing groups showed that the predictive model for 3D sand casting forming efficiency achieved an accuracy of 94.88%.

关键词： inkjet bonding 3D printing sand casting printing parameters forming efficiency

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Influence of thermoplastic polyurethane (TPU) and printing parameters on the thermal and mechanical performance of polylactic acid (PLA) / thermoplastic polyurethane (TPU) polymer

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POLYMER TESTING 2025年 143卷

作者： Hamidi, Muhammad Nafiz Abdullah, Jamaluddin Mahmud, Abdus Samad Hassan, Muhammad Hafiz Zainoddin, Ahmad Yasier Univ Sains Malaysia Nibong Tebal Sch Mech Engn Nibong Tebal 14300 Pulau Pinang Malaysia

Polylactic acid (PLA) is a polymer widely used for 3D printing process owing to its mechanical properties which are high strength and flexural modulus and environmentally friendly. However, PLA is also a brittle polymer with low impact resistance. This weakness can be compensated by combining PLA with other polymer like Thermoplastic polyurethane (TPU) that is widely used to improve mechanical properties of PLA. In polymer 3D printing process, printing parameters affect the thermo-mechanical properties of the printed products. This study investigates the influence of TPU and various printing parameters on thermal and mechanical properties of PLA/TPU polymer blends. It provides more precise understanding on how each printing parameters and different TPU ratio affect the mechanical and thermal properties. It also helps in determining the significant parameters for better PLA/TPU blend print. This exploration of parameter effects adds novel insights, enhancing applicability in practical 3D printing processes. Six different TPU ratio was used which are 10 %-50 % by weight while the parameters being tested are printing speed, raster angle, layer thickness and printing temperature. The differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) were conducted to assess the thermal properties while a tensile test was conducted to evaluate the mechanical properties. ANOVA analysis was employed for the data analysis. It was found that TPU altered the thermal properties of PLA by reducing the cold crystallization temperature, T-cc, enthalpy of crystallization, Delta H-c and enthalpy of melting, Delta H-m. The mechanical strength reduced by 64 % but the ductility improved up to 900 %. Based on ANOVA analysis, it can be concluded that influence of printing parameters on the mechanical properties are layer thickness > printing speed > raster angle > printing temperature in descending order.

关键词： Polylactic acid (PLA) Thermoplastic polyurethane (TPU) Tensile test printing parameters ANOVA

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Novel heterogeneous 3D printing process of protein-polysaccharide gel containing orange juice sacs: Optimization of material properties and printing parameters

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INTERNATIONAL JOURNAL OF BIOLOGICAL MACROMOLECULES 2025年第Pt 2期305卷 141277页

作者： Kong, Demei Zhang, Min Mujumdar, Arun S. Luo, Zhenjiang Jiangnan Univ Sch Food Sci & Technol State Key Lab Food Sci & Resources Wuxi 214122 Jiangsu Peoples R China Jiangnan Univ Jiangsu Prov Int Joint Lab Fresh Food Smart Proc & Wuxi 214122 Jiangsu Peoples R China Jiangnan Univ China Gen Chamber Commerce Key Lab Fresh Food Proc Wuxi 214122 Jiangsu Peoples R China McGill Univ Dept Bioresource Engn Macdonald Campus Montreal PQ Canada Haitong Ninghai Foods Co Ltd R&D Ctr Ninghai Zhejiang Peoples R China Jiangnan Univ Sch Food Sci & Technol Wuxi 214122 Jiangsu Peoples R China

The rapid advancement of 3D food printing technology for heterogeneous systems has been driven by increasing consumer demand for personalized meals, enhanced nutrition, and overall wellness. By using kappa-carrageenan (KC), konjac gum (KGM), and whey protein isolate (WPI), this study developed a thermoreversible composite gel (WPI-KC-KGM) for temperature-controlled extrusion, focusing on the effect of the KC to KGM ratio on the composite gel's rheological properties and printability. Rheological tests indicated that KGM reduced the thermal sensitivity of KC, with the K7M3 formulation being optimal for minimizing sensitivity while maintaining thermoreversibility. printing accuracy analysis revealed that K5M5 samples achieved the best pore area (1.392 cm2) and fidelity (96.66 %), while K7M3 samples exhibited the highest support similarity (95.78 %). For the WPI-KCKGM (K7M3) composite gel containing 3 wt% orange juice sacs, the recommended printing settings are a nozzle diameter of 2.5 mm, a speed of 20 mm/s, and a temperature of 40 degrees C, resulting in aesthetically pleasing and clearly defined planar and stereoscopic products.

关键词： Heterogeneous 3D printing Whey protein isolate kappa-Carrageenan Konjac gum printing parameters

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Effects of fused deposition modeling (FDM) printing parameters on quality aspects of polycaprolactone (PCL) for coronary stent applications: A review

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JOURNAL OF BIOMATERIALS APPLICATIONS 2025年

作者： Ng, Kuang Yee Muhammad, Noorhafiza Noor, Siti Noor Fazliah Mohd Rahim, Shayfull Zamree Abd. Saleh, Mohd Shuhidan Muhammad, Nur Amalina Ahmad, Asnul Hadi Muduli, Kamalakanta Univ Malaysia Perlis Fac Mech Engn & Technol Arau 02600 Perlis Malaysia Univ Malaysia Perlis Ctr Excellence Geopolymer & Green Technol Geopolymer & Green Technol Arau Malaysia Univ Sains Malaysia Adv Med & Dent Inst Dent Stimulat & Virtual Learning Res Excellence Consortium Kepala Batas Malaysia Univ Sains Malaysia Sch Mech Engn Engn Campus Nibong Tebal Malaysia Univ Malaysia Pahang Al Sultan Abdullah Fac Mech & Automot Engn Technol Pekan Malaysia Papua New Guinea Univ Technol Mech Engn Dept Lae Papua N Guinea

Fused deposition modeling (FDM) is emerging as a promising technique for manufacturing bioresorbable stents (BRS), particularly for coronary artery disease treatment. Polycaprolactone (PCL) has emerged as a favored material due to its biocompatibility, controlled degradation rate and mechanical properties. This review provides a comprehensive analysis of the effects of key FDM printing parameters on the quality aspects of PCL-based BRS, focusing on morphological, mechanical and biological characteristics. This review also highlights inconsistencies in previous studies, particularly in the impact of these parameters on stent dimensions and mechanical properties, emphasizing the need for standardization in experimental methodologies. Additionally, the current gaps in research related to the mechanical and biological performances of PCL-based BRS are discussed, with a call for further studies on long-term effects. This review aims to guide future research by offering insights into optimizing FDM parameters for improving the overall performance and clinical outcomes of PCL-based BRS.

关键词： Fused deposition modeling polycaprolactone bioresorbable stents 3D printing printing parameters

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Effects of printing parameters on the properties of 316L stainless steel fabricated by fused filament fabrication

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RAPID PROTOTYPING JOURNAL 2025年第5期31卷 968-980页

作者： Chen, Run Zhao, Qixin Wang, Sisi Hu, Zhonglue Dong, Weiping Li, Xiping Shiju, E. Wang, Linlin Zhejiang Normal Univ Jinhua Peoples R China Zhejiang Normal Univ Coll Engn Jinhua Peoples R China

PurposeThis study aims to explore the impact of printing parameters, specifically raster angle and layer thickness, on the microstructure and mechanical properties of green and sintered parts produced through filament-based fused filament fabrication (FFF) using a self-developed filament. The goal is to improve the quality and performance of the final sintered ***/methodology/approachA filament containing 92 Wt.% 316L stainless steel with polyoxymethylene (POM)-based binder was formulated and evaluated for flexibility through a buckling resistance test. Green parts were printed with varying raster angles (+45 degrees/-45 degrees, 0 degrees/90 degrees) and layer thicknesses (0.2 mm, 0.3 mm), followed by catalytic debinding and high-temperature sintering. Microstructure, dimensional accuracy and mechanical properties, including microhardness, tensile strength and elongation at break, were analyzed to identify optimal *** raster angle of (+45 degrees/-45 degrees) produced denser interlayer bonding and a more compact green part structure, whereas a thicker layer (0.3 mm) resulted in a looser structure with larger pores. The optimal combination of +45 degrees/-45 degrees raster angle and 0.2 mm layer thickness achieved the highest relative density (99.37%) and superior mechanical properties: microhardness (216.83 HV), tensile strength (467.59 MPa) and elongation at break (16.81%).Originality/valueA 92 Wt.% 316L stainless-steel filament for FFF was independently developed and near dense steel components were successfully fabricated. This study provides new insight into developing a novel formula of filament and optimizing printing parameters for FFF technology.

关键词： 316L stainless steel Fused filament fabrication Buckling resistance test method printing parameters

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Binder jet 3D printing of 316L stainless steel: A Taguchi analysis of the dependence of density and mechanical properties on the printing parameters

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JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T 2025年 34卷 337-347页

作者： Zago, M. Segata, G. Perina, M. Molinari, A. Univ Trento Dept Ind Engn Via Sommar 9 I-38123 Trento Italy Mimest S r l Via Lavoro 30 I-38063 Avio Italy

Most of the research on Binder Jetting 3D printing of AISI316L stainless steel has focused on optimizing the sintering cycle, with less emphasis on the effect of printing parameters on the properties in the sintered state. This study aims to investigate the influence of printing parameters on density, mechanical properties in both the green and sintered states. A Taguchi model was employed to experimentally study four parameters (printhead speed, dark body, powder applicator speed, and shell thickness) at three levels using an L9 orthogonal array. The results showed that green density ranged from 51.3% f 0.9%-57.0% f 0.9%, while a sintered density of 98.6% f 0.08% was achieved. Mechanical testing revealed green strengths between 1.8 f 0.1 MPa and 6.1 f 0.8 MPa, while tensile tests provided yield strength of 175.1 f 3.5 MPa, ultimate tensile strength (UTS) of 532 f 9.7 MPa, and elongation at break of 87.7% f 7.5%. ANOVA analysis indicated a statistically significant effect of the dark body (binder saturation) on density and mechanical properties. In the green state, increasing binder saturation enhances green density and bending strength. However, in the sintered state, higher binder saturation results in lower densification and UTS. Powder applicator speed also demonstrated statistical relevance for green density, where lower speeds produced higher density. Conversely, shell thickness and printhead speed had negligible effects on the properties investigated. These findings highlight the most significant printing parameters and their impact of target properties. Additionally, linear models were developed as a tool for optimizing printing parameters based on the desire density and mechanical outcomes.

关键词： BinderJet 3D printing Stainless steel printing parameters Taguchi analysis

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Short carbon fiber-reinforced PLA composites: influence of 3D-printing parameters on the mechanical and structural properties

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IRANIAN POLYMER JOURNAL 2024年第8期33卷 1065-1074页

作者： Alkabbanie, Rasha Aktas, Bulent Demircan, Gokhan Yalcin, Serife Harran Univ Engn Fac Dept Mech Engn Sanliurfa Turkiye Harran Univ Arts & Sci Fac Dept Phys Sanliurfa Turkiye

3D printing, particularly "fused filament fabrication" (FFF), plays a crucial role in Industry 4. FFF is widely used for creating complex structures and multi-material parts across various industries such as food industry, fashion industry, and manufacturing sectors. The properties of FFF-produced objects are remarkably affected by printing parameters. This study explores the impact of printing parameters and the addition of short carbon fibers on the strength of polylactic acid (PLA) printed samples. The lowering layer height, increasing feed rate and extrusion temperature boost impact strength, while a smaller raster angle enhances it. Meanwhile, an improved flexural strength is achieved by adjusting layer height, extrusion temperature, and raster angle. Higher extrusion temperatures enhance tensile strength, microstructure, and reduce porosity. Lower layer height improves flexural and impact strength (28.05% increase in 0.1 mm layer height), higher feed rate boosts strengths (12.56% improvement in 7 mm3/s feed rate), and elevated extrusion temperatures enhance impact strength (14.49% increase in 230 degrees C extrusion temperature) but reduce flexural strength (14.44% decrease). Incorporating carbon fibers in PLA negatively affects the microstructure but increases crystallinity, raising the melting temperature and lowering cold-crystallization temperature. The introduction of carbon fibers into PLA results in a complex interplay of mechanical and thermal properties.

关键词： Carbon fiber PLA composite printing parameters Mechanical properties Thermal properties

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Additive manufacturing of oriented chopped carbon fiber reinforced mullite refractory via extrusion-based technique- Effects of slurry rheological behavior and 3D printing parameters

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CERAMICS INTERNATIONAL 2024年第24期50卷 55964-55971页

作者： Li, Saisai Xia, Jin Xin, Jiaxuan Cheng, Can Chen, Ruoyu Anhui Univ Technol Key Lab Met Emission Reduct & Resources Recycling Minist Educ Maanshan 243002 Anhui Peoples R China Anhui Univ Technol Adv Ceram Res Ctr Sch Mat Sci & Engn Maanshan 243002 Anhui Peoples R China Anhui Univ Technol Sch Met Engn Maanshan 243002 Anhui Peoples R China Nanjing Tech Univ Coll Elect Engn & Control Sci Nanjing 211816 Jiangsu Peoples R China Missouri Univ Sci & Technol Dept Mat Sci & Engn Rolla MO 65409 USA

This study investigated the fabrication of oriented chopped carbon fiber-reinforced mullite-based refractory using extrusion-based 3D printing technology. Dispersants were incorporated into the printing paste to optimize its rheological properties. The effects of carbon fiber content on paste rheology and castable flowability were also evaluated. At dispersant and carbon fiber contents of 0.2 wt% and 0.3 wt%, respectively, the paste exhibited pronounced shear thinning behavior and notable structural recovery, significantly enhancing its printability. Furthermore, precise adjustments in air pressure and layer height, along with an analysis of shear rate distribution during printing, contributed to improved structural accuracy of the printed bodies. Post-printing, the chopped carbon fibers were oriented in the mullite matrix. Following sintering, the flexural strength of the 3Dprinted specimens increased from 6.1 MPa to 6.7 MPa, with concurrent improvements in fracture toughness compared to carbon fiber-reinforced mullite refractory specimens produced by casting.

关键词： Additive manufacturing Oriented chopped carbon fiber-reinforced mullite refractory Rheology printing parameters Fracture energy

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Influences of printing parameters on mechanical properties of recycled PET and PETG using fused granular fabrication technique

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POLYMER TESTING 2024年 132卷

作者： Nguyen, Phan Quoc Khang Panta, Jojibabu Famakinwa, Tosin Yang, Richard (Chunhui) Ahmed, Aziz Stapleton, Michael Sassaman, Doug Snabes, Samantha Craff, Charlotte Western Sydney Univ Ctr Adv Mfg Technol Sch Engn Design & Built Environm Sydney NSW 2751 Australia Univ Wollongong Sch Civil Min Environm & Architectural Engn Wollongong NSW 25000 Australia Re 3D Inc 1100 Hercules Ave 220 Houston TX 77058 USA

This research presents an investigation of the feasibility of recycled polyethylene terephthalate (rPET) and glycol-modified polyethylene terephthalate (rPETG) thermoplastics using the fused granular fabrication (FGF) 3D printing technique. It focuses on the effects of FGF printing parameters on the mechanical properties of rPET and rPETG printed parts using a Gigabot X 3D printer. The design of experiments (DOE) was first performed considering the main FGF 3D printing parameters such as layer thickness, infill density and number of contours. The experimental studies were then carried out to study the effects of printing parameters on the tensile properties based on the DOE. The effect of interlayer bonding of printed parts on the tensile properties was also evaluated using finite element-based multiscale modelling. Scanning electron microscopy (SEM) and Fourier transformation infrared (FTIR) spectroscopy were used to observe the fracture morphology and chemical structure of post-FGF printing products. The tensile test results indicate that the highest tensile strength of 26.4 MPa was obtained for rPET when using a 1.1-mm layer thickness, a 70% infill density, and 3 contours, whereas, for rPETG, the maximum tensile strength of 44.8 MPa was attained with a 1.2-mm layer thickness, a 100% infill density, and 2 contours. FTIR analysis confirms no significant changes of characteristic peaks for PET in the printed products, suggesting that rPET and rPETG are viable materials for FGF printing. Thermal stability studies also reveal that the glass transition temperature and onset degradation temperatures are not significantly affected by the printing parameters. The study demonstrates the potential of rPET and rPETG as sustainable alternatives to virgin materials and provides insights into the optimal processing conditions for achieving highquality 3D printed parts via the FGF technique.

关键词： Fused granular fabrication (FGF) printing parameters Numerical analysis Recycled polyethylene terephthalate glycol modified (rPETG) Tensile properties 3D-printing

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