Review Article

Advancements in Polymer-based 3D Printing Materials

Tianxing Cai*

Department of Chemical and Biomolecular Engineering, Lamar University, USA

Submitted: March 30, 2024; Published: April 15, 2024

*Corresponding author: Tianxing Cai, Department of Chemical and Biomolecular Engineering, Lamar University, USA

How to cite this article: Tianxing Cai*. Advancements in Polymer-based 3D Printing Materials. JOJ Material Sci. 2024; 8(4): 555743. DOI:10.19080/JOJMS.2024.08.555743

Abstract

The field of 3D printing has undergone remarkable advancements, fueled by innovations in polymer-based materials. This review paper provides a comprehensive overview of recent progress in polymer-based 3D printing materials, focusing on their synthesis, properties, and applications. Beginning with an exploration of traditional polymers such as PLA and ABS, this review delves into emerging materials like photopolymers, elastomers, and biodegradable polymers. Furthermore, it examines the influence of additives, reinforcements, and nanomaterials on enhancing the mechanical, thermal, and functional properties of printed parts. Special attention is given to novel techniques such as multi-material printing and voxel-level control, enabling intricate geometries and tailored material properties. The paper also discusses challenges and future directions in polymer-based 3D printing, including scalability, recycling, and sustainability. Overall, this review highlights the transformative impact of polymer materials on advancing the capabilities and applications of 3D printing technology.

Keywords: 3D printing; Thermal resistance; Biocompatibility; Thermoplastics; Photopolymers; Elastomers

Introduction

As shown in Figure 1, 3D printing, also known as additive manufacturing, is a revolutionary technology that enables the creation of three-dimensional objects layer by layer from digital designs [1,2]. Unlike traditional subtractive manufacturing processes, which involve cutting away material from a solid block, 3D printing builds objects layer by layer, offering unprecedented design freedom and complexity [3]. This technology has garnered significant attention across various industries due to its ability to produce customized, intricate parts with relatively minimal material waste and lead times [4]. From aerospace to healthcare, 3D printing has found applications in prototyping, product development, tooling, and even in the production of end-use parts [5,6].

Polymer-based 3D printing has emerged as a revolutionary technology with vast potential across various industries, including aerospace, automotive, healthcare, and consumer goods. This review paper aims to explore the recent advancements in polymer-based 3D printing materials, highlighting their significance, challenges, and future prospects. In the realm of 3D printing, materials play a pivotal role in determining the properties, performance, and functionality of printed objects [7]. The choice of material can impact factors such as strength, flexibility, durability, thermal resistance, and even biocompatibility. Different materials offer distinct advantages and limitations, catering to diverse application requirements [7]. For instance, thermoplastics like PLA and ABS are commonly used for their ease of printing and versatility, while photopolymers are preferred for their ability to produce highly detailed, smooth-surfaced objects [8]. As 3D printing technology advances, there is a growing demand for materials that can meet increasingly stringent performance criteria and enable the production of complex, functional parts [9]. With the rapid evolution of 3D printing technologies, there is a growing demand for high-performance polymers that can meet the diverse requirements of additive manufacturing processes. This review seeks to provide a comprehensive understanding of the latest developments in polymer materials tailored for 3D printing applications. By synthesizing current research and innovations, it aims to inform researchers, engineers, and industry professionals about the state-of-the-art materials available and the potential avenues for further exploration.

The purpose of this review is to provide a comprehensive overview of recent advancements in polymer-based materials for 3D printing. Polymer materials, which encompass a wide range of organic compounds, are among the most commonly used materials in additive manufacturing. This review aims to delve into the synthesis methods, properties, and applications of polymer-based materials, with a focus on the latest developments and emerging trends. By examining the progress in polymerbased 3D printing materials, this review seeks to elucidate the transformative impact of these materials on the capabilities and applications of 3D printing technology. Additionally, the review will discuss challenges and future directions in the field, addressing topics such as scalability, recycling, and sustainability, to provide insights into the ongoing evolution of polymer-based 3D printing. The objectives of this review paper include:

a) To survey the recent advancements in polymer-based 3D printing materials, including novel techniques.

b) To evaluate the performance characteristics of these materials, such as mechanical properties, and biocompatibility.

c) To analyze the applications and potential use cases of polymer-based 3D printing materials across various industries.

d) To identify the challenges and limitations associated with existing materials and propose strategies for overcoming them.

e) To discuss future directions and emerging trends in the development of polymer materials for 3D printing, such as sustainable polymers and functionalized materials. By achieving these objectives, this review paper aims to contribute to the advancement of polymer-based 3D printing technologies and facilitate their widespread adoption in diverse industrial sectors.

Methodology

The literature search conducted in this review paper is based on a systematic approach employed to ensure comprehensive coverage of relevant studies. Multiple academic databases, including but not limited to PubMed, Scopus, IEEE Xplore, and Web of Science, were queried using keywords such as “polymer-based 3D printing,” “additive manufacturing materials,” and “advanced polymers.” Both peer-reviewed journals and conference proceedings were considered. The selection criteria for relevant studies included their publication date (within the last five years to ensure currency), relevance to polymer materials used in 3D printing processes, and their contribution to advancing the understanding or application of these materials. Additionally, studies were evaluated based on their methodological rigor, experimental design, and the novelty of their findings. Non- English language studies were excluded, and efforts were made to encompass a diverse range of perspectives and research approaches to provide a comprehensive overview of the subject matter.

Traditional Polymer-Based Materials

Commonly used polymers in 3D printing, such as Polylactic Acid (PLA) and Acrylonitrile Butadiene Styrene (ABS), offer distinct characteristics that make them popular choices in various applications [10,11]. PLA, derived from renewable resources like cornstarch or sugarcane, is biodegradable and emits less harmful fumes during printing compared to ABS, making it environmentally friendly [10,11]. It boasts good rigidity and strength, making it suitable for prototyping, hobbyist projects, and consumer goods [12,13]. ABS, on the other hand, is known for its durability, impact resistance, and heat tolerance, making it ideal for functional parts in automotive, electronics, and household appliances [12,13]. Both PLA and ABS are widely available, affordable, and compatible with most desktop 3D printers, making them accessible options for hobbyists and professionals alike [10-13].

The synthesis methods for polymers used in 3D printing typically involve extrusion or resin curing processes [14]. PLA is synthesized through the fermentation of plant-based sugars into lactic acid, which is then polymerized to form long chains of PLA molecules [15]. ABS, a thermoplastic polymer, is produced through a process called emulsion polymerization, where monomers like acrylonitrile, butadiene, and styrene are polymerized in an aqueous medium [16]. Once synthesized, these polymers can be further processed into filament or resin forms suitable for 3D printing [8,14,15].

The properties of PLA and ABS make them versatile materials for a wide range of applications in 3D printing [16]. PLA exhibits good layer adhesion, minimal warping, and a glossy surface finish, making it suitable for aesthetic models, decorative items, and educational tools [16]. ABS, while more challenging to print due to its tendency to warp and emit fumes, offers superior mechanical properties, chemical resistance, and post-processing capabilities, making it suitable for functional prototypes, mechanical parts, and engineering applications [17]. Despite their advantages, both PLA and ABS have limitations that need to be considered. PLA is prone to brittleness and degradation under high temperatures, limiting its use in applications requiring heat resistance or load-bearing capabilities [18]. ABS, while durable and heat-resistant, emits potentially harmful fumes during printing, requiring adequate ventilation or enclosure [19]. Additionally, ABS is more prone to warping and requires a heated print bed and controlled printing environment to mitigate these issues [20]. Understanding the properties, synthesis methods, and advantages and limitations of commonly used polymers such as PLA and ABS is essential for optimizing their use in 3D printing applications [11].

Emerging Polymer-Based Materials

Photopolymers, elastomers, and biodegradable polymers represent a diverse range of materials that are increasingly gaining traction in the field of 3D printing for their unique properties and applications [21]. Photopolymers, for instance, are materials that undergo polymerization when exposed to light, typically ultraviolet (UV) light [22]. This process allows for high-resolution printing and the creation of detailed, intricate structures with smooth surface finishes [23]. Elastomers, on the other hand, are polymers characterized by their elasticity and flexibility [24]. They can stretch and return to their original shape, making them suitable for applications requiring rubber-like properties, such as gaskets, seals, and flexible prototypes [25]. Biodegradable polymers, as the name suggests, are materials that degrade naturally over time, making them environmentally friendly alternatives to traditional polymers derived from fossil fuels [26].

The synthesis methods and characteristics of these specialized polymers vary depending on their composition and intended applications [27]. Photopolymers are typically synthesized through photopolymerization processes, where liquid resin formulations containing monomers and photoinitiators are selectively cured layer by layer using UV light [28]. This allows for precise control over curing times and resolutions, resulting in highquality printed parts [28]. Elastomers are synthesized through techniques such as addition polymerization or condensation polymerization, resulting in materials with tailored mechanical properties, such as varying degrees of elasticity and hardness [29]. Biodegradable polymers are often derived from renewable resources such as plant-based sugars or starches and synthesized through polymerization processes similar to traditional polymers, with the added benefit of being environmentally sustainable [30,31]. The applications and potential advantages of photopolymers, elastomers, and biodegradable polymers in 3D printing are vast and diverse [32]. Photopolymers are commonly used in industries such as jewelry, dentistry, and prototyping, where intricate details and smooth surface finishes are critical [33]. Elastomers find applications in automotive, aerospace, and medical fields, where flexibility, resilience, and impact resistance are essential [34]. Biodegradable polymers are increasingly being utilized in sustainable product design, packaging, and biomedical applications, offering the advantage of reducing environmental impact and promoting circular economy practices [35]. These specialized polymers offer unique properties and capabilities that extend the possibilities of 3D printing technology, opening up new avenues for innovation and creativity in various industries [36].

Enhancement Strategies

Additives, reinforcements, and nanomaterials play crucial roles in enhancing the properties of polymers used in 3D printing, allowing for the creation of parts with improved mechanical, thermal, and functional characteristics [37]. Additives are substances added to polymer formulations in small quantities to impart specific properties or enhance performance [38]. Common additives include plasticizers, flame retardants, and UV stabilizers, which can improve flexibility, fire resistance, and weathering resistance, respectively [39]. Reinforcements, such as fibers (e.g., carbon fiber, glass fiber) or particles (e.g., silica, graphene), are incorporated into polymers to increase strength, stiffness, and toughness [40]. Nanomaterials, including nanoparticles and nanotubes, offer unique properties such as high surface area-tovolume ratio, exceptional strength, and electrical conductivity, enabling further enhancements in polymer performance [41,42].

The mechanisms of enhancement vary depending on the type of additive, reinforcement, or nanomaterial used [43]. For instance, fibers and particles act as physical reinforcements within the polymer matrix, distributing stress more effectively and preventing crack propagation [44]. This results in improved mechanical properties such as higher tensile strength, modulus, and impact resistance [45,46]. Nanomaterials, on the other hand, can alter the polymer’s microstructure and interface properties at the nanoscale, leading to enhancements in thermal conductivity, electrical conductivity, and barrier properties [47,48]. Additionally, additives like plasticizers can increase polymer chain mobility, reducing brittleness and improving flexibility, while flame retardants can inhibit the spread of flames and smoke generation, enhancing fire resistance [49,50].

Examples of enhanced properties and applications resulting from the incorporation of additives, reinforcements, and nanomaterials in polymers for 3D printing abound across various industries [51]. Carbon fiber-reinforced polymers (CFRP) offer exceptional strength-to-weight ratios and are used in aerospace, automotive, and sporting goods applications [52,53]. Nanocomposites, comprising polymers and nanoscale fillers like graphene or clay nanoparticles, exhibit improved mechanical properties, thermal stability, and electrical conductivity, making them suitable for advanced electronics, structural components, and biomedical implants [54,55]. Furthermore, functional additives such as antimicrobial agents and conductive fillers enable the production of customized medical devices, electronics housings, and smart textiles with tailored properties [56,57]. The integration of additives, reinforcements, and nanomaterials into polymer matrices continues to drive innovation and expand the capabilities of 3D printing technology across a wide range of applications [8].

Advanced Techniques

Multi-material printing and voxel-level control are two advanced techniques that have revolutionized the capabilities of 3D printing technology, enabling the production of complex, multifunctional objects with unprecedented precision and versatility [58,59]. Multi-material printing allows for the simultaneous deposition of multiple materials or colors within the same printed object, offering designers and engineers the flexibility to incorporate different properties and functionalities into their designs [60,61]. This technique is achieved through the use of dual or multi-extruder systems, where each extruder is loaded with a different material or color [62].

Voxel-level control, on the other hand, refers to the precise manipulation of individual volumetric pixels (voxels) within a 3D printed object, allowing for localized variations in material properties, density, or color [63]. Unlike traditional layer-based printing, which treats each layer as a uniform slice of material, voxel-level control enables designers to control the composition and characteristics of each voxel within the object, leading to unprecedented levels of complexity and functionality [64]. This technique is made possible through advanced software algorithms and hardware systems that enable precise deposition and manipulation of materials at the voxel level, enabling the creation of objects with tailored mechanical, thermal, or optical properties [65].

The applications and benefits of multi-material printing and voxel-level control are diverse and far-reaching, spanning industries such as aerospace, automotive, healthcare, and consumer goods [58]. In aerospace and automotive applications, multi-material printing allows for the production of lightweight, high-performance components with integrated functionality, such as embedded sensors, conduits, or reinforcement structures [3,36,66,67]. In healthcare, voxel-level control enables the fabrication of patient-specific implants and prosthetics with customized mechanical properties and bioactive features, improving patient outcomes and reducing recovery times [68]. Furthermore, in consumer goods and electronics, these techniques facilitate the creation of personalized products with enhanced aesthetics, functionality, and performance, driving innovation and competitiveness in the marketplace [69]. Multimaterial printing and voxel-level control represent powerful tools for advancing the capabilities of 3D printing technology and unlocking new opportunities for design, manufacturing, and product development across various industries [59].

Challenges and Future Directions

Polymer-based 3D printing has revolutionized manufacturing by enabling rapid prototyping and customization. However, scalability remains a significant challenge in this technology [8]. Traditional 3D printing methods, such as fused deposition modeling (FDM), suffer from slow printing speeds and limited build sizes [70,71]. As the demand for larger, more intricate objects grows, scalability issues become increasingly pronounced [72]. Moreover, maintaining consistent print quality and structural integrity across larger prints presents additional hurdles. These limitations hinder the widespread adoption of polymer-based 3D printing in industrial settings where mass production is essential [73,67].

Recycling and sustainability concerns loom large in the realm of polymer-based 3D printing [74]. The process often generates substantial waste, including unused polymer filaments, support materials, and failed prints [75,76]. Moreover, the materials used in 3D printing, such as thermoplastics, can be challenging to recycle efficiently [77]. This results in environmental strain and contributes to the growing problem of plastic pollution [77]. Additionally, concerns arise regarding the sustainability of feedstock materials, as many polymers utilized in 3D printing are derived from non-renewable resources [78,79].

In response to these challenges, ongoing research efforts focus on addressing scalability issues and improving the sustainability of polymer-based 3D printing [21,80]. Innovations in printing technologies, such as continuous liquid interface production (CLIP) and selective laser sintering (SLS), aim to enhance printing speeds and enable larger-scale production [36,81]. Furthermore, researchers are exploring alternative, eco-friendly materials derived from renewable sources, such as biodegradable polymers and recycled plastics [82]. Additionally, advancements in recycling technologies, such as filament extrusion systems and closed-loop recycling processes, offer promising avenues for reducing waste and promoting a circular economy within the 3D printing industry [83]. By tackling scalability and sustainability concerns head-on, ongoing research endeavors pave the way for a more efficient, environmentally conscious future for polymer-based 3D printing [84,85].

Discussion

In this review paper on “Advancements in Polymer-based 3D Printing Materials,” the synthesized findings from the selected studies are interpreted and analyzed to provide insights into the current landscape of polymer materials for additive manufacturing. It involves a comparative analysis of different studies, examining the synthesis methods, properties, and applications of various polymer-based materials. Beginning with traditional polymers such as PLA and ABS and extending to emerging materials like photopolymers, elastomers, and biodegradable polymers, this review assesses the evolution of materials used in 3D printing. Furthermore, it explores the impact of additives, reinforcements, and nanomaterials on enhancing the mechanical, thermal, and functional properties of printed parts, as well as novel techniques such as multi-material printing and voxel-level control, enabling intricate geometries and tailored material properties. It also addresses challenges and future directions in polymer-based 3D printing, including scalability, recycling, and sustainability, echoing the concerns raised in the abstract. Through this comprehensive analysis, the review paper offers valuable insights into the transformative impact of polymer materials on advancing the capabilities and applications of 3D printing technology.

Conclusion

Recent advancements in polymer-based materials have had profound implications for the field of 3D printing, driving innovation and expanding the capabilities of additive manufacturing technology. The development of high-performance polymers with enhanced mechanical properties, such as strength, flexibility, and heat resistance, has opened up new possibilities for creating functional end-use parts through 3D printing. These materials offer superior performance compared to traditional thermoplastics, making them suitable for a wide range of applications across industries, including aerospace, automotive, healthcare, and consumer goods. Additionally, advancements in biocompatible and bioresorbable polymers have revolutionized medical 3D printing, enabling the production of patientspecific implants, prosthetics, and drug delivery systems with unprecedented precision and compatibility.

Looking ahead, future research in polymer-based 3D printing should focus on several key areas to further enhance the technology’s capabilities and address existing challenges. Firstly, there is a need for continued exploration of novel polymer formulations and composite materials tailored specifically for additive manufacturing processes. This includes optimizing material properties such as printability, adhesion, and postprocessing characteristics to achieve greater versatility and reliability in 3D printing applications. Additionally, research efforts should aim to improve the sustainability of polymer-based 3D printing by investigating eco-friendly materials, recycling techniques, and circular manufacturing processes. Furthermore, advancements in multi-material and multi-functional printing technologies hold promise for unlocking new opportunities in creating complex, integrated systems with diverse material properties, paving the way for more efficient and cost-effective manufacturing solutions. By pursuing these research directions, the field of polymer-based 3D printing can continue to evolve and revolutionize industries while addressing pressing societal and environmental concerns.

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