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Ms. Alessia Romani
Department of Chemistry, Materials and Chemical Engineering "Giulio Natta" - Politecnico di Milano

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0 Industrial Design
0 circular economy
0 Materials engineering
0 Additive manufactoring
0 Product Design and Development

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Journal article
Published: 15 July 2021 in Technologies
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Fused filament fabrication allows the direct manufacturing of customized and complex products although the layer-by-layer appearance of this process strongly affects the surface quality of the final parts. In recent years, an increasing number of post-processing treatments has been developed for the most used materials. Contrarily to other additive manufacturing technologies, metallization is not a common surface treatment for this process despite the increasing range of high-performing 3D printable materials. The objective of this work is to explore the use of physical vapor deposition sputtering for the chromium metallization of thermoplastic polymers and composites obtained by fused filament fabrication. The thermal and mechanical properties of five materials were firstly evaluated by means of differential scanning calorimetry and tensile tests. Meanwhile, a specific finishing torture test sample was designed and 3D printed to perform the metallization process and evaluate the finishing on different geometrical features. Furthermore, the roughness of the samples was measured before and after the metallization, and a cost analysis was performed to assess the cost-efficiency. To sum up, the metallization of five samples made with different materials was successfully achieved. Although some 3D printing defects worsened after the post-processing treatment, good homogeneity on the finest details was reached. These promising results may encourage further experimentations as well as the development of new applications, i.e., for the automotive and furniture fields.

ACS Style

Alessia Romani; Andrea Mantelli; Paolo Tralli; Stefano Turri; Marinella Levi; Raffaella Suriano. Metallization of Thermoplastic Polymers and Composites 3D Printed by Fused Filament Fabrication. Technologies 2021, 9, 49 .

AMA Style

Alessia Romani, Andrea Mantelli, Paolo Tralli, Stefano Turri, Marinella Levi, Raffaella Suriano. Metallization of Thermoplastic Polymers and Composites 3D Printed by Fused Filament Fabrication. Technologies. 2021; 9 (3):49.

Chicago/Turabian Style

Alessia Romani; Andrea Mantelli; Paolo Tralli; Stefano Turri; Marinella Levi; Raffaella Suriano. 2021. "Metallization of Thermoplastic Polymers and Composites 3D Printed by Fused Filament Fabrication." Technologies 9, no. 3: 49.

Review
Published: 29 June 2021 in Sustainability
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The transition toward circular economy models has been progressively promoted in the last few years. Different disciplines and strategies may significantly support this change. Although the specific contribution derived from design, material science, and additive manufacturing is well-established, their interdisciplinary relationship in circular economy contexts is relatively unexplored. This paper aims to review the main case studies related to new circular economy models for waste valorization through extrusion-based additive manufacturing, circular materials, and new design strategies. The general patterns were investigated through a comprehensive analysis of 74 case studies from academic research and design practice in the last six-year period (2015–2021), focusing on the application fields, the 3D printing technologies, and the materials. Further considerations and future trends were then included by looking at the relevant funded projects and case studies of 2021. A broader number of applications, circular materials, and technologies were explored by the academic context, concerning the practice-based scenario linked to more consolidated fields. Thanks to the development of new strategies and experiential tools, academic research and practice can be linked to foster new opportunities to implement circular economy models.

ACS Style

Alessia Romani; Valentina Rognoli; Marinella Levi. Design, Materials, and Extrusion-Based Additive Manufacturing in Circular Economy Contexts: From Waste to New Products. Sustainability 2021, 13, 7269 .

AMA Style

Alessia Romani, Valentina Rognoli, Marinella Levi. Design, Materials, and Extrusion-Based Additive Manufacturing in Circular Economy Contexts: From Waste to New Products. Sustainability. 2021; 13 (13):7269.

Chicago/Turabian Style

Alessia Romani; Valentina Rognoli; Marinella Levi. 2021. "Design, Materials, and Extrusion-Based Additive Manufacturing in Circular Economy Contexts: From Waste to New Products." Sustainability 13, no. 13: 7269.

Research article
Published: 02 May 2021 in Advanced Engineering Materials
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Within the complex framework of additive manufacturing, direct ink writing (DIW) processes significantly contribute to extending the range of 3D‐printable materials (i.e., thermosetting resins, ceramics, hydrogels). Thanks to this technology, viscous inks are easily extruded for the creation of 3D structures. Nevertheless, the quick recovery of the solid‐like behavior after extrusion remains one of the most crucial open issues for 3D‐printable inks. The main goal herein is to improve the printability of a UV‐curable thermosetting composite ink reinforced with mechanically recycled glass fiber composites by modifying its rheological behavior. The overall process is optimized, leading to the definition of the optimal extrusion parameters for these types of materials. Furthermore, the retraction mode is successfully developed for the DIW of recycled composites. Additional features are achieved, thanks to the aforementioned improvements, such as 3D complex shapes, assembled pieces, and/or moving built‐in mechanisms, increasing the number of new potential applications of recycled glass fiber‐reinforced polymers.

ACS Style

Andrea Mantelli; Alessia Romani; Raffaella Suriano; Marinella Levi; Stefano Turri. Direct Ink Writing of Recycled Composites with Complex Shapes: Process Parameters and Ink Optimization. Advanced Engineering Materials 2021, 2100116 .

AMA Style

Andrea Mantelli, Alessia Romani, Raffaella Suriano, Marinella Levi, Stefano Turri. Direct Ink Writing of Recycled Composites with Complex Shapes: Process Parameters and Ink Optimization. Advanced Engineering Materials. 2021; ():2100116.

Chicago/Turabian Style

Andrea Mantelli; Alessia Romani; Raffaella Suriano; Marinella Levi; Stefano Turri. 2021. "Direct Ink Writing of Recycled Composites with Complex Shapes: Process Parameters and Ink Optimization." Advanced Engineering Materials , no. : 2100116.

Journal article
Published: 27 February 2021 in Polymers
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Despite the growing global interest in 3D printed carbon fiber reinforced polymers, most of the applications are still limited to high-performance sectors due to the low effectiveness–cost ratio of virgin carbon fibers. However, the use of recycled carbon fibers in 3D printing is almost unexplored, especially for thermoset-based composites. This paper aims to demonstrate the feasibility of recycled carbon fibers 3D printing via UV-assisted direct ink writing. Pyrolyzed recycled carbon fibers with a sizing treatment were firstly shredded to be used as a reinforcement of a thermally and photo-curable acrylic resin. UV-differential scanning calorimetry analyses were then performed to define the material crosslinking of the 3D printable ink. Because of the poor UV reactivity of the resin loaded with carbon fibers, a rheology modifier was added to guarantee shape retention after 3D printing. Thanks to a customized 3D printer based on a commercial apparatus, a batch of specimens was successfully 3D printed. According to the tensile tests and Scanning Electron Microscopy analysis, the material shows good mechanical properties and the absence of layer marks related to the 3D printing. These results will, therefore, pave the way for the use of 3D printed recycled carbon fiber reinforced polymers in new fields of application.

ACS Style

Andrea Mantelli; Alessia Romani; Raffaella Suriano; Marco Diani; Marcello Colledani; Essi Sarlin; Stefano Turri; Marinella Levi. UV-Assisted 3D Printing of Polymer Composites from Thermally and Mechanically Recycled Carbon Fibers. Polymers 2021, 13, 726 .

AMA Style

Andrea Mantelli, Alessia Romani, Raffaella Suriano, Marco Diani, Marcello Colledani, Essi Sarlin, Stefano Turri, Marinella Levi. UV-Assisted 3D Printing of Polymer Composites from Thermally and Mechanically Recycled Carbon Fibers. Polymers. 2021; 13 (5):726.

Chicago/Turabian Style

Andrea Mantelli; Alessia Romani; Raffaella Suriano; Marco Diani; Marcello Colledani; Essi Sarlin; Stefano Turri; Marinella Levi. 2021. "UV-Assisted 3D Printing of Polymer Composites from Thermally and Mechanically Recycled Carbon Fibers." Polymers 13, no. 5: 726.

Conference paper
Published: 31 August 2020 in Transactions on Petri Nets and Other Models of Concurrency XV
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New spaces for the co-creation of Assistive devices have been increasing according to the current lack in specific products for everyday user needs satisfaction. Moreover, Open Innovation is gradually increasing the user role in product development thanks to new digital technologies spread. Nevertheless, the knowledge and the affordance of this bottom-up solutions is still limited amongst the potential users. The aim of this work is to show and investigate one application of the Virtual Reality related to Assistive Technology customization, as well as the customization process for the user. Starting from a Co-design approach, variables for customization were detected on specifically co-created products for users with rheumatic diseases. By means of specific 3D modeling tools and an online platform, an Open Source online configurator was then developed for the customization of these products. In this way, customized STL files of the objects can be downloaded and created by using low cost Additive Manufacturing technologies. Consequently, affordable Assistive products for specific needs can be easily spread, increasing the users quality of life.

ACS Style

Alessia Romani; Marinella Levi. Parametric Design for Online User Customization of 3D Printed Assistive Technology for Rheumatic Diseases. Transactions on Petri Nets and Other Models of Concurrency XV 2020, 174 -182.

AMA Style

Alessia Romani, Marinella Levi. Parametric Design for Online User Customization of 3D Printed Assistive Technology for Rheumatic Diseases. Transactions on Petri Nets and Other Models of Concurrency XV. 2020; ():174-182.

Chicago/Turabian Style

Alessia Romani; Marinella Levi. 2020. "Parametric Design for Online User Customization of 3D Printed Assistive Technology for Rheumatic Diseases." Transactions on Petri Nets and Other Models of Concurrency XV , no. : 174-182.

Journal article
Published: 11 August 2020 in Materials
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Despite the large use of composites for industrial applications, their end-of-life management is still an open issue for manufacturing, especially in the wind energy sector. Additive manufacturing technology has been emerging as a solution, enhancing circular economy models, and using recycled composites for glass fiber-reinforced polymers is spreading as a new additive manufacturing trend. Nevertheless, their mechanical properties are still not comparable to pristine materials. The purpose of this paper is to examine the additive re-manufacturing of end-of-life glass fiber composites with mechanical performances that are comparable to virgin glass fiber-reinforced materials. Through a systematic characterization of the recyclate, requirements of the filler for the liquid deposition modeling process were identified. Printability and material surface quality of different formulations were analyzed using a low-cost modified 3D printer. Two hypothetical design concepts were also manufactured to validate the field of application. Furthermore, an understanding of the mechanical behavior was accomplished by means of tensile tests, and the results were compared with a benchmark formulation with virgin glass fibers. Mechanically recycled glass fibers show the capability to substitute pristine fillers, unlocking their use for new fields of application.

ACS Style

Alessia Romani; Andrea Mantelli; Raffaella Suriano; Marinella Levi; Stefano Turri. Additive Re-Manufacturing of Mechanically Recycled End-of-Life Glass Fiber-Reinforced Polymers for Value-Added Circular Design. Materials 2020, 13, 3545 .

AMA Style

Alessia Romani, Andrea Mantelli, Raffaella Suriano, Marinella Levi, Stefano Turri. Additive Re-Manufacturing of Mechanically Recycled End-of-Life Glass Fiber-Reinforced Polymers for Value-Added Circular Design. Materials. 2020; 13 (16):3545.

Chicago/Turabian Style

Alessia Romani; Andrea Mantelli; Raffaella Suriano; Marinella Levi; Stefano Turri. 2020. "Additive Re-Manufacturing of Mechanically Recycled End-of-Life Glass Fiber-Reinforced Polymers for Value-Added Circular Design." Materials 13, no. 16: 3545.