Affordable commercial desktop 3-D printers and filaments have introduced additive manufacturing to all disciplines of science and engineering. With rapid innovations in 3-D printing technology and new filament materials, material vendors are offering specialty multifunctional metal-reinforced polymers with unique properties. Studies are necessary to understand the effects of filament composition, metal reinforcements, and print parameters on microstructure and mechanical behavior. In this study, densities, metal vol%, metal cross-sectional area %, and microstructure of various metal-reinforced Polylactic Acid (PLA) filaments were characterized by multiple methods. Comparisons are made between polymer microstructures before and after printing, and the effect of printing on the metal-polymer interface adhesion has been demonstrated. Tensile response and fracture toughness as a function of metal vol% and print height was determined. Tensile and fracture toughness tests show that PLA filaments containing approximately 36 vol% of bronze or copper particles significantly reduce mechanical properties. The mechanical response of PLA with 12 and 18 vol% of magnetic iron and stainless steel particles, respectively, is similar to that of pure PLA with a slight decrease in ultimate tensile strength and fracture toughness. These results show the potential for tailoring the concentration of metal reinforcements to provide multi-functionality without sacrificing mechanical properties.

We describe a sol-gel synthetic method for the production of praseodymium-doped yttrium aluminum garnet (YAG) nanoparticles suitable for X-ray inducible photodynamic therapy (X-PDT). Our sol-gel based approach was optimized by varying temperature and time of calcination, resulting in nanoparticles that were smooth, spherical, and 50–200 nm in crystallite size. The powders were uniformly coated with a thin (10 nm) layer of silica to facilitate surface conjugation with functional moieties. Measurements of photon flux revealed that coated and uncoated powders emitted a similar photon emission spectrum in response to 50 keVp X-rays. We also determined that the presence of silica did not significantly reduce flux and the emission peak had a maximum at approximately 320 nm. Thus, these YAG:Pr powders are suitable candidates for future in vivo X-PDT studies.

Fused filament fabrication (FFF) systems utilize a wide variety of commercially available filaments, including Acrylonitrile Butadiene Styrene (ABS), as well as their variants. However, the effect of filament composition, reinforcements (chopped fibers and nanotubes), and 3-D printing variables on the microstructure and thermomechanical behavior is not well understood, and systematic studies are needed. In this work, different types of ABS materials with and without carbon fiber and carbon nanotube reinforcements were printed with multiple print layer heights. The microstructure, elastic behavior, tensile behavior, and fracture toughness of 3-D printed materials were characterized. ABS material systems printed at a low print layer height of 0.1 mm outperformed those printed at a larger height of 0.2 mm. Carbon nanotube reinforcements result in significant improvement in the strength and elastic modulus of ABS materials. Printed coupons of ABS with carbon nanotubes achieve an ultimate strength of 34.18 MPa, while a premium grade ABS coupon achieved 28.75 MPa when printed with the same print layer heights. Samples of ABS with chopped carbon fiber show an ultimate strength of 27.25 MPa, due primarily to the significant porosity present in the filament. Elastic moduli and fracture toughness measured using dynamic and mechanical methods show similar trends as a function of layer height. The effects of different materials, reinforcements, and printing parameters on the microstructure and mechanical properties are discussed in detail.

The mechanical behavior of 90 vol% (Ta1−xWx)C–10 vol% WC (x ≈ 0.2) [90(Ta0.8W0.2)C–10WC] composites is described, achieving a significant enhancement in mean fracture strength compared with nominally pure TaC prepared under identical processing conditions (from 114 to 362 MPa), and a higher characteristic strength (from 188 to 377 MPa), while maintaining the same Weibull modulus of 13. The fracture strengths correspond to calculated critical flaw sizes in the range of 5–10 μm and are consistent with the microstructure observations presented. The 90(Ta0.8W0.2)C–10WC composite begins densification at an onset sintering temperature of 1503 K, which is 500 K lower than TaC. It also exhibits enhanced densification by inhibiting grain growth at sintering temperatures up to 2173 K, therefore resulting in a relative density of 98% compared with 80% for TaC. These results show a promising guideline from which ceramic additions can be chosen to enhance the densification and functionality of ultrahigh‐temperature ceramics.

Rapid innovations in 3-D printing technology have created a demand for multifunctional composites. Advanced polymers like amorphous thermoplastic polyetherimide (PEI) can create robust, lightweight, and efficient structures while providing high-temperature stability. This work manufactured ULTEM, a PEI-based polymer, and carbon-fiber-infused ULTEM multi-material composites with varying layering patterns (e.g., AAABBB vs. ABABAB) using fused filament fabrication (FFF). The microstructure of fractured surfaces and polished cross-sections determined that the print quality of layers printed closer to the heated bed was higher than layers closer to the top surface, primarily due to the thermal insulating properties of the material itself. Mechanical properties of the multi-material parts were between those of the single-material parts: an ultimate tensile strength and elastic modulus of 59 MPa and 3.005 GPa, respectively. Multi-material parts from the same filaments but with different layering patterns showed different mechanical responses. Prints were of higher quality and demonstrated a higher elastic modulus (3.080 GPa) when consecutive layers were printed from the same filament (AAABBB) versus parts with printed layers of alternating filaments (ABABAB), which showed a higher ultimate strength (62.04 MPa). These results demonstrate the potential for creatively designing multi-material printed parts that may enhance mechanical properties.