Abstract
The current study investigates the mechanical characteristics of polymer matrix composites (PMCs) having aluminum powder reinforcements, fabricated by fused deposition modeling (FDM). Polymer matrix composite was prepared by amalgamating polylactic acid (PLA) by blending with aluminum powder reinforcement particles in the following compositions: 10 wt% and 20 wt%. The composite filaments were fabricated with a twin-screw extrusion technique. The microstructural characteristic composite samples were investigated using a scanning electron microscope (SEM). The mechanical characteristics such as hardness, ultimate tensile strength (UTS), yield strength (YS), and percentage elongation (% EL) of unreinforced PLA composite and aluminum powder-reinforced PLA composites were compared. It was identified that with the incorporation of aluminum powder reinforcements, hardness, UTS, and YS were enhanced, and a reduction in percentage elongation was identified. These characteristics were examined to understand the distribution of aluminum powder reinforcements in the PLA matrix and its influences on the processing parameters of the study. With the 20 wt% addition of aluminum to PLA, the tensile strength increased by 46%, and the yield strength increased by 84%. A reduction in ductility was noted for every incremental addition of aluminum to PLA.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig1_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig2_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig3_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig4_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig5_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig6_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig7_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig8_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig9_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig10_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40033-022-00406-1/MediaObjects/40033_2022_406_Fig11_HTML.jpg)
Similar content being viewed by others
References
Standard A. F2792, Standard Terminology for Additive Manufacturing Technologies. West Conshohocken, Pa, USA: ASTM International (2012)
C.W. Hull, Apparatus for Production of Three-Dimensional Objects by Stereolithography, Google Patents (1986)
G.N. Levy, R. Schindel, J.-P. Kruth, Rapid manufacturing and rapid tooling with layer manufacturing (LM) technologies, state of the art and future perspectives. CIRP Ann. Manuf. Technol. 52(2), 589–609 (2003)
B. Tymrak, M. Kreiger, J. Pearce, Mechanical properties of components fabricated with open-source 3-D printers under realistic environmental conditions. Mater. Des. 58, 242–246 (2014)
Q. Sun, G. Rizvi, C. Bellehumeur, P. Gu, Effect of processing conditions on the bonding quality of FDM polymer filaments. Rapid Prototyp. J. 14(2), 72–80 (2008)
P. Tran, T.D. Ngo, A. Ghazlan, D. Hui, Bimaterial 3D printing and numerical analysis of bio-inspired composite structures under in-plane and transverse loadings. Compos. Part B Eng. 108, 210–223 (2017)
R. Melnikova, A. Ehrmann, K. Finsterbusch, 3D printing of textile-based structures by fused deposition modelling (FDM) with different polymer materials, in Iop Conference Series: Materials Science and Engineering, IOP Publishing (2014)
B. Caulfield, P. McHugh, S. Lohfeld, Dependence of mechanical properties of polyamide components on build parameters in the SLS process. J. Mater. Process. Technol. 182(1), 477–488 (2007)
C.R. Garcia, J. Correa, D. Espalin, J.H. Barton, R.C. Rumpf, R. Wicker, V. Gonzalez, 3D printing of anisotropic metamaterials. Prog. Electromagn. Res. Lett. 34, 75–82 (2012)
H. Gu, C. Ma, J. Gu, J. Guo, X. Yan, J. Huang, Q. Zhang, Z. Guo, An overview of multifunctional epoxy nanocomposites. J. Mater. Chem. C 4(25), 5890–5906 (2016)
J. Gu, X. Yang, Z. Lv, N. Li, C. Liang, Q. Zhang, Functionalized graphite nanoplatelets/ epoxy resin nanocomposites with high thermal conductivity. Int. J. Heat Mass. Transf. 92, 15–22 (2016)
J. Dou, Q. Zhang, M. Ma, J. Gu, Fast fabrication of epoxy-functionalized magnetic polymer core-shell microspheres using glycidyl methacrylate as monomer via photo-initiated miniemulsion polymerization. J. Magn. Magn. Mater. 324(19), 3078–3082 (2012)
E. Kroll, D. Artzi, Enhancing aerospace engineering students’ learning with 3D printing wind-tunnel models. Rapid Prototyp. J. 17(5), 393–402 (2011)
K.V. Wong, A. Hernandez, A review of additive manufacturing. ISRN Mech. Eng. 2012, 1 (2012)
D.B. Short, Use of 3D printing by museums: educational exhibits, artifact education, and artifact restoration. 3D Print Addit. Manuf. 2(4), 209–15 (2015)
S.V. Murphy, A. Atala, 3D bioprinting of tissues and organs. Nat. Biotechnol. 32(8), 773–785 (2014)
S.K. Malhotra, K. Goda, M.S. Sreekala, Part one introduction to polymer composites, in Polymer Composites, 1st edn, Wiley-VCH (2012)
S.H. Huang, P. Liu, A. Mokasdar, L. Hou, Additive manufacturing and its societal impact: a literature review. Int. J. Adv. Manuf. Technol. 67(5–8), 1191–1203 (2013)
M. Ouhsti, B. El Haddadi, S. Belhouideg, Effect of printing parameters on the mechanical properties of parts fabricated with open-source 3D printers in PLA by fused deposition modeling. Mech. Mech. Eng. 22(4), 895–907 (2018)
C. Buchanan, V.P. Matilainen, A. Salminen, L. Gardner, Structural performance of additive manufactured metallic material and cross-sections. J. Constr. Res. 136, 35–48 (2017)
W. Wu, P. Geng, G. Li, D. Zhao, H. Zhang, J. Zhao, Influence of layer thickness and raster angle on the mechanical properties of 3D-printed PEEK and a comparative mechanical study between PEEK and ABS. Materials 8(9), 5834–5846 (2015)
Y. Ibrahim, G.W. Melenka, R. Kempers, Fabrication and tensile testing of 3D printed continuous wire polymer composites. Rapid Prototyp. J. 24(7), 1131–1141 (2018)
M.S. Chaudhry, A. Czekanski, Evaluating FDM process parameter sensitive mechanical performance of elastomers at various strain rates of loading. Materials 13(14), 1–10 (2020)
J.A. Ghani, I.A. Choudhury, H.H. Hassan, Application of Taguchi method in the optimization of end milling parameters. J. Mater. Process. Technol. 145(1), 84–92 (2004)
C. Mendonsa, K. Naveen, P. Upadhyaya, V.D. Shenoy, Influence of FDM process parameters on build time using Taguchi and ANOVA approach. Int. J. Sci. Res. 14(2), 2319–7064 (2013)
P.K. Gurrala, S. Regalla, Part strength evolution with bonding between filaments in fused deposition modelling: this paper studies how coalescence of filaments contributes to the strength of final FDM part. Virtual Phys. Prototyp. 9, 141–149 (2014)
J. Singh, K. Kumar, G.R. Kumar, Effect of filling percentage and raster style on tensile behavior of FDM produced PLA parts at different build orientation. Mater. Today Proc. (in press)
A. Phogat, D. Chhabra, V. Sindhu, A. Ahlawatt, Analysis of wear assessment of FDM printed specimens with PLA, multi-material and ABS via hybrid algorithms. Mater. Today Proc. (in press)
E.P.S. Mohammed Basheer, R. Rajkumar, V.P. Karthikeyan, K.M. Pradeep, Microstructural characterization and defects analysis of FDM based composite material (PLA-G-CF). Mater. Today Proc. (in press)
N. Lokesh, B.A. Praveena, J. Sudheer Reddy et al., Evaluation on the effect of printing process parameter through Taguchi approach on mechanical properties of 3D printed PLA specimens using FDM at constant printing temperature. Mater. Today Proc. 52, 1288–1293 (2022)
M. Hikmat et al., Investigation of tensile property-based Taguchi method of PLA parts fabricated by FDM 3D printing technology. Results Eng. 11, 100264 (2021)
I. Fekete, F. Ronkay, L. Lendvai, Highly toughened blends of poly (lactic acid) (PLA) and natural rubber (NR) for FDM-based 3D printing applications: the effect of composition and infill pattern. Polym. Test. 99, 107205 (2021)
H. Vardhan et al., Investigation of tensile properties of sprayed aluminium based PLA composites fabricated by FDM technology. Mater. Today Proc. 33, 1599–1604 (2020)
D. Sethuram, P.G. Koppad, H. Shetty, M. Alipour, S. Kord, Characterization of graphene reinforced Al-Sn nanocomposite produced by mechanical alloying and vacuum hot pressing. Mater. Today Proc. 5, 24505–24514 (2018)
G. Cicala, D. Giordano, C. Tosto, G. Filippone, A. Recca, I. Blanco, Polylactide (PLA) filaments a biobased solution for additive manufacturing: correlating rheology and thermomechanical properties with printing quality. Materials 11, 1191 (2018)
Y. He, W. Jiao, F. Yang, Development of resin matrix composite molding process. J. Fiber Compos. 2, 7–13 (2011)
M.Q. Shaikh, P. Singh, K.H. Kate, M. Freese, S.V. Atre, Finite element-based simulation of metal fused filament fabrication process: distortion prediction and experimental verification. J. Mater. Eng. Perform. 30, 5135–5149 (2021)
A.K. Sood, R. Ohdar, S. Mahapatra, Parametric appraisal of mechanical property of fused deposition modeling processed parts. Mater. Des. 31, 287–295 (2010)
H. Li, T. Wang, J. Sun, Z. Yu, The effect of process parameters in fused deposition mmodelingon bonding degree and mechanical properties. Rapid Prototyp. J. 24, 80–92 (2018)
R. Sharma, R. Singh, R. Penna, F. Fraternali, Investigations for mechanical properties of Hap, PVC and PP based 3D porous structures obtained through biocompatible FDM filaments. Compos. B Eng. 132, 237–243 (2018)
Funding
This research work has not received any funding.
Author information
Authors and Affiliations
Corresponding author
Ethics declarations
Conflict of interest
Authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Vinay, D.L., Keshavamurthy, R. & Tambrallimath, V. Enhanced Mechanical Properties of Metal filled 3D Printed Polymer Composites. J. Inst. Eng. India Ser. D 104, 181–195 (2023). https://doi.org/10.1007/s40033-022-00406-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40033-022-00406-1