One class of state-of-the-art lightweight, energy-efficient materials with enhanced material properties is "architected cellular solids." Their exotic properties (e.g., high strength-to-weight ratio, high energy absorption capability and tunable multiphysical properties) mainly stem from their rationally designed underlying architectures (e.g., cell topology and cell connectivity) and partially from the properties of their constituent materials. [1] Cellular solids, so-called cellular-based "metamaterials," upon showing unprecedented properties, have recently received considerable attention due to their potential applications in aerospace, automotive, energy, robotics and biomedical sectors as high-performance lightweight panels, energy absorbers, morphing structures, noise reduction, waveguide devices, programmable battery electrodes, and bioimplantable medical devices. [2] Recently, advances in "3D printing," interchangeably called "additive manufacturing" (AM), have shed light on strategies for design and realization of advanced materials (including "cellular solids" and "architected metamaterials") with controlled material composition and architectural complexity. A large number of studies have been conducted to investigate the correlation between specific mechanical properties and the architecture of 3D-printed advanced materials. [3] Fast prototyping, material saving, waste minimization, design freedom, and the capability to manufacture complex architectures are the main 3D printing advantages. [4] 3D printing is a fabrication process for constructing free-form materials and structures from a computer-aided design model. The printing process typically involves layerupon-layer fabrication that enables the production of complex geometries that would be impossible by conventional manufacturing processes. [5] Several methods can be adopted for 3D printing: direct metal laser sintering (DMLS), selective laser melting (SLM), and electron beam melting (EBM) for printing metallic powders; selective laser sintering (SLS) for printing polymeric and metallic powders; laminated object manufacturing (LOM), direct foam writing, 3D extrusion freeforming of ceramics (EFF), and lithography-based ceramic manufacturing (LCM) for ceramic-based materials; stereolithography apparatus (SLA) and digital light projection (DLP) for printing photopolymeric resins; and fused deposition modeling (FDM) for printing thermoplastic polymers. [6] The simplicity, reliability, affordability (minimal waste, low processing and operational cost), multimaterial (multinozzle) printing capability, and adaptability to new materials, and composites have made FDM one of the most
As a renewable source of cellulose, wood chips are transformed in this study to reinforce bio-based thermoplastic filaments for fused deposition modelling (FDM). A new processing method is developed for adding wood-fibers to polylactic acid (PLA) polymers to produce wood-fiber reinforced PLA filaments in order to 3D print high-performance composites. Dogbone samples are 3D printed with the produced filaments to evaluate their elastic and fracture properties as well as internal microstructure, with various weight fractions of wood-fiber. The experimental results demonstrate increased stiffness and ultimate strength and reduced density for composites with optimum wood-fiber content, compared to the pure PLA specimens. Furthermore, following the growing interest in lightweight cellular solids, wood-fiber reinforced PLA filaments are used to 3D print cellular materials with optimized microarchitectures. It was demonstrated that using wood-fiber reinforced composites for FDM 3D printing of advanced materials is a promising approach to not only extend the material properties of biopolymers but also to offer a new class of lightweight and sustainable structural materials. The experimental results on as-built 3D printed cells, compared with the results of a detailed computational analysis on as-designed cells, elicit that the designed architected cellular solids made of wood-fiber PLA composites can exhibit a considerably higher stiffness and ultimate strength than the conventional PLA hexagonal honeycombs.
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