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A new methodology to fabricate polymer–metal parts through hybrid fused filament fabrication

2025Artigo de investigação Acesso aberto
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datacite.subject.fosEngenharia e Tecnologia::Engenharia Mecânica
dc.contributor.authorSilva, Sofia F.
dc.contributor.authorRosado, Pedro M. S.
dc.contributor.authorSampaio, Rui F. V.
dc.contributor.authorPragana, João P. M.
dc.contributor.authorBragança, Ivo M. F.
dc.contributor.authorAssunção, Eurico
dc.contributor.authorSilva, Carlos M. A.
dc.contributor.authorBragança, Ivo
dc.date.accessioned2026-09-18T11:07:03Z
dc.date.available2026-09-18T11:07:03Z
dc.date.issued2025
dc.description.abstractThis paper introduces a new methodology that enables the production of polymer–metal parts through hybrid additive manufacturing. The approach combines fused filament fabrication (FFF) of polymers with adhesive bonding of metal inserts, applied during layer-by-layer construction. The work is based on unit cells designed and fabricated using eco-friendly materials—polylactic acid (PLA) and aluminum—which were subsequently analyzed for build quality and for mechanical performance under tensile lap-shear and three-point bending tests. The acquired knowledge in terms of optimal processing parameters for attaining strong polymer–metal bonds was then applied for the fabrication and testing of prototypes representing modular corner connectors for framing applications. Results on build quality demonstrate that issues, such as lumps and warping, can be solved by finetuning the 3D printing stages of the proposed methodology. In terms of destructive testing, significant improvements in the mechanical performance of PLA can be achieved, demonstrating the feasibility of the proposed methodology in integrating the lightweight properties of polymers with the stiffness of metals. This enables the development of innovative, sustainable and eco-friendly solutions that align with the growing demand for eco-friendly materials and processes in manufacturing.eng
dc.identifier.citationSilva, S. F., Rosado, P. M. S., Sampaio, R. F. V., Pragana, J. P. M., Bragança, I. M. F., Assunção, E., & Silva, C. M. A. (2025). A new methodology to fabricate polymer–metal parts through hybrid fused filament fabrication. Sustainability, 17(10), 4254. https://doi.org/10.3390/su17104254
dc.identifier.doi10.3390/su17104254
dc.identifier.issn2071-1050
dc.identifier.urihttp://hdl.handle.net/10400.21/23082
dc.language.isoeng
dc.peerreviewedyes
dc.publisherMDPI
dc.relationUIDB/50022/2020
dc.relationC644876810-00000019
dc.relation.hasversionhttps://www.mdpi.com/2071-1050/17/10/4254
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/
dc.subjectAdditive manufacturing
dc.subjectFused filament fabrication
dc.subjectAdhesive bonding
dc.subjectPolymer–metal parts
dc.titleA new methodology to fabricate polymer–metal parts through hybrid fused filament fabricationeng
dc.typeresearch article
dspace.entity.typePublication
oaire.citation.issue10
oaire.citation.titleSustainability
oaire.citation.volume17
oaire.versionhttp://purl.org/coar/version/c_970fb48d4fbd8a85
person.familyNameBragança
person.givenNameIvo
person.identifier.ciencia-idAD1C-FCD3-0E95
person.identifier.orcid0000-0001-5409-619X
person.identifier.scopus-author-id55671241900
relation.isAuthorOfPublication7205d347-961d-49ea-a212-a15930de3c41
relation.isAuthorOfPublication.latestForDiscovery7205d347-961d-49ea-a212-a15930de3c41

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