Fused deposition modeling represents a flexible and relatively inexpensive alternative for the production of custom-made polymer lattices. However, its limited accuracy and resolution lead to geometric irregularities and poor mechanical properties when compared with the digital design. Although the link between geometric features and mechanical properties of lattices has been studied extensively, the role of manufacturing parameters has received little attention. Additionally, as the size of cells/struts nears the accuracy limit of the manufacturing process, the interaction between geometry and manufacturing parameters could be decisive. Hence, the influence of three geometric and two manufacturing parameters on the mechanical behavior was evaluated using a fractional factorial design of experiments. The compressive behavior of two miniature lattice structures, the truncated octahedron and cubic diamond, was evaluated, and multilinear regression models for the elastic modulus and plateau stress were developed. Cell size, unit cell type, and strut diameter had the largest impact on the mechanical properties, while the influence of feedstock material and layer thickness was very limited. Models based on factorial design, although limited in scope, could be an effective tool for the design of customized lattice structures.

This study explores the flexural behavior of continuous fiber-reinforced composite sandwich structures built entirely using material extrusion additive manufacturing. The continuous fiber additive manufacturing system used in this study works sequentially, thus enabling the addition of fiber reinforcement just in the face sheets, where it is most effective. Three-point bending tests were carried out on sandwich panel specimens built using thermoplastic reinforced with continuous glass fiber to quantify the effect of fiber reinforcement and infill density in the flexural properties and failure mode. Sandwich structures containing continuous fiber reinforcement had higher flexural strength and rigidity than unreinforced sandwiches. On the other hand, an increase in the lattice core density did not improve the flexural strength and rigidity. The elastic modulus of fiber-reinforced 3D-printed sandwich panels exceeded the predictions of the analytical models; the equivalent homogeneous model had the best performance, with a 15% relative error. However, analytical models could not correctly predict the failure mode: wrinkle failure occurs at 75% and 30% of the critical load in fiber-reinforced sandwiches with low- and high-density cores, respectively. Furthermore, no model is currently available to predict interlayer debonding between the matrix and the thermoplastic coating of fiber layers. Divergences between analytical models and experimental results could be attributed to the simplifications in the models that do not consider defects inherent to additive manufacturing, such as air gaps and poor interlaminar bonding.

The implementation of Industry 4.0 has integrated manufacturing, electronics, and engineering materials, leading to the creation of smart parts (SPs) that provide information on production system conditions. However, SP development faces challenges due to limitations in manufacturing processes and integrating electronic components. This systematic review synthesizes scientific articles on SP fabrication using additive manufacturing (AM), identifying the advantages and disadvantages of AM techniques in SP production and distinguishing between SPs and smart spare parts (SSPs). The methodology involves establishing a reference framework, formulating SP-related questions, and applying inclusion criteria and keywords, initially resulting in 1603 articles. After applying exclusion criteria, 70 articles remained. The results show that while SP development is advancing, widespread application of AM-manufactured SP is recent. SPs can anticipate production system failures, minimize design artifacts, and reduce manufacturing costs. Furthermore, the review highlights that SSPs, a subcategory of SPs, primarily differs by replacing conventional critical parts in the industry, offering enhanced functionality and reliability in industrial applications. The study concludes that continued research and development in this field is essential for further advancements and broader adoption of these technologies.