A review on composite materials and process parameters optimisation for the fused deposition modelling process

Fused deposition modelling is the most significant technique in additive manufacturing (AM) that refers to the process where successive layers of material are deposited in a computer-controlled environment to create a three-dimensional object. The main limitations of using fused deposition modelling (FDM) process in the industrial applications are the narrow range of available materials and parts fabricated by FDM are used only as demonstration or conceptual parts rather than as functional parts. Recently, researchers have studied many ways in order to increase the range of materials available for the FDM process which resulted in the increase in the scope of FDM in various manufacturing sectors. Most of the research are focussed on the composite materials such as metal matrix composites, ceramic composites, natural fibre-reinforced composites and polymer matrix composites. This article intends to review the research carried out so far in developing samples using different composite materials and optimising their process parameters for FDM in order to improve different mechanical properties and other desired properties of the FDM components.     

Investigating the shape memory properties of 4D printed polylactic acid (PLA) and the concept of 4D printing onto nylon fabrics for the creation of smart textiles

3D printing is an ever growing industry that provides many benefits to the advanced manufacturing and design industry. However, parts tend to be static, rigid, and lack multi-purpose use. Recently, a new technology has emerged that uses 3D printing to print parts with the ability to change shape over time when exposed to different external stimuli. This new technology has been called 4D printing. Creation of a new material that is capable of changing shape when exposed to different stimuli and possess the ability to be 3D printed can be a difficult and a long process. Due to this strenuous process, the potential of a common fused deposition modelling material, poly(lactic) acid (PLA), for use in 4D printing is investigated and the concept of combining PLA with nylon fabric for the creation of smart textiles is explored. PLA possesses thermal shape memory behaviour and maintains these abilities when combined with nylon fabric that can be thermomechanically trained into temporary shapes and return to their permanent shapes when heated.     

Design and development of a customised knee positioning orthosis using low cost 3D printers

Off-the-shelf orthoses used in rehabilitation medicine present challenges in the lack of individual comfort offered and in the support of the different motor conditions of the affected individuals. Although custom-made orthoses address these issues, their current fabrication method consists of a laborious and material wasteful process performed by skilled orthotists. Combining 3D scanning, 3D modelling and 3D printing, this paper proposes and assesses a method for the fabrication of custom-made products for rehabilitation medicine. In collaboration with CMRA, a Hospital dedicated to rehabilitation, the method is applied to the design of a customised knee positioning orthosis for a patient with cerebral palsy. This project is exploratory on the capabilities of the use of 3D printing in patient specific customisation of orthoses. Having developed, prototyped and tested four different concepts with the patient, from which one was successfully accepted, it is possible to demonstrate the potential of industrialisation of these technologies.     

Numerical study of the interfaces of 3D‐printed concrete using discrete element method

3D concrete printing is an additive manufacturing method which reduces the time and improves the efficiency of the construction process. Structural behavior of printed elements is strongly influenced by the properties of the material and the interface surfaces. The printing process creates interface surfaces between layers in the horizontal and vertical directions. The bond strength between layers is the most critical property of printed elements. In this paper, the structural behavior of printed elements is studied using the discrete element method. The material is modelled using discrete particles with bonding between them. A new discrete model of a multilayer geometry is presented to study the behavior of the interfaces of printed concrete. The layers are made up of randomly placed particles to simulate the heterogeneous nature of concrete. The numerical model is developed to simulate the flexural behavior of multilayer specimens. A four‐point flexural test is simulated considering the interface surfaces between layers. This numerical model provides relevant results to improve the behavior of this kind of structural elements. The aim of this work is to provide a discrete element model to predict the mechanical behavior of 3D concrete printed components.