Iacopo Bianchi

Marche Polytechnic University | Università degli Studi di Ancona · Department of Industrial Engineering and Mathematical Sciences (DIISM)

This paper provides a comprehensive evaluation of using 3D-printed composite molds to produce components for the automotive sector in carbon fiber-reinforced polymers (CFRPs). Two molds in Carbon PA, i.e. PA6 reinforced with 20% by weight short carbon fibers, were realized via fused filament fabrication and subjected to multiple thermal cycles to s...

Hydrogen has emerged as a promising energy vector for internal combustion engines or fuel cell electric vehicles, offering the potential to significantly reduce environmental impacts. To store and transport hydrogen efficiently, high-pressure type IV tanks produced using carbon fibre-reinforced polymers are typically used. However, composite materi...

The present work aims to study the effect of printing orientation angle and heat treatment on the mechanical properties and microstructure of 17-4 PH stainless steel 3D-printed parts obtained by the binder jetting process to assess the suitability of the process and material for rapid tooling applications. To this purpose, tensile specimens were pr...

Metal material extrusion is a family of metal additive manufacturing that includes atomic diffusion additive manufacturing (ADAM) and bound metal deposition (BMD). In the literature, there are just a few cost models for ADAM and no one for BMD. The paper presents an analytic cost model for BMD. It considers the entire process: pre-processing, print...

The present paper aims to assess the effect of different infill percentages and patterns on the compressive mechanical properties of specimens in Polyamide PA6 reinforced with 20% glass fibers (GF) and 10% carbon fibers (CF) printed using the Fused Deposition Modeling (FDM) technology. According to the ASTM D695-15 standard, cylindrical specimens w...

The present paper aims at studying the environmental and economic impacts of an innovative Filament Winding (FW) process used to realize a tubular shape structural component in Carbon Fiber Reinforced Polymer (CFRP). To this purpose, the Life Cycle Assessment (LCA) and Life Cycle Costing (LCC) methodologies were applied using a “from cradle to grav...

IIn this work, the heating distribution on similar and dissimilar friction stir welded joints in aluminium and magnesium alloys sheets was studied. Friction Stir Welding processes were performed using constant rotational and welding speeds of 1500 rpm and 60 mm/min, respectively. In order to obtain a completely non-intrusive and temperature monitor...

The advent of 3D printing technology in the construction field, as for many other industries, represents a technological upgrade. It introduces a paradigm shift in the way we approach construction and architecture, opening up new horizons and unprecedented possibilities. Indeed, due to its ability for infill optimization and reduction in material c...

A widespread problem of manufacturing processes is represented by the occurrence of tool wear that can lead to both poor surface finish and poor mechanical properties in the workpiece. This issue affects also additive manufacturing technologies such as the material extrusion technique. In this process, the wear mechanisms of the extrusion nozzle ca...

The present work aims at investigating the impact of heat treatments on the mechanical, environmental and economic performances of components in carbon fibre polyetheretherketone (PEEK) composite produced using the Fused Deposition Modelling technique. The mechanical properties of PEEK can be strongly improved by performing heat treatments to maxim...

Raw material production represents one of the major issues of additive manufacturing as it can be an expensive and environmentally impactful phase. One example is provided by the light-curing resins used in vat photopolymerization processes. To this purpose, this study aims at evaluating the use of recovered polyamide powders as filler for photocur...

The present investigation aims at studying the effect of carbon nanotubes (CNTs) content on the mechanical performances of carbon fiber reinforced polymer (CFRP) composite materials. To this purpose, percentages of carbon nanotubes, ranging from 0.5 to 4%, were dispersed in the epoxy resin used to impregnate carbon fibers. Tensile and flexural test...

The present work aims at studying the effect of the reinforcing fabric areal weight on the mechanical properties of composite laminates in carbon-fiber-reinforced polymers. Three different pre-impregnated 2 × 2 twill weaves, characterized by the different areal weight values of 380, 630, and 800 g/m2 were used to produce laminates. These areal weig...

In the last years, carbon ceramic brakes are preferred to traditional cast iron ones for their lightweight, high temperature resistance, and long service life, even though their manufacturing involves the use of high temperature processes and energy-intensive materials such as carbon fibers. Within the European Life Project “CIRCE”, a novel recover...

Recently, Università Politecnica delle Marche and COMEC Innovative srl are involved in the research project “Smart Tow Winding” funded by MIUR (Ministry of Education, University and Research), concerning the development of an innovative process for the realization of a pressure vessel through Filament Winding (FW) technology. In this context, a des...

Ethylene vinyl acetate (EVA) is a thermoplastic material largely used in the footwear industry. Indeed, it is employed to produce outsoles and midsoles with high shock absorption. For producing these parts of the shoes, EVA is injected into a heated mold. During this process, gates and runners, which are necessary to allow a correct infill of the m...

The present research aims at studying the effect of the graphene oxide content on the flexural properties of an epoxy resin, generally used as matrix in carbon fiber reinforced materials. To this purpose, flexural tests were performed at room temperature on specimens in epoxy resin reinforced using different graphene contents, ranging from 0.1 to 3...

Toe caps are fundamental components of safety footwear used to prevent injuries, which can be caused by falling objects. They can be realized by exploiting different materials (metal, composites, and polymers) and manufacturing processes (stamping, injection molding, compression molding, etc.). However, they have always to fulfill the stringent req...

The present study aims at investigating the effect of process parameters on environmental sustainability of 3D printing of short fiber-reinforced polymer composites. A preliminary study allowed defining the printing parameters, in terms of printing speed, extrusion temperature and layer thickness, which guarantee low energy consumption. Then, the e...

Toe cap for safety shoes is an extremely important protective equipment to prevent injuries caused by falling objects. It can be considered that more than 600 millions toe caps are disposed every year, without the possibility of disassembly them from the shoes. This represents a serious concern and sustainable solutions must be found to decrease th...

3D Printing consists in the manufacturing of three-dimensional products by depositing material, usually layer by layer. Since material is added only where needed, these techniques have the potential to minimize waste production, leading to a reduction of cost, energy consumption and environmental impacts with respect to traditional production proce...

The present work aims at studying both the mechanical properties and environmental impacts of two 3D printable composites materials: glass fiber reinforced polyamide (GlassPA) and bio-based hemp fiber reinforced polylactide (HempPLA). Hence, this study aims to provide a comprehensive overview of the two considered materials, supporting the sustaina...

Toe caps are fundamental components of safety footwear used to prevent injuries which can be caused by falling objects. They can be realized by exploiting different materials (metal, composites and plastics) and manufacturing processes (stamping, injection molding, compression molding, etc.). However, they have always to fulfill the stringent requi...

In next years, as the CFRP waste production is expected to increase, recovery and recycling systems to maximize the end-of-life value of these materials are highly necessary. A possible solution has been proposed within the CIRCE (Circular Economy Model for Carbon Fibre Prepregs) EU LIFE project (LIFE ENV/IT/000155), developed as a collaboration b...

In the present paper, the environmental impact of an innovative technology, based on a zero-waste approach, for reclaiming carbon fiber prepreg scraps is assessed. The innovative process, proposed within the European project CIRCE, aims at reclaiming scraps produced during the cutting operation of virgin prepreg, avoiding the waste materials landfi...