Faculty Publications

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    3D printing of fly ash-based syntactic foams
    (Elsevier, 2021) Doddamani, M.; Gupta, N.
    In addition to the ease of fabrication using a wide range of forming processes, thermoplastic polymers are recyclable, which is a strong driving force behind their industrial applications. This chapter deals with manufacturing thermoplastic matrix lightweight composites called syntactic foams (SFs) using in the fused filament fabrication 3D printing process. High-density polyethylene (HDPE) is used as the matrix material and fly ash cenospheres are used as the filler. The development of SFs with cenospheres serves a dual purpose of beneficial utilization of industrial waste fly ash and a reduction in the component cost. Hollow fly ash cenospheres are mixed with HDPE to form a cenosphere/HDPE blend, which is extruded in the form of filaments for commercial 3D printers. Single-screw extruder parameters are optimized to develop eco-friendly SF filaments with minimum cenosphere fracture and homogeneous mixing of constituents. Fly ash-based SFs are successfully 3D printed for mechanical characterization and their properties are observed to be comparable to injection molded specimens of the same compositions. 3D printing of industrial components is successfully demonstrated with potential weight saving capabilities of 8% in addition to reduced polymer consumption to the tune of 4.64 million tons globally per year. © 2022 Elsevier Inc. All rights reserved.
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    Experimental investigation on vibration and static deflection of 3D printed functionally graded triply periodic minimal surface beams
    (Elsevier, 2025) Kurup, M.; Jeyaraj, P.
    This research work presents a comprehensive experimental investigation on free vibration and static deflection behavior of functionally graded triply periodic minimal surface (FG-TPMS) beams. The grading in these beams is obtained by changing the wall thickness of the TPMS unit cell layer wise. Polylactic acid filament is used to print the samples through the fused filament fabrication approach. The study explores the influence of various geometrical dimensions, with specific emphasis on the unit cell size and its graded pattern through the thickness. Four primary lattice cells, namely, gyroid, primitive, diamond, and IWP (I-graph & wrapped package-graph), are chosen for analysis. The findings from this study provide valuable insights, demonstrating that a specific lattice cell pattern with appropriate grading has the potential to enhance the vibration properties and deflection characteristics of 3D-printed samples. This knowledge is crucial for designing lightweight and efficient structures, particularly in the context of advancements in additive manufacturing technologies. © 2026 Elsevier Inc. All rights reserved..
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    Thermal Buckling of 3D Printed Auxetic Core Sandwich Beams
    (Springer, 2025) Dattam, V.K.; Pitchaimani, J.; Doddamani, M.
    Experimental investigation carried out on the thermal deflection behavior of 3D printed poly lactic acid sandwich beams possessing positive, negative, and zero Poisson’s ratio cellular cores is presented. Using a fused deposition modelling based 3D printer, sandwich beams were fabricated and investigated for thermal buckling under different heating conditions. Influence of Poisson’s ratio of the core and orientation of the beam on thermal buckling were also studied. It is found that Poisson's ratio of the core influences the thermal deflection of the beams remarkably. The sandwich beam having a vertically oriented core with zero Poisson's ratio exhibited superior buckling resistance compared to the other two cases. © The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.
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    Antimicrobial Metal-organic Frameworks
    (Wiley-VCH Verlag, 2025) Murugesan, S.
    Metal-organic frameworks (MOFs) belong to a 3D porous material, which is made of metal ions connected together by organic moieties (ligands). Also, it often underlies between coordination compounds and materials science. Owing to its highly porous structure and other functional properties such as high surface area and surface energy, it has been widely used in various applications, especially in electronics and biomedical sectors by tailor-made cations. MOF-based various substrates, including scaffolds, thin films, hydrogels, and 3D-printed structures showed remarkable improvement in various biological characteristics like cell differentiation, tissue regeneration, controlled drug release, and antimicrobial properties combined with mechanical stability. Antimicrobial MOFs are widely used for tissue regeneration as infections are the major reason for scaffolds or implants failure. This chapter deals only with various antimicrobial-based MOF substrates for a range of biomedical applications, such as tissue/organ regeneration, wound dressing materials, 3D-printed scaffolds, and drug delivery systems. © 2025 Wiley-VCH GmbH.
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    3D Printing & Mechanical Characteristion of Polylactic Acid and Bronze Filled Polylactic Acid Components
    (Institute of Physics Publishing helen.craven@iop.org, 2018) Aveen, K.P.; Vishwanath Bhajathari, F.; Jambagi, S.C.
    Rapid prototyping (RP) technologies have emerged as fabrication methods to obtain engineering components within a short span of time. Desktop 3D printing, also referred as Additive Manufacturing (AM) technology is a powerful method of rapid prototyping technique that can fabricate three-dimensional engineering components. Poly Lactic acid (PLA) is a green alternative to petrochemical commodity plastics, used in packaging, agricultural products, disposable materials, textiles, and automotive composites, 3-D printing technology enables fabrication of PLA and bronze filled PLA, which has less tensile and flexural modulus. In order for 3D printed parts to be useful for engineering applications, the mechanical properties of the material will play an important role in the functioning of the components. In the present study, commercial grade PLA & bronze filled PLA has been considered as material for preparation of samples using desktop 3D printer. The samples were tested for their mechanical characteristics like Tensile and flexural strength properties. The test Samples were fabricated using 3D printing with different layer height and with different layer build-up speed. Comparison between the PLA & bronze filled PLA based on the experimental results are discussed and found PLA has superior tensile and flexural property when compared to Bronze filled PLA. © Published under licence by IOP Publishing Ltd.
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    3D-Printing Technology: A Review
    (Institute of Electrical and Electronics Engineers Inc., 2024) Mahapatra, R.K.; Kaliyath, Y.; Shet, N.S.V.; Satapathi, G.S.; Mahapatro, S.R.; Lakshmu Naidu, M.L.
    The process of digital fabrication, commonly known as 3D printing, involves gradually adding materials to a geometric representation to produce actual items. The advantages of 3D printing for industrial use include little material waste, simple manufacturing, minimal human participation, minimal post-processing, and energy efficiency. In this study, we provide insights on the development of 3D printing, its history, current state, uses, and potential future directions. There is a detailed explanation of various materials that work with each sort of 3D printing procedure. © 2024 IEEE.
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    3D printing for rapid sand casting—A review
    (Elsevier Ltd, 2017) Upadhyay, M.; Sivarupan, T.; El Mansori, M.
    There are many 3D printing technologies available, and each technology has its strength and weakness. The 3D printing of sand moulds, by binder jetting technology for rapid casting, plays a vital role in providing a better value for the more than 5000 years old casting industry by producing quality and economic sand moulds. The parts of the mould assembly can be manufactured by precisely controlling the process parameters and the gas producible materials within the printed mould. A functional mould can be manufactured with the required gas permeability, strength, and heat absorption characteristics, and hence the process ensures a high success rate of quality castings with an optimised design for weight reduction. It overcomes many of the limitations in traditional mould design with a very limited number of parts in the mould assembly. A variety of powders, of different particle size or shape, and bonding materials can be used to change the thermal and physical properties of the mould and hence provide possibilities for casting a broad range of alloys. Limited studies have been carried out to understand the relationship between the characteristics of the printed mould, the materials used, and the processing parameters for making the mould. These deficiencies need to be addressed to support the numerical simulation of a designed part, to optimise the success rate and for economic as well as environmental reasons. Commonly used binders in this process, e.g. furan resins, are carcinogenic or hazardous, and hence there is a vital need for developing new or improved bonding materials. © 2017 The Society of Manufacturing Engineers
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    A comprehensive review on 3D printing advancements in polymer composites: technologies, materials, and applications
    (Springer Science and Business Media Deutschland GmbH, 2022) Jagadeesh, P.; Madhu, M.; Rangappa, S.M.; Karfidov, K.; Gorbatyuk, S.; Khan, A.; Doddamani, M.; Siengchin, S.
    3D printing is a constantly expanding technology that represents one of the most exciting and disruptive production possibilities available today. This technology has gained global recognition and garnered considerable attention in recent years. However, technological breakthroughs, particularly in the field of material science, continue to be the focus of research, particularly in terms of future advancements. The 3D printing techniques are employed for the manufacturing of advanced multifunctional polymer composites due to their mass customization, freedom of design, capability to print complex 3D structures, and rapid prototyping. The advantages of 3D printing with multipurpose materials enable solutions in challenging locations such as outer space and extreme weather conditions where human involvement is not possible. Each year, numerous research papers are published on the subject of imbuing composites with various capabilities such as magnetic, sensing, thermal, embedded circuitry, self-healing, and conductive qualities by the use of innovative materials and printing technologies. This review article discusses the various 3D printing techniques used in the manufacture of polymer composites, the various types of reinforced polymer composites (fibers, nanomaterials, and particles reinforcements), the characterization of 3D printed parts, and their applications in a various industries. Additionally, this review discussed the limitations of 3D printing processes, which may assist future researchers in increasing the utility of their works and overcoming the shortcomings of previous works. Additionally, this paper discusses processing difficulties, anisotropic behavior, stimuli-responsive characteristics (shape memory and self-healing materials), CAD constraints, layer-by-layer appearance, and void formation in printed composites. Eventually, the promise of maturing technology is discussed, along with recommendations for research activities that are desperately required to realize the immense potential of operational 3D printing. © 2022, The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature.
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    Dynamic mechanical analysis of 3D printed eco-friendly lightweight composite
    (Elsevier Ltd, 2020) Doddamani, M.
    Dynamic mechanical analysis (DMA) is conducted on 3D printed eco-friendly environmentally pollutant fly ash cenosphere/HDPE lightweight composite. Cenospheres with varying volume % are mixed with HDPE, filament extruded and fed to FDM based 3D printer. Higher crystallinity % is observed in prints compared to respective filaments owing to differential cooling rates in extrusion and printing. Crystallinity drops with cenosphere addition owing to pseudo lubricating effect. The crystallinity of prints is higher than their respective filaments. Storage (E?), loss modulus (E?), and damping (Tan ?) increase with increasing cenosphere content in printed lightweight composite. HDPE with 60 by volume % of cenospheres registered higher values, implying the potential of eco-friendly 3D printed lightweight composite to be utilized for weight-sensitive structures. © 2020 Elsevier Ltd
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    Mechanical behaviour of 3D printed lightweight nano-composites
    (Bentham Science Publishers, 2021) Doddamani, M.
    Background: The nanoclay (NC) and Glass Micro Balloons (GMB) based reinforced polymer composites are explored extensively through traditional processing methods. NC shows substantial enhancement in mechanical properties. Polymer composites developed by reinforcing GMB fillers provide a substantial reduction in weight, which is essential in the marine, aerospace, and au-tomotive field. In this study, an attempt is made by developing polymer nanocomposites by reinforcing NC and GMB particles. Objective: The paper deals with 3-dimensional printing (3DP) of lightweight Nanocomposite Foam (NF) developed by mixing nanoclay (NC) and glass micro balloons (GMB) in high-density polyethylene (HDPE). The NF blend is prepared by keeping NC at 5 weight %. Subsequently, GMBs are added by volume (20-60%) to NC/HDPE blend to realize lightweight NFs. Methods: The lightweight feedstock filaments are developed by extruding the blends using a single screw extruder. The extruded NF filaments are used as input in a 3D printer to print NFs. The density of extruded filaments and prints is measured. The printed NFs are subjected to tensile and flexu-ral testing. Results and Conclusion: With an increase in GMB loading, the density of both filaments and prints decreases. Compared to neat HDPE, printed NFs show ~30% weight-reducing potential. The tensile, flexural modulus and strength increases with GMB loading. NFs exhibited superior mechanical performance as compared to HDPE and NC/HDPE. Further, the property map reveals that the 3D-printed NFs show superior tensile, flexural modulus, and strength in comparison with injection and compression-molded foams. © 2021 Bentham Science Publishers.