3D Printing Materials Science
Description
Comprehensive study of materials used in additive manufacturing including thermoplastics, photopolymers, metals, ceramics, and advanced composite materials.
Learning Objectives
Students will understand the fundamental properties of various 3D printing materials including mechanical, thermal, and chemical characteristics, select appropriate materials for specific applications, understand material processing requirements, implement proper storage and handling procedures, evaluate material compatibility with different printing technologies, and assess material performance for end-use applications.
Topics (14)
Photopolymerization mechanisms, acrylate and methacrylate chemistries, photoinitiators, curing kinetics, standard vs engineering resins, biocompatible formulations, and resin handling safety.
USP Class VI materials, ISO 10993 biocompatibility testing, PEEK and medical-grade polymers, titanium alloys for implants, sterilization compatibility, and regulatory pathways for medical devices.
Tensile testing (ASTM D638), impact testing, flexural properties, thermal analysis (DSC, TGA), chemical resistance testing, fatigue testing, and anisotropy characterization in printed parts.
Material cost per part calculations, waste factor analysis, support material costs, powder utilization rates, economies of scale, supplier cost structures, and total cost of ownership models.
Material classification systems, property requirements for AM, material forms (filaments, resins, powders), quality standards, and material-technology compatibility matrices.
PLA characteristics and biodegradability, ABS strength and temperature resistance, PETG chemical resistance and flexibility, engineering plastics (PC, PA, PEI), processing temperatures, and application guidelines.
Powder morphology and flowability, particle size distribution, stainless steel alloys, titanium alloys, aluminum alloys, Inconel and superalloys, powder recycling, and contamination control.
Ceramic powder characteristics, binder systems, debinding processes, sintering mechanisms, alumina and zirconia systems, silicon carbide, bioceramics, and dimensional control challenges.
Carbon fiber reinforcement, glass fiber composites, continuous vs chopped fiber systems, metal-filled filaments, wood-filled materials, fiber orientation control, and interface mechanics.
Moisture absorption in thermoplastics, drying procedures, vacuum storage systems, inert atmosphere handling for metal powders, resin shelf life management, and contamination prevention protocols.
Conductive polymers and metal-filled filaments, magnetic materials, soluble support materials (PVA, HIPS), transparent materials, flexible elastomers (TPU), and color-changing materials.
Thermoplastic recycling processes, failed print rework, biodegradable materials, recycled filament production, powder reuse in SLS, lifecycle assessment methodologies, and circular economy principles.
Incoming material inspection, batch testing protocols, material traceability systems, certification standards, supplier qualification processes, and quality assurance documentation.
Graphene-enhanced materials, nanocomposites, shape-memory polymers, self-healing materials, bio-based polymers, metamaterials, and molecular-level printing approaches.