The continuous growth of additive manufacturing in worldwide industrial and research fields is driven by its main feature which allows the customization of items according to the customers’ requirements and limitations. There is an expanding competitiveness in the product development sector as well as applicative research that serves special-use domains. Besides the direct use of additive manufacturing in the production of final products, 3D printing is a viable solution that can help manufacturers and researchers produce their support tooling devices (such as molds and dies) more efficiently, in terms of design complexity and flexibility, timeframe, costs, and material consumption reduction as well as functionality and quality enhancements. The compatibility of the features of 3D printing of molds with the requirements of low-volume production and individual-use customized items development makes this class of techniques extremely attractive to a multitude of areas. This review paper presents a synthesis of the use of 3D-printed polymeric molds in the main applications where molds exhibit a major role, from industrially oriented ones (injection, casting, thermoforming, vacuum forming, composite fabrication) to research or single-use oriented ones (tissue engineering, biomedicine, soft lithography), with an emphasis on the benefits of using 3D-printed polymeric molds, compared to traditional tooling.

Two classes of thermal protection systems composed of a carbon-fibre-reinforced (CFRP) layer and an ablative material layer joined with a thermo-resistant ceramic adhesive were developed. The two classes differ in the composition of the ablative material reinforcing compound. In the first class, the ablative material is based on micronic-sized cork granules, and in the second class, the ablative material is reinforced with carbonic felt. For both classes of thermal protection systems, the reinforcement material was impregnated in simple phenolic resin, and nanometric additive, consisting of silicon carbide nanoparticles added in two different weight contents (1 and 2% by weight) relative to the resin. The thermal conductivity for the ablative materials in the thermal protection systems structure was determined. A test facility using oxy-butane flame was developed through which the thermal protection systems developed were tested at extreme temperatures, to simulate some thermal conditions in space applications. The materials were characterised from a morphostructural point of view using optical and scanning electron microscopy after thermal testing. The TPS composed of the carbon-felt-based ablative layer showed improved behaviour compared to the cork-based ablative ones in terms of the temperature increase rate during thermal conductivity testing, mass loss, as well as morphostructural appearance and material erosion after oxy-butane testing. The nSiC-based samples in both sets of TPSs showed improved behaviour compared to the un-filled ones, considering the temperature increase, mass loss, and morphostructure of the eroded material.

The complexity of sandwich structures is a challenge for aeronautics designers. Sandwich construction is widely used in both the aerospace and commercial industries because it is an extremely lightweight structural approach with high rigidity and strength/weight ratios. Although today's technology offers the possibility to combine a variety of materials for these structure solutions, in aviation only a few materials are accepted. This paper presents the technological process of making these sandwich structures, as well as a study of the characterization and testing of a sandwich structure to analyze the behavior from a mechanical point of view. The conclusions of the paper represent an experimental basis on which further research will be built.