Applied Chemical Engineering

UV–V’s Analytical Monitoring of Dye-Modified Polymers in FDM-AM Applications

Malak Fadel Mahdi

National Central of Hematology, Mustansiriyah University, Baghdad,10052, Iraq

Sarah salam Ali

Department of Analytics Laboratories, Al-Farahidi University, Baghdad, 10111，Iraq

Hayder Hamid Abbas Al-Anbari

College of Pharmacy, University of Al-Ameed, Karbala, 56001,Iraq

Muntadher Abed Hussein

Al-Manara College For Medical Sciences,University of Manara, Amarah, Maysan, 62001,Iraq

Salah Abdulhadi Salih

Department of Pharmacy, Al-Nisour University, Nisour Seq. Karkh, Baghdad, 10015,Iraq

Ammar S. Al Khafaji

Department of Pharmaceutics, Al-Zahrawi University College, Karbala, 56001,Iraq

Wael Dheaa Kadhim Al Ghezy

Department of Dentistry, Mazaya University College, Dhi Qar,21974, Iraq

Duha Abed Almuhssen Muzahim

Department of Dentistry, Mazaya University College, Dhi Qar,21974, Iraq

Sanan Thaer Abdalwahab

College of Pharmacy, Al-Turath University, Baghdad,10013, Iraq

Maha H. Philip Rahmani

College of Pharmacy, Al-Bayan University, Baghdad, Iraq

DOI: https://doi.org/10.59429/ace.v8i4.5754

Keywords: FDM additive manufacturing; dye-modified polymers; UV–V’s spectroscopy; analytical monitoring; functional materials; polymer characterization; spectral stability; ASTM standards

---

Abstract

The integration of functional dyes into thermoplastic polymers has emerged as a promising route to enhance material performance and expand application potential in fused deposition modeling additive manufacturing (FDM-AM). Dye-modified polymers exhibit unique optical, thermal, and mechanical properties that can be tailored for specialized applications, such as sensing, biomedical devices, and aesthetic-driven prototyping. However, systematic monitoring and characterization of dye incorporation remain challenging due to issues of uniform dispersion, thermal degradation during extrusion, and post-processing stability. Ultraviolet–visible (UV–V’s) spectroscopy provides a non-destructive, highly sensitive analytical tool for evaluating dye–polymer interactions, quantifying dye concentration, and monitoring spectral stability after the FDM-AM process. This article presents a comprehensive study of UV–V’s analytical monitoring of dye-modified polymers, with an emphasis on process-induced changes in absorbance spectra, wavelength shifts, and intensity variations. Using ASTM-referenced protocols, the study highlights the role of dye loading, extrusion temperature, and layer deposition on the optical response of the printed materials. The results indicate that UV–V’s monitoring enables early detection of dye leaching, polymer degradation, and non-uniformity in filament fabrication, thereby providing a reliable framework for quality control and functional assessment in AM workflows. The research establishes UV–V’s spectroscopy as an indispensable analytical technique for advancing the state-of-the-art in functional dye–polymer systems tailored for FDM-AM, while identifying pathways for optimizing process parameters to achieve stable and reproducible material performance.

---

References

[1]. Subramani, R. (2025). Optimizing process parameters for enhanced mechanical performance in 3D printed impellers using graphene-reinforced polylactic acid (G-PLA) filament. Journal of Mechanical Science and Technology, 1-11.

[2]. Ismail, A. I. (2025). Genetically engineered 3D printed functionally graded-lignin, starch, and cellulose-derived sustainable biopolymers and composites: A critical review. International Journal of Biological Macromolecules, 145843.

[3]. Lazarus, B., Raja, S., Shanmugam, K., & Yishak, S. (2024). Analysis and Optimization of Thermoplastic Polyurethane Infill Patterns for Additive Manufacturing in Pipeline Applications.

[4]. Mohammed Ahmed Mustafa, S. Raja, Layth Abdulrasool A. L. Asadi, Nashrah Hani Jamadon, N. Rajeswari, Avvaru Praveen Kumar, "A Decision-Making Carbon Reinforced Material Selection Model for Composite Polymers in Pipeline Applications", Advances in Polymer Technology, vol. 2023, Article ID 6344193, 9 pages, 2023. https://doi.org/10.1155/2023/6344193

[5]. Kang, X., Jiang, K., Ge, S., Wei, K., Zhou, Y., Xu, B. B., ... & Zhang, X. (2025). Frontier in Advanced Luminescent Biomass Nanocomposites for Surface Anticounterfeiting. ACS nano, 19(12), 11547-11575.

[6]. Olaiya, N. G., Maraveas, C., Salem, M. A., Raja, S., Rashedi, A., Alzahrani, A. Y., El-Bahy, Z. M., & Olaiya, F. G. (2022). Viscoelastic and Properties of Amphiphilic Chitin in Plasticised Polylactic Acid/Starch Biocomposite. Polymers, 14(11), 2268. https://doi.org/10.3390/polym14112268

[7]. Praveenkumar, V., Raja, S., Jamadon, N. H., & Yishak, S. (2023). Role of laser power and scan speed combination on the surface quality of additive manufactured nickel-based superalloy. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 14644207231212566.

[8]. Randhawa, K. S. (2024). Synthesis, Properties, and Environmental Impact of Hybrid Pigments. The Scientific World Journal, 2024(1), 2773950.

[9]. Theng, A. A. S., Jayamani, E., Subramanian, J., Selvaraj, V. K., Viswanath, S., Sankar, R., ... & Rusho, M. A. (2025). A review on industrial optimization approach in polymer matrix composites manufacturing. International Polymer Processing.

[10]. Raja, S., Rusho, M. A., Singh, C., Khalaf, A. M., Ismael, S. H., Qader, E. A. A., ... & Kumar, A. P. (2024). Surface functionalization of bio-based polymers in FDM: A pathway to enhanced material performance. Applied Chemical Engineering, 7(3).

[11]. Subramani, R., Rusho, M. A., Thimothy, P., Mustafa, W. W., Ali, S. T., Hashim, R. D., ... & Kumar, A. P. (2024). Synthesis and characterization of high-performance sustainable polymers for FDM applications. Applied Chemical Engineering, 7(4).

[12]. Massaroni, C., Saroli, V., Aloqalaa, Z., Presti, D. L., & Schena, E. (2025). Extrusion‐Based Fused Deposition Modeling for Printing Sensors and Electrodes: Materials, Process Parameters, and Applications. SmartMat, 6(4), e70027.

[13]. Ahmed, W., Zaneldin, E., & El Hassan, A. (2023). Investigating the Integrity and Failure Characteristics of Deteriorated Polymeric 3D-Printed Components as Candidates for Structural and Construction Applications. Buildings, 13(10), 2402.

[14]. Melzer, D., Džugan, J., Koukolíková, M., Rzepa, S., & Vavřík, J. (2021). Structural integrity and mechanical properties of the functionally graded material based on 316L/IN718 processed by DED technology. Materials Science and Engineering: A, 811, 141038.

[15]. S., R., & A., J. R. (2023). Selection of Polymer Extrusion Parameters By Factorial Experimental Design – A Decision Making Model. Scientia Iranica, (), -. doi: 10.24200/sci.2023.60096.6591

[16]. S., Aarthi, S., Raja, Rusho, Maher Ali, Yishak, Simon, Bridging Plant Biotechnology and Additive Manufacturing: A Multicriteria Decision Approach for Biopolymer Development, Advances in Polymer Technology, 2025, 9685300, 24 pages, 2025. https://doi.org/10.1155/adv/9685300

[17]. Selvaraj, V. K., Subramanian, J., Krishna Rajeev, P., Rajendran, V., & Raja, S. Optimization of conductive nanofillers in bio‐based polyurethane foams for ammonia‐sensing application. Polymer Engineering & Science.

[18]. Subramani, R., & Yishak, S. (2024). Utilizing Additive Manufacturing for Fabricating Energy Storage Components From Graphene‐Reinforced Thermoplastic Composites. Advances in Polymer Technology, 2024(1), 6464049.

[19]. Ali, M. (2023). Improving 3D Printability and Functional Performance of Polyethylene across Visible and IR Spectrums through IR Transparent Pigmentation and Polyolefin Additives.

[20]. Subramani Raja, Ahamed Jalaludeen Mohammad Iliyas, Paneer Selvam Vishnu, Amaladas John Rajan, Maher Ali Rusho, Mohamad Reda Refaa, Oluseye Adewale Adebimpe. Sustainable manufacturing of FDM-manufactured composite impellers using hybrid machine learning and simulation-based optimization. Materials ScienceinAdditive Manufacturing 2025, 4(3), 025200033. https://doi.org/10.36922/MSAM025200033

[21]. Bikiaris, N. D., Koumentakou, I., Samiotaki, C., Meimaroglou, D., Varytimidou, D., Karatza, A., ... & Papageorgiou, G. Z. (2023). Recent advances in the investigation of poly (lactic acid)(PLA) nanocomposites: incorporation of various nanofillers and their properties and applications. Polymers, 15(5), 1196.

[22]. Subramani, R., Leon, R. R., Nageswaren, R., Rusho, M. A., & Shankar, K. V. (2025). Tribological Performance Enhancement in FDM and SLA Additive Manufacturing: Materials, Mechanisms, Surface Engineering, and Hybrid Strategies—A Holistic Review. Lubricants, 13(7), 298.

[23]. Rajan, K., Samykano, M., Kadirgama, K., Harun, W. S. W., & Rahman, M. M. (2022). Fused deposition modeling: process, materials, parameters, properties, and applications. The International Journal of Advanced Manufacturing Technology, 120(3), 1531-1570.

[24]. Raja, S., Ali, R. M., Sekhar, K. C., Jummaah, H. M., Hussain, R., Al-shammari, B. S. K., ... & Kumar, A. P. (2024). Optimization of sustainable polymer composites for surface metamorphosis in FDM processes. Applied Chemical Engineering, 7(4).

[25]. Johnson, J. C., Nozik, A. J., & Michl, J. (2013). The role of chromophore coupling in singlet fission. Accounts of chemical research, 46(6), 1290-1299.

[26]. Raja, S., Rusho, M. A., Guru, T. S., Eldalawy, R., Hassen, A. F., Hashim, R. D., ... & Kumar, A. P. (2024). Optimizing catalytic surface coatings in FDM-Printed sustainable materials: Innovations in chemical engineering. Applied Chemical Engineering, 7(4).

[27]. Liu, Q., & Urban, M. W. (2023). Stimulus-responsive macromolecules in polymeric coatings. Polymer Reviews, 63(2), 289-323.

[28]. Abdelhamid, Z., Mohamed, H., & Kelouwani, S. (2024). The use of machine learning in process–structure–property modeling for material extrusion additive manufacturing: a state-of-the-art review. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 46(2), 70.

[29]. Subramani, R., Vijayakumar, P., Rusho, M. A., Kumar, A., Shankar, K. V., & Thirugnanasambandam, A. K. (2024). Selection and Optimization of Carbon-Reinforced Polyether Ether Ketone Process Parameters in 3D Printing—A Rotating Component Application. Polymers, 16(10), 1443.

[30]. Raja, S., Praveenkumar, V., Rusho, M. A., & Yishak, S. (2024). Optimizing additive manufacturing parameters for graphene-reinforced PETG impeller production: A fuzzy AHP-TOPSIS approach. Results in Engineering, 24, 103018.

[31]. Selvaraj, V. K., Subramanian, J., Lazar, P., Raja, S., Jafferson, J. M., Jeevan, S., ... & Zachariah, A. A. (2024, February). An Experimental and Optimization of Bio-Based Polyurethane Foam for Low-Velocity Impact: Towards Futuristic Applications. In International Conference on Advanced Materials Manufacturing and Structures (pp. 244-261). Cham: Springer Nature Switzerland.

[32]. Raja, S., Jayalakshmi, M., Rusho, M. A., Selvaraj, V. K., Subramanian, J., Yishak, S., & Kumar, T. A. (2024). Fused deposition modeling process parameter optimization on the development of graphene enhanced polyethylene terephthalate glycol. Scientific Reports, 14(1), 30744.

[33]. Arunprasand, T. R., & Nallasamy, P. (2024). Advancements in optimizing mechanical performance of 3d printed polymer matrix composites via microstructural refinement and processing enhancements: A comprehensive review. Mechanics of Advanced Materials and Structures, 1-19.

[34]. Ashebir, D. A., Hendlmeier, A., Dunn, M., Arablouei, R., Lomov, S. V., Di Pietro, A., & Nikzad, M. (2024). Detecting multi-scale defects in material extrusion additive manufacturing of fiber-reinforced thermoplastic composites: a review of challenges and advanced non-destructive testing techniques. Polymers, 16(21), 2986.

[35]. Ng, W. L., Goh, G. L., Goh, G. D., Ten, J. S. J., & Yeong, W. Y. (2024). Progress and opportunities for machine learning in materials and processes of additive manufacturing. Advanced Materials, 36(34), 2310006.

[36]. Carrola, M., Asadi, A., Zhang, H., Papageorgiou, D. G., Bilotti, E., & Koerner, H. (2021). Best of both worlds: Synergistically derived material properties via additive manufacturing of nanocomposites. Advanced Functional Materials, 31(46), 2103334.

[37]. Yeo, J., Jung, G. S., Martín-Martínez, F. J., Ling, S., Gu, G. X., Qin, Z., & Buehler, M. J. (2018). Materials-by-design: computation, synthesis, and characterization from atoms to structures. Physica scripta, 93(5), 053003.