Virtual and Physical Prototyping

Optimization and Recycling Strategies in 3D Printing of Composite Materials

Additive manufacturing has transformed modern fabrication by enabling the layer wise construction of complex geometries directly from digital models. Among its most significant advancements is the integration of composite materials into 3D printing processes, allowing the combination of polymers, metals, ceramics, and continuous or short fiber reinforcements to produce components with enhanced mechanical, thermal, and functional properties. From aerospace structures to biomedical devices and lightweight automotive parts, 3D printed composites are redefining design freedom and performance optimization. The convergence of material science, process engineering, and computational modeling has accelerated the development of multifunctional and high performance composite systems tailored for rapid prototyping and end use applications. As digital workflows increasingly connect virtual design, simulation, and physical fabrication, composite additive manufacturing is emerging as a central pillar in next generation prototyping strategies.

Traditional prototyping methods often face limitations in material selection, structural customization, production time, and cost efficiency. The ability to print composite materials enables engineers to achieve superior strength to weight ratios, tailored anisotropic properties, and integrated functionality within a single manufacturing step. This advancement supports lightweighting initiatives, sustainability goals, and high performance requirements across critical industries. Moreover, integrating computational design tools, topology optimization, and process simulation with composite 3D printing enhances predictive capability and reduces trial and error experimentation. However, challenges remain in interfacial bonding, defect control, process parameter optimization, repeatability, and large scale implementation. Addressing these challenges is essential to fully exploit the potential of composite additive manufacturing. Advancing research in this area strengthens the link between virtual prototyping and validated physical components, enabling more reliable, efficient, and application driven innovation.

This Article Collection invites original research articles and review papers within the scope of Virtual and Physical Prototyping that explore advances in 3D printing of composite materials and their integration into digital design and prototyping workflows. Topics of interest include, but are not limited to: novel composite feedstocks and reinforcement strategies; continuous fiber and short fiber reinforced printing; multi material and hybrid manufacturing approaches; process modeling and simulation; microstructure characterization and property prediction; interfacial mechanics and failure analysis; in situ monitoring and quality control; topology optimization for composite printing; sustainability and recyclability of printed composites; and industrial case studies demonstrating virtual to physical validation. Contributions bridging computational modeling, experimental prototyping, and real world applications are particularly encouraged to highlight the synergy between digital design environments and advanced composite fabrication technologies.

Keywords: Additive manufacturing, Composite materials, 3D printing, Virtual prototyping, Process modeling and optimization

All manuscripts submitted to this Article Collection will undergo a full peer-review; the Guest Advisor for this Collection will not be handling the manuscripts (unless they are an Editorial Board member).

Please review the journal scope and author submission instructions prior to submitting a manuscript.

The deadline for submitting manuscripts is 31 March 2027.

Please contact Zhan Yu at [email protected] with any queries and discount codes regarding this Article Collection.

Please be sure to select "Optimization and Recycling Strategies in 3D Printing of Composite Materials" from the drop-down menu in the submission system.

Dr. Ibrahim Alarifi received his Ph.D. in 2017 from the Department of Mechanical Science and Engineering at Wichita State University. After having the lecturer experience, he joined the Department of Mechanical Engineering at Majmaah University in 2012. I received tenure and promotion to Associate Professor in 2018. He is currently working in the same department as a Professor, ME Head of Dept from 2017 to the present. Director of Engineering & Applied Sciences Research Center from 2019 to current, ME Quality Coordinator from 2017 to current, and Dean for Academic Affairs of Common First Year at Majmaah University from 2018 to current. Throughout his research experience, he has published 137 journal papers and 18 conference proceedings, edited 2 books, authored 4 book chapters and 1 laboratory manual, received 6 funded proposals, 10 patents, and 4 honors/awards, presented 10 presentations, chaired many international conferences, and reviewed several manuscripts in international journals and conference proceedings and 1 MS and 10 BS students have already graduated under his supervision and started working in different locations worldwide. According to the Web of Science, his scholarly activities (with h-Index 44 and i10-index 40) have been cited more than 5816 times and recognized by Stanford University’s list (published by Elsevier) of the World’s Top 2% of the Most-Cited Scientists in Single Year Citation Impact 2021, 2022, 3023, and 2024.

Dr. Sanjay Mavinkere Rangappa, is a Principal Research Scientist and Associate Professor and also 'Advisor within the office of the President for University Promotion and Development towards International goals' at King Mongkut’s University of Technology North Bangkok, Bangkok, Thailand. He is an Executive Editor of Book Cluster: Fiber Science and Fibrous Composite Materials, Elsevier. He is a Former Associate Editor of Heliyon Elsevier (Materials Science) and Associate Editor of Frontier Materials Journals. Also acting as a Board Member and Editor of various international journals in the fields of materials science and composites. He is a reviewer for more than 250 International Journals (for Nature, Elsevier, Springer, Sage, Taylor & Francis, Wiley, American Society for Testing and Materials, American Society of Agricultural and Biological Engineers, IOP, Hindawi, NC State University USA, ASM International, Emerald Group, Bentham Science Publishers, Universiti Putra, Malaysia), also a reviewer for book proposals, and international conferences. In addition, he has published more than 425 articles in high-quality international peer-reviewed journals indexed by SCI/Scopus, 13 editorial corners, 100 book chapters, 70 books as an Editor (Published by lead publishers such as Elsevier, Springer, Taylor & Francis, Wiley), authored 3 books published by Elsevier and also presented research papers at national/international conferences. His more than 25 articles got top-cited in various top journals (Journal of Cleaner Production, Carbohydrate Polymers, International Journal of Biological Macromolecules, Journal of Natural Fibers, Journal of Industrial Textiles). He is a lead editor of Several special issues. Based on google scholar, the number of citations amounts to 39000+ and his present H-index is 100 with i10-Index of 475. In addition, I US Patent, 11 UK Design Patent, 1 Thailand Patent and 5 Indian patents are granted. He has delivered keynote and invited talks at various international conferences and workshops held in Russia, South Africa, Ukraine, Malaysia, India, Indonesia. He is an Academic Visitor to School of Mechanical and Design Engineering, University of Portsmouth, Portsmouth, United Kingdom (2024). Visiting Professor for Universiti Malaysia Terengganu (UMT), Malaysia, (2025-2027), Visiting Researcher to Laboratory of Biocomposite Technology, Institute of Tropical Forestry and Forest Products (INTROP), Universiti Putra Malaysia (2019), Visiting Professor of Brawijaya University-Indonesia (2024), Top Research Scientist Fellow of University Negeri Malang-Indonesia (2024), Visiting Professor to School of Polymer Science and Technology, Mahatma Gandhi University (MGU), India, (2024-2025), Adjunct Professor to Mechanical Engineering Department, University of Brawijaya, Indonesia (2024-2025), Visiting Professor of University Technology Malaysia (UTM) (2025), Visiting Professor of University Malaya, Malaysia (2025). His current research areas include Natural fiber composites, Polymer Composites, and Advanced Material Technology. He has received a ‘Top Peer Reviewer 2019’ award, Global Peer Review Awards, Powered by Publons, Web of Science Group. The KMUTNB selected him for the ‘Outstanding Young Researcher’ Award 2020 and Outstanding Researcher’ Award 2021. He is recognized by Stanford University’s list (published by Elsevier) of the World’s Top 1% of the Most-Cited Scientists in Career and Single Year Citation Impact for 6 consecutive years from 2019 to 2025’ (Overall Top 5th Rank in Thailand and Top 2nd Rank Under Polymers Category in Thailand for 2023). He is listed in ‘Top 100 Scientists’ in Thailand, by AD Scientific Index. (2nd Best Scientist in the Country-Mechanical Engineering, Thailand).