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Additive manufacturing (AM) is growing economically because of its cost-effective design flexibility. However, it faces challenges such as interlaminar weaknesses and reduced strength because of product anisotropy. Therefore, the purpose of this study is to develop a methodology that integrates design for additive manufacturing (AM) principles with fused filament fabrication (FFF) to address these challenges, thereby enhancing product reliability and strength.

Developed through case analysis and literature review, this methodology focuses on design methodology for AM (DFAM) principles applied to FFF for high mechanical performance applications. A DFAM database is constructed to identify common requirements and establish design rules, validated through a case study.

Existing DFAM approaches often lack failure theory integration, especially in FFF, emphasizing mechanical characterizations over predictive failure analysis in functional parts. This methodology addresses this gap by enhancing product reliability through failure prediction in high-performance FFF applications.

While some DFAM methods exist for high-performance FFF, they are often specific cases. Existing DFAM methodologies typically apply broadly across AM processes without a specific focus on failure theories in functional parts. This methodology integrates FFF with a failure theory approach to strengthen product reliability in high-performance applications.

The purpose of this study is to examine how well reinforced concrete structures can be shielded against concrete carbonation using anti-carbonation coatings based on synthetic polymer.

Applying free radical polymerization, an acrylate terpolymer emulsion that a surfactant had stabilized was created. A thermogravimetric analysis, minimum film-forming temperature, Fourier transform infrared spectroscopy and particle size distribution are used to characterize the prepared eco-friendly water base acrylate terpolymer emulsion. Using three different percentages of the acrylate terpolymer emulsion produced, 35%, 45% and 55%, the anti-carbonation coating was formed. Tensile strength, tensile strain, elongation, crack-bridging ability, carbon dioxide permeability, chloride ion diffusion, average pull-off adhesion strength, water vapor transmission, gloss, wet scrub resistance, QUV/weathering and storage stability are the characteristics of the anti-carbonation coating.

The formulated acrylate terpolymer emulsion enhances anti-carbonation coating performance in CO₂ permeability, Cl-diffusion, crack bridging, pull-off adhesion strength and water vapor transmission. The formed coating based on the formulated acrylate terpolymer emulsion performed better than its commercial counterpart.

To protect the steel embedded in concrete from corrosion and increase the life span of concrete, the surface of cement is treated with an anti-carbonation coating based on synthetic acrylate terpolymer emulsion.

In addition to saving lives from building collapse, it maintains the infrastructure for the long run.

The anti-carbonation coating, which is based on the synthetic acrylate terpolymer emulsion, is environmentally benign and stops the entry of carbon dioxide and chlorides, which are the main causes of steel corrosion in concrete.

To improve the thermal performance of base fluid, nanoparticles of three types are dispersed in the base fluid. A novel theory of non-Fourier heat transfer is used for design and development of models. The thermal performance of sample fluids is compared to determine which types of combination of nanoparticles are the best for an optimized enhancement in thermal performance of fluids. This article aims to: (i) investigate the impact of nanoparticles on thermal performance; and (ii) implement the Galerkin finite element method (GFEM) to thermal problems.

The mathematical models are developed using novel non-Fourier heat flux theory, conservation laws of computational fluid dynamics (CFD) and no-slip thermal boundary conditions. The models are approximated using thermal boundary layer approximations, and transformed models are solved numerically using GFEM. A grid-sensitivity test is performed. The accuracy, correction and stability of solutions is ensured. The numerical method adopted for the calculations is validated with published data. Quantities of engineering interest, i.e. wall shear stress, wall mass flow rate and wall heat flux, are calculated and examined versus emerging rheological parameters and thermal relaxation time.

The thermal relaxation time measures the ability of a fluid to restore its original thermal state, called thermal equilibrium and therefore, simulations have shown that the thermal relaxation time associated with a mono nanofluid has the most substantial effect on the temperature of fluid, whereas a ternary nanofluid has the smallest thermal relaxation time. A ternary nanofluid has a wider thermal boundary thickness in comparison with base and di- and mono nanofluids. The wall heat flux (in the case of the ternary nanofluids) has the most significant value compared with the wall shear stresses for the mono and hybrid nanofluids. The wall heat and mass fluxes have the highest values for the case of non-Fourier heat and mass diffusion compared to the case of Fourier heat and mass transfer.

An extensive literature review reveals that no study has considered thermal and concentration memory effects on transport mechanisms in fluids of cross-rheological liquid using novel theory of heat and mass [presented by Cattaneo (Cattaneo, 1958) and Christov (Christov, 2009)] so far. Moreover, the finite element method for coupled and nonlinear CFD problems has not been implemented so far. To the best of the authors’ knowledge for the first time, the dynamics of wall heat flow rate and mass flow rate under simultaneous effects of thermal and solute relaxation times, Ohmic dissipation and first-order chemical reactions are studied.

This study aims to comprehensively investigate the mixed-mode fracture behavior and mechanical properties of selective laser sintering (SLS) polyamide 12 (PA12) components, considering different build orientations and layer thicknesses. The primary objectives include the following. Conducting mixed-mode fracture and mechanical analyses on SLS PA12 parts. Investigating the influence of build orientation and layer thickness on the mechanical properties of SLS-printed components. Examining the fracture mechanisms of SLS-produced Arcan fracture and tensile specimens through experimental methods and finite element analyses.

The research used a combination of experimental techniques and numerical analyses. Tensile and Arcan fracture specimens were fabricated using the SLS process with varying build orientations (X, X–Y, Z) and layer thicknesses (0.1 mm, 0.2 mm). Mechanical properties, including tensile strength, modulus of elasticity and critical stress intensity factor, were quantified through experimental testing. Mixed-mode fracture tests were conducted using a specialized fixture, and finite element analyses using the J-integral method were performed to calculate fracture toughness. Scanning electron microscopy (SEM) was used for detailed morphological analysis of fractured surfaces.

The investigation revealed that the highest tensile properties were achieved in samples fabricated horizontally in the X orientation with a layer thickness of 0.1 mm. Additionally, parts manufactured with a layer thickness of 0.2 mm exhibited favorable mixed-mode fracture behavior. The results emphasize the significance of build orientation and layer thickness in influencing mechanical properties and fracture behavior. SEM analysis provided valuable insights into the failure mechanisms of SLS-produced PA12 components.

This study contributes to the field of additive manufacturing by providing a comprehensive analysis of the mixed-mode fracture behavior and mechanical properties of SLS-produced PA12 components. The investigation offers novel insights into the influence of build orientation and layer thickness on the performance of such components. The combination of experimental testing, numerical analyses and SEM morphological observations enhances the understanding of fracture behavior in additive manufacturing processes. The findings contribute to optimizing the design and manufacturing of high-quality PA12 components using SLS technology.

In this study, response surface methodology (RSM) is applied to a three-point bending stiffness analysis of low-cost material (PLA) specimens printed using FDM technology to analyze the performance of different internal lattice structures (Octet and IsoTruss principally). The purpose of this study is to extend the definition from a discrete (lattice) model to an analytical one for its use in subsequent design phases, capable of optimizing the type of cell to be used and its defining parameters to find the best stiffness-to-weight ratio.

The representative function of their mechanical behavior is extrapolated through a two-variable polynomial model based on the cell size and the thickness of the beam elements characterizing it. The polynomial is obtained thanks to several tests performed according to the scheme of RSM. An analysis on the estimation errors due to discontinuities in the physical specimens is also conducted. Physical tests applied to the specimens showed some divergences from the virtual (ideal) behavior of the specimens.

The study allowed to validate the RSM models proposed to predict the behavior of the system as the size, thickness and type of cells vary. Changes in stiffness and weight of specimens follow linear and quadratic models, respectively. This generally allows to find optimal design points where the stiffness-to-weight ratio is at its highest.

Although the literature provides numerous references to studies characterizing and parameterizing lattice structures, the industrial/practical applications concerning lattice structures are often still detached from theoretical research and limited to achieving functioning models rather than optimal ones. The approach here described is also aimed at overcoming this limitation. The software used for the design is nTop. Subsequent three-point bending tests have validated the reliability of the model derived from the method’s application.

Material extrusion-based additive manufacturing is a prominent manufacturing technique to fabricate complex geometrical three-dimensional (3D) parts. Despite the indisputable advantages of material extrusion-based technique, the poor surface and subsurface integrity hinder the industrial application of this technology. The purpose of this study is introducing the hot air jet treatment (HAJ) technique for surface treatment of additive manufactured parts.

In the presented research, novel theoretical formulation and finite element models are developed to study and model the polishing mechanism of printed parts surface through the HAJ technique. The model correlates reflow material volume, layer width and layer height. The reflow material volume is a function of treatment temperature, treatment velocity and HAJ velocity. The values of reflow material volume are obtained through the finite element modeling model due to the complexity of the interactions between thermal and mechanical phenomena. The theoretical model presumptions are validated through experiments, and the results show that the treatment parameters have a significant impact on the surface characteristics, hardness and dimensional variations of the treated surface.

The results demonstrate that the average value of error between the calculated theoretical results and experimental results is 14.3%. Meanwhile, the 3D plots of Ra and Rq revealed that the maximum values of Ra and Rq reduction percentages at 255°C, 270°C, 285°C and 300°C treatment temperatures are (35.9%, 33.9%), (77.6%,76.4%), (94%, 93.8%) and (85.1%, 84%), respectively. The scanning electron microscope results illustrate three different treatment zones and the treatment-induced and manufacturing-induced entrapped air relief phenomenon. The measured results of hardness variation percentages and dimensional deviation percentages at different regimes are (8.33%, 0.19%), (10.55%, 0.31%) and (−0.27%, 0.34%), respectively.

While some studies have investigated the effect of the HAJ process on the structural integrity of manufactured items, there is a dearth of research on the underlying treatment mechanism, the integrity of the treated surface and the subsurface characteristics of the treated surface.

This study aims to evaluate the potential of using the in-nozzle impregnation approach to reuse recycled PET (RPET) to develop continuous banana fiber (CBF) reinforced bio-composites. The mechanical properties and fracture morphology behavior are evaluated to establish the relationships between layer spacing–microstructural characteristics–mechanical properties of CBF/RPET composite.

This study uses RPET filament developed from post-consumer PET bottles and CBF extracted from agricultural waste banana sap. RPET serves as the matrix material, while CBF acts as the reinforcement. The test specimens were fabricated using a customized fused deposition modeling 3D printer. In this process, customized 3D printer heads were used, which have a unique capability to extrude and deposit print fibers consisting of a CBF core coated with an RPET matrix. The tensile and flexural samples were 3D printed at varying layer spacing.

The Young’s modulus (E), yield strength (sy) and ultimate tensile strength of the CBF/RPET sample fabricated with 0.7 mm layer spacing are 1.9 times, 1.25 times and 1.8 times greater than neat RPET, respectively. Similarly, the flexural test results showed that the flexural strength of the CBF/RPET sample fabricated at 0.6 mm layer spacing was 47.52 ± 2.00 MPa, which was far greater than the flexural strength of the neat RPET sample (25.12 ± 1.94 MPa).

This study holds significant social implications highlighting the growing environmental sustainability and plastic waste recycling concerns. The use of recycled PET material to develop 3D-printed sustainable structures may reduce resource consumption and encourages responsible production practices.

The key innovation lies in the concept of in-nozzle impregnation approach, where RPET is reinforced with CBF to develop a sustainable composite structure. CBF reinforcement has made RPET a superior, sustainable, environmentally friendly material that can reduce the reliance on virgin plastic material for 3D printing.

This study aims to present an experimental approach to develop a high-strength 3D-printed recycled polymer composite reinforced with continuous metal fiber.

The continuous metal fiber composite was 3D printed using recycled and virgin acrylonitrile butadiene styrene-blended filament (RABS-B) in the ratio of 60:40 and postused continuous brass wire (CBW). The 3D printing was done using an in-nozzle impregnation technique using an FFF printer installed with a self-modified nozzle. The tensile and single-edge notch bend (SENB) test samples are fabricated to evaluate the tensile and fracture toughness properties compared with VABS and RABS-B samples.

The tensile and SENB tests revealed that RABS-B/CBW composite 3D printed with 0.7 mm layer spacing exhibited a notable improvement in Young’s modulus, ultimate tensile strength, elongation at maximum load and fracture toughness by 51.47%, 18.67% and 107.3% and 22.75% compared to VABS, respectively.

This novel approach of integrating CBW with recycled thermoplastic represents a significant leap forward in material science, delivering superior strength and unlocking the potential for advanced, sustainable composites in demanding engineering fields.

Limited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.

The current study aims to develop a 3D-printed continuous metal fiber-reinforced recycled thermoplastic composite using an in-nozzle impregnation technique.

Recycled acrylonitrile butadiene styrene (RABS) plastic was blended with virgin ABS (VABS) plastic in a ratio of 60:40 weight proportion to develop a 3D printing filament that was used as a matrix material, while post-used continuous brass wire (CBW) was used as a reinforcement. 3D printing was done by using a self-customized print head to fabricate the flexural, compression and interlaminar shear stress (ILSS) test samples to evaluate the bending, compressive and ILSS properties of the build samples and compared with VABS and RABS-B samples. Moreover, the physical properties of the samples were also analyzed.

Upon three-point bend, compression and ILSS testing, it was found that RABS-B/CBW composite 3D printed with 0.7 mm layer width exhibited a notable improvement in maximum flexural load (L_max), flexural stress at maximum load (sf_max), flex modulus (E_f) and work of fracture (WOF), compression modulus (E_c) and ILSS properties by 30.5%, 49.6%, 88.4% 13.8, 21.6% and 30.3% respectively.

Limited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.

Polymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing the fabrication of gears without the aid of support structures and subsequent assembly. However, there are constraints in the process that negatively affect its adoption compared to other additive technologies such as material extrusion to produce gears. This study aims to demonstrate that it is possible to overcome the problems due to the physics of the process to produce accurate mechanism.

Technological aspects such as orientation, wheel-shaft thicknesses and degree of powder recycling were examined. Furthermore, the evolving tooth profile was considered as a design parameter to provide a manufacturability map of gear-based mechanisms.

Results show that there are some differences in the functioning of the gear depending on the type of powder used, 100% virgin or 50% virgin and 50% recycled for five cycles. The application of a groove on a gear produced with 100% virgin powder allows the mechanism to be easily unlocked regardless of the orientation and wheel-shaft thicknesses. The application of a specific evolutionary profile independent of the diameter of the reference circle on vertically oriented gears guarantees rotation continuity while preserving the functionality of the assembled mechanism.

In the literature, there are various studies on material aging and reuse in the PBF-LB/P process, mainly focused on the powder deterioration mechanism, powder fluidity, microstructure and mechanical properties of the parts and process parameters. This study, instead, was focused on the functioning of gears, which represent one of the applications in which this technology can have great success, by analyzing the two main effects that can compromise it: recycled powder and vertical orientation during construction.