A Methodological Framework for Assessing the Influence of Process Parameters on Strand Stability and Functional Performance in Fused Filament Fabrication.

With an ever-increasing material and design space available for Fused Filament Fabrication (FFF) technology, fabrication of complex three-dimensional structures with functional performance offers unique opportunities for product customization and performance-driven design. However, ensuring the quality and functionality of FFF-printed parts remains a significant challenge, as material-, process-, and system-level factors introduce variability and potentially hinder the translation of bulk material properties in the respective FFF counterparts. To this end, the present study presents a methodological framework for assessing the influence of process parameters on FFF strand stability and functional performance through a systematic analysis of FFF structural elements (1D stacks of FFF strands and 3D blocks), in terms of dimensional deviation from nominal geometry and resistivity, corresponding to the printability and functionality attributes, respectively. The influence of printing parameters on strand stability was investigated in terms of dimensional accuracy and surface morphology, employing optical microscopy and micro-computed tomography (mCT) for dimensional deviation analysis. In parallel, electrical resistance measurements were carried out to assess the effect of different process parameter combinations and toolpath patterns on functional performance. In low-level structural elements, strand height (H) was found to induce the greatest influence on FFF strand dimensional accuracy and resistivity, with higher H values leading to a reduction in resistivity of up to 38% in comparison with filament feedstock; however, this occurred at the cost of increased dimensional deviation. At higher structural levels, the overall effect of process parameters was found to be less pronounced, indicating that the translation of 1D strand properties to 3D blocks is subject to a trade-off due to competing mechanisms that facilitate/hinder current flow. Overall, the proposed framework enables the quantification of the influence of process parameters on the selected response variables, contributing to the development of standard operating procedures and recommendations for selecting optimal process parameters to achieve the desired process stability and functional performance in FFF.

3D Printing Processability of a Thermally Conductive Compound Based on Carbon Nanofiller-Modified Thermoplastic Polyamide 12.

A polyamide (PA) 12-based thermoplastic composite was modified with carbon nanotubes (CNTs), CNTs grafted onto chopped carbon fibers (CFs), and graphene nanoplatelets (GNPs) with CNTs to improve its thermal conductivity for application as a heat sink in electronic components. The carbon-based nanofillers were examined by SEM and Raman. The laser flash method was used to measure the thermal diffusivity in order to calculate the thermal conductivity. Electrical conductivity measurements were made using a Keithley 6517B electrometer in the 2-point mode. The composite structure was examined by SEM and micro-CT. PA12 with 15 wt% of GNPs and 1 wt% CNTs demonstrated the highest thermal conductivity, and its processability was investigated, utilizing sequential interdependence tests to evaluate the composite material behavior during fused filament fabrication (FFF) 3D printing processing. Through this assessment, selected printing parameters were investigated to determine the optimum parametric combination and processability window for the composite material, revealing that the selected composition meets the necessary criteria to be processable with FFF.

Mechanical Enhancement of Cytocompatible 3D Scaffolds, Consisting of Hydroxyapatite Nanocrystals and Natural Biomolecules, Through Physical Cross-Linking.

Bioinspired scaffolds mimicking natural bone-tissue properties holds great promise in tissue engineering applications towards bone regeneration. Within this work, a way to reinforce mechanical behavior of bioinspired bone scaffolds was examined by applying a physical crosslinking method. Scaffolds consisted of hydroxyapatite nanocrystals, biomimetically synthesized in the presence of collagen and l-arginine. Scaffolds were characterized by X-ray diffraction, Fourier transform infrared spectroscopy, scanning electron microscopy (SEM), microcomputed tomography, and nanoindentation. Results revealed scaffolds with bone-like nanostructure and composition, thus an inherent enhanced cytocompatibility. Evaluation of porosity proved the development of interconnected porous network with bimodal pore size distribution. Mechanical reinforcement was achieved through physical crosslinking with riboflavin irradiation, and nanoindentation tests indicated that within the experimental conditions of 45% humidity and 37 °C, photo-crosslinking led to an increase in the scaffold's mechanical properties. Elastic modulus and hardness were augmented, and specifically elastic modulus values were doubled, approaching equivalent values of trabecular bone. Cytocompatibility of the scaffolds was assessed using MG63 human osteosarcoma cells. Cell viability was evaluated by double staining and MTT assay, while attachment and morphology were investigated by SEM. The results suggested that scaffolds provided a cell friendly environment with high levels of viability, thus supporting cell attachment, spreading and proliferation.