Complex structures derived from computer design may be produced using 3D printing enabling rapid prototyping and manufacturing. The need for more efficient printed polymer laminated composites will increase as printed polymeric components have limited mechanical properties and functions. The use of 3D printing in the production of composite materials offers a variety of advantages, including high accuracy, cheap cost, and geometry customization. Charles Hull first developed the process of mixing materials to create parts from 3D modeled data in the 1980s, and it is sometimes referred to as additive manufacturing, 3D printing, or rapid prototyping (RP) [1–2]. By mixing materials, this process creates objects while minimizing waste and upholding dimensional accuracy [3]. The process begins with the creation of a mesh 3D computerized model using acquired image data created in a computer-aided design (CAD) application. Prior to actually sending the meshed data to the 3D printing machine, an STL (Surface Tessellation Language) file is often created. This file can then be separated into a two-dimensional layer in a built-in format.
Thermoplastic polymeric materials such as ABS, polylactic acid (PLA), polyamide (PA), and polycarbonate (PC), as well as thermoset polymer parts, can be processed using 3D printing processes [4–9]. (i.e., epoxy resin). Epoxies are highly oxidized polymers that require heating or ultraviolet cure to complete the polymerization process. Initially less viscous, their viscosity slowly rises over the curing process [10–12]. Epoxies are consequently suitable for thermally and UV printing methods. Regardless of the choice of the material, rapid prototyping composites have also discovered promising utility in the aviation sector for producing complex, less dense materials [13], architectural style sectors for designing structures [14], the art and design sectors for reproducing artifacts [15], and the healthcare industries for printing tissues and organs [16]. Nevertheless, the bulk of 3D printing-made polymeric materials are still used as concept models instead of functional goods since polymeric objects lack the strength and functionality to be fully operational and load-concentrated locations. The application of polymeric parts produced by additive manufacturing is constrained by these drawbacks.
By combining the primary component (i.e., matrix) and reinforcement agents, 3D printed polymeric materials solve those problems by creating certain structures with highly required structural quality features as opposed to components that can achieve by themselves [17]. The development of polymeric matrix composites (PMC) with excellent mechanical characteristics and functions is supported by the incorporation of particle, fiber, and nano-reinforcing agents into polymeric materials.
Conventional composite production techniques like molding, casting, and machining generate parts with complex structures during metal removal techniques [18]. The capacity to control the complicated surfaces is restricted, despite the fact that the manufacturing process and composites’ efficacy will be well controlled and known in current techniques. Utilizing additive manufacturing (AM) technology, complex materials can be made without any waste. The dimensions and forms of composite structures can be precisely controlled by using Computer-aided design. As a result, composite constructions that are 3D printed manage to balance flexibility with parts that are more efficient. Even though the 3D printing method has attracted a lot of interest in the last 30 years, the majority of investigations primarily focused on the development of operational methods and the construction of pure natural polymers. Even by way, in current history, huge advances have been made in the creation of printed polymeric materials with enhanced quality.
A number of printing techniques were employed to make polymeric materials. While some, such as stereolithography, fused deposition modeling (FDM), selective laser melting (SLM), and three-dimensional plotting, have been designed and assembled, the others are currently under development and have only been applied by a small number of authors. Each method for creating composite things has its own advantages and disadvantages. The starting materials, processing rate, precision specifications, pricing, and performance criteria for the finished part all influence the manufacturing approach that is used. Fused deposition-modeled printers represent the most widely used machines for producing polymeric materials. Thermoplastic polymers such as PCs, ABS, and PLA are frequently utilized due to their low melting points. The extrusion of plastic filament is controlled by Fused deposition modeling printers. In fused deposition modeling, the filaments get partially molten just at the nozzle and are crushed in extruded layers by layers on a printing platform. Upon the platforms, they merge with one another before being hardened as final parts. Variable process parameters, such as print size, will be used to control the printing characteristics of parts, printing orientation, raster size, layers height, air gap, and raster orientations.
Melaka et al. carried out a research study using ABS as the polymer matrices and Kevlar fibers as reinforcements. The composites were made with varied volumetric percentages of 4 percentage, 8 percentage, and 10 percent to test their tensile characteristics. Elastic constant and strength properties were shown to rise as filler contents were increased [19]. Perez et al. compared the fluctuation in strength properties with different fillers. The specimens were made using matrices made of ABS. In contrast to the original ABS specimen, Titanium dioxide, jute fiber, and thermoplastic elastomers were each applied separately. Comparing ABS-Titanium dioxide to unadulterated ABS, strength was enhanced, but strength was reduced for thermoplastic elastomers and jute fibers [20]. Thermal conductivity was examined by Vijay et al. using the copper nanoparticles incorporation. The nanoparticle's form would have a significant impact on the desirable characteristics of copper was incorporated in two different amounts: 2.50 weight percent and 5.0 weight percent. The content was raised by the inclusion of five-weight percent Copper. The results were reliable through the use of computer simulations [21].
Brennan et al. looked at the enhancement of mechanical characteristics for a small load of carboxylic and hydroxy molecular orbitals in graphene. The necessary characteristics for fused deposition modeling-printed items would be greatly enhanced by the inclusion of nanofiller materials. When little about 0.10 weight percentage of graphene was added, the multifunction feature has been shown to enhance [22]. Through the use of the three-dimensional printing method, Lin et al. carried out a preliminary investigation to enhance the mechanical, thermal, and dielectric properties. Nanostructures, nevertheless, will improve one feature while degrading another [23]. As per Sandoval et al. [24], the inclusion of 10 percent carbon nanotubes enhanced strength properties by 7.50 percent; however, there was a reduction in ductility to failing and a rise in fracture toughness. According to Wei et al. hypothesis, the incorporation of a 5.60 weight percentage of graphene oxide to ABS matrices would cause a four-fold improvement in the conductivity of the polymeric nanocomposites [25]. Weng et al. [26] 's study of nanoclay explored the possibility that Titania incorporation can enhance thermostability.
The filaments characterization of PC-ABS filaments supplemented with graphite nanoparticles was extensively researched by Vijay et al. The fillers were employed in weight percentages of 0.20 percent, 0.40 percent, 0.60 percent, and 0.80 percent. The distribution of filler material in filament made with the twin-screw extruded technique was usefully shown by the scanning electron microscope and element spectrum. The extruded wire's size was unaffected by the filler's existence [27]. Throughout this research, the manufactured filaments were restricted to the investigation of distribution properties; no research on the creation of three-dimensional-printed components was done. In order to better comprehend the effects of fillers incorporation and their function in industrial applications, the present paper examines 3D-printed parts and the assessment of their surface roughness.
Some polymeric materials function as ductile materials and have unique characteristics. Such a polymeric material having a higher ductility and resilience rating is PLA polymer. Under specific strain circumstances, it can exhibit brittle behavior. A small number of carbon nanotubes were added to PLA to balance out some qualities and enhance the mechanical stability and cost value [28]. A new family of polymers with increased strength and processing capacity is produced by the polymeric fusion of carbon nanotubes and PLA. It is the preferred type for fused deposition modeling due to the mixture of these two polymeric materials yields more flexibility stage of manufacture than carbon nanotubes and higher strength as compared to PLA [29–30]. The incorporation of micro-size or nano-size agents can enhance the material's characteristics. Nanoparticles perform better than microparticles because of their higher surface-to-volume ratios, capacity to build networked linkages with polymer matrices, and capability to distribute uniformly [31]. Polymer carbon nanotubes are used in a broad range of technical fields, like automobile, aviation, building, and packing, by adding nanoscale reinforcements to the polymer matrices. A highly desirable substance, carbon nanotubes feature two-dimensional crystalline structures, extremely exceptional electrical and thermal conductance, and improved mechanical characteristics. Carbon nanotubes are used in metals, ceramics, and polymeric products as a result of their unique characteristics [32–33]. Polymeric nanocomposites, notably carbon nanotubes as reinforcements, have found widespread use in sectors such as semiconductors, renewable technology, aviation, and automobile. Higher aspect ratios and surface area than other kinds of reinforcing agents like carbon fibers and so forth. Carbon nanotubes are 2D structures with superior electric, physical, and thermodynamic properties. Material characteristics will greatly enhance with the incorporation of carbon nanotubes as reinforcing agents. The production of nanocomposite filament, the investigation of desirable technical qualities, and the absence of ideal process variables were the three main areas of unexplored investigation, according to a thorough examination of the works of literature. To illustrate, begin by saying that 3D-printed polymeric goods had a small selection of technical uses since it was challenging to attain the appropriate physical, mechanical, and thermal qualities. Secondly, there haven't been many investigations on the application of carbon nanotubes as reinforcing in the creation of polymeric matrixes using fused deposition modeling. Finally, there remains sizable limited knowledge in the creation of thin layers with elevated industrial applications in the mechanical research of polymeric composites. Last but not least, a very little amount of PLA was employed as polymer matrices.