Overview

This book presents a unique approach to developing lightweight feedstock material for 3D printing of structural components for weight-sensitive structural applications across aerospace, automobile, and marine regimes. In addition to making wide feedstock materials choices available for AM industry, the content also presents a novel approach of 3D printing of lightweight core sandwich composites, all at once. It discusses the process of fused filament fabrication (FFF) as one of the most widely used additive manufacturing (AM) techniques to fabricate lightweight complex functional parts with zero tooling cost, lower energy, and reduced material consumption. The chapters presented in this book deal with a special class of lightweight feedstock material development, synthesis of the developed filaments, optimization of 3D printing parameters on a commercially available FFF-based printer, mechanical and dynamic property investigations of prints, and finally demonstration of 3D-printed industrial-scale lightweight components. This book guides students, researchers, and industrial professionals in lightweight materials design and development.

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Dr. Mrityunjay Doddamani is Associate Professor in the Department of Mechanical and Materials Engineering at the Indian Institute of Technology (IIT), Mandi, Himachal Pradesh, India, where he leads the Advanced Manufacturing Lab with research focused on 3D printing of lightweight composites. His research focus is on structure–property correlation of lightweight composites. His expertise includes advanced manufacturing and structural analysis of composites, understanding the effect of mechanical loading (static and dynamic) on the microstructure and mechanical properties, and failure analysis therein. Dr. Mrityunjay has published more than 75 journal articles in journals of international repute. He is featured in the top 2% scientist “Updated Science wide author database of standardized citation indicators” published by Elsevier 2021, 2022. Mrityunjay’s research has been supported by various funding agencies in India and abroad. He is Recipient of Visiting Scientist Fellowship from the Office of Naval Research Global, Singapore. He is serving as Editorial Board Member of the Materials Circular Economy Journal by Springer-Nature. He is Inventor of two Indian patents. Dr. H. S. Bharath is Assistant Professor at the Department of Mechanical Engineering, Siddaganga Institute of Technology, Tumakuru, Karnataka, India. He obtained his B.E. (Mechanical) and M.Tech. (Manufacturing Science and Engineering) from Visvesvaraya Technological University, Belagavi. He completed his Ph.D. at the National Institute of Technology Karnataka (NITK), Surathkal, Mangaluru. His major research interests include 3D printing, sandwich composites, and syntactic foams. He has published tenpapers in reputed international journals. Dr. Pavana Prabhakar is Charles G. Salmon Assistant Professor in the Departments of Mechanical Engineering and Civil and Environmental Engineering at the University of Wisconsin–Madison, where she leads the Manufacturing and Mechanics Lab (MaMeL) with research focused on advanced manufacturing and mechanics of lightweight composite materials. Her work involves conducting foundational research on mechanics-based materials designs (computationally and experimentally) of composites and their fabrication by advancing relevant manufacturing techniques. Her research occurs at the intersection of solid mechanics, advanced manufacturing, materials science, and computational science. Her current and previous research involves extensive computational and experimental investigation of failure and damage in lightweight composites for structural applications. Her expertise includes micromechanical and structural analysis of composites using computational modeling, understanding the effect of extreme environments on the microstructure and mechanical properties, and failure analysis of structural materials using novel approaches. Dr. Prabhakar has published more than 30 journal articles in highly regarded journals. She received prestigious awards like NSF CAREER in 2021, ONR Young Investigator Program Award in 2019, and AFOSR Young Investigator Program Award in 2015. She also received the Destech Young Composites Research Award in 2019 and Ph.D. Research Scholarship Award in 2012, both from the American Society for Composites, for outstanding composite materials research focused on composite materials. Dr. Suhasini Gururaja is Associate Professor in the Department of Aerospace Engineering at Auburn University, USA. Prof. Suhasini’s research focuses on a major theme in advanced composites that correlates the material microstructure with its performance. Prof. Suhasini’s research group—Advanced Materials and Processing Laboratory (AMPL)—explores issues at the intersection of composite microstructure, composite manufacturing, and structural integrity. She has achieved this through developing and leading intertwined research activities in damage development and progression, process modeling, and advanced manufacturing of composites. Before joining academia, Dr. Suhasini worked at GE Global Research (Bengaluru, India) and Boeing Commercial Airlines (Everett, WA, USA).

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