Additive manufacturing provides high design flexibility, but its use is restricted by limited mechanical properties compared to conventional production methods. As technology is still emerging, several approaches exist in the literature for quantifying and improving mechanical properties. In this study, we investigate characterizing materials’ response of additive manufactured structures, specifically by fused deposition modeling (FDM). A comparative analysis is achieved for four different tensile test specimens for polymers based on ASTM D3039 and ISO 527-2 standards. Comparison of specimen geometries is studied with the aid of computations based on the Finite Element Method (FEM). Uniaxial tensile tests are carried out, after a careful examination of different slicing approaches for 3D printing. We emphasize the effects of the chosen slicer parameters on the position of failures in the specimens and propose a simple formalism for measuring effective mechanical properties of 3D-printed structures.

The additive manufacturing of natural fibre-reinforced polymers is a pivotal method in developing sustainable engineering solutions. Using the fused filament fabrication method, the current study investigates the additive manufacturing of hemp-reinforced polybutylene succinate (PBS) alongside its mechanical characterization. Two types of hemp reinforcement are considered: short fibres (max. length smaller than 2 mm) and long fibres (max. length smaller than 10 mm), which are compared against non-reinforced (pure) PBS. A detailed analysis is performed regarding the determination of suitable 3D printing parameters (overlap, temperature, nozzle diameter). In a comprehensive experimental study, additionally to general analyses regarding the influence of hemp reinforcement on the mechanical behaviour, the effect of printing parameters is determined and discussed. Introducing an overlap in the additive manufacturing of the specimens results in improved mechanical performance. The study highlights that the Young’s modulus of PBS can be improved by 63% by introducing hemp fibres in conjunction with overlap. In contrast, hemp fibre reinforcement reduces the tensile strength of PBS, while this effect is less pronounced considering overlap in the additive manufacturing process.

In this study, we report on the visco-elastic response during start-up and cessation of shear of a novel bio-based liquid crystal polymer. The ensuing morphological changes are analyzed at different length scales by in-situ polarized optical microscopy and wide-angle X-ray diffraction. Upon inception of shear, the polydomain texture is initially stretched, at larger strain break up processes become increasingly important, and eventually a steady state texture is obtained. The shear stress response showed good coherence between optical and rheo-X-ray data. The evolution of the orientation parameter coincides with the evolution of the texture: the order parameter increases as the texture stretches, drops slightly in the break up regime, and reaches a constant value in the plateau regime. The relaxation of the shear stress and the polydomain texture showed two distinct processes with different timescales: The first is fast contraction of the stretched domain texture; the second is the slow coalescence of the polydomain texture. The timescale of the orientation parameter’s relaxation matched with that of the slow coalescence process. All processes were found to scale with shear rate in the tested regime. These observations can have far reaching implications for the processing of liquid crystal polymers as they indicate that increased shear rates during processing can correspond to an increased relaxation rate of the orientation parameter and, therefore, a decrease in anisotropy and material properties after cooling.

Additive manufacturing is an emerging technology and provides high design flexibility to customers. Fused deposition modeling (FDM) is an economical and promising additive manufacturing method. Due to its many advantages, FDM received great attention in recent years, and comprehensive studies are being undertaken to investigate the properties of FDM-printed polymers and polymer composites. As a result of the manufacturing technology employed in FDM, inner structures are changed with different process parameters, and thus, anisotropic properties are observed. Moreover, composite filaments such as particle- or fiber-reinforced polymers already have anisotropy before FDM printing. In this study, we investigate the effect of different process parameters, namely layer thickness and raster width on FDM-printed copper-reinforced poly(lactic acid) (PLA). Mechanical characterizations with a high-resolution camera are carried out for analyzing the deformation behaviors. Optical microscopy characterizations are performed to observe the mesostructural changes with various process parameters. Scanning electron microscopy (SEM) and an energy-dispersive X-ray spectroscopy (EDS) analysis are conducted for investigating the microstructure, specifically, copper particles in the PLA matrix. A 2D digital image correlation code with a machine learning algorithm is applied to the optical characterization and SEM-EDS images. In this way, micro- and mesostructural features, as well as the porosity ratios of the specimens are investigated. We prepare the multiscale homogenization by finite element method (FEM) simulations to capture the material’s response, both on a microscale and a mesoscale. We determined that the mesostructure and, thereby, the mechanical properties are significantly changed with the aforementioned process parameters. A lower layer thickness and a greater raster width led to a higher elasticity modulus and ultimate tensile strength (UTS). The optical microscopy analysis verified this statement: Decreasing the layer thickness and increasing the raster width result in larger contact lines between adjacent layers and, hence, lower porosity on the mesoscale. Realistic CAD images were prepared regarding the mesostructural differences and porosity ratios. Ultimately, all these changes are accurately modeled with mesoscale and multiscale simulations. The simulation results are validated by laboratory experiments.

Aligned with the Sustainability Development Goals (SDGs), we present the complete methodology of preparing bio-based polymer filaments to be used in additive manufacturing, specifically by means of so-called Fused Filament Fabrication (FFF) in 3D printing. Filament production and 3D printing were both developed and optimised in this work. First, we focused on the steps of producing and optimising the extrusion process of unreinforced polylactic acid (PLA) composite filaments. Second, we studied the resulting material properties by discussing the selection of a specimen geometry and the international standards adequate for FFF 3D printing. Moreover, we investigated the process parameters in order to achieve reliable structures. Based on the reinforcement material (stereocomplex fibres (Sc-PLA fibre) and bi-component fibres (bi-co PLA fibre), base-matrices were selected for producing un-reinforced filaments. In this way, we present the complete preparation approach by identifying problems and pitfalls for fostering studies of bio-based polymer filaments.