Polymeric composites in extrusion‐based additive manufacturing: a systematic review

• Published in: Polymer composites Vol. 45; no. 8; pp. 6741 - 6770
• Main Authors: Rodrigues, Alina de Souza Leão, Pires, Ana Caroline Batista, Barbosa, Patrícia Alves, Silveira, Zilda de Castro
• Format: Journal Article
• Language: English
• Published: Hoboken, USA John Wiley & Sons, Inc 10-06-2024; Blackwell Publishing Ltd
• Subjects: 3D printing; Additive manufacturing; Biodegradable materials; Carbon fiber reinforced plastics; Extrusion; Filaments; fused filament fabrication; Glass fiber reinforced plastics; Manufacturing; Polyamide resins; Polymer matrix composites; Raw materials; reinforced polymers; Reinforcing materials; state‐of‐the‐art; Systematic review; Three dimensional composites
• ISSN: 0272-8397; 1548-0569
• DOI: 10.1002/pc.28269

Solid composites used in material extrusion additive manufacturing have experienced considerable expansion over the past 5 years, incorporating functional properties into 3D‐printed objects. This paper presents a systematic review that aims to: (I) analyze the current state of development in the field; (II) quantify and categorize the adopted polymeric matrices, reinforcing materials, feedstock shapes, characterization strategies, and extrusion mechanisms; and (III) identify the applications, limitations, and trends for future research. The PRISMA statement was followed and the databases Scopus, Web of Science, and PubMed were consulted. Among the 116 included studies, the use of customized filaments surpassed the commercially available ones, with particulate matter being the most common form of filler when melt‐mixed with the polymer. Polyamide is the most widely adopted matrix (30.3%), followed by PLA (22.0%) and ABS (17.4%). In terms of reinforcements, carbon fiber (32.4%), glass fiber (12.5%), and ceramics (12.5%) compose the podium as the most frequently used, with nanofillers receiving increasing attention. In the conducted analysis, no standardized protocols were identified that clearly encompassed the entire process from feedstock formulation to technical prototype fabrication. At last, recycling, exploration of biodegradable materials, and 4D printing were identified as the main opportunities for future research.
Highlights
Reinforced polymers enable the enhancement of properties for 3D‐printed parts.
Composite feedstock is usually formulated and mixed before printing.
3D printers with filament‐ or screw‐based extrusion mechanisms have been used.
Mechanical and morphological analyses are common in material characterization.
No identified applications were employed in real‐world scenarios.
Summary of the methods adopted and major results obtained in this review.