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Applied Sciences
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Applications of Novel Materials and Surfaces in Additive Manufacturing
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Applications of Novel Materials and Surfaces in Additive Manufacturing

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Additive Manufacturing Technologies".

Deadline for manuscript submissions: closed (20 June 2024) | Viewed by 6002

Special Issue Editors

Dr. Tomislav Cigula

E-Mail Website
Guest Editor
Faculty of Graphic Arts, University of Zagreb, 10000 Zagreb, Croatia
Interests: surface phenomenon; chemical processing; coatings; printing plates
Dr. Marina Vukoje

E-Mail Website1 Website2
Guest Editor
Faculty of Graphic Arts, University of Zagreb, 10000 Zagreb, Croatia
Interests: paper recycling; thermochromic inks; printing ink; ageing of paper; paper; coatings; FTIR of paper
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Raša Urbas

E-Mail Website
Guest Editor
Faculty of Natural Sciences and Engineering, University of Ljubljana, Ljubljana, Slovenia
Interests: printing; printing inks; graphic prepress; printing for blind and visually impaired

Special Issue Information

Dear Colleagues,

Additive manufacturing provides a powerful tool for various applications in different fields. Nowadays, a number of available additive processes and materials are used in additive manufacturing. To tackle challenges arising from legislation change and manufacturing trends, researchers need to constantly develop new materials and processes. Additionally, introducing new materials could enable better manufacturing results and more efficient processing. This Special Issue aims to present new ideas and potential solutions in additive manufacturing by proposing and characterizing novel materials, as well as the material processing technologies and processing settings.

This Special Issue will publish high quality original research papers dealing with:

  • Material preparation procedures;
  • Material characterization methods and procedures;
  • Material recyclability and life cycle assessment;
  • Material application processes;
  • Surface properties and structure;
  • Enhancing surface functionality;
  • Assessment of products made via additive manufacturing;
  • Additive manufacturing processes.

Dr. Tomislav Cigula
Dr. Marina Vukoje
Prof. Dr. Raša Urbas
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • mechanical properties of material
  • chemical properties of material
  • material recyclability
  • surface functionality
  • additive manufacturing process
  • composites
  • process optimization

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (5 papers)

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Research

16 pages, 6842 KiB  
Article
Tribological Analysis of Fused Filament Fabrication PETG Parts Coated with IGUS
by Moises Batista, Delia Tenorio, Irene Del Sol and Juan Manuel Vazquez-Martinez
Appl. Sci. 2024, 14(16), 7161; https://doi.org/10.3390/app14167161 - 15 Aug 2024
Cited by 1 | Viewed by 716
Abstract
This paper studied the tribological behaviour of parts manufactured using fused filament fabrication (FFF) technology with PETG (polyethylene terephthalate glycol) coated with IGUS tribological filaments. The research focuses on analysing how these multi-material parts behave under different loads. The objective of this study [...] Read more.
This paper studied the tribological behaviour of parts manufactured using fused filament fabrication (FFF) technology with PETG (polyethylene terephthalate glycol) coated with IGUS tribological filaments. The research focuses on analysing how these multi-material parts behave under different loads. The objective of this study is to evaluate the wear resistance and friction coefficient of parts coated with different thicknesses of IGUS material. The methodology employs pin-on-disc (PoD) tribological tests to measure behaviour under various load conditions and coating thicknesses. The results indicate that increasing the coating thickness improves surface stability and reduces roughness, although it does not significantly affect the average friction coefficient. This research concludes that coating thickness has a moderate impact on surface quality and that the applied load significantly influences the depth and width of the wear groove. This contribution is valuable for the field of additive manufacturing as it provides a better understanding of how to optimise the tribological properties of parts manufactured using FFF, which is crucial for industrial applications where wear and friction are critical factors. The practical application includes the potential improvement of components in the automotive and aerospace industries. Full article
(This article belongs to the Special Issue Applications of Novel Materials and Surfaces in Additive Manufacturing)
►▼ Show Figures

Figure 1

Figure 1
<p>Scheme of specimens and manufacturing strategies.</p> Full article ">Figure 2
<p>Images of PETG specimens coated with IGUS manufactured with FFF: (<b>a</b>) with 0.3 mm coating thickness; (<b>b</b>) with 0.6 mm coating thickness; (<b>c</b>) with 0.9 mm coating thickness.</p> Full article ">Figure 3
<p>Evolution of surface quality in terms of (<b>a</b>) Sa, (<b>b</b>) Sz, and (<b>c</b>) Sdc.</p> Full article ">Figure 4
<p>Evolution of tests conducted on specimens coated with 0.3 mm coating.</p> Full article ">Figure 5
<p>Evolution of tests conducted on specimens coated with 0.6 mm coating.</p> Full article ">Figure 6
<p>Evolution of tests conducted on specimens coated with 0.9 mm coating.</p> Full article ">Figure 7
<p>Evolution of the average coefficient of friction.</p> Full article ">Figure 8
<p>Particles detached during the tribological tests.</p> Full article ">Figure 9
<p>Evolution of the wear groove width.</p> Full article ">Figure 10
<p>Evolution of the wear groove depth.</p> Full article ">
15 pages, 2621 KiB  
Article
In Vitro Study of the Surface Roughness, Hardness, and Absorption of an Injection-Molded Denture Base Polymer, Manufactured under Insufficient Mold Solidification
by Bozhana Chuchulska, Mariya Dimitrova and Boyan Dochev
Appl. Sci. 2024, 14(7), 2906; https://doi.org/10.3390/app14072906 - 29 Mar 2024
Cited by 1 | Viewed by 1322
Abstract
The current study sought to investigate the changes in surface hardness, roughness, and moisture absorption of the Vertex ThermoSens polymer (Vertex Dental, 3D Systems, The Netherlands) following immersion in artificial saliva for various periods (7, 14, and 28 days). A total of 60 [...] Read more.
The current study sought to investigate the changes in surface hardness, roughness, and moisture absorption of the Vertex ThermoSens polymer (Vertex Dental, 3D Systems, The Netherlands) following immersion in artificial saliva for various periods (7, 14, and 28 days). A total of 60 rectangular specimens with dimensions of 20 mm in length, 20 mm in width, and 3 mm in thickness were made. Due to insufficient mold solidification, these specimens were made utilizing the injection molding process. A Mitutoyo Surftest 4 roughness meter (Mitutoyo, Aurora, IL, USA) was used to measure the surface roughness of the test materials. The ThermoSens polymer hardness was assessed using the Shor method and D—HSD scale, while absorption was measured with a Sartorius analytical balance. Results indicated the highest mean hardness after 28 days (M = 77.6) (Surface 1) and the lowest for the control group (M = 59) (Surface 2). The maximum surface roughness occurred in direction 2.2 pre-immersion (Ra = 2.88 μm) and 7 days post-removal (Ra = 2.95 μm). The control group exhibited the lowest absorption (Wsp = 1.524 mg/mm3), with the highest mean values over 28 days (Wsp = 1.541 mg/mm3). The elevated flask and plaster temperature slowed polymer solidification, resulting in longer macromolecules and improved mechanical properties and surface features. Full article
(This article belongs to the Special Issue Applications of Novel Materials and Surfaces in Additive Manufacturing)
►▼ Show Figures

Figure 1

Figure 1
<p>The position of the specimen in the injection mold.</p> Full article ">Figure 2
<p>Test specimens before and after immersion in artificial saliva.</p> Full article ">Figure 3
<p>Measuring roughness using the Mitutoyo Surftest 4 roughness meter.</p> Full article ">Figure 4
<p>Hardness measurement using the EQUOTIP hardness tester (Screening Eagle Technologies AG, Zurich, Switzerland).</p> Full article ">Figure 5
<p>Mean and SD values for the investigated Surface 1 and Surface 2 for the tested periods.</p> Full article ">Figure 6
<p>The mean value of the HSD hardness of the investigated surfaces.</p> Full article ">Figure 7
<p>Measuring the mass of a test body with a Sartorius balance (Sartorius Stedim Filters Inc., Yauco, Puerto Rico).</p> Full article ">Figure 8
<p>The water absorption of the experimental specimens after immersion in artificial saliva for different time frames.</p> Full article ">
12 pages, 12659 KiB  
Article
Impact Fracture Resistance of Fused Deposition Models from Polylactic Acid with Respect to Infill Density and Sample Thickness
by Dubravko Banić, Katarina Itrić Ivanda, Marina Vukoje and Tomislav Cigula
Appl. Sci. 2024, 14(5), 2035; https://doi.org/10.3390/app14052035 - 29 Feb 2024
Cited by 2 | Viewed by 868
Abstract
Fused deposition modeling (FDM) is widely employed in prototyping due to its cost-effectiveness, speed, and ability to produce detailed and functional prototypes using a variety of materials. Simultaneously, consideration for the use of biodegradable polymers and a general reduction in their usage while [...] Read more.
Fused deposition modeling (FDM) is widely employed in prototyping due to its cost-effectiveness, speed, and ability to produce detailed and functional prototypes using a variety of materials. Simultaneously, consideration for the use of biodegradable polymers and a general reduction in their usage while enhancing the production of polymer-based products is at the forefront of sustainable practices and environmental consciousness. This study investigates the impact fracture resistance of FDM models fabricated from Polylactic Acid (PLA), examining the influence of infill density (50% and 100% infill) and sample thickness (2 mm, 3 mm, and 5 mm). Optical microscopy, FTIR spectroscopy, and SEM analysis of PLA filament and fractured FDM PLA surfaces in impacted samples were conducted to ascertain the influence of process parameters on impact damage and failure mechanisms. The results indicate that a 100% infill profile with a 2 mm thickness should be avoided due to unpredictable behavior under impact. Conversely, a 5 mm thickness demonstrates significantly higher durability in comparison to a 50% infill profile. Optimal impact strength is observed in samples with a 3 mm thickness, suggesting potential material savings with 50% infill without compromising mechanical properties. The findings contribute valuable insights for refining FDM parameters and advancing the understanding of material behaviors in sustainable manufacturing practices. Full article
(This article belongs to the Special Issue Applications of Novel Materials and Surfaces in Additive Manufacturing)
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Figure 1

Figure 1
<p>Fracture resistance of PLA FDM models with 50% infill: (<b>a</b>) impact on bottom layer, and (<b>b</b>) impact on upper layer.</p> Full article ">Figure 2
<p>Fracture resistance of PLA FDM models with 100% infill.</p> Full article ">Figure 3
<p>Micrograph of PLA FDM models after mechanical testing; (<b>a</b>) 2 mm sample made with 50% infill (front view under a magnification of 5×), (<b>b</b>) 5 mm sample made with 50% infill (front view under a magnification of 5×), (<b>c</b>) 3 mm sample made with 100% infill (cross-section view under a magnification of 5×), and (<b>d</b>) 5 mm sample made with 100% infill (front view under a magnification of 5×).</p> Full article ">Figure 3 Cont.
<p>Micrograph of PLA FDM models after mechanical testing; (<b>a</b>) 2 mm sample made with 50% infill (front view under a magnification of 5×), (<b>b</b>) 5 mm sample made with 50% infill (front view under a magnification of 5×), (<b>c</b>) 3 mm sample made with 100% infill (cross-section view under a magnification of 5×), and (<b>d</b>) 5 mm sample made with 100% infill (front view under a magnification of 5×).</p> Full article ">Figure 4
<p>SEM micrograph of PLA filament cross-section.</p> Full article ">Figure 5
<p>SEM micrograph of the interior of the 3D print made with 50% infill.</p> Full article ">Figure 6
<p>SEM micrograph of 3D print made with 100% infill; (<b>a</b>) side view under a magnification of 50×, (<b>b</b>) side view under a magnification of 200×, and (<b>c</b>) cross-section view under a magnification of 50×.</p> Full article ">Figure 7
<p>SEM micrograph of 3D print made with 100% infill (cross section view under magnification of 200×).</p> Full article ">Figure 8
<p>FTIR spectra of PLA FDM models made with 100% infill and neat PLA filament.</p> Full article ">
13 pages, 3121 KiB  
Article
Legibility of Sans-Serif Typeface on Different Paper Grades Made from Invasive Alien Plant Species
by Klementina Možina, Dorotea Kovačević and Klemen Možina
Appl. Sci. 2024, 14(3), 1281; https://doi.org/10.3390/app14031281 - 3 Feb 2024
Viewed by 978
Abstract
Invasive alien plant species (IAPS) may cause threats to native biodiversity in ecosystems. Researchers have been investigating all the possible ways that they can be used effectively for other purposes. Since IAPS are capable of forming cellulose fibre nets, in this research, papers [...] Read more.
Invasive alien plant species (IAPS) may cause threats to native biodiversity in ecosystems. Researchers have been investigating all the possible ways that they can be used effectively for other purposes. Since IAPS are capable of forming cellulose fibre nets, in this research, papers were made from three different types of IAPS (Japanese knotweed, giant goldenrod, and black locust). This research examined these IAPS papers and their effectiveness when used as printing substrates. In comparison to commercial office paper, the differences in basic, surface, optical, and microscopic properties were measured. As a widely used technology, inkjet printing was applied. We tested a commonly used sans-serif typeface (which has been established as being more legible than other typefaces in previous research) in three different type sizes (i.e., 8, 10, and 12 pt). According to the results, paper made from IAPS could offer some usable properties and acceptable legibility, especially when printing typefaces with specific attributes, such as moderate counter size, higher x-height, and minimal differences in the letter stroke width, are used. An appropriate typographic tonal density should be achieved in combination with an adequate letter size, e.g., 10 pt type size when a sans-serif typeface is used. Full article
(This article belongs to the Special Issue Applications of Novel Materials and Surfaces in Additive Manufacturing)
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Figure 1

Figure 1
<p>Field intensities printed on commercial office paper (S1), Japanese knotweed paper (S2), giant goldenrod paper (S3), and black locust paper (S4).</p> Full article ">Figure 2
<p>Letter “a” characters at 50× magnification (Arial, 8 pt) and their binary pictures on commercial office paper (S1), Japanese knotweed paper (S2), giant goldenrod paper (S3), and black locust paper (S4).</p> Full article ">Figure 3
<p>Samples of 8 pt and 10 pt Arial typeface printed on commercial office paper (S1), Japanese knotweed paper (S2), giant goldenrod paper (S3), and black locust paper (S4).</p> Full article ">Figure 4
<p>Average reading time for texts in different type sizes (8 pt, 10 pt, and 12 pt) printed on commercial office paper (S1), Japanese knotweed paper (S2), giant goldenrod paper (S3), and black locust paper (S4).</p> Full article ">Figure 5
<p>Average reading time for texts printed on commercial office paper (S1), Japanese knotweed paper (S2), giant goldenrod paper (S3), and black locust paper (S4).</p> Full article ">Figure 6
<p>Correctness of participants’ answers across conditions, i.e., different papers (commercial office paper (S1), Japanese knotweed paper (S2), giant goldenrod paper (S3), and black locust paper (S4)) and different type sizes (8 pt, 10 pt, and 12 pt).</p> Full article ">
22 pages, 27637 KiB  
Article
Comparison of Quality of Porous Structure Specimens Produced by Different Additive Technologies and from Different Materials
by Jozef Tkac, Teodor Toth, Ondrej Mizera, Vieroslav Molnar, Gabriel Fedorko and Miroslav Dovica
Appl. Sci. 2024, 14(2), 648; https://doi.org/10.3390/app14020648 - 12 Jan 2024
Cited by 1 | Viewed by 1258
Abstract
Lattice and gyroid structures are often subjected to additive technologies to produce various types of products, and the current market has a number of 3D printers that can be used for their production. The quality of the products produced in this way can [...] Read more.
Lattice and gyroid structures are often subjected to additive technologies to produce various types of products, and the current market has a number of 3D printers that can be used for their production. The quality of the products produced in this way can be assessed on the basis of technical parameters and the filament used. Such an approach, however, is insufficient. In terms of quality, other product parameters need to be assessed, such as the surface texture and the internal structure’s porosity. For such an assessment, we can use the industrial tomography method and the method of roughness measurement via an optical microscope. The paper presents research on the assessment of the surface texture and porosity in lattice and gyroid structures. For the research, two types of test specimens—a specimen with a lattice structure and a specimen with a gyroid structure—were prepared. The obtained results proved that the 3D printing technology directly impacted the surface texture and porosity. For experimental specimens produced by SLS technology, we found that it was very important to carefully remove the excess powder, as unremoved powder can significantly affect the porosity results. For specimens produced by FDM technology, the research confirmed that some “gaps” between the layers were not pores but defects created during specimen production. When analyzing the surface using the Alicon Infinite G5 optical microscope, we found that the measured roughness results were directly impacted by the specimen’s surface color, the structure’s geometry, and the ambient light, which was confirmed by a red lattice experimental specimen, the surface of which could not be scanned. Based on the above, it can be stated that the selection of 3D technology for additive production needs must be given adequate attention regarding the quality of the created structures and textures. Full article
(This article belongs to the Special Issue Applications of Novel Materials and Surfaces in Additive Manufacturing)
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Figure 1

Figure 1
<p>Dimension and shape of porous structure 3D model filled with (<b>a</b>) lattice structure and (<b>b</b>) gyroid structure.</p> Full article ">Figure 2
<p>Types of experimental specimens.</p> Full article ">Figure 3
<p>Data processing and assessment methodology.</p> Full article ">Figure 4
<p>Measurement principle using the Alicona Infinite G5 optical microscope [<a href="#B28-applsci-14-00648" class="html-bibr">28</a>].</p> Full article ">Figure 5
<p>Gray lattice specimen (SLS method)—representation of unremoved excess powder, impurities, and pores on CT in sections. (<b>a</b>) Lattice specimen FRONT plane; (<b>b</b>) lattice specimen TOP plane; (<b>c</b>) gyroid specimen FRONT plane; (<b>d</b>) Gyroid specimen TOP plane.</p> Full article ">Figure 6
<p>Gray specimens (SLS method)—representation of reconstructed surface: (<b>a</b>) lattice, (<b>b</b>) gyroid.</p> Full article ">Figure 7
<p>Red specimens (FDM method)—representation of material and pore layering on CT in sections. (<b>a</b>) Lattice FRONT plane; (<b>b</b>) lattice TOP plane; (<b>c</b>) gyroid FRONT plane; (<b>d</b>) gyroid TOP plane.</p> Full article ">Figure 8
<p>Red specimens (FDM method)—representation of reconstructed surface: (<b>a</b>) lattice; (<b>b</b>) gyroid.</p> Full article ">Figure 9
<p>Black specimens (FDM method)—representation of material and pore layering on CT in sections. (<b>a</b>) Lattice FRONT plane; (<b>b</b>) lattice TOP plane; (<b>c</b>) gyroid FRONT plane; (<b>d</b>) gyroid TOP plane.</p> Full article ">Figure 10
<p>Black specimens (FDM method)—representation of reconstructed surface: (<b>a</b>) lattice; (<b>b</b>) gyroid.</p> Full article ">Figure 11
<p>Assessment of lattice structures’ porosity: (<b>a</b>) red sample (FDM method); (<b>b</b>) gray sample (SLS method).</p> Full article ">Figure 12
<p>Assessment of the wall thickness of the lattice gray specimen (SLS method) using the wall thickness analysis module: (<b>a</b>) FRONT plane; (<b>b</b>) TOP plane.</p> Full article ">Figure 13
<p>Measurement of the diameter in gray lattice specimen (SLS method): (<b>a</b>) Gaussian feature; (<b>b</b>) minimum circumscribed feature; (<b>c</b>) maximum inscribed feature.</p> Full article ">Figure 14
<p>View of the strut cross-section in the lattice structure (FDM method): (<b>a</b>) red; (<b>b</b>) black.</p> Full article ">Figure 15
<p>Measurement of the gyroid structure’s wall thickness: (<b>a</b>) gray (SLS method); (<b>b</b>) red (FDM method); (<b>c</b>) black (FDM method).</p> Full article ">Figure 16
<p>Illustration of deviations when comparing manufactured gray specimens (SLS method) to the CAD model: (<b>a</b>) lattice; (<b>b</b>) gyroid.</p> Full article ">Figure 17
<p>Illustration of deviations when comparing manufactured red specimens (FDM method) to the CAD model: (<b>a</b>) lattice; (<b>b</b>) gyroid.</p> Full article ">Figure 18
<p>Illustration of deviations when comparing manufactured black specimens (FDM method) to the CAD model: (<b>a</b>) lattice; (<b>b</b>) gyroid.</p> Full article ">Figure 19
<p>Red gyroid specimen (FDM method)—scan from the upper side.</p> Full article ">Figure 20
<p>Gray gyroid specimen (SLS method)—scan from the upper side.</p> Full article ">Figure 21
<p>Gray lattice specimen (SLS method)—scan from the upper side.</p> Full article ">Figure 22
<p>Black gyroid specimen (FDM method)—scan from the upper side.</p> Full article ">Figure 23
<p>Black lattice specimen (FDM method)—scan from the upper side.</p> Full article ">
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