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This paper aims to establish an appropriate annealing method, which is necessary for shape stability and to evaluate their potential degradation performance of 1-, 3- and 5-layer material extruded polylactic-acid specimens by enhancing their thermal and mechanical properties.

The distortion of each layered printed specimen subjected to degradation was calculated in x- and y-direction. Each layered specimen was subjected to annealing at 70°C, 80°C and 90°C for 2 h and at 80°C for 1, 4, 8 and 16 h. Thermal, molecular weight and mechanical properties were calculated using, differential scanning calorimetry, gel permeation chromatography and tensile testing machine, respectively.

In the x-direction, distortion was 16.08 mm for one-layer non-annealed printed specimens and decreased by 73% and 83% for 3- and 5-layer, respectively, while each layered non-annealed specimen subjected to degradation at 37°C for one month. Within the outlined study, annealing treatment enhances properties such as the degree of crystallinity (%χ) up to 34%, Young’s modulus (E) by 30% and ultimate tensile strength by 20% compared to the non-annealed specimens.

The future research accomplishments will be concentrated on the design, development and optimisation of degraded biomedical implants using material extrusion thin films including drug delivery system and fixation plates.

The printed thin specimens subjected to degradation were investigated. This research developed a new understanding of the effect of the annealing temperature and time on the mechanical, thermal and molecular weight properties for each layered specimen.

This paper aims to investigate the potential for 4D deformation of the smallest building blocks of the material extrusion additive manufacturing (MEAM) process: single extrudates produced with a single material. In contrast to previous 4D printing approaches where property-variations are realised across multiple layers or with complex composites, this study hypothesises that residual strain varies from top-to-bottom within a single printed extrudate and that this offers an opportunity to achieve controllable 4D printing with the smallest possible resolution (single lines in a single layer).

The influences of bed temperature, printing temperature, printing speed, extrusion width, extrusion thickness and activation temperature are quantified in terms of residual strain and 4D curvature.

An almost fourfold variation in curvature was achieved, printing speed and layer thickness greatly affected 4D deformation: the maximum curvature was increased by >600% compared to the minimum curvature when varying printing speed. In addition to rigorous parametric characterisation, a case study demonstrates the 4D deformation of a flat single-layer lattice into a 3D self-formed stent structure comprised of intricate single-extrudate struts. A separate case study demonstrates the resilience of the method by showing results to translate to alternative materials, with alternative printing hardware and with a different 4D activation procedure.

This study successfully proves a new way to achieve intricate 3D structures with the MEAM process, which would be impossible without 4D deformation due to their intricacy and the need for support material. The findings are also relevant to research into undesired warping due to the quantification of residual strain.

Extrusion width, the width of printed filaments, affects multiple critical aspects in mechanical properties in material extrusion additive manufacturing: filament geometry, interlayer load-bearing bonded area and fibre orientation for fibre-reinforced composites. However, this study aims to understand the effects of extrusion width on 3D printed composites, which has never been studied systematically.

Four polymers with and without short-fibre reinforcement were 3D printed into single-filament-wide specimens. Tensile properties, mechanical anisotropy and fracture mechanisms were evaluated along the direction of extruded filaments (F) and normal to the interlayer bond (Z). Extrusion width, nozzle temperature and layer height were studied separately via single-variable control. The extrusion width was controlled by adjusting polymer flow in the manufacturing procedure (gcode), where optimisation can be achieved with software/structure design as opposed to hardware.

Increasing extrusion width caused a transition from brittle to ductile fracture, and greatly reduced directional anisotropy for strength and ductility. For all short fibre composites, increasing width led to an increase in strain-at-break and decreased strength and stiffness in the F direction. In the Z direction, increasing width led to increased strength and strain-at-break, and stiffness decreased for less ductile materials but increased for more ductile materials.

The transformable fracture reveals the important role of extrusion width in processing-structure-property correlation. This study reveals a new direction for future research and industrial practice in controlling anisotropy in additive manufacturing. Increasing extrusion width may be the simplest way to reduce anisotropy while improving printing time and quality in additive manufacturing.

This study/paper aims to develop fundamental understanding of mechanical properties for multiple fibre-reinforced materials by using a single-filament-wide tensile-testing approach.

In this study, recently validated single-filament-wide tensile-testing specimens were used for four polymers with and without short-fibre reinforcement. Critically, this specimen construct facilitates filament orientation control, for representative longitudinal and transverse composite directions, and enables measurement of interlayer bonded area, which is impossible with “slicing” software but essential in effective property measurement. Tensile properties were studied along the direction of extruded filaments (F) and normal to the interlayer bond (Z) both experimentally and theoretically via the Kelly–Tyson model, bridging model and Halpin–Tsai model.

Even though the four matrix-material properties varied hugely (1,440% difference in ductility), consistent material-independent trends were identified when adding fibres: ductility reduced in both F- and Z-directions; stiffness and strength increased in F but decreased or remained similar in Z; Z:F strength anisotropy and stiffness anisotropy ratios increased. Z:F strain-at-break anisotropy ratio decreased; stiffness and strain-at-break anisotropy were most affected by changes to F properties, whereas strength anisotropy was most affected by changes to Z properties.

To the best of the authors’ knowledge, this is the first study to assess interlayer bond strength of composite materials based on measured interlayer bond areas, and consistent fibre-induced properties and anisotropy were found. The results demonstrate the critical influence of mesostructure and microstructure for three-dimensional printed composites. The authors encourage future studies to use specimens with a similar level of control to eliminate structural defects (inter-filament voids and non-uniform filament orientation).