Fused filament fabrication is a popular extrusion 3D printing technology because of its affordability and accessibility. However, the approach often suffers from printing errors that result in wasted time, materials and energy. Convolutional neural networks can be trained to recognise a wide spectrum of printing anomalies from image data in real time, but past work has been limited to a few defect classifications at a time. Here, we introduce a fault detection system, designed to identify a range of errors without interrupting the printing process. Real-time detection is achieved using a pre-trained image recognition and pattern recognition convolutional neural network (CNN) with two mounted cameras on the print bed and a nozzle camera. Two CNN models are developed to classify images into common 3D printing errors for the two camera systems. The nozzle camera model achieves a high validation accuracy of 97.7%. The side camera model achieves comparable performance with a validation accuracy of 97.6%. To integrate the two CNNs into one unified system, a logic-based priority framework was used to improve reliability beyond individual model accuracies by resolving conflicting predictions and leveraging complementary viewing angles from both camera types to detect a broader range of defects. The data fusion framework identifies 12 common errors and has significantly improved the robustness of error classification, in-situ and in real-time, with inference times as small as 220 milliseconds. The results demonstrate the feasibility of a robust multi-input fault detection system to advance the reliability of extrusion 3D printing.

Electrification, including emerging technologies such as structural supercapacitors, is critical in realizing carbon-neutral transportation. A fundamental challenge is the trade-off between mechanical properties and energy storage capabilities. We report the fabrication of structural supercapacitors with a novel fibre-fibre interface to improve the interlaminar strength and encapsulation while considering the effect of structural resin on energy storage performance. The synthesized graphene nanoplatelets-modified electrodes attain a high specific surface area of ∼231 m² g⁻¹ - outperforming comparable carbon-based electrodes. We learned that the use of a gel-polymer electrolyte (GPE) separator containing 60 wt% Li-salt eliminates the requirement of electrolyte infusion and showed the highest values for conductivity for the cell produced using GPE. The implementation of glass fabrics (GFs) into the GPE improved the flexural modulus by ∼22%, while retaining the mechanical strength of the cells. The multifunctional performance of the produced SSCs were on par or even outperformed the performances of SSCs reported in literature. A proof-of-concept prototype demonstrates that gel-polymer electrolyte cells can retain charges for longer than those with a glass fibre separator. Cumulatively, these offer the possibility of conventional composite manufacturing techniques to scale-up and eliminate delamination issues arising from different thermal expansion coefficients which also addresses the balance between mechanical stability and electrochemical performance. Our findings support the advancement of durable, lightweight energy storage and delivery systems for sustainable transportation, with potential applications in robotics and wearable technologies.

Where the trunk of a tree splits into co-dominant branches, wood fibres are highly interlocked. Such an arrangement of fibres has been shown to impart superior strength and toughness to this critical junction. Here, wavy patterns are 3D printed with a liquid crystal polymer (LCP) to evaluate the potential of wood-inspired localized adaptations to improve the robustness of junctions between orthotropic struts. The highly anisotropic, fibrillar microstructure of LCPs is harnessed by Fused Filament Fabrication, yielding Young's modulus and tensile strength reaching 30 GPa and 500 MPa respectively. However, unidirectional 3D-prints subjected to normal tensile stresses show weak interfaces, like in wood. To overcome this weakness, sinusoidal, helix and saw-tooth patterns are 3D-printed to create interlocking between layers. A trade-off is established between uniaxial tension and short-beam shear with increasing interlocking angle of the sinusoidal pattern. We find that the work associated with crack propagation in Mode I is increased three-fold compared to a unidirectional pattern, through extrinsic toughening. When applied to a more complex load case in a curved beam in four-point bending, helix-patterning at the junction zone increases the maximum load by 88 %. By locally controlling anisotropy via waviness, this method opens the possibility of improving toughness and transverse properties where the stress state is multi-axial without adding mass in future recyclable structural materials.

Design for composite material additive manufacturing is governed by multiple process variables that can be computationally expensive to optimize. This is especially true when considering discrete variables, such as the material type to be used, which lead to a lot of possible solutions that have to be evaluated. Here, we propose a workflow for optimizing topology and fiber placement of 3D volumetric structures based on mechanical performance under multiple load cases and environmental impact. An eco-informed material selection from a set fibers and polymers is followed by a methodology to optimize the manufacturing setting. By performing these two steps sequentially, the number of input parameter sets to be tested is reduced in a combinatorial scale, along with the computational cost. The framework can be easily extended by adapting the analyses and holds significant promise for the design of additive manufactured sustainable structures.

In this study, a 3D-printed biomimetic overlapping curl structure inspired by spider silk molecular structure, containing sacrificial bonds and hidden lengths, is studied as a toughening mechanism for a bio-based epoxy. Experimental results of the fracture phenomena of the overlapping curl-reinforced bio-based epoxy identify three toughening mechanisms triggered by the overlapping curl: (1) crack re-initiation, (2) overlapping curl bridging, and (3) epoxy ligament. First, the integrated overlapping curl creates a void within the epoxy matrix. As the crack tip reaches the end of this void, the crack re-initiates. Then, as the hidden length of overlapping curl unfolds, it leads to a bridging effect in resisting crack growth. In addition, for the smallest hidden length, an epoxy ligament is formed due to crack branching, significantly improving the energy release rate. The epoxy fracture energy release rate increased by 13 %. The overall modest improvement is attributed to the large plastic dissipation energy of the epoxy and the relatively low overlapping curl load-capacity. However, when expanding the design space numerically, it was shown that as the failure load of the overlapping curl increases, the bridging effect increases progressively. The introduction of the bio-inspired overlapping curl structure into bio-based epoxy proves the concept of a toughening strategy for developing high-performance sustainable composite materials.

Carbon fibre reinforced plastic (CFRP) exhibits complex optical behaviour due to its anisotropy and highly scattering surface. These optical characteristics pose significant challenges for the automated laser-based inspection systems used in CFRP manufacturing, as they lead to variations in light interaction with the material, affecting the accuracy and reliability of inspections. To investigate this complex optical behaviour, an inverse optical model based on the Multi-Gaussian method has been developed. Laser speckle patterns from the CFRP surface are decomposed into multiple Gaussian components to model the material's optical properties. A greedy optimisation algorithm is employed to estimate the optimal coefficients for the Gaussian sets, which are further refined by introducing negative amplitude Gaussian components. These enhancements improve the optimisation, resulting in a better correlation between the Multi-Gaussian model and actual laser speckle measurements.

Spider silk is known for its excellent strength and fracture resistance properties due to its molecular design structure, characterized by sacrificial bonds and hidden lengths. These structures have inspired reinforcements of synthetic polymer materials to enhance toughness. In this study, we mimic these natural toughening mechanisms by designing and manufacturing 3D-printed polymeric structures incorporating overlapping curls consisting of coiling fiber with sacrificial bonds and hidden lengths. Utilizing the liquid rope coiling effect, we manufactured overlapping curls using three polymers: polylactic acid (PLA), liquid crystal polymer (LCP), and polyamide 6 (PA6). Uniaxial tensile tests were performed to characterize the mechanical properties of overlapping curl as a function of geometries, post-treatments, and material constitutive parameters. Our results show that single-sided overlapping curls can fully unfold while double-sided curls are prone to premature failure. Heat-pressure post-treatment was found to significantly increase the load-capacity of the sacrificial bonds by up to [Formula presented] due to increased contact area. However, the defects introduced in the fibre after the break of the sacrificial bonds, make the structure more susceptible to premature failure, limit the complete unfolding of the hidden length, and lead to a decrease up to [Formula presented] of the toughness. To guarantee the complete unfolding of the hidden lengths and improve the toughness, we demonstrate that selecting a polymer material with either high fracture strength (e.g., LCP, [Formula presented]) or high fracture strain (e.g., PA6, >2) is crucial, and increase toughness up to [Formula presented] and [Formula presented], respectively.

Since the inception of fibre-reinforced composite materials, they have been widely acknowledged for their unparalleled weight-to-performance ratio. Nonetheless, concerns are escalating regarding the environmental impact of these materials amidst global warming and pollution. This perspective explores a ground-breaking shift towards harnessing living organisms to produce composite materials. Living composites not only offer sustainable, carbon-capturing alternatives but also afford an unprecedented level of control over shape and anisotropy. Recent advancements in biology, particularly genetic engineering and sequencing, have provided extraordinary control over living organisms. Coupled with ever-evolving additive manufacturing techniques, these breakthroughs enable the construction of engineered living materials from the ground up. Here, we explore the key factors propelling the emergence of engineered living materials for structural applications and delves into the capabilities of living organisms that can be harnessed for creating functional materials, including harvesting energy, forming structures, sensing/adapting, growing and remodelling. Incorporating living organisms can revolutionise manufacturing for renewable and sustainable composite materials, unlocking previously unattainable functionalities.

This work explores a spatial printing method to fabricate continuous fiber-reinforced thermoplastic composites (CFRTPCs), which can achieve exceptional mechanical performance. For models giving complex 3D stress distribution under loads, typical planar-layer based fiber placement usually fails to provide sufficient reinforcement due to their orientations being constrained to planes. The effectiveness of fiber reinforcement could be maximized by using multi-axis additive manufacturing (MAAM) to better control the orientation of continuous fibers in 3D-printed composites. Here, we propose a computational approach to generate 3D toolpaths that satisfy two major reinforcement objectives: (1) following the maximal stress directions in critical regions and (2) connecting multiple load-bearing regions by continuous fibers. Principal stress lines are first extracted in an input solid model to identify critical regions. Curved layers aligned with maximal stresses in these critical regions are generated by computing an optimized scalar field and extracting its iso-surfaces. Then, topological analysis and operations are applied to each curved layer to generate a computational domain that preserves fiber continuity between load-bearing regions. Lastly, continuous fiber toolpaths aligned with maximal stresses are generated on each surface layer by computing an optimized scalar field and extracting its iso-curves. A hardware system with dual robotic arms is employed to conduct the physical MAAM tasks depositing polymer or fiber reinforced polymer composite materials by applying a force normal to the extrusion plane to aid consolidation. When comparing to planar-layer based printing results in tension, up to 644% failure load and 240% stiffness are observed on shapes fabricated by our spatial printing method. We demonstrate the versatility of our approach through various complex load cases which demonstrate their successful implementation of continuous fiber printing in 3D.

Silica-based glasses can be shaped into complex geometries using a variety of additive manufacturing technologies. While the three-dimensional printing of glasses opens unprecedented design opportunities, the development of up-scaled, reliable manufacturing processes is crucial for the broader dissemination of this technology. Here, we design and study phase-separating resins that enable light-based 3D printing of oxide glasses with high-aspect-ratio features and enhanced manufacturing yields. The effect of the resin composition on the microstructure, mechanical properties and delamination resistance of parts printed by digital light processing is investigated with the help of printing experiments, compression tests and electron microscopy analysis. The chemical composition and microstructure of the cured resins were found to strongly affect the stiffness, delamination resistance, and calcination behavior of printed parts. These findings provide useful guidelines to enhance the reliability and yield of the DLP printing process of multicomponent silica-based glasses.

In addition to the well-documented resource efficiency and geometrical freedom, Digital Fabrication (DFAB) revolutionizes architecture by integrating functionalities into building elements, unlocking untapped potential from the micro- to the macroscales. This study uses binder-jet printed sand for a DFAB prototype—Fireplace2—tailored for indoor heating. Named after its traditional counterpart, Fireplace2 showcases DFAB’s prowess in crafting precise microclimates for heightened thermal comfort. Our research, tuning mechanical and thermal properties across micro and meso scales, illustrates DFAB's utility in architects' hands for crafting tailored microclimates. This approach manipulates the effective thermal conductivity and macroscale topology for stability against toppling (0.8 kN). A vertical infill porosity gradient establishes a surface temperature gradient, countering ventilation-induced thermal gradients. With a minimal operational temperature vertical gradient (+0.2°C), complying with international comfort standards (Predicted Mean Vote −0.23, People Dissatisfied 6%), Fireplace2 stands testament to DFAB’s microclimate-shaping capabilities despite challenges like foot-level ventilation. The study propels DFAB into a sustainable paradigm, aligning occupant comfort with environmental consciousness, thereby fostering more efficient and enjoyable indoor spaces.

Organic polymer-based composite materials with favorable mechanical performance and functionalities are keystones to various modern industries; however, the environmental pollution stemming from their processing poses a great challenge. In this study, by finding an autonomous phase separating ability of fungal mycelium, a new material fabrication approach is introduced that leverages such biological metabolism-driven, mycelial growth-induced phase separation to bypass high-energy cost and labor-intensive synthetic methods. The resulting self-regenerative composites, featuring an entangled network structure of mycelium and assembled organic polymers, exhibit remarkable self-healing properties, being capable of reversing complete separation and restoring ≈90% of the original strength. These composites further show exceptional mechanical strength, with a high specific strength of 8.15 MPa g.cm⁻³, and low water absorption properties (≈33% after 15 days of immersion). This approach spearheads the development of state-of-the-art living composites, which directly utilize bioactive materials to “self-grow” into materials endowed with exceptional mechanical and functional properties.

Signaling pathways in fungi offer a profound avenue for harnessing cellular communication and have garnered considerable interest in biomaterial engineering. Fungi respond to environmental stimuli through intricate signaling networks involving biochemical and electrical pathways, yet deciphering these mechanisms remains a challenge. In this review, an overview of fungal biology and their signaling pathways is provided, which can be activated in response to external stimuli and direct fungal growth and orientation. By examining the hyphal structure and the pathways involved in fungal signaling, the current state of recording fungal electrophysiological signals as well as the landscape of fungal biomaterials is explored. Innovative applications are highlighted, from sustainable materials to biomonitoring systems, and an outlook on the future of harnessing fungi signaling in living composites is provided.

Recent numerical studies have suggested the potential of substrates with streamwise-preferential permeability to reduce drag in turbulent boundary layers. Such a substrate is theorized to facilitate relaxation of the no-slip condition and thereby reduce the skin friction. So far, these beneficial effects have not been demonstrated experimentally yet and therefore the scope of this work is to present this concept in air flow where the substrate geometry satisfies the theoretical permeability requirements for an expected reduction in drag. For this, a three-dimensional-printed structure with anisotropic permeability (φxz=2.7, φxy=3.9) and small pores (s≈250μm), akin to an acoustic liner, was developed. The substrate was investigated using direct force measurements and 2D-2C PIV in the range of U∞≈5-35 ms-1, corresponding to frictional Reynolds numbers of Reτ≈430-1960. Results show an increase in drag of 0%<ΔCD<8% and, while contrasting the model predictions, this agrees with DNS data on structures with similar geometric properties when using the inverse wall-normal Forchheimer coefficient, or inertial permeability, as the equivalent roughness parameter. Hence the present results constitute the first experimental evidence that this is the governing property for the drag behavior of acoustic liners. The absence of the predicted beneficial flow modulation effects is attributed to the investigated substrate not strictly satisfying the theoretical framework assumptions on characteristic length scales. However, to expand beyond this structural limitation, we analytically derive that, for realistic, geometrically resolved cases, this length scale mismatch is unavoidable and thereby render it unfeasible to model the substrate as a continuum for the virtual-origin approach. We expect that translating the abstraction of substrates with streamwise-preferential permeability into physical realisations relevant for practical applications would result in structures very similar to riblets.