Adoption Of Additive Manufacturing Research Articles

Experimental validation of auxetic stent designs: three-point bending of 3D printed Titanium prototypes

Experimental validation of auxetic stent designs: three-point bending of 3D printed Titanium prototypes

Towards a practice-based framework for supply chain resilience in the context of additive manufacturing technology adoption

ABSTRACT Additive manufacturing (AM), also known as 3D printing, is widely believed to enhance supply chain resilience (SCR). However, there is a lack of empirical frameworks to provide directions for practitioners and scholars in this regard. Motivated by the dynamic capabilities view, this exploratory survey research aims to overcome this gap. To this end, empirical data are collected from a heterogeneous sample of experts involved in different industries at the forefront of AM. These data are used to explore pathways through which AM adoption leads to enhancing SCR via different resilience practices. More specifically, the collected data are analyzed to explain how AM adoption affects different resilience practices and how these practices in turn affect SCR. Based on these findings, a preliminary practice-based framework is developed that can support practitioners in deploying AM-enabled resilience practices aimed at generating the supply chain (SC) capabilities necessary for dealing with SC vulnerabilities and therefore enhancing SCR. Moreover, relevant propositions are put forward that reflect these findings and open up avenues for future research.

A Methodology for the Rapid Qualification of Additively Manufactured Materials Based on Pore Defect Structures

Additive manufacturing (AM) can create net or near-net-shaped components while simultaneously building the material microstructure, therefore closely coupling forming the material and shaping the part in contrast to traditional manufacturing with distinction between the two processes. While there are well-heralded benefits to AM, the widespread adoption of AM in fatigue-limited applications is hindered by defects such as porosity resulting from off-nominal process conditions. The vast number of AM process parameters and conditions make it challenging to capture variability in porosity that drives fatigue design allowables during qualification. Furthermore, geometric features such as overhangs and thin walls influence local heat conductivity and thereby impact local defects and microstructure. Consequently, qualifying AM material within parts in terms of material properties is not always a straightforward task. This article presents an approach for rapid qualification of AM fatigue-limited parts and includes three main aspects: (1) seeding pore defects of specific size, distribution, and morphology into AM specimens, (2) combining non-destructive and destructive techniques for material characterization and mechanical fatigue testing, and (3) conducting microstructure-based simulations of fatigue behavior resulting from specific pore defect and microstructure combinations. The proposed approach enables simulated data to be generated to validate and/or augment experimental fatigue data sets with the intent to reduce the number of tests needed and promote a more rapid route to AM material qualification. Additionally, this work suggests a closer coupling between material qualification and part certification for determining material properties at distinct regions within an AM part.

Oral and maxillofacial surgeons' views on the adoption of additive manufacturing: findings from a nationwide survey.

Hospitals in many European countries have implemented Additive Manufacturing (AM) technology for multiple Oral and Maxillofacial Surgery (OMFS) applications. Although the technology is widely implemented, surgeons also play a crucial role in whether a hospital will adopt the technology for surgical procedures. The study has two objectives: (1) to investigate how hospital type (university or non-university hospital) influences surgeons' views on AM, and (2) to explore how previous experience with AM (AM experience or not) influences surgeons' views on AM. An online questionnaire to capture surgeons' views was designed, consisting of 11 Likert scale questions formulated according to the Consolidated Framework for Implementation Research (CFIR). The questionnaire was sent to OMF surgeons through the channel provided by the Association of Oral and Maxillofacial Surgery in Sweden. Data were analyzed using the Mann-Whitney U test to identify significant differences among OMF surgeons in terms of organizational form (i.e., university hospital or non-university hospital) and experience of AM (i.e., AM experience or no-experience). In total, 31 OMF surgeons responded to the survey. Views of surgeons from universities and non-universities, as well as between surgeons with experience and no-experience, did not show significant differences in the 11 questions captured across five CFIR domains. However, the "individual characteristics" domain in CFIR, consisting of three questions, did show significant differences between surgeons' experience with AM and no-experience (P-values: P = 0.01, P = 0.01, and P = 0.04). Surgeons, whether affiliated with university hospitals or non-university hospitals and regardless of their prior experience with AM, generally exhibit a favorable attitude towards AM. However, there were significant differences in terms of individual characteristics between those who had prior experience with AM and those who did not. This investigation facilitates the implementation of AM in OMFS by reporting on the views of OMF surgeons on AM.

Framework for Adoption of Metal Additive Manufacturing in the Oil and Gas Industry in Africa

The oil and gas industry in Africa is under mounting pressure to elevate operational efficiency and curb costs, even as supply chain challenges stemming from the pandemic persist. Additive manufacturing (AM) emerges as a unique solution with the potential to free segments of the industry from conventional supply chains. This study introduces a framework tailored to the distinctive challenges and opportunities of the African oil and gas sector, aiming to facilitate the effective adoption of metal AM. Considering constraints such as supply chain limitations, unstable electricity supply, remote locations, and limited manufacturing facilities, this framework intends to guide stakeholders in leveraging the transformative potential of AM technology while overcoming potential barriers. Leveraging a literature review, expert insights, and real-world scenarios, the study assesses the current state of metal AM in the oil and gas sector. The framework's applicability is demonstrated through a case study of the Nigerian National Petroleum Company (NNPC) Limited, while acknowledging the specific African context. It uncovers the existing state of metal AM in Africa and identifies various facilities along with their constraints. Encompassing domains such as prototyping, customized tooling, complex component fabrication, and spare part production, the framework addresses challenges like cultural shifts, quality control, and facility sustainability. It offers key stages encompassing technology assessment, workforce training, and strategic planning to drive the transition toward additive manufacturing. The adoption of metal AM in Africa's oil and gas sector holds the potential to significantly enhance operational efficiency and competitiveness, yet it necessitates overcoming multifaceted challenges. The proposed framework presents a strategic roadmap for harnessing this technology's transformative potential. By embracing innovation and surmounting region-specific obstacles, Africa's oil and gas industry can attain enhanced efficiency, cost-effectiveness, and adaptability

Unveiling the Environmental and Economic Implications of Additive Manufacturing on Inbound Transportation

This studyaims to investigate the impact of additive manufacturing (AM) on the sustainability of inbound transportation. By combining insights from existing literature and interviews with professionals in the additive manufacturing field, we present a comprehensive analysis of this subject. Drawing upon both literature review and interview perspectives, it is evident that AMsignificantly influences the sustainabledimension of transportation. A key attribute of additive manufacturing is its inherent efficiency, resulting in minimized waste generation during production. This stands in contrast to traditional manufacturing methods, which involve material reduction to achieve desired shapes. The streamlined process of additive manufacturing requires fewer raw materials, thereby reducing environmental impact. The transportability of filament powder in bulk form further contributes to these sustainability gains, reducing material volume and transportation frequency. Consequently, emissions associated with additive manufacturing-related transportation are lowered. Recycling of materials is also structured within a broader framework, deviating from the conventional model of product returns to manufacturers.Despite its potential, our empirical findings suggest that the adoption of additive manufacturing doesn't consistently lead to cost reduction compared to conventional methods. The applicability of additive manufacturing remains limited to specific product ranges. Nevertheless, cost savings can occur in the realm of inbound transportation due to factors such as reduced transportation frequency and the transport-friendly nature of raw material containers. Furthermore, the efficiency of raw material usage in additive manufacturing contributes to economic benefits. Unlike conventional manufacturing, additive processes don't require extensive raw material inventories.Economic considerations extend to the adoption of distributed manufacturing systems. While centralized systems minimize raw material transportation, they may increase transportation distance for the final products. Conversely, distributed systems increase raw material travel but decrease product transportation distance. The study underscores that while distributed manufacturing offers advantages, it impacts transportation costs.In essence, this study sheds light on the complex interplay between additive manufacturing and inbound transportation sustainability. It underscores how additive manufacturing's inherent efficiencies and material characteristics have ramifications for environmental and economic dimensions. Through a blend of theoretical insights and empirical evidence, this research contributes to the broader discourse on sustainable manufacturing practices.

Advances in Additive Manufacturing Techniques for Electrochemical Energy Storage

AbstractThe increasing adoption of additive manufacturing (AM), also known as 3D printing, is revolutionizing the production of wearable electronics and energy storage devices (ESD) such as batteries, supercapacitors, and fuel cells. This surge can be attributed to its outstanding process versatility, precise control over geometrical aspects, and potential to reduce costs and material waste. In this comprehensive review, major AM processes like inkjet printing, direct ink writing, fused deposition modeling, and selective laser sintering/melting along with possible configurations and architectures, are elaborately discussed for each bespoke ESD. The application of 3D‐printed energy storage devices in wearable electronics, Internet of Things (IoT)‐based devices, and electric vehicles are also mentioned in the review. The role of AM in facilitating the production of solid‐state batteries has also revolutionized the electric vehicle (EV) industry. Recent progress in the field of AM of energy systems with solid electrolytes and potential future directions such as 4D printing to incorporate stimuli‐responsive behavior in 3D‐printed materials, biomimetic design optimization, and additive manufacturing of ESD in a micro‐gravity environment have also been highlighted. Extensive research and continuous progress in this field are expected to enhance the longetivity, industrial scalability, and electrochemical performance of 3D‐printed energy storage devices in future.

Layout and geometry optimization design for 3D printing of self-supporting structures

As the demand for high-performance structures in various scenarios continues to rise, the complexity of engineering structures also increases, necessitating the development of advanced design methods and the additive manufacturing (AM) of sophisticated structures. While the layout optimization method based on the ground structure technique can produce optimized designs, the gravity-induced overhang effect during the printing process often requires additional support materials. The use of additional support materials during the printing process can result in higher material costs or the need for post-processing to remove the support structures, significantly hindering the adoption of AM in practice. This paper presents an optimization framework to obtain self-support optimization designs and provides a practical validation for the effectiveness of the proposed framework. Firstly, a self-support point-line structure is obtained via the layout and geometry optimization, considering overhang constraints. Secondly, the point-line structure is transformed into a physical model with nodal expansion considered (i.e., taking into account the overlapping of members at nodes). Finally, the physical models are sliced and printed using both a plastic Fused Deposition Modeling (FDM) printer and a metal Wire Arc Additive Manufacturing (WAAM) printer. The results confirm that the proposed process is effective for both plastic and metal printing, demonstrating its exceptional versatility.

Mechanical and Tribological Performance of Carbon Fiber-Reinforced PETG for FFF Applications

With the increasing adoption of Additive Manufacturing in the industry, driven by its efficiency, productivity, and project profitability, materials have undergone significant evolution to enhance process performance and part properties. One of the processes employed to enhance these properties involves the incorporation of various types of reinforcements. This aims to ensure that the material acquires a proportion of the properties of the added reinforcement. Consequently, the options for material selection expand depending on the application. Hence, there is a need to understand how specific reinforcements modify the properties of these materials. For this reason, this study investigates the modification of mechanical properties in a PETG matrix through the incorporation of short carbon fiber (CF) reinforcements, driven by their industrial relevance. To achieve this, the Fused Filament Fabrication (FFF) process will be utilized to produce a series of standardized specimens made of both PETG and CF-reinforced PETG, with variations in layer height and extrusion temperature. Subsequently, these specimens will undergo mechanical evaluation in tension and compression, following the relevant standards for each case. Finally, distinctions between both materials will be analyzed, based on the data obtained from tensile and compression tests. The incorporation of carbon fiber reinforcement shows a detrimental effect, leading to a decrease in the material’s stress (39.23 N/mm2 vs. 48.41 N/mm2 for the conventional material). As expected, due to the nature of the reinforcement (short fibers), the deformation of the material also decreases (2.13% compared to 2.9%).

Part Deflection Measurements of AM-Bench IN718 3D Build Artifacts.

One of the primary barriers for adoption of additive manufacturing (AM) had been the uncertainty in the performance of AM parts due to residual stresses/strains. The rapid melting and solidification which occurs during AM processes result in high residual stresses/strains that produce significant part distortion. While efforts to mitigate residual stresses, such as post-process heat treatment, can reduce these effects, they nullify the benefits of the as-built component microstructure. Therefore, the ability to predict as-built component residual stresses and component deflection is crucial. AM-Bench seeks to provide modelers with high-fidelity data in well-characterized AM components to aid in model development and calibration. The measurements reported here are part of the 3D builds of nickel-based superalloy IN718 test objects for the CHAL-AMB2022-01-PD modeling challenges. The part deflection measurements were performed using a coordinate measurement machine after the part was partially separated from the build plate.

Critical success factors of additive manufacturing for higher sustainable competitive advantage in supply chains

The manufacturing economy of a nation has to be competent and sustainable to develop technology, generate employment opportunities, serve customers with innovative products at competitive prices, provide best quality and services, and participate in global trade to boost the world economy. Adoption of new technology is important for firms to remain successful and achieve sustainable competitive advantage in the production and distribution of goods/services. The purpose of this study is to explore the critical success factors (CSFs) affecting the adoption of Additive Manufacturing (AM) in mainstream manufacturing in enhancing supply chain competitiveness and sustainability. As a methodological contribution, this research uses a mixed methods' approach. An Exploratory Factor Analysis (EFA) derives five CSFs: 'customized production with speed'; 'sustainable production'; 'flexible manufacturing system (FMS) for complex products'; 'standardization in AM industry'; and 'digital skills & infrastructure’. The Analytical Hierarchic Process (AHP) shows the weights of factors. TOPSIS (Technique for order of preference by similarity to ideal solution) ranks the four manufacturing enterprises based on EFA factors. Decision Making Trial and Evaluation Laboratory (DEMATEL) establishes the cause-effect relationship among factors. This study finds that 'customized production with speed’ is the most influential causal factor and ‘sustainable production’ the main effect factor. AM adoption helps industrial sectors in advancing with new technologies, advanced materials, and organizational structures so as to enhance the competitiveness and sustainability of manufacturing supply chains. It has a great potential to reconfigure supply chain (SC) structures in such a way that sustainable competitive advantage is achieved with less lead time and negligible adverse impact on the environment.

Blockchain-Empowered Distributed Additive Manufacturing-as-a-Service: An Architectural Perspective

Additive Manufacturing (AM) is transforming the way that we fabricate, deliver, and consume a wide range of products and components, including those for consumers, medical devices, automobiles, and aircraft. In AM, 3D-printers are used to fabricate products by depositing material in a layer-by-layer fashion, leading to extremely low marginal production costs and significantly simplifying the manufacturing supply chain by providing the opportunity for production that is much closer to consumers. With extremely low marginal costs, AM facilities can quickly scale their production up and down, or redirect their resources to produce entirely different types of goods to meet dynamic market demands. However, most AM companies that employ 3D-printers have not yet upgraded their operations in a way that improves their supply chain. In this paper, we first offer an overview on the state-of-the-art of AM supply chains and then present a novel blockchain-empowered system architecture, namely, Additive Manufacturing-as-a Service (AMaaS), that can facilitate the speedy adoption of AM in manufacturing industries. Finally, we identify several major research challenges in terms of market design, control algorithms, and security, as well as research directions to tackle them.

Digital Twin Certified: Employing Virtual Testing of Digital Twins in Manufacturing to Ensure Quality Products

Quality products are a main focus for manufacturers. Product users only determine a product to be a quality product if it performs in operation to the user’s perceived standard. Product manufactures need to take a product lifecycle quality (PLQ) perspective of quality and not simply focus on manufacturing quality control, which is more accurately specification control. Manufacturing is the key phase where products take their physical form. There are increasing costs and decreasing risks of different physical quality strategies. The information provided using digital twins and virtual testing promises to be both low risk and cost and has the potential to predict what the customer will experience in operation by testing products passively with data and actively with simulation to destruction. Digital Twin Certified (DTC) is proposed as the methodology for accomplishing this. DTC will be especially important for the adoption of additive manufacturing.

A multi-period multiple parts mixed integer linear programming model for AM adoption in the spare parts supply Chain

ABSTRACT This research proposes a multi-period multiple parts mixed-integer linear programming optimization model for the trade-off analysis of spare parts supply through computer numerical control (CNC) manufacturing and additive manufacturing (AM). The multiple spare parts have different characteristics such as volume, shape size, and geometry complexity. The model focuses on minimizing lead times and thus reducing downtime costs. Scenario analyses are developed for some parameters to assess the robustness of the model. The analysis shows that the mix between AM-based spare parts and CNC-based spare parts is sensitive to changes in demand. For the given data, the findings demonstrate that AM is cost-effective with spare parts having high geometry complexity while CNC-based manufacturing is economically feasible for spare parts with low geometry complexity and large sizes. The proposed model can support decision-makers in selecting the optimal manufacturing method for multiple spare parts having different characteristics and attributes. The paper concludes with limitations and future directions.

Application of additive manufacturing for a sustainable healthcare sector: Mapping current research and establishing future research agenda

Additive manufacturing (AM), an Industry 4.0 technology, is revolutionizing healthcare continuously for the welfare of society. This study aims to perform a systematic review of AM literature in the healthcare sector to analyse the current state of the art and provide future research directions. The study provides a detailed analysis of AM applications in the sector along with key trends in literature, the benefits of AM adoption, and the barriers to its implementation. Then, using CIMO (Context, Intervention, Mechanism, Outcome) logic, the study provides an AM capabilities framework to assist the planning and decision-making of stakeholders. The study also uses the TCCM (Theory, Context, Characteristics and Methodology) framework to identify gaps in the literature and provides potential future research directions. Findings reveal that AM can provide timely and customizable healthcare solutions at affordable prices. The study has valuable theoretical, managerial, and social implications that can help improve patients' quality of life and bring social change, thus accelerating its widespread adoption.

A minireview on 3D printing for electrochemical water splitting electrodes and cells

The adoption of additive manufacturing (also known as 3D printing) for electrochemically related applications is receiving increased attention from the research community, particularly for water electrolysis driven by renewable energy. Additive manufacturing has demonstrated its great potential in the structural design of complex geometry and customization. Given the recent development of several fast-prototyping materials and methods, examining the gaps of electrocatalytic electrode materials and apparatus between the lab scale and industrial scale is important. In this paper, we have summarized the state-of-art 3D printing technologies and 3D printing techniques used in water electrolysis systems—both electrodes and reaction cells. The suitability and advantages of 3D printing methods in developing and designing water-splitting reaction systems are thoroughly discussed. In addition, recent progress demonstrating 3D-printed electrodes and water-splitting cells is reviewed. Finally, future directions for this developing field of research are given along with current difficulties.

Investigating impacts of FDM printing parameters and geometrical features on void formation in 3D printed automotive components

Additive manufacturing (AM) has opened a world of new possibilities in the automotive industry by offering high flexibility in design, shortening production time, and producing lightweight and customizable parts. Despite these advantages, the high risk of defect formation associated with AM processes and the difficulty of defect detection in quality control stages have hindered the rapid adoption of AM in the automotive industry. Mechanical tests are destructive tests which are usually used for quality control of conventionally fabricated components. However, they are not practical for quality control of AM parts since, due to the higher risk of defects, a higher number of AM parts should be mechanically tested which is time-consuming and expensive. Hence, rather than destructive mechanical tests, automakers require non-destructive imaging techniques for AM parts to characterize defects for a high number of samples at the quality control stage. This study aims to examine the impact of printing parameters and geometrical features on the void formation of an automotive component (car window holder). These outcomes will be helpful in the establishment of non-invasive quality control for the window car holder which is based on imaging techniques. For this purpose, a window car holder was printed with varying printing parameters using the FDM technique. Based on the geometry of the component, two regions with distinct geometrical features were specified and analyzed using Micro-CT. Results indicate that by increasing printing speed (30 to 60 mm/min) and temperature (230 °C to 250 °C), voids fraction decreased. Conversely, when increasing the printing layer thickness (0.1 to 0.3 mm), the void fraction increased. It was also concluded that void formation in regions with curved surfaces and overhang structures is significantly higher compared to edges with an angle of 90 ° to 60 °. These results offer a platform to reduce the risk of defect formation in 3D-printed automotive parts, improving quality control.

Direct additive manufacturing of metal parts for automotive applications

Additive manufacturing or three-dimensional (3D) printing offers tremendous opportunities for the automotive industry to reduce vehicle weight and improve vehicle performance through consolidating parts, tailoring material properties, enabling multifunctional components, and simplifying manufacturing processes. However, additive manufacturing research for direct manufacturing of automotive components is limited, partially because of the sheer volume of automotive production. In this paper, we explore the potential of direct manufacturing of metallic vehicle components using additive manufacturing coupled with the generative design approach. Using a radar mounting bracket as an example, we show that desired part strength and safety performance can be achieved with 42 % weight reduction and simplified manufacturing and assembly process. A production cost analysis was also conducted based on two mainstream additive manufacturing systems. The result suggests that the cost of metal powder is the limiting factor for wider adoption of additive manufacturing in the automotive industry.

An approach to evaluate the wear of customized manufacturing fixtures through the analysis of 3D scan data

With the recent gain in popularity and adoption of additive manufacturing in various industrial sectors, quality assessments to determine the functionality of 3D printed parts are critical. This holds especially when the parts are subjected to wear as in the case of the production of customized fixtures. Some reinforced polymeric materials for additive manufacturing can be employed as a substitute for low-resistance metals like Aluminium. In this paper, a custom-made tribometer was used to simulate the wear of 3D printed fixtures of Alumide material for sheet metal inspection operations. Contact 3D scanning is used to monitor the condition of the fixture for increasing numbers of wear cycles. This study aims to calculate the wear volume of cylindrical pins starting from the surface points of 3D scan data. The methodology employs alpha shapes to obtain the progression of the volume and area of the worn zone. Experimental tests to evaluate the wear volume were carried out to compare the durability of Alumide to that of Aluminium, filling the gap of previous literature, which had focused exclusively on diametral wear. The findings indicate a better wear resistance for Alumide specimens and this work contributes to broadening the knowledge about the wear behaviour and the lifetime of 3D printed parts.

Adoption of additive manufacturing technology: drivers, barriers and impacts on upstream supply chain design

PurposeThis paper investigates how the adoption of additive manufacturing (AM) impacts upstream supply chain (SC) design and considers the influence of drivers and barriers towards the adoption.Design/methodology/approachTen case studies investigating AM adoption by Original Equipment Manufacturers (OEMs) in five industries were conducted. This research is driven by a literature-based framework, and the results are discussed according to the theory of transaction cost economics (TCE).FindingsThe case studies reveal four patterns of AM adoption that affect upstream SC design (due to changes in supply base or types of buyer–supplier relationships): make, buy, make and buy and vertical integration. A make or buy decision is based on the level of experience with the technology, on the AM application (rapid manufacturing, prototyping or tooling) and on the need of control over production. Other barriers playing a role in the decision are the high initial investments and the lack of skills and knowledge.Originality/valueThis paper shows how different decisions regarding AM adoption result in different SC designs, with a specific focus on the upstream SC and changes in the supply base. This research is among the first to provide empirical evidence on the impact of AM adoption on upstream SCs and to identify drivers of the make or buy decision when adopting AM through the theoretical lens of TCE.