Selective laser sintering (SLS) is a powder bed fusion technology that uses a laser source to melt selected regions of a polymer powder bed based on 3D model data. Components with complex geometry are then obtained using a layer-by-layer strategy. This additive manufacturing technology is a very complex process in which various multiphysical phenomena and different mechanisms occur and greatly influence both the quality and performance of printed parts. This review describes the physical phenomena involved in the SLS process such as powder spreading, the interaction between laser beam and powder bed, polymer melting, coalescence of fused powder and its densification, and polymer crystallization. Moreover, the main characterization approaches that can be useful to investigate the starting material properties are reported and discussed.

In this research, an innovative procedure is proposed to elaborate Raman spectra obtained from nanostructured and disordered solids. As a challenging case study, biochar, a bio-derived carbon based material, was selected. The complex structure of biochar (i.e., channeled surface, inorganic content) represents a serious challenge for Raman characterization. As widely reported, the Raman spectra are closely linked to thermal treatments of carbon material. The individual contributions to the Raman spectra are difficult to identify due to the numerous peaks that contribute to the spectra. To tackle this problem, we propose a brand new approach based on the introduction, on sound theoretical grounds, of a mixed Gaussian-–Lorentzian lineshape. As per the experimental part, biochar samples were carbonized in an inert atmosphere at various temperatures and their respective spectra were successfully decomposed using the new lineshape. The evolution of the structure with carbonization temperature was investigated by Raman and XRD analysis. The results of the two techniques fairly well agree. Compared to other approaches commonly reported in the literature this method (i) gives a sounder basis to the lineshape used in disordered materials, and (ii) appears to reduce the number of components, leading to an easier understanding of their origin.

The development of 3D printed composites showing increased stiffness and strength thanks to the use of continuous carbon fibers has offered new prospects for Fused Filament Fabrication (FFF) technique. This work aims to investigate the microstructure and mechanical properties of 3D printed CCF/PA composites with various layups, and also to apply predictive models. The mechanical properties of the printed parts were directly related to the adopted laminate layup as well as to the microstructure and defects induced by the FFF process. The highest stiffness and strength were reported for longitudinal composites, where the fibers are unidirectionally aligned in the loading direction. In addition, it was found that the reduction in tensile properties obtained for cross-ply and quasi-isotropic laminate layups can be described by using the Angle Minus Longitudinal. A step-like failure with extensive fibers breakage and pull-out was observed for the longitudinal composites. By contrast, the rupture mode of the quasi-isotropic laminates mainly exhibited debonding between beads. Moreover, the predictions obtained using the Volume Average Stiffness method and Classical Laminate Theory were in good agreement with the tensile test results. This work could help engineers to design complex laminates with specific mechanical requirements by tailoring the orientation of continuous carbon fibers.

Electrical and thermal conductivity of composites which contain carbon-based fillers in an epoxy matrix were investigated. The fillers were dispersed in the liquid matrix by using three roll mill equipment. The filler/matrix mixture was cast in a mold and then cured, thus obtaining composite specimens. Multiwall carbon nanotubes, graphene-like nanoplatelets, and graphite were used as fillers and their effect on conductivity was investigated. Electrical and thermal conductivity were measured at different filler loads. It was found that the formation of percolation paths greatly enhanced electrical conductivity, although they were not so effective in improving thermal conductivity. The behavior of composites containing each single filler was compared with that of hybrid composites containing combinations of two different fillers. Results show that fillers with different aspect ratios displayed a synergetic effect resulting in a noticeable improvement of electrical conductivity. However, only a small effect on thermal conductivity was observed.