3D printing technology was developed nearly 30 years ago. One of its characteristics is that instead of removing materials, 3D printing creates 3D elements directly from CAD models, adding one layer of material on another. This offers a beneficial capability of making complex elements in terms of shape and materials, impossible to be manufactured by traditional methods. Owing to intensive research in recent years, considerable progress has been achieved in the development and commercialisation of new innovative processes of 3D printing by fused deposition modeling (FDM), including printing of composite materials. The study outlines the main methods of creating polymer composite structures using FDM technology.

This paper presented a new approach to decision making support of defects assessment in metal matrix composites (MMC). It is a continuation of the authors’ papers in terms of a uniform method of casting defects assessment. The idea of this paper was to design an open-access application (follow-up system called Open Atlas of Casting Defects (OACD)) in the area of industry and science. This a new solution makes it possible to quickly identify defect types considering the new classification of casting defects. This classification complements a classical approach by adding a casting defect group called structure defects, which is especially important for metal matrix composites. In the paper, an application structure, and the possibility of its use in casting defects assessment were introduced.

Metal matrix composites (MMCs) are a special class of materials carrying combined properties that belongs to alloys and metals according to market demands. Therefore, they are used in different areas of industry, and the properties of this type of material are useful in engineering applications. Machining of such composites is of great importance to finalize the fabrication process with improved part quality. However, the process implies several challenges due to the complexity of the cutting processes and random material structure. The current study aims to examine machinability characteristics. Effects of turning a metal matrix composite built of Al₂O₃ sinter, saturated with an EN AC-44000 AC-AlSi₁₁ alloy, are presented in this paper. In the present study, a turning process of new metal matrix composites was carried out to determine the state-of-the-art material for various engineering applications. During the turning process, the cutting forces, a tool’s wear, and surface roughness were investigated. Further, the SEM (scanning electron microscope) analysis of cutting inserts was performed. The influence of MMC structure on the machining process and surface roughness was studied. The Al₂O₃ reinforcements were used in different graininess. Effects of conventional turning of the metal matrix composite with Al₂O₃ sinter of FEPA (Federation of European Producers of Abrasives) 046 and FEPA 100 grade were compared. Results analysis of these tests showed the necessity of continuing research on turning metal matrix composites built of an AlSi alloy and Al₂O₃ ceramic reinforcement. The study showed the properties of MMCs that influenced machinability. In this paper, the influence of feed rate’s value on surface roughness was carried out. The significant tool wear during the turning of the MMC was proved.

Hybrid metal matrix composites (HMMCs) are a special type of material, possessing combined properties that belong to alloys and metals according to market demands. Therefore, they are used in different areas of industry and the properties of this type of material are useful in engineering applications, e.g., in aircraft engines and electrotechnical parts. The structure of the material requires a number of scientific studies to develop an appropriate processing technology. The paper presents the susceptibility of material from the HMMCs group with the EN AC-44300 (AISi12(Fe)) aluminum alloy matrix with a two-component reinforcement made of alumina particles (AP) and aluminosilicate fibers (AF) to thermal treatment with a laser beam. During this process, laser engraving of the researched material with variable beam power P_av and variable speed of the laser head v_l were carried out. A metallographic analysis of the material was carried out. After laser engraving, surface structural changes of the material were determined. The properties of the surface geometric structure of processed material were also examined. Presented studies concern laser engraving on the surface of composite from the HMMC group, which was made by vacuum infiltration. Thanks to this method, it is possible both to produce shaped and precise composite castings with saturated reinforcement and to consequently minimize machining losses. Metal–ceramic composites from the HMMC group are hard-to-machine materials which create problems during machining. The aim of these studies was to develop a laser engraving technology with Al matrix composite with the addition of Al₂O₃ particles and aluminosilicate fibers, which constitute the reinforcement. The focus was on the selection of engraving parameters (beam power and speed of movement of the laser head). Clear examples of engraving, suitable for macro-assessment, were obtained with minimal change in the initial surface structure of the composite.

The study examined the degradation process of various types of polymers used to form models using the fused deposition modeling (FDM) and three-dimensional printing (3DP) methods and used in the investment casting method. Commercial filaments made of polylactide (PLA), acrylonitrile butadiene styrene terpolymer (ABS), high-impact polystyrene (HIPS), polyamide 12 (PA12), poly(methyl methacrylate) (PMMA), and polypropylene (PP) were used to produce gypsum molds. The assessment included organic volatile compounds (VOCs) released during mold heating and model degradation, which is characteristic of this technological process. The screening qualitative chromatographic analysis of decomposition products sampled from various points of the production hall made it possible to define potential threats related to the processing of selected polymers and the necessary preventive measures. Furthermore, passive diffusion-type samplers were used at the sampling stage of VOCs emitted to the gaseous phase to reduce nuisance and user interference. Studies have been completed to characterize the thermoplastic polymer degradation process. The coupled thermogravimetry (TGA) with analysis of gaseous products by infrared spectroscopy with Fourier transformation (FT-IR) has been used. The presented results are the first to compare and rate the use of this still-developing novel aspect of castings by the method of fused models. Graphical abstract