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Additive manufacturing (AM) has transformed the production of complex parts, though high-performance composite filament development in this field is still limited. The primary objective of this study is the development of production setup of continuous fiber reinforced polymer (CFRP) composite filament for fused deposition modeling (FDM) applications. Despite their enhanced strength-to-weight ratio and mechanical properties, integrating CFRP composites into AM presents challenges like fiber alignment, breakage, interfacial adhesion, and process optimization. This study aims to address the above-mentioned challenges by developing a robust production setup for CFRP filament tailored for FDM. The design phase of the setup included gear driven CFRP winding system, extrusion system, heating system and pulling spool system. Upon the fabrication of the setup, CFRP was produced using PLA and glass fiber and the technique preserved the integrity and continuity of the reinforcement throughout the filament. Uniaxial tensile testing was performed to assess the mechanical performance of the produced filament. The experimental results demonstrated a significant improvement in tensile strength (146.75 MPa) and Young’s Modulus (4.95 GPa) at a fiber volume fraction of 2.8% for the composite filament and these values were in Line with the theoretical results. The tensile strength of the Continuous Glass Fiber-PLA showed an increase of 2.4 times while the young’s modulus yielded an increase of 1.35 times in comparison to the neat polymer. Scanning electron microscopy analysis of the fractured composite samples showed sufficient polymer impregnation and strong interfacial bonding. The energy dispersive X-ray spectroscopy was conducted confirming the polymer impregnation uniformity. The thermal characterization by differential scanning calorimetry and Thermogravimetric analysis validated the composite filament’s suitability for FDM printing. The outcomes of this study help to push forward the current advancements in AM using composite filament, paving the way for stronger, lightweight, and reliable printed structures. The insights gained are instrumental in expanding the application of composite AM in aerospace, automotive, and industrial sectors where high-performance materials are critical.

Currently, the emergence of a novel human coronavirus disease, named COVID-19, has become a great global public health concern causing severe respiratory tract infections in humans. Yet, there is no specific vaccine or treatment for this COVID-19 where anti-disease measures rely on preventing or slowing the transmission of infection from one person to another. In particularly, there is a growing effort to prevent or reduce transmission to frontline healthcare professionals. However, it is becoming an increasingly international concern respecting the shortage in the supply chain of critical single-use personal protective equipment (PPE). To that scope, we aim in the present work to provide a comprehensive overview of the latest 3D printing efforts against COVID-19, including professional additive manufacturing (AM) providers, makers and designers in the 3D printing community. Through this review paper, the response to several questions and inquiries regarding the following issues are addressed: technical factors connected with AM processes; recommendations for testing and characterizing medical devices that additively manufactured; AM materials that can be used for medical devices; biological concerns of final 3D printed medical parts, comprising biocompatibility, cleaning and sterility; and limitations of AM technology.

The dynamic mechanical behavior of 3D-printed CF-PEKK composites has been studied using the split Hopkinson pressure bar (SHPB). Three sets of samples with different infill densities (20, 50, and 100%) were impacted at different impact pressures (1.4, 1.7, 2.0, 2.4 bar) to characterize their dynamic behavior in terms of strain rate, stress, and strain performance. Moreover, the samples’ dynamic response and failure behavior are cross-referenced with each infill density sample's microstructural behavior and physical parameters, which can give an excellent dynamic response under different strain rate ranges. The results showed that dynamic stress and strain behavior are proportional to the infill density with a maximum dynamic stress of approximately 90 MPa with 100% infill density. In addition, the behavior of the transmitted wave during the dynamic impact showed that a sample with less infill density could attenuate/absorb dynamic impact. These results obtained under this impact pressure indicate the high precision and repeatability of the SHPB approach for the tested 3D composites under dynamic loading and prove that the striker bar velocity significantly impacts the amplitudes of different recorded waves to understand the behavior in detail. In addition, high-speed camera images also showed that the 3D-printed composite sample showed that using a higher infill density enhanced both the damage performance and the impact resistance of the three-dimensionally printed composites at each impact pressure because of the minimized intensity and the amount of final macro damage. This study is useful and helpful for design engineers to study the influence of the process parameter of infill on the dynamic behavior of printed composite materials and confirms the growing interest in 3D printing of composite materials to be employed in different engineering applications which are not limited to static or quasi-static loading circumstances but mainly include dynamic loading conditions.

Additive manufacturing (AM) has arisen as a transformative technology for manufacturing complex geometries with enhanced mechanical properties, particularly in the realm of continuous fiber-reinforced polymer composites (CFRPCs). Among various AM techniques, fused deposition modeling (FDM) stands out as a promising method for the fabrication of CFRPCs due to its versatility, ease of use, flexibility, and cost-effectiveness. Several research papers on the AM of CFRPs via FDM were summarized and therefore this review paper provides a critical examination of the process-printing parameters influencing the AM process, with a focus on their impact on mechanical properties. This review covers details of factors such as fiber orientation, layer thickness, nozzle diameter, fiber volume fraction, printing temperature, and infill design, extracted from the existing literature. Through a visual representation of the process parameters (printing and material) and properties (mechanical, physical, and thermal), this paper aims to separate out the optimal processing parameters that have been inferred from various research studies. Furthermore, this analysis critically evaluates the current state-of-the-art research, highlighting advancements, applications, filament production methods, challenges, and opportunities for further development in this field. In comparison to short fibers, continuous fiber filaments can render better strength; however, delamination issues persist. Various parameters affect the printing process differently, resulting in several limitations that need to be addressed. Signifying the relationship between printing parameters and mechanical properties is vital for optimizing CFRPC fabrication via FDM, enabling the realization of lightweight, high-strength components for various industrial applications.

Nowadays, COVID-19 also known as novel coronavirus has become a global pandemic by causing severe respiratory tract infections in humans without any definite treatment or vaccine. Therefore, disease control measures include slowing down or averting the transfer of this viral infection from person to person. Continuous efforts are carried out to avoid the transmission of this disease to frontline healthcare personnel using single-use personal protective equipment (PPE). However, a critical shortage in this equipment around the world is becoming an alarming concern. Therefore, it is vital to present a possible alternative to overcome the acute shortage of protective gear such as face masks against this infectious disease which can have universal accessibility and is easily available. Additive manufacturing (AM), also known as 3D printing, is a possible solution to overcome the shortage of protective gear and can play a vital role in supporting their conventional production supplies during this global pandemic situation. In this context, this paper provides a brief background study of COVID-19, its conventional preventive measure, and a detailed overview regarding the latest AM efforts including designers’ providers and makers in the 3D printing community. Moreover, numerous inquiries and questions such as technical factors, testing recommendations and characterization methods and biological concerns such as biocompatibility and sterilization for the AM manufactured medical devices are addressed in this paper. In the end, two examples of AM medical devices, i.e., face mask and Ambu bag ventilator, are presented and studied through numerical simulations.

With reduced cancer mortality in recent years, increased efforts must be put into safeguarding cancer survivors' long-term quality of life (QOL). Fertility preservation is recognised as a key component of QOL in survivorship. Concerns about fertility have been seen to significantly impact cancer patients' emotional and mental health as, generally, both malignancy and its treatment may cause a temporary or permanent reduction in infertility. This article reviews the primary effects of radiation therapy on male and female gonads and has further highlighted procedures through which the functioning of these organs can be protected before or during radiation treatment. We have also emphasised the importance of the establishment of multidisciplinary tumour boards and patient education regarding future reproductive function which is an important component of the care of individuals with cancer. This article highlights that infertility is a persistent and major concern that can add to long-term stress in cancer survivors, and education about fertility preservation before the initiation of any treatment is especially important.