Research progress of additive manufacturing of high-performance polymers and the applications

Xie Wendi; Mu Xiaoxiao; Guo Yuxiong; Feng Libang; Zhang Xiaoqin; Wang Xiaolong

doi:10.12086/oee.2021.210137

[1] Herzberger J, Sirrine J M, Williams C B, et al. Polymer design for 3D printing elastomers: recent advances in structure, properties, and printing[J]. Prog Polym Sci, 2019, 97: 101144.

[2] Paolini A, Kollmannsberger S, Rank E. Additive manufacturing in construction: A review on processes, applications, and digital planning methods[J]. Addit Manuf, 2019, 30: 100894.

[3] Chandrasekaran S, Duoss E B, Worsley M A, et al. 3D printing of high performance cyanate ester thermoset polymers[J]. J Mater Chem A, 2018, 6(3): 853–858.

[4] Turner B N, Gold S A. A review of melt extrusion additive manufacturing processes: II. Materials, dimensional accuracy, and surface roughness[J]. Rapid Prototyp J, 2015, 21(3): 250–261.

[5] Guo N N, Leu M C. Additive manufacturing: Technology, applications and research needs[J]. Front Mech Eng, 2013, 8(3): 215–243.

[6] Frazier W E. Metal additive manufacturing: A review[J]. J Mater Eng Perform, 2014, 23(6): 1917–1928.

[7] Chia H N, Wu B M. Recent advances in 3D printing of biomaterials[J]. J Biol Eng, 2015, 9: 4.

[8] Melchels F P W, Feijen J, Grijpma D W. A review on stereolithography and its applications in biomedical engineering[J]. Biomaterials, 2010, 31(24): 6121–6130.

[9] Gibson I, Shi D P. Material properties and fabrication parameters in selective laser sintering process[J]. Rapid Prototyp J, 1997, 3(4): 129–136.

[10] Stansbury J W, Idacavage M J. 3D printing with polymers: Challenges among expanding options and opportunities[J]. Dent Mater, 2016, 32(1): 54–64.

[11] Kruth J P, Wang X, Laoui T, et al. Lasers and materials in selective laser sintering[J]. Assem Autom, 2003, 23(4): 357–371.

[12] Ligon S C, Liska R, Stampfl J, et al. Polymers for 3D printing and customized additive manufacturing[J]. Chem Rev, 2017, 117(15): 10212-10290.

[13] Narupai B, Nelson A. 100th anniversary of macromolecular science viewpoint: Macromolecular materials for additive manufacturing[J]. ACS Macro Lett, 2020, 9(5): 627–638.

[14] Ang T H, Sultana F S A, Hutmacher D W, et al. Fabrication of 3D chitosan-hydroxyapatite scaffolds using a robotic dispensing system[J]. Mater Sci Eng, 2002, 20(1–2): 35-42.

[15] Landers R, Hübner U, Schmelzeisen R, et al. Rapid prototyping of scaffolds derived from thermoreversible hydrogels and tailored for applications in tissue engineering[J]. Biomaterials, 2002, 23(23): 4437-4447.

[16] Oh C H, Hong S J, Jeong I, et al. Development of robotic dispensed bioactive scaffolds and human adipose-derived stem cell culturing for bone tissue engineering[J]. Tissue Eng Part C Methods, 2010, 16(4): 561-571.

[17] Lewis J A. Direct-write assembly of ceramics from colloidal inks[J]. Curr Opin Solid State Mater Sci, 2002, 6(3): 245-250.

[18] Raney J R, Compton B G, Mueller J, et al. Rotational 3D printing of damage-tolerant composites with programmable mechanics[J]. Proc Natl Acad Sci USA, 2018, 115(6): 1198–1203.

[19] Kotikian A, Truby R L, Boley J W, et al. 3D printing of liquid crystal elastomeric actuators with spatially programed nematic order[J]. Adv Mater, 2018, 30(10): 1706164.

[20] Bagheri A, Jin J Y. Photopolymerization in 3D printing[J]. ACS Appl Polym Mater, 2019, 1(4): 593-611.

[21] Chatani S, Kloxin C J, Bowman C N, et al. The power of light in polymer science: Photochemical processes to manipulate polymer formation, structure, and properties[J]. Polym Chem, 2014, 5(7): 2187-2201.

[22] Jin J, Yang J F, Mao H C, et al. A vibration-assisted method to reduce separation force for stereolithography[J]. J Manuf Process, 2018, 34: 793–801.

[23] Kim G B, Lee S, Kim H, et al. Three-dimensional printing: Basic principles and applications in medicine and radiology[J]. Korean J Radiol, 2016, 17(2): 182–197.

[24] Gross B C, Erkal J L, Lockwood S Y, et al. Evaluation of 3D printing and its potential impact on biotechnology and the chemical sciences[J]. Anal Chem, 2014, 86(7): 3240–3253.

[25] Tumbleston J R, Shirvanyants D, Ermoshkin N, et al. Continuous liquid interface production of 3D objects[J]. Science, 2015, 347(6228): 1349-1352.

[26] Liska R, Schuster M, Inführ R, et al. Photopolymers for rapid prototyping[J]. J Coat Technol Res, 2007, 4(4): 505–510.

[27] Fortney A, Fossum E. Soluble, semi-crystalline PEEK analogs based on 3, 5-difluorobenzophenone: Synthesis and characterization[J]. Polymer, 2012, 53(12): 2327–2333.

[28] Elhattab K, Sikder P, Walker J M, et al. Fabrication and evaluation of 3-D printed PEEK scaffolds containing Macropores by design[J]. Mater Lett, 2020, 263: 127227.

[29] Feng P, Wu P, Gao C D, et al. A multimaterial scaffold with tunable properties: toward bone tissue repair[J]. Adv Sci, 2018, 5(6): 1700817.

[30] Su Y W, He J K, Jiang N, et al. Additively-manufactured poly-ether-ether-ketone (PEEK) lattice scaffolds with uniform microporous architectures for enhanced cellular response and soft tissue adhesion[J]. Mater Des, 2020, 191: 108671.

[31] Deng Y, Shi X Y, Chen Y, et al. Bacteria-triggered pH-responsive osteopotentiating coating on 3D-printed polyetheretherketone scaffolds for infective bone defect repair[J]. Ind Eng Chem Res, 2020, 59(26): 12123-12135.

[32] Zalaznik M, Kalin M, Novak S. Influence of the processing temperature on the tribological and mechanical properties of poly-ether-ether-ketone (PEEK) polymer[J]. Tribol Int, 2016, 94: 92–97.

[33] Yang C C, Tian X Y, Li D C, et al. Influence of thermal processing conditions in 3D printing on the crystallinity and mechanical properties of PEEK material[J]. J Mater Process Technol, 2017, 248: 1–7.

[34] Hu B, Duan X B, Xing Z H, et al. Improved design of fused deposition modeling equipment for 3D printing of high-performance PEEK parts[J]. Mech Mater, 2019, 137: 103139.

[35] Zheng J B, Kang J F, Sun C N, et al. Effects of printing path and material components on mechanical properties of 3D-printed polyether-ether-ketone/hydroxyapatite composites[J]. J Mech Behav Biomed Mater, 2021, 118: 104475.

[36] Yaragalla S, Zahid M, Panda J K, et al. Comprehensive enhancement in thermomechanical performance of melt-extruded PEEK filaments by Graphene incorporation[J]. Polymers, 2021, 13(9): 1425.

[37] Guo Y X, Ji Z Y, Zhang Y, et al. Solvent-free and photocurable polyimide inks for 3D printing[J]. J Mater Chem A, 2017, 5(31): 16307-16314.

[38] Hegde M, Meenakshisundaram V, Chartrain N, et al. 3D printing all-aromatic polyimides using mask-projection stereolithography: processing the nonprocessable[J]. Adv Mater, 2017, 29(31): 1701240.

[39] Zhang F, Tuck C, Hague R, et al. Inkjet printing of polyimide insulators for the 3D printing of dielectric materials for microelectronic applications[J]. J Appl Polym Sci, 2016, 133(18): 43361.

[40] Herzberger J, Meenakshisundaram V, Williams C B, et al. 3D printing all-aromatic polyimides using stereolithographic 3D printing of polyamic acid salts[J]. ACS Macro Lett, 2018, 7(4): 493-497.

[41] Guo Y X, Xu J W, Yan C Y, et al. Direct ink writing of high performance architectured polyimides with low dimensional shrinkage[J]. Adv Eng Mater, 2019, 21(5): 1801314.

[42] Qin S Y, Jiang Y, Ji Z Y, et al. Three-dimensional printing of high-performance polyimide by direct ink writing of hydrogel precursor[J]. J Appl Polym Sci, 2021, 138(27): 50636.

[43] Wang C Y, Ma S Q, Li D D, et al. 3D printing of lightweight polyimide honeycombs with the high specific strength and temperature resistance[J]. ACS Appl Mater Interfaces, 2021, 13(13): 15690-15700.

[44] Jiang S L, Liao G X, Xu D D, et al. Mechanical properties analysis of polyetherimide parts fabricated by fused deposition modeling[J]. High Perform Polym, 2019, 31(1): 97-106.

[45] Wu T, Jiang P, Zhang X Q, et al. Additively manufacturing high-performance bismaleimide architectures with ultraviolet-assisted direct ink writing[J]. Mater Des, 2019, 180: 107947.

[46] Gouzman I, Atar N, Grossman E, et al. 3D printing of bismaleimides: from new ink formulation to printed thermosetting polymer objects[J]. Adv Mater Technol, 2019, 4(10): 1900368.

[47] Gan X P, Wang J Z, Wang Z H, et al. Simultaneous realization of conductive segregation network microstructure and minimal surface porous macrostructure by SLS 3D printing[J]. Mater Des, 2019, 178: 107874.

[48] Sun S J, Gan X P, Wang Z H, et al. Dynamic healable polyurethane for selective laser sintering[J]. Addit Manuf, 2020, 33: 101176.

[49] Peng S Q, Li Y W, Wu L X, et al. 3D printing mechanically robust and transparent polyurethane elastomers for stretchable electronic sensors[J]. ACS Appl Mater Interfaces, 2020, 12(5): 6479-6488.

[50] Joo H, Cho S. Comparative studies on polyurethane composites filled with polyaniline and graphene for DLP-Type 3D printing[J]. Polymers, 2020, 12(1): 67.

[51] Gama N, Ferreira A, Barros-Timmons A. 3D printed cork/polyurethane composite foams[J]. Mater Des, 2019, 179: 107905.

[52] Wang R M, Zheng S R, Zheng Y P. 3-Matrix materials[M]//Wang R M, Zheng S R, Zheng Y P. Polymer Matrix Composites and Technology. Cambridge: Woodhead Publishing, 2011: 101-548.

[53] Hmeidat N S, Kemp J W, Compton B G. High-strength epoxy nanocomposites for 3D printing[J]. Compos Sci Technol, 2018, 160: 9-20.

[54] Lin D, Jin S Y, Zhang F, et al. 3D stereolithography printing of graphene oxide reinforced complex architectures[J]. Nanotechnology, 2015, 26(43): 434003.

[55] Park G T, Lee S J, Kim B G, et al. High thermally conductive epoxy composite inks cured by infrared laser irradiation for two-dimensional/three-dimensional printing technology[J]. J Compos Mater, 2020, 54(29): 4635-4643.

[56] Liu L, Ying G B, Wen D, et al. Aqueous solution-processed MXene (Ti3C2Tx) for non-hydrophilic epoxy resin-based composites with enhanced mechanical and physical properties[J]. Mater Des, 2021, 197: 109276.

[57] Jiang Q X, Zhang H G, Rusakov D, et al. Additive manufactured carbon nanotube/epoxy nanocomposites for heavy-duty applications[J]. ACS Appl Polym Mater, 2021, 3(1): 93–97.

[58] Mei H, Ali Z, Yan Y K, et al. Influence of mixed isotropic fiber angles and hot press on the mechanical properties of 3D printed composites[J]. Addit Manuf, 2019, 27: 150-158.

[59] Compton B G, Lewis J A. 3D-printing of lightweight cellular composites[J]. Adv Mater, 2014, 26(34): 5930-5935.

[60] Griffini G, Invernizzi M, Levi M, et al. 3D-printable CFR polymer composites with dual-cure sequential IPNs[J]. Polymer, 2016, 91: 174-179.

[61] Hao W F, Liu Y, Zhou H, et al. Preparation and characterization of 3D printed continuous carbon fiber reinforced thermosetting composites[J]. Polym Test, 2018, 65: 29–34.

[62] Sano Y, Matsuzaki R, Ueda M, et al. 3D printing of discontinuous and continuous fibre composites using stereolithography[J]. Addit Manuf, 2018, 24: 521–527.

[63] Jiang Z R, Erol O, Chatterjee D, et al. Direct ink writing of Poly(tetrafluoroethylene) (PTFE) with tunable mechanical properties[J]. ACS Appl Mater Interfaces, 2019, 11(31): 28289-28295.

[64] Zhang Y X, Yin M J, Ouyang X, et al. 3D μ-printing of polytetrafluoroethylene microstructures: A route to superhydrophobic surfaces and devices[J]. Appl Mater Today, 2020, 19: 100580.

[65] Wu T, Jiang P, Ji Z Y, et al. 3D printing of high-performance isocyanate ester thermosets[J]. Macromol Mater Eng, 2020, 305: 2000397.

[66] Lu Y, Ng K W J, Chen H, et al. The molecular design of photo-curable and high-strength benzoxazine for 3D printing[J]. Chem Commun, 2021, 57(27): 3375–3378.