Bin Zou

The mechanical properties of continuous-fiber-reinforced composites in FDM-3D printing are significantly influenced by process parameters. However, research in this area is constrained by printing equipment, control software, and material preparation. This study examines how the tensile and interlaminar shear properties of CCF/PA and CF/PEEK are affected by continuous-fiber nozzle temperature, platform temperature, and printing speed. Studies indicate that enhancing the nozzle temperature can notably improve mechanical properties by enhancing material flowability, ensuring consistent fiber encapsulation and reducing pore defects. Increasing the platform temperature initially boosts both tensile strength and ILSS, but, beyond a certain point, these properties decline. Inadequate platform temperature can result in uneven infiltration and diffusion among deposited CCF/PA paths, leading to void defects. Conversely, excessive platform temperature can cause semi-molten CCF/PA layers to be vulnerable to nozzle pressure and scraping, resulting in continuous-fiber debonding and interlayer tearing. Furthermore, lower printing speeds extend the melt wetting time between adjacent paths, promoting diffusion and adhesion for enhanced performance. Following an experimental investigation, the optimal parameters are identified as a nozzle temperature of 295 °C, a platform temperature of 240 °C, and a printing speed of 3 mm/s. This research provides valuable guidance for the practical production of continuous-fiber-reinforced composites using FDM-3D printing.

Fused deposition technology has been successfully used for the fabrication of continuous hybrid fiber reinforced composites (CHFRC), and both the hybrid ratio and fiber layout exert a significant influence on the mechanical properties of the additive manufactured parts. In this study, the effects of the hybrid ratio and fiber layout of continuous carbon/glass fiber on the mechanical properties of 3D printed inter/intralayer hybrid composites were investigated. Additionally, the hybrid effect was considered in the mixing law to predict the tensile strength of CHFRCs with inter/intralayer layouts. Results indicate that compared to interior placement, placing glass fibers on the exterior gives CHFRCs a 10%–20% increase in tensile strength. Moreover, exterior glass fiber placement results in a 29% increase in flexural strength at a hybrid ratio of 0.5 compared to interior placement. Furthermore, the modified tensile strength prediction model maintains estimation errors within 3.7%.

The multimaterial hybrid additive manufacturing (MHAM) technology needs the integration and combination of different processes at the hardware as well as software level. However, many software programs for MHAM technologies still rely on single‐process computer‐aided manufacturing (CAM) software (slicing software) and data postprocessing at the software level. Discrete, cumbersome, and nonstandardized data preparation processes hinder the industrialization of MHAM technologies. This article develops an integrated CAM framework for MHAM technology which combines stereolithography and material extrusion processes. It achieves full process integration, covering multimaterial model modeling, slicing, compound process path planning, and G‐code generation, providing specialized data support for multiprocess collaborative manufacturing of “coating‐curing‐blowing‐extrusion‐curing.” A slicing strategy of variable layer height was proposed, with multiple matrix material layers corresponding to a single filling material layer, solving the problem of inconsistent printing resolution of different processes. Various multimaterial ceramic parts were designed and printed through the self‐developed multimaterial 3D printer. The results indicated that the distribution of the matrix and filling materials was consistent with the model design and process planning, and the multimaterial interfaces were well bonded and presented a jagged morphology.

Clinical photothermal therapy for preventing bone tumor recurrence faces dual challenges: systemic toxicity risks from intravenous photosensitizer delivery and insufficient control of photothermal specificity. To address these limitations, we developed a stereolithography (SLA)-based additive manufacturing system for fabricating graphene oxide (GO)-reinforced SiOC/Si₃N₄ bioceramic scaffolds that integrate three functional components: a mechanically robust Si₃N₄ matrix, photothermally active SiOC, and osteoinductive GO. Initially, the polysiloxane KH570-H was synthesized, functioning as both a SiOC precursor and a photosensitive polymer, and subsequently formulated with 0-0.8 wt% GO/Si₃N₄ to develop SLA-compatible ceramic slurries. To address GO-induced light scattering defects, a GO content-photosensitive parameters predictive model was established, improving the dimensional accuracy of printed green bodies by 12.5% compared to non-optimized counterparts. Following sintering post-treatment, 0-0.8 wt% GO/SiOC/Si₃N₄ composite ceramics were fabricated, with the 0.2 wt% GO variant sintered at 1,300^oC demonstrating optimal multifunctional performance. The compressive strength of the Gyroid unit TPMS scaffold with a porosity of 60% reached 41.88 MPa. Notably, the 0.2 wt% GO formulation showed superior cell proliferative capacity, as evidenced by fluorescence microscopy observations of confluent cell monolayers with extensive pseudopodial extensions, indicative of active osteogenic interactions. Under 808 nm near-infrared irradiation (1 W/cm²), the scaffold achieved rapid photothermal activation, reaching the therapeutic threshold of 47.8°C within 10 minutes in a physiomimetic microenvironment. This photothermally functional GO/SiOC/Si₃N₄ scaffold offers a promising dual-functional solution for post-tumor bone regeneration, combining structural adaptability with spatiotemporally controlled therapeutic precision.