Structure and Properties of Additive Manufactured Polymer Components ()

Cover
Structure and Properties
of Additive Manufactured
Polymer Components
Copyright
Contributors
Foreword
Preface
Part 1: Introduction
Additive manufacturing technologies for polymer composites: State-of-the-art and future trends
	Chapter Outline
	1 - Additive manufacturing
	2 - Engineering and manufacturing process
		2.1 - Engineering process
		2.2 - AM technologies
		2.3 - Extrusion technologies
		2.4 - Laser technologies
		2.5 - Flash technologies
		2.6 - Jet technologies
	3 - 3D printing of polymer composites
		3.1 - Material extrusion composites
		3.2 - Vat photopolymerization composites
	4 - Future trends
	5 - Conclusions
	References
Development of new nanocomposites for 3D printing applications
	Abstract
	Keywords
	Chapter Outline
	Nomenclature
	1 - Introduction
	2 - Nanocomposites
	3 - Additive manufacturing and nanocomposites
		3.1 - Materials extrusion
			3.1.1 - Fused filament fabrication
				3.1.1.1 - Graphene
				3.1.1.2 - Nanoclay and silica
				3.1.1.3 - Carbon nanotubes
				3.1.1.4 - Carbon nanofibers
				3.1.1.5 - Nanocellulose
				3.1.1.6 - Carbon black (CB)
				3.1.1.7 - Metals and metal-oxides
				3.1.1.8 - Liquid deposition modeling
		3.2 - Materials powder bed fusion
			3.2.1 - Selective laser sintering
		3.3 - Vat photopolymerization
			3.3.1 - Stereolithography
		3.4 - Sheet lamination
	4 - Conclusion and future outlook
	References
Part 2: Frequently Used Additive Manufacturing Process Categories
Section 2.1: General Aspects
Effect of 3D printing
conditions on the microand
macrostructure and
properties of high-performance
thermoplastic composites
	Abstract
	Keywords
	Chapter Outline
	1 - Introduction
	2 - Influence of constituent materials on the formation of microstructure
		2.1 - Formation of the interfacial region during materials extrusion additive manufacturing and the resultant microstructur...
		2.2 - Effect of inclusion phase
	3 - Influence of processing parameters
		3.1 - Influence of feedstock material and conditioning parameters
		3.2 - Influence of melt processing parameters
		3.3 - Influence of extrusion parameters
		3.4 - Influence of deposition parameters
		3.5 - Influence of post-treatment
	4 - Conclusion
	Acknowledgments
	References
Additive manufacturing/3D printing of polymer nanocomposites: structure-related multifunctional properties
	Abstract
	Keywords
	Chapter Outline
	1 - Introduction
	2 - 3D printing of standard polymers
		2.1 - Overview of 3D printing processes and associate materials
		2.2 - Materials descriptions
		2.3 - Process-based methods to improve properties
		2.4 - Concluding remarks
	3 - Continuous fiber composite 3D printing
		3.1 - Overview of 3D printing of continuous fiber composite materials
	4 - Nanocomposite 3D printing
		4.1 - Why use polymer nanocomposites?
		4.2 - 3D printing of low loading graphene-polymer nanocomposites employing FFF 3D printing
	5 - Ceramic nanocomposite 3D printing
	References
Numerical simulation of additive manufacturing of polymers and polymer-based composites
	Chapter Outline
	1 - Introduction
	2 - From CAD to FEA
		2.1 - General workflow
		2.2 - FFF applications
		2.3 - SLS applications
	3 - Thermomechanical modeling of AM processes
		3.1 - Thermal problem
			3.1.1 - Heat equation
			3.1.2 - SLS boundary and initial conditions
			3.1.3 - FFF boundary and initial conditions
			3.1.4 - SLS heat source model
		3.2 - Mechanical problem
		3.3 - Material modeling
			3.3.1 - Mass density in SLS
			3.3.2 - Thermal conductivity in SLS
			3.3.3 - Specific heat capacity and latent heat
			3.3.4 - Linear thermo-elasticity
			3.3.5 - Thermo(linear)viscoelasticity
			3.3.6 - Plastic and viscoplastic deformation
			3.3.7 - Reinforced polymers
			3.3.8 - Crystallization kinetics
	4 - Numerical simulation of solid parts
		4.1 - Mechanical behavior of printed materials and structures
		4.2 - Multiscale ICME of printed parts
		4.3 - Microscale material modeling
		4.4 - Mesoscale material modeling
		4.5 - Macroscale structural modeling
		4.6 - Linking with process simulation
		4.7 - Applications
	5 - Conclusions
	References
Section 2.2: Powder Bed Fusion (in particular: Selective Laser Sintering (SLS))
Powder quality and electrical conductivity of selective laser sintered polymer composite components
	Chapter Outline
	1 - Introduction
	2 - Powder quality and fundamentals for selective laser sintering
		2.1 - The intrinsic properties of SLS polymer powders
			2.1.1 - Thermodynamic properties of polymers
			2.1.2 - Rheological properties of polymers
			2.1.3 - Optical properties of polymer
		2.2 - Extrinsic properties
			2.2.1 - Particle size and shape
			2.2.2 - Flowability and packing efficiency of powder
	3 - Electric conductive composite powder for SLS
		3.1 - Segregated networks of conductive fillers
		3.2 - Effect of composite powders preparation methods
			3.2.1 - Melt mixing
			3.2.2 - Solution mixing
			3.2.3 - Mechanical mixing
			3.2.4 - Liquid phase absorption and deposition
		3.3 - Effect of conductive fillers type
		3.4 - Effect of polymer matrix type
	4 - Conclusion and perspectives
	Acknowledgments
	References
Section 2.3: Material Extrusion (in particular: Fused Filament Fabrication (FFF))
Section 2.3.1: Particulate and Short Fiber Reinforced Polymer Composites
Extrusion deposition additive manufacturing with fiber-reinforced thermoplastic polymers
	1 - Introduction
	2 - Heat transfer in extrusion deposition additive manufacturing
		2.1 - Heat transfer mechanisms in EDAM
		2.2 - Prediction of temperature evolution in EDAM
	3 - Melting and crystallization
		3.1 - Evolution of the degree of crystallinity
	4 - Layer adhesion
		4.1 - Interlayer fusion bonding in extrusion deposition additive manufacturing
		4.2 - Fusion bonding of fiber-reinforced semicrystalline polymers
		4.3 - Interdiffusion of polymer chains
		4.4 - Degree of bonding developed during the EDAM process
	5 - Thermoviscoelasticity in the EDAM process
		5.1 - Modeling
		5.2 - Material characterization
	6 - Shrinkage and shape change
		6.1 - Shape change
	7 - Simulation framework
	8 - ADDITIVE3D—simulation framework for EDAM
	References
Quality of polymeric tribocompound powders and its influence on microstructure and mechanical/tribologica...
	Chapter Outline
	1 - Introduction
		1.1 - Structure and mechanical/tribological properties of extrudable UHMWPE-based polymer composites
	2 - Materials and experimental methods
	3 - Results and discussion
	4 - Computer-aided design of extrudable UHMWPE-based polymer composites with prescribed antifriction and mechanical behavior
	5 - Comparison of the structure, tribological, and mechanical properties of extrudable UHMWPE-based polymer composites fabr...
	6 - Conclusions
	References
Effect of filament quality, structure, and processing parameters on the properties of fused filament fabr...
	Chapter Outline
	1 - Introduction
		1.1 - General aspects and importance of structure—property relationships of additive manufactured parts
		1.2 - State of the art of processing–structure–property relationships of AM polymer and polymer composite components
			1.2.1 - FFF processing studies
			1.2.2 - Mechanical properties of fiber-reinforced printed materials
			1.2.3 - Tribological behavior of printed materials
		1.3 - Objectives of present contribution
	2 - AM method used
		2.1 - Principle of FFF process
		2.2 - Operating conditions of FFF device
	3 - Materials investigated
		3.1 - Types of polymers and composites used
		3.2 - Quality of the filaments
			3.2.1 - Variation in filament diameter
			3.2.2 - Cross-section analysis
			3.2.3 - Density of filaments
			3.2.4 - Fiber content and fiber length distribution
			3.2.5 - Porosity of the filaments
			3.2.6 - Surface quality of the filaments
		3.3 - Geometry of test samples
	4 - Processing parameters and related microstructures of FFF samples produced
		4.1 - Basic production parameters for printed samples
		4.2 - Microstructural details of selected PETG and PA samples
			4.2.1 - Filament orientation within the printed bending specimens
			4.2.2 - Effect of layer thickness on the structure of SENB samples
			4.2.3 - Density of printed BEND samples
			4.2.4 - Humidity
			4.2.5 - Surfaces of printed tribo-specimens
		4.3 - Structural details of iglidur J260
			4.3.1 - Density values of printed versus injection molded bending and bushing samples
			4.3.2 - Porosities of the iglidur J260 samples (printing vs. injection molded)
		4.4 - Overview of the determined microstructural details of selected PETG and PA samples and of iglidur J260
	5 - Mechanical properties of FFF samples
		5.1 - PETG and CF-PETG
		5.2 - PA6, PA12, and their carbon fiber-reinforced composites
		5.3 - Comparison of characteristic values for the PETG and PA-based specimens
		5.4 - Mechanical properties of iglidur J260 material and comparison
	6 - Tribological behavior of FFF samples
		6.1 - Samples and testing
		6.2 - Results achieved with PETG- and PA-based tribomaterials
			6.2.1 - Wear rates
			6.2.2 - Wear mechanisms
		6.3 - Results achieved with iglidur J260 and comparison between the different materials
	7 - General consequences for improvements
		7.1 - Mechanical properties
		7.2 - Tribological properties
	Acknowledgments
	References
Influence of printing parameters and filament quality on structure and properties of polymer composite co...
	Abstract
	Keywords
	Chapter Outline
	1 - Introduction
	2 - Enhancement of mechanical properties of FDM parts
		2.1 - A novel fused deposition modeling process with an auxiliary heating device
			2.1.1 - Effect of auxiliary heating temperatures and raster angles on tensile properties of FDM parts
			2.1.2 - Microstructures of FDM specimens printed with the auxiliary heating device
			2.2 - Physical modification of printing materials
	3 - Dimensional accuracy of FDM parts prepared by polymer composites
	4 - Requirements of polymer composite materials for FDM technique
	5 - Conclusions
	Acknowledgments
	References
Section 2.3.2: Continuous Fiber Reinforced Polymer Composites
Printing of three-dimensional polymer composite structures with continuous fiber reinforcement
	Chapter Outline
	1 - Introduction and motivation
	2 - 3D-printing processes for the processing of fiber-reinforced thermoplastic composites
	3 - Integration of continuous reinforcing fibers in extrusion based 3D printing processes
	4 - Orienting continuous reinforcing fibers with extrusion based 3D printing processes
	5 - Semifinished continuous fiber-reinforced polymer products for extrusion based 3D printing processes
	6 - Equipment for extrusion based 3D-printing of continuous fiber-reinforced polymers
	7 - Extrusion based 3D printing processes for continuous fiber-reinforced polymer composites
	8 - Evaluation of process potential and outlook
	References
On structure-mechanical and tribological property relationships of additive manufactured continuous carbo...
	1 - Introduction
		1.1 - Fused filament fabrication
		1.2 - Mechanical properties of printed composites
		1.3 - Tribological properties of printed composites
	2 - Raw materials
	3 - Microstructural characterization of 3D printed materials
		3.1 - Microstructure of 3D printed thin layer
		3.2 - Quantification of void content in 3D printed CF/PA6 composites
		3.3 - Formation of voids within 3D printed CF/PA6 composites
	4 - Characterization of mechanical performance
		4.1 - Tensile properties of 3D printed PA6 and SCFRPA6
		4.2 - Tensile, flexural, and fracture properties of 3D printed CF/PA6 composites
		4.3 - Effects of voids on the mechanical performance of CF/PA6 composites
	5 - Tribological properties of 3D printed CF/PA6 composites
		5.1 - Wear testing
		5.2 - Effect of printing orientations
		5.3 - Effects of fiber orientation
	6 - Concluding remarks
	References
Section 2.4: Material Jetting (in particular: Droplet Ink Writing (DIW))
Direct ink writing of polymers and their composites, and related applications
	Chapter Outline
	1 - Introduction
	2 - Polymer inks for direct writing and applications
		2.1 - Conductive polymers and composites for electronics
			2.2 - Biocompatible polymers and composites for biomedicines
			2.3 - Photosensitive polymers for UV-assisted DIW 3D printing
	3 - Conclusions and perspectives
	References
Material aspects during additive manufacturing of nano-cellulose composites
	Chapter Outline
	1 - Introduction
	2 - Selection of bioink for 3D printing
	3 - Properties of cellulose
	4 - Cellulose for 3D printing
		4.1 - Cellulose as ink for additive manufacturing
		4.2 - Cellulose as matrix for 3D printing
	5 - Cellulose-synthetic polymer composites
	6 - Cellulose-biodegradable polymer composites
	7 - Cellulose/natural polymer composites
	8 - Bioprinting
	9 - 4D printing
	10 - Conclusion
	References
Index
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