Investigation into the Acoustic Properties of Polylactic Acid Sound-Absorbing Panels Manufactured by 3D Printing Technology: The Influence of Nozzle Diameters and Internal Configurations.

Sound-absorbing panels are widely used in the acoustic design of aircraft parts, buildings and vehicles as well as in sound insulation and absorption in areas with heavy traffic. This paper studied the acoustic properties of sound-absorbing panels manufactured with three nozzle diameters (0.4 mm, 0.6 mm and 0.8 mm) by 3D printing from three types of polylactic acid filaments (Grey Tough PLA; Black PLA Pro; Natural PLA) and with six internal configurations with labyrinthine zigzag channels (Z1 and Z2). The absorption coefficient of the sample with the Z2 pattern, a 5.33 mm height, a 0.6 mm nozzle diameter and with Black PLA Pro showed the maximum value (α = 0.93) for the nozzle diameter of 0.6 mm. Next in position were the three samples with the Z1 pattern (4 mm height) made from all three materials used and printed with a nozzle diameter of 0.4 mm with a sound absorption coefficient value (α = 0.91) at 500 Hz. The highest value of the sound transmission loss (56 dB) was found for the sample printed with a nozzle size of 0.8 mm with the Z2 pattern (8 mm height) and with Black PLA Pro. The extruded material, the nozzle diameter and the internal configuration had a significant impact on the acoustic performance of the 3D-printed samples.

Mechanical Properties and Microstructure of Inconel 718 Lattice Structures Produced by Selective Laser Melting Process.

This article presents the results of an analysis regarding the microstructure, mechanical strength, and microhardness of two kinds of samples built through selective laser melting with Inconel 718, the most frequently used alloy in metal additive manufacturing due to its excellent mechanical properties. The sample geometry was made up of two types of lattice structures with spherical and hyperbolical stiffness elements. The goals of these studies are to determine how homogenization heat treatment influences the microhardness and the mechanical properties of the specimens and to identify the structure with the best mechanical properties. The analysis showed that heat treatment was beneficial because the regular dendritic structure disappears, the δ phase precipitates at the grain boundaries, and both the γ and γ″ phases dissolve. It has also been shown that the structures with hyperbolical stiffness elements have better compressive strength than the structures with the elliptical structures, with a 47.6% increase for the as-fabricated structures and an approximate 50% increase for the heat-treated structure.

Thermal and Sound Insulation Properties of Organic Biocomposite Mixtures.

Sustainable building materials with excellent thermal stability and sound insulation are crucial for eco-friendly construction. This study investigates biocomposites made from cellulose pulp reinforced with beeswax, fir resin, and natural fillers like horsetail, rice flour, and fir needles. Eight formulations were obtained, and their thermal resistance, oxidation temperature, and acoustic properties were evaluated. Biocomposites exhibited significant improvements compared to conventional materials. Oxidation temperature onset increased by 60-70 °C compared to polyurethane foam or recycled textiles, reaching 280-290 °C. Sound absorption coefficients ranged from 0.15 to 0.78, with some formulations exceeding 0.5 across mid-frequencies, indicating good sound-dampening potential. These findings demonstrate the promise of these biocomposites for sustainable construction, offering a balance of thermal and acoustic performance alongside environmental and health benefits.

Sound Absorption Performance and Mechanical Properties of the 3D-Printed Bio-Degradable Panels.

The 3D printing process allows complex structures to be obtained with low environmental impact using biodegradable materials. This work aims to develop and acoustically characterize 3D-printed panels using three types of materials, each manufactured at five infill densities (20%, 40%, 60%, 80% and 100%) with three internal configurations based on circular, triangular, and corrugated profiles. The highest absorption coefficient values (α = 0.93) were obtained from the acoustic tests for the polylactic acid material with ground birch wood particles in the triangular configuration with an infill density of 40%. The triangular profile showed the best acoustic performance for the three types of materials analysed and, from the point of view of the mechanical tests, it was highlighted that the same triangular configuration presented the highest resistance both to compression (40 MPa) and to three-point bending (50 MPa). The 40% and 60% infill density gave the highest absorption coefficient values regardless of the material analyzed. The mechanical tests for compression and three-point bending showed higher strength values for samples manufactured from simple polylactic acid filament compared to samples manufactured from ground wood particles. The standard defects of 3D printing and the failure modes of the interior configurations of the 3D-printed samples could be observed from the microscopic analysis of the panels. Based on the acoustic results and the determined mechanical properties, one application area for these types of 3D-printed panels could be the automotive and aerospace industries.

3D-Printed PLA Molds for Natural Composites: Mechanical Properties of Green Wax-Based Composites.

The first part of this paper is dedicated to obtaining 3D-printed molds using poly lactic acid (PLA) incorporating specific patterns, which have the potential to serve as the foundation for sound-absorbing panels for various industries and aviation. The molding production process was utilized to create all-natural environmentally friendly composites. These composites mainly comprise paper, beeswax, and fir resin, including automotive function as the matrices and binders. In addition, fillers, such as fir needles, rice flour, and Equisetum arvense (horsetail) powder, were added in varying amounts to achieve the desired properties. The mechanical properties of the resulting green composites, including impact and compressive strength, as well as maximum bending force value, were evaluated. The morphology and internal structure of the fractured samples were analyzed using scanning electron microscopy (SEM) and an optical microscopy. The highest impact strength was measured for the composites with beeswax, fir needles, recyclable paper, and beeswax fir resin and recyclable paper, 19.42 and 19.32 kJ/m2, respectively, while the highest compressive strength was 4 MPa for the beeswax and horsetail-based green composite. Natural-material-based composites exhibited 60% higher mechanical performance compared to similar commercial products used in the automotive industry.

Fused Filament Fabrication of Short Glass Fiber-Reinforced Polylactic Acid Composites: Infill Density Influence on Mechanical and Thermal Properties.

Fused Filament Fabrication (FFF) is one of the frequently used material extrusion (MEX) additive manufacturing processes due to its ability to manufacture functional components with complex geometry, but their properties depend on the process parameters. This paper focuses on studying the effects of process parameters, namely infill density (25%, 50%, 75%, and 100%), on the mechanical and thermal response of the samples made of poly(lactic acid) (PLA) reinforced with short glass fibers (GF) produced using FFF process. To perform a comprehensive analysis, tensile, flexural, compression, differential scanning calorimetry (DSC), and thermal gravimetric analysis (TGA) tests were used. The paper also aims to manufacture by FFF process of composite structures of the fuselage section type, as structural elements of an unmanned aerial vehicle (UAV), and their testing to compression loads. The results showed that the tensile, flexural and compression strength of the additive manufactured (AMed) samples increased with the increase of infill density and therefore, the samples with 100% infill density provides the highest mechanical characteristics. The AMed samples with 50% and 75% infill density exhibited a higher toughness than samples with 100% infill. DSC analyses revealed that the glass transition (Tg), and melting (Tm) temperature increases slightly as the infill density increases. Thermogravimetric analyses (TGA) show that PLA-GF filament loses its thermal stability at a temperature of about 311 °C and the increase in fill density leads to a slight increase in thermal stability and the complete degradation temperature of the AMed material. The compression tests of the fuselage sections manufactured by FFF made of PLA-GF composite showed that their stiffening with stringers oriented at an angle of ±45° ensures a higher compression strength than the stiffening with longitudinal stringers.

Compression and Bending Properties of Short Carbon Fiber Reinforced Polymers Sandwich Structures Produced via Fused Filament Fabrication Process.

Additive manufacturing, through the process of thermoplastic extrusion of filament, allows the manufacture of complex composite sandwich structures in a short time with low costs. This paper presents the design and fabrication by Fused Filament Fabrication (FFF) of composite sandwich structures with short fibers, having three core types C, Z, and H, followed by mechanical performance testing of the structures for compression and bending in three points. Flatwise compression tests and three-point bending have clearly indicated the superior performance of H-core sandwich structures due to dense core structures. The main modes of failure of composite sandwich structures were analyzed microscopically, highlighting core shear buckling in compression tests and face indentation in three-point bending tests. The strength-mass ratio allowed the identification of the structures with the best performances considering the desire to reduce the mass, so: the H-core sandwich structures showed the best results in compression tests and the C-core sandwich structures in three-point bending tests. The feasibility of the FFF process and the three-point bending test of composite wing sections, which will be used on an unmanned aircraft, have also been demonstrated. The finite element analysis showed the distribution of equivalent stresses and reaction forces for the composite wing sections tested for bending, proving to validate the experimental results.

Infill Density Influence on Mechanical and Thermal Properties of Short Carbon Fiber-Reinforced Polyamide Composites Manufactured by FFF Process.

In three-dimensional (3D) printing, one of the main parameters influencing the properties of 3D-printed materials is the infill density (ID). This paper presents the influence of ID on the microstructure, mechanical, and thermal properties of carbon fiber-reinforced composites, commercially available, manufactured by the Fused Filament Fabrication (FFF) process. The samples were manufactured using FFF by varying the infill density (25%, 50%, 75%, and 100%) and were subjected to tensile tests, three-point bending, and thermal analyses by Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA). It was shown that the samples with 100% ID had the highest values of both tensile, 90.8 MPa, and flexural strengths, 114 MPa, while those with 25% ID had the lowest values of 56.4 MPa and 62.2 MPa, respectively. For samples with infill densities of 25% and 50%, the differences between the maximum tensile and flexural strengths were small; therefore, if the operating conditions of the components allow, a 25% infill density could be used instead of 50%. After DSC analysis, it was found that the variation in the ID percentage determined the change in the glass transition temperature from 49.6 °C, for the samples with 25% ID, to 32.9 °C, for those with 100% ID. TGA results showed that the samples with IDs of 75% and 100% recorded lower temperatures of onset degradation (approximately 344.75 °C) than those with infill densities of 25% and 50% (348.5 °C, and 349.6 °C, respectively).

The Influence of Solar Sintering on Copper Heat Exchanger Parts with Controlled 3D-Printed Morphology.

From a scientific point of view, heat transfer is different in solar furnaces compared with classical ones and the influence of direct concentrated solar radiation on sintered parts needs to be studied in detail to determine the feasibility of solar furnaces in manufacturing small workpieces. This study was performed on cylindrical samples with controlled morphology obtained by a powder metallurgy 3D printing technique. All samples were heated with a heating rate of 120 ± 10 °C/minute, with 0, 1, 2, 3, 4 and 5 min holding times at 900 °C and 930 °C. The morphology of the samples was analyzed microscopically, the microhardness was determined before and after sintering, and the results were correlated with the sintering parameters (temperature, heating rate and holding time). The best results were obtained at 930 °C with 5 min holding time from the microhardness value and microstructure point of view.

Compressive Behaviour of Lattice Structures Manufactured by Polyjet Technologies.

Additive manufacturing (AM) techniques can help to reduce the time and cost for manufacturing complex shaped parts. The main goal of this research was to determine the best strength structure of six different types of lattice cells, manufactured using the Poly Jet AM technology. In order to perform the tests, six samples with the same structure were created for each lattice type. For testing the samples in compression, an electromechanical test machine was used. finite element analysis (FEA) analysis was used in order to determine the area where the greatest stresses occured and to estimate the maximal compressive strength. The strongest structure was determined by obtaining the maximal compressive strength. This was calculated in two ways: as a ratio between the maximal supported force and the mass of the sample (N/g) and as a ratio between the maximal supported force and the critical section of the sample (MPa).

Mechanical Performances of Lightweight Sandwich Structures Produced by Material Extrusion-Based Additive Manufacturing.

Material Extrusion-Based Additive Manufacturing Process (ME-AMP) via Fused Filament Fabrication (FFF) offers a higher geometric flexibility than conventional technologies to fabricate thermoplastic lightweight sandwich structures. This study used polylactic acid/polyhydroxyalkanoate (PLA/PHA) biodegradable material and a 3D printer to manufacture lightweight sandwich structures with honeycomb, diamond-celled and corrugated core shapes as a single part. In this paper, compression, three-point bending and tensile tests were performed to evaluate the performance of lightweight sandwich structures with different core topologies. In addition, the main failure modes of the sandwich structures subjected to mechanical tests were evaluated. The main failure modes that were observed from mechanical tests of the sandwich structure were the following: face yielding, face wrinkling, core/skin debonding. Elasto-plastic finite element analysis allowed predicting the global behavior of the structure and stressing distribution in the elements of lightweight sandwich structures. The comparison between the results of bending experiments and finite element analyses indicated acceptable similarity in terms of failure behavior and force reactions. Finally, the three honeycomb, diamond-celled and corrugated core typologies were used in the leading edge of the wing and were impact tested and the results created favorable premises for using such structures on aircraft models and helicopter blade structures.

Reliability and lifetime assessment of glider wing's composite spar through accelerated fatigue life testing.

The evaluation of the reliability and the lifetime of aerospace components has become an important segment of the design stage. The aeronautical components are subjected to complex, rigorous tests and have a long test life. The main goal in the field of aviation is to have components with high reliability and quality and to meet the mandatory requirements and regulations. The spars are stiffening components positioned along the wing and which take up most of the load and are tested for fatigue over a long period of time. The spar which was analysed in this study has a sandwich structure with GFRP (glass fiber reinforced plastic) skin and foam core. In this paper, the performances in the static and dynamic conditions of the GFRP-foam sandwich structures cut out of the composite spar of a glider were analysed. Additionally, using accelerated techniques based on the three-point fatigue bending test, the main reliability indicators of the GFRP-foam sandwich structures were determined. Using the statistical processing of the experimental data and the Inverse Power Law-Weibull acceleration model, the mean number of cycles to failure, in normal testing conditions of the GFRP-foam specimens was determined, with a value of 102,814. Using the accelerated testing techniques of the GFRP-foam sandwich structures an important decrease of the test time (8.43 times) was obtained.

Influence of Internal Innovative Architecture on the Mechanical Properties of 3D Polymer Printed Parts.

The utilization of polymer-based materials is quickly expanding. The enterprises of today are progressively seeking techniques to supplant metal parts with polymer-based materials as a result of their light weight, simple support and modest costs. The ceaselessly developing requirement for composite materials with new or enhanced properties brings about the preparation of different polymer mixes with various arrangements, morphologies and properties. Fused filament fabrication processes such as 3D-printing are nowadays shaping the actual pathway to a full pallet of materials, from art-craft to biomaterials. In this study, the structural and mechanical behavior of three types of commercially available filaments comprised of synthetic poly(acrylonitrile-co-butadiene-co-styrene) (ABS), poly(lactic acid) (PLA) and poly(lactic acid)/polyhydroxyalkanoate reinforced with bamboo wood flour composite (PLA/PHA BambooFill) were assessed through mechanical testing and optical microscopy, aiming to understand how the modifications that occur in the printed models with internal architecture are influencing the mechanical properties of the 3D-printed material. It has been determined that the material printed from PLA presents the highest compression strength, three-point bending and shock resistance, while the ABS shows the best tensile strength performance. A probability plot was used to verify the normality hypothesis of data for the tensile strength, in conjunction with the Anderson-Darling statistic test. The results of the statistic indicated that the data were normally distributed and that there is a marked influence of the internal architecture of the 3D-printed models on the mechanical properties of the printed material.