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Polylactic acid (PLA) has gained considerable attention as an alternative to petroleum-based materials due to environmental concerns. We fabricated implant models with fused filament fabrication (FFF) 3D printers using PLA, and the accuracies of these PLA models were compared with those of plaster models made from silicone impressions and resin models made with digital light processing (DLP). A base model was obtained from an impact-training model. The scan body was mounted on the plaster, resin, and PLA models obtained from the base model, and the obtained information was converted to stereolithography (STL) data by the 3D scanner. The base model was then used as a reference, and its data were superimposed onto the STL data of each model using Geomagic control. The horizontal and vertical accuracies of PLA models, as calculated using the Tukey–Kramer method, were 97.2 ± 48.4 and 115.5 ± 15.1 μm, respectively, which suggests that the PLA model is the least accurate among the three models. In both cases, significant differences were found between PLA and gypsum and between the PLA and resin models. However, considering that the misfit of screw-retained implant frames should be ≤150 µm, PLA can be effectively used for fabricating implant models.

Three-dimensional printing/additive manufacturing (3DP/AM) for tissue engineering and regenerative medicine (TE/RM) applications is a multifaceted research area encompassing biology, material science, engineering, and the clinical sciences. Although being quite mature as a research area, only a handful of clinical cases have been reported and even fewer commercial products have made it to the market. The regulatory pathway and costs associated with the introduction of bioresorbable materials for TE/RM have proven difficult to overcome, but greater access to 3DP/AM has spurred interest in the processing and availability of existing and new bioresorbable materials. For this purpose, herein, we introduce a series of medical-grade filaments for fused deposition modelling/fused filament fabrication (FDM/FFF) based on established and Federal Drug Administration (FDA)-approved polymers. Manufacturability, mechanical characterization, and accelerated degradation studies have been conducted to evaluate the suitability of each material for TE/RM applications. The comparative data serves to introduce these materials, as well as a benchmark to evaluate their potential in hard and soft tissue engineering from a physicochemical perspective.

The additive manufacturing (AM) fused filament fabrication (FFF) technology is widely used today with different kinds of thermoplastic materials, including polyethylene terephthalate glycol (PETG). One of the major problems of parts produced by AM-FFF technology is the anisotropy of their mechanical properties. Therefore, it is very important to understand the effect of build strategy and post-processing on the mechanical properties and failure behavior of the FFF-PETG components. This research aims to examine the influence of 3D-print orientations, post-processing heat treatments and reinforcement of the material with carbon fibers, on the mechanical properties of FFF-PETG specimens. For this purpose, three different standard building orientations, flat, one-edge and upright specimens were printed. Tensile testing was carried out to obtain the mechanical properties of the FFF-PETG specimens for the different 3D-print orientations and post-processing. The specimens were characterized by visual testing, stereo microscopy, and SEM microscopy to examine the fracture surface after tensile test. The upright-melted specimens reached the same tensile strength as the as-printed flat and on-edge orientations specimens. The fracture surface of all three orientations is brittle and it typically starts by a mirror pattern that evolves into cleavage plates.

Fused filament fabrication (FFF) technique is one of the most frequently used additive manufacturing (AM) technologies for printing ABS and many other thermoplastic materials. The anisotropy of the mechanical properties of 3D-printed parts manufactured by FFF technology is still of major concern when using this technique. Thus, the component’s orientation, build strategy and printing parameters affect the mechanical properties, and failure mechanisms are of crucial importance. This research aims to partly fill this gap by studying the structure and mechanical behavior of FFF-ABS specimens, and by performing fracture surface analysis by the three-point bend flexural test. A series of tests were conducted to determine the flexural properties of tilted specimens at 0°, 15°, 30°, 45°, 60° and 75° inclination angles relative to the machine platform. The work describes manufacture method of the specimens, experimental procedures, and outcomes from the mechanical and structural characterizations of the FFF-ABS specimens. Overall, two main failure modes were observed for the tested specimens: (1) inter-layer/ inter-raster bond failure (typical for upright specimens) and (2) intra-layer/trans-raster failure (typical for on-edge specimens). A mixed inter-layer/ intra-layer mode was found for the specimens tilted in-between the 15o and 60o range.

In recent years, 3D printing technology has played an essential role in fabricating customized products at a low cost and faster in numerous industrial sectors. Fused deposition modeling (FDM) is one of the most efficient and economical 3D printing techniques. Various materials have been developed and studied, and their properties, such as mechanical, thermal, and electrical, have been reported. Numerous attempts to improve FDM products’ properties for applications in various sectors have also been reported. Still, their applications are limited due to the materials’ availability and properties compared to traditional fabrication methods. In 3D printing, the process parameters are crucial factors for improving the product's properties and reducing the machining time and cost. Researchers have recently investigated many approaches for expanding the range of materials and optimizing the FDM process parameters to extend the FDM process’s possibility into various industrial sectors. This paper reviews and explains various techniques used in 3D printing and the various polymers and polymer composites used in the FDM process. The list of mechanical investigations carried out for different materials, process parameters, properties, and the FDM process's potential application was discussed. This review is expected to indicate the materials and their optimized parameters to achieve enhanced properties and applications. Also, the article is highly anticipated to provide the research gaps to sustenance future research in the area of FDM technologies. Graphical abstract

The increase in accessibility of fused filament fabrication (FFF) machines has inspired the scientific community to work towards the understanding of the structural performance of components fabricated with this technology. Numerous attempts to characterize and to estimate the mechanical properties of structures fabricated with FFF have been reported in the literature. Experimental characterization of printed components has been reported extensively. However, few attempts have been made to predict properties of printed structures with computational models, and a lot less work with analytical approximations. As a result, a thorough review of reported experimental characterization and predictive models is presented with the aim of summarizing applicability and limitations of those approaches. Finally, recommendations on practices for characterizing printed materials are given and areas that deserve further research are proposed.

The current paper studies the influence of geometrical parameters of the fused deposition modeling (FDM)—fused filament fabrication (FFF) 3D printing process on printed part strength for open source desktop 3D printers and the most popular material used for that purpose—i.e., polylactic acid (PLA). The study was conducted using a set of different nozzles (0.4, 0.6, and 0.8 mm) and a range of layer heights from the minimum to maximum physical limits of the machine. To assess print strength, a novel assessment method is proposed. A tubular sample is loaded in the weakest direction (across layers) in a three-point bending fixture. Mesostructure evaluation through scanning electronic microscopy (SEM) scans of the samples was used to explain the obtained results. We detected a significant influence of geometric process parameters on sample mesostructure, and consequently, on sample strength.

Recently, Fused Filament Fabrication (FFF), one of the most encouraging additive manufacturing (AM) techniques, has fascinated great attention. Although FFF is growing into a manufacturing device with considerable technological and material innovations, there still is a challenge to convert FFF-printed prototypes into functional objects for industrial applications. Polymer components manufactured by FFF process possess, in fact, low and anisotropic mechanical properties, compared to the same parts, obtained by using traditional building methods. The poor mechanical properties of the FFF-printed objects could be attributed to the weak interlayer bond interface that develops during the layer deposition process and to the commercial thermoplastic materials used. In order to increase the final properties of the 3D printed models, several polymer-based composites and nanocomposites have been proposed for FFF process. However, even if the mechanical properties greatly increase, these materials are not all biodegradable. Consequently, their waste disposal represents an important issue that needs an urgent solution. Several scientific researchers have therefore moved towards the development of natural or recyclable materials for FFF techniques. This review details current progress on innovative green materials for FFF, referring to all kinds of possible industrial applications, and in particular to the field of Cultural Heritage.

Additive manufacturing (AM) is the fabrication of real three-dimensional objects from metals, ceramics, or plastics by adding material, usually as layers. There are several variants of AM; among them material extrusion (ME) is one of the most versatile and widely used. In MEAM, molten or viscous materials are pushed through an orifice and are selectively deposited as strands to form stacked layers and subsequently a three-dimensional object. The commonly used materials for MEAM are thermoplastic polymers and particulate composites; however, recently innovative formulations of highly-filled polymers (HP) with metals or ceramics have also been made available. MEAM with HP is an indirect process, which uses sacrificial polymeric binders to shape metallic and ceramic components. After removing the binder, the powder particles are fused together in a conventional sintering step. In this review the different types of MEAM techniques and relevant industrial approaches for the fabrication of metallic and ceramic components are described. The composition of certain HP binder systems and powders are presented; the methods of compounding and filament making HP are explained; the stages of shaping, debinding, and sintering are discussed; and finally a comparison of the parts produced via MEAM-HP with those produced via other manufacturing techniques is presented.

Additive manufacturing is a promising tool that has proved its value in various applications. Among its technologies, the fused filament fabrication 3D printing technique stands out with its potential to serve a wide variety of applications, ranging from simple educational purposes to industrial and medical applications. However, as many materials and composites can be utilized for this technique, the processability of these materials can be a limiting factor for producing products with the required quality and properties. Over the past few years, many researchers have attempted to better understand the melt extrusion process during 3D printing. Moreover, other research groups have focused on optimizing the process by adjusting the process parameters. These attempts were conducted using different methods, including proposing analytical models, establishing numerical models, or experimental techniques. This review highlights the most relevant work from recent years on fused filament fabrication 3D printing and discusses the future perspectives of this 3D printing technology.