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.

Progress in composite materials has led to their use in applications where improved mechanical and resistance characteristics are required. Most composites are obtained in such a way that they present specific mechanical properties and/or have the role of both a thermal conductor and insulator; these properties are important, specific, specialized, and useful. The advantages of these materials compared to the classic ones are as follows: low weight, high resistance to wear and corrosion, and mechanical characteristics consistent with the subsequent use of the product. The slightly high costs of these materials are justified by their precision, the quality of the products obtained, and the fact that their use leads to increased reliability, maintenance, and, in the cases of the automotive and aeronautical industries, reduced energy consumption. This paper aims to bring to readers’ attention the latest research related to glass fibre-reinforced composite materials in transport-related applications, such as automotive and aeronautic applications, including the manufacturing of unmanned aerial vehicles (UAVs). Considering the long period of use, the recycling and reuse of composite materials used in aeronautical transport is a must considering the environmental aspects and the need of achieving a circular economy. In recent years, considerable efforts have been made to find new alternatives to improve the performance and durability of materials in the aeronautical transport sector.

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.

This paper presents the development, characterization, and testing of PP/PE-g-MA composites with 10 and 15 wt% surface-modified aramid fibers, and aluminum-based pigment, as covers for a small drone body for collision protection. The successful fiber surface modification with SiO₂ by the sol–gel method using TEOS was confirmed by FTIR, SEM, and EDS analyses. The composites were characterized by FTIR and SEM analyses and surface energy and water contact angle measurements and tested in terms of tensile, flexural, impact, and thermal properties. The materials exhibited hydrophobic character and compact and uniform morphostructures, with increased surface energy with fiber content owed to improved adhesion between modified fibers and the matrix. Compared to the control sample, composites with modified fibers showed an increase by 20% in tensile strength, and 36–52% in the modulus, and an increase by 26–33% in flexural strength and 30–47% in the modulus, with higher values at room temperature. Impact resistance of modified fiber composites showed an increase by 20–40% compared to the control sample, due to improved interaction between SiO₂-modified fibers and maleic anhydride, which inhibits crack formation, allowing higher energies’ absorption. The composites were vacuum-thermoformed on 3D-printed molds as a two-part cover for the body of a drone, successfully withstanding the flight test.