Purpose: Continuous fiber reinforced thermoplastic composites (CFRTPCs) are becoming more significant in industrial applications but are limited by the high cost of molds, the manufacturing boundedness of complex constructions and the inability of special fiber alignment. The purpose of this paper is to put forward a novel three-dimensional (3D) printing process for CFRTPCs to realize the low-cost rapid fabrication of complicated composite components. Design/methodology/approach: For this purpose, the mechanism of the proposed process, which consists of the thermoplastic polymer melting, the continuous fiber hot-dipping and the impregnated composites extruding, was investigated. A 3D printing equipment for CFRTPCs with a novel composite extrusion head was developed, and some composite samples have been fabricated for several mechanical tests. Moreover, the interface performance was clarified with scanning electron microscopy images. Findings: The results showed that the flexural strength and the tensile strength of these 10 Wt.% continuous carbon fiber (CCF)/acrylonitrile-butadiene-styrene (ABS) specimens were improved to 127 and 147 MPa, respectively, far greater than the one of ABS parts and close to the one of CCF/ABS (injection molding) with the same fiber content. Moreover, these test results also exposed the very low interlaminar shear strength (only 2.81 MPa) and the inferior interface performance. These results were explained by the weak meso/micro/nano scale interfaces in the 3D printed composite parts. Originality/value: The 3D printing process for CFRTPCs with its controlled capabilities for the orientation and distribution of fiber has great potential for manufacturing of load-bearing composite parts in the industrial circle.

Fused deposition modeling (FDM) is a rapidly growing three-dimensional (3D) printing technology and has great potential in medicine. Polyether-ether-ketone (PEEK) is a biocompatible high-performance polymer, which is suitable to be used as an orthopedic/dental implant material. However, the mechanical properties and biocompatibility of FDM-printed PEEK and its composites are still not clear. In this study, FDM-printed pure PEEK and carbon fiber reinforced PEEK (CFR-PEEK) composite were successfully fabricated by FDM and characterized by mechanical tests. Moreover, the sample surfaces were modified with polishing and sandblasting methods to analyze the influence of surface roughness and topography on general biocompatibility (cytotoxicity) and cell adhesion. The results indicated that the printed CFR-PEEK samples had significantly higher general mechanical strengths than the printed pure PEEK (even though there was no statistical difference in compressive strength). Both PEEK and CFR-PEEK materials showed good biocompatibility with and without surface modification. Cell densities on the “as-printed” PEEK and the CFR-PEEK sample surfaces were significantly higher than on the corresponding polished and sandblasted samples. Therefore, the FDM-printed CFR-PEEK composite with proper mechanical strengths has potential as a biomaterial for bone grafting and tissue engineering applications.

Over the past few decades, there has been an increasing interest in the fabrication of complex high-resolution three-dimensional (3D) architectures at micro/nanoscale. These architectures can be obtained through conventional microfabrication methods including photolithography, electron-beam lithography, femtosecond laser lithography, nanoimprint lithography, etc. However, the applications of these fabrication methods are limited by their high costs, the generation of various chemical wastes, and their insufficient ability to create high-aspect-ratio 3D structures. High-resolution 3D printing has recently emerged as a promising solution, as it is capable of building multifunctional 3D constructs with optimal properties. Here we present a review on the principles and the recent advances of high-resolution 3D printing techniques, including two-photon polymerization (TPP), projection microstereoLithography (PµSL), direct ink writing (DIW) and electrohydrodynamic printing (EHDP). We also highlight their typical applications in various fields such as metamaterials, energy storage, flexible electronics, microscale tissue engineering scaffolds and organ-on-chips. Finally, we discuss the challenge and perspective of these high-resolution 3D printing techniques in technical and application aspects. We believe that high-resolution 3D printing will eventually revolutionize the microfabrication processes of 3D architectures with high product quality and diversified materials. It will also find applications in a wide scope.

Additive manufacturing has been used to develop a variety of scaffold designs for clinical and industrial applications. Mechanical properties (i.e., compression, tension, bending, and torsion response) of these scaffolds are significantly important for load-bearing orthopaedic implants. In this study, we designed and additively manufactured porous metallic biomaterials based on two different types of triply periodic minimal surface structures (i.e., gyroid and diamond) that mimic the mechanical properties of bone, such as porosity, stiffness, and strength. Physical and mechanical properties, including compressive, tensile, bending, and torsional stiffness and strength of the developed scaffolds, were then characterised experimentally and numerically using finite element method. Sheet thickness was constant at 300 μm, and the unit cell size was varied to generate different pore sizes and porosities. Gyroid scaffolds had a pore size in the range of 600–1200 μm and a porosity in the range of 54–72%, respectively. Corresponding values for the diamond were 900–1500 μm and 56–70%. Both structure types were validated experimentally, and a wide range of mechanical properties (including stiffness and yield strength) were predicted using the finite element method. The stiffness and strength of both structures are comparable to that of cortical bone, hence reducing the risks of scaffold failure. The results demonstrate that the developed scaffolds mimic the physical and mechanical properties of cortical bone and can be suitable for bone replacement and orthopaedic implants. However, an optimal design should be chosen based on specific performance requirements.

Refractory high-entropy alloys (HEAs) have excellent mechanical properties, which could make them the substitutes of some superalloys. However, the high melting point of refractory HEAs leads to processing problems when using traditional processing techniques. In this study, a single BCC solid solution of NbMoTaW alloy was formed by selective laser melting (SLM) with a linear energy density of up to 2.83 J/mm. The composition distribution was analyzed, and the element with a lower melting point and lower density showed a negative deviation (no more than 5%) of the molar ratio in the formed alloy. The HEA shows an excellent microstructure, microhardness, and corrosion resistance performance compared with traditional superalloys, making it a new substitute metal with great application prospects in aerospace and energy fields.