Advances in 3D-Printed Polymeric Materials for Sustainable Thermal and Acoustic Insulation

Abstract

Additive manufacturing (AM) creates a way of producing engineered polymeric systems with programmable porosity, shapes, and multi-functionality that is innovative for producing sustainable thermal and acoustic insulation solutions. This document reviews new advances in engineering 3-Dimensions printed porous polymers and how the structure of these materials influences their properties. The research focuses on important design aspects of these materials, including: infill density, unit-cell topology, pore size, and triply periodic minimal surfaces (TPMS) and includes a detailed review of the relationship of design aspects and three key properties (density, thermal conductivity, and sound absorption). Examples of engineered and environmentally friendly systems, such as Polylactic Acid (PLA) lattices, polymer/aerogel composites, bio-fiber composites, and recycled nonwoven composites, offer pathways to low-impact, high-performance insulation. Although standardization issues, durability under in-service conditions, and challenges when scaling production remain significant hurdles for large scale production, opportunities future technology developments include multi-material printing, hierarchical architecture based on triply periodic minimal surfaces (TPMS), smart/4Dimensions printed insulators (insulators that are adaptive based on environmental conditions), and the creation of tunable, lightweight and resilient insulators are highlighted. The document concludes with a review of the identified gaps in research and suggested directions for future development of large-scale sustainable thermal and acoustic solutions through integration of material chemistry, additive manufacturing (AM) process control and physics-based modeling.