Additive Manufacturing Research Articles

Drilling parameter optimisation for three-dimensional prints of acrylonitrile butadiene styrene

Abstract Over the past decade, additive manufacturing has transformed the industry, leading to a range of innovative products. In this study, the acrylonitrile butadiene styrene specimen was produced using the fused deposition modeling process. To assess the effectiveness of additive manufacturing parts in final product development, it’s crucial to establish the optimal drilling process parameters to minimize thrust force and torque. The investigation utilized two different drill geometries. Drilling with an end mill resulted in a 24.22% reduction in thrust force and a 12.37% decrease in torque compared to using a twist drill. Additionally, factors such as orientation, infill density, feed rate, and drill geometry have a significant impact on drilling forces.

Paste extrusion‐based 3D printing of fiber‐reinforced ultra high‐temperature ceramics

AbstractUltra–high‐temperature ceramics (UHTCs) are valued for their extremely high melting temperatures and resistance to active oxidation. However, their low fracture strengths and the difficulties in shaping them into complex geometries hamper their widespread application. This study aims to fabricate zirconium diboride–silicon carbide (ZrB2‐SiC) composites reinforced with aligned SiC fibers by formulating suspensions containing a preceramic polymer, ZrB2, and SiC fibers. This study assessed the influence of fiber alignment on electrical and thermal conductivities, as well as on mechanical strength. The results revealed a significant enhancement in thermal conductivity, particularly when the fibers were aligned, effectively doubling it compared with the non‐aligned parts. Additionally, increasing the fiber content significantly improved the fracture strength, with composites containing 22.5 vol% fibers reaching fracture strengths over 57 MPa. However, the final values did not meet the theoretical expectations because the porosity in pyrolyzed parts exceeded 10%. Furthermore, the study demonstrated a 10‐fold increase in electrical conductivity with fiber alignment compared to that for non‐aligned composites. These results highlight the capability of paste extrusion‐based additive manufacturing in tailoring ultra–high‐temperature ceramic matrix composites (UHTCMCs) with aligned fibers, realizing their suitability for aerospace applications.

Static and dynamic open loop control of selective laser flash sintering conducted with direct current electric fields

AbstractSelective laser flash sintering utilizes a scanning laser as a heat source to locally initiate flash sintering in the regions scanned by the laser. A key challenge towards utilizing this process for additive manufacturing (AM) is the induced electrical current that arises during flash sintering. With traditional scan patterns conducted with static electric fields, electrical and thermal runaway and associated thermal shock cracking occur. In this study, several open‐loop control strategies with static and dynamic applied electric fields were utilized to control peak currents. These strategies were shown to be effective in reducing peak currents to below 1.0 µA and reducing the severity of, but not completely eliminating cracking. Alternative strategies are suggested that could lead to complete elimination of cracks.

Functionally Graded Metamaterials: Fabrication Techniques, Modeling, and Applications—A Review

Functionally Graded Metamaterials (FGMMs) constitute an innovative class of materials within the realm of additive manufacturing (AM), attracting substantial attention from material science and research communities. These materials, characterized by unique designs and gradient properties, are not commonly found in nature but are deliberately engineered through the arrangement of subwavelength structures. The distinct attributes of such materials have propelled them into significant prominence across various industries, including automotive, aerospace, medical, electronics, and agriculture. This review paper aims to present a comprehensive overview of a range of techniques applied in the fabrication, design, theoretical models, and simulation methods related to these materials. It delves into the assessment of such material’s performance, specifically focusing on mechanical, thermal, and electromagnetic properties. Moreover, this review addresses advancements, challenges, and potential solutions in the field. Ultimately, it delivers valuable insights to researchers, practitioners, and stakeholders, enhancing their understanding of FGMMs and their significance in the broader context.

Integration of nanomaterials in FDM for enhanced surface properties: Optimized manufacturing approaches

This article presents a comprehensive review of advanced techniques for integrating nanomaterials into fused deposition modeling (FDM) processes, addressing prevalent challenges such as limited surface quality and wear resistance in traditional FDM-printed parts. The integration of nanomaterials offers potential solutions to these issues by enhancing surface properties. This review explores key methodologies, including direct nanoparticle mixing with polymer filaments, in-situ polymerization, and surface coating techniques, and demonstrates their impact on improving surface roughness and wear resistance. Specifically, nanomaterial-enhanced composites achieve up to a 30% reduction in surface roughness and a 40% improvement in wear resistance compared to conventional materials. To optimize manufacturing processes, we apply the Taguchi method to identify critical process parameters such as extrusion temperature, print speed, layer thickness, and nanoparticle concentration that influence surface properties. Our simulations and analysis of variance (ANOVA) indicate that optimal settings can enhance surface quality by 25% and improve wear resistance by 35%. The proposed methodologies and theoretical framework lay the groundwork for experimental validation, which will involve testing the optimized parameters and assessing their practical impact. This research advances the field of additive manufacturing by providing novel insights into nanomaterial integration, paving the way for improved FDM technology with applications spanning aerospace, biomedical engineering, and beyond. The findings contribute significantly to overcoming existing limitations and enhancing the performance of FDM-printed parts.

Digital Light Processing Followed by Pressureless Sintering of Metal-Reinforced Ceramics: Adjustment of Process Parameters and Correlation with Composites Properties

AbstractDigital light processing (DLP) belongs to additive manufacturing techniques and is frequently used in shaping ceramics. The paper concerns the adjustment of the DLP method to metal-reinforced ceramics, especially dispersions containing high concentrations of Al2O3 (45 vol%) and molybdenum or nickel particles (0.5 vol%). Different glycol acrylates, deflocculants (polyelectrolytes and diammonium hydrogen citrate), and photoinitiators (Omnirad group) were examined regarding their influence on the rheological properties of the dispersions and the cure depth under the external halide UV lamp and LED projector built into the 3D printer. In the examined systems, the cationic polyelectrolyte KD1 dissolved in 2-butanone allowed to obtain dispersions of the lowest viscosity. Printing parameters (light exposure time, single layer height) were matched, and the properties of the materials were examined. The Vickers hardness of the sintered bodies equalled 19.4 GPa, 14.5 GPa and 17.3 GPa for Al2O3, Al2O3-Ni and Al2O3-Mo samples, respectively. The microstructure was analyzed using SEM, followed by EDS and XRD. The addition of only 0.5 vol% of Ni has improved the fracture toughness of alumina by up to 36–40% (according to Niihara and Anstis equations). The exemplary objects in the form of cog wheels were printed and densified at 1550 °C in a reductive atmosphere of Ar/H2.

Energy-efficient FDM printing of sustainable polymers: Optimization strategies for material and process performance

The integration of sustainable polymers in fused deposition modeling (FDM) 3D printing offers a promising pathway toward reducing the environmental impact of additive manufacturing. However, the energy-intensive nature of FDM processes presents a significant challenge to the overall sustainability of this technology. In this study, we explore the use of bio-based and recycled polymers in FDM printing and develop optimization strategies to reduce energy consumption without compromising material and print performance. Our results demonstrate that by systematically optimizing key printing parameters such as extrusion temperature, print speed, and layer height it is possible to achieve up to 20% energy savings. Additionally, we find that novel material formulations and advanced thermal management techniques enhance the mechanical properties of printed objects by up to 15%, all while minimizing energy use. This research not only advances the field of sustainable 3D printing but also provides a framework for the development of next-generation materials and processes that align with the principles of a circular economy.

Minimally invasive detection of buprenorphine using a carbon-coated 3D-printed microneedle array.

Amachine learning-assisted 3D-printed conducting microneedle-based electrochemical sensing platformwas developed for wireless, efficient, economical, and selective determination of buprenorphine. The developed microneedle array-based sensing platform used 3D printing and air spray coating technologies for rapid and scalable manufacturing of a conducting microneedle surface. Upon optimization and understanding of the electrode stability, redox behavior, and electrochemical characteristics of as-prepared conducting microneedle array, the developed electrochemical platform was investigated for monitoring different levels of buprenorphine in the artificial intestinal fluid and found to be highly sensitive and selective towards buprenorphine for a wide detection range from 2 to 140μM, with a low limit of detection of 0.129μM. Furthermore, to make the sensing platform user accessible, the experimentally recorded sensing data was used to train a machine learning model and develop a web application for the numerical demonstration of buprenorphine levels at the point of site. Finally, the proof-of-concept study demonstrated that by advancing our prevailing 3D printing and additive manufacturing techniques, a low-cost, user-accessible, and compelling wearable electrochemical sensor could be manufactured for minimally invasive determination of buprenorphine in interstitial fluid.

A novel treatment of solute drag and solute trapping at a solid–liquid interface during rapid solidification of multicomponent alloys

AbstractIn response to the renewed interest in solute drag and solute trapping models fueled by their applications to additive manufacturing, a novel treatment is proposed to describe the diffusional behaviors of solute at a migrating solid–liquid interface during rapid solidification of multicomponent alloys. While the treatment is still built on irreversible thermodynamics and linear kinetic law, its novelty lies in breaking up the classical trans‐interface diffusional flux into two separate fluxes one is the transferred‐back flux with its ending point at the interface and the other is the bumping‐back flux with its starting point at the interface. This novel treatment entails three significant improvements in reference to the existing models. Firstly, it reveals that the degree of solute drag is dependent on the ratio of liquid diffusive speed over interface diffusive speed. Secondly, a novel relation between the distribution coefficient and interface velocity is derived. It amends the confusing behavior seen in Aziz’s without‐drag continuous growth model. Thirdly, the proposed treatment eliminates the need of prescribing the degree of solute drag parameter for the kinetic phase diagram calculation. The numerical solution to the proposed model is presented, and it is ready to be used for the kinetic phase diagram calculation.

Three-Dimensional Numerical Simulation of High-Speed Shear Crushing of High-Density Fluid

Plasma atomization is a technology that can produce high sphericity, small particle diameters, and high-purity copper powder, which is of great significance for the development of metal additive manufacturing. At present, although plasma atomization can realize the industrial preparation of spherical copper powder, there are still some problems, such as unclear understanding of the atomization process and a lack of theoretical support for powder quality control. This leads to the inability to predict the average particle diameter of powder in advance based on the actual atomization conditions and to optimize the process parameters, which seriously affects the further development of the plasma atomization process. We mainly studied the non-stationary simulation of a DC argon plasma torch. The purpose of this paper was to study the specific influence law of the average particle diameter of the powder in the process of plasma atomization by means of numerical simulation and experimental observation. The aim was to establish the mapping relationship between the atomization condition and the average particle diameter of the powder and realize the controllable preparation of the plasma atomized powder. At the same time, we used industrial-grade plasma atomization equipment to carry out pulverizing experiments to verify the plasma atomization theory and the powder average particle diameter control scheme proposed in this paper, thus proving the reliability of this study.

Influence of robot-guide strategies on the geometry of directed energy deposition components

Directed energy deposition (DED) for additive manufacturing applications is commonly realized by the usage of industrial robots. The DED processing end effectors are usually mounted on industrial robot systems and can, therefore, be moved and oriented in up to many degrees of freedom. However, the design of the powder nozzle and the programming of the robot can limit the movement options. For this reason, translational movements, as with conventional 3D printers, are still common today. The end effector is usually guided horizontal over the component surface although welding in position (PA) is preferred in general. It may be necessary to tilt the end effector in order to gain advantages during processing due to the constrained position. This is particularly advantageous for overhang structures and is often realized with the help of a turn-tilt positioning table in combination with an industrial robot. However, this approach is, in some cases, not possible due to geometrical constrains. To extend applications in this direction, advanced methods for slicing the components and programming the robot movements are necessary. The main aspect of this work is the development, testing, and evaluation of a multidimensional DED manufacturing approach. This is tested on a thin-walled component with defined overhang areas and compared with conventional approaches. Different strategies are assessed in terms of the geometrical match of the target geometry. Influences of strategies on the results are evaluated. It can be shown that multidimensional path planning approaches lead to a better match of the target geometry.

Additive manufacturing of biphasic architectured structure and analysis of its mechanical and functional response

Additive manufacturing of biphasic architectured structure and analysis of its mechanical and functional response

Additive Manufacturing for Skew Magnetization Fixture of Annular Magnet

Additive Manufacturing for Skew Magnetization Fixture of Annular Magnet

Development of a fuzzy analytic hierarchy process model, sensitivity analysis, and addressing barriers to additive manufacturing implementation in small- and medium-sized enterprises (SMEs)

Additive manufacturing (AM) is gaining popularity worldwide due to its potential to revolutionize manufacturing processes, improve product customization, and reduce waste. Nevertheless, small- and medium-sized enterprises (SMEs) encounter major challenges when implementing AM technologies. The objective of this research is to utilize the fuzzy analytic hierarchy process (FAHP) to identify and prioritize the critical challenges that impede the implementation of AM for SMEs. The study employs a two-stage methodology. First, a thorough literature review and expert discussions identify 15 major barriers to AM adoption. Second, a systematic model is proposed to establish a ranking of these barriers, which is based on the FAHP. The results are validated using sensitivity analysis to ensure the robustness of the findings. Additionally, potential solutions to overcome these barriers are discussed. The research indicates that the two most significant barriers for SMEs are the high costs of equipment and the scarcity of skilled designers. The model that has been presented is a valuable resource for SME managers and practitioners, as it allows them to make strategic and informed decisions that facilitate the efficient implementation of AM. This research is groundbreaking in its comprehensive analysis of the prioritization and ranking of AM implementation barriers, with a particular emphasis on SMEs. It offers essential insights for future research and practical applications.

Materials for 3D printing in healthcare sector: A review.

Additive Manufacturing (AM) encompasses various techniques creating intricate components from digital models. The aim of incorporating 3D printing (3DP) in the healthcare sector is to transform patient care by providing personalized solutions, improving medical procedures, fostering research and development, and ultimately optimizing the efficiency and effectiveness of healthcare delivery. This review delves into the historical beginnings of AM's 9 integration into medical contexts exploring various categories of AM methodologies and their roles within the medical sector. This survey also dives into the issue of material requirements and challenges specific to AM's medical applications. Emphasis is placed on how AM processes directly enhance human well-being. The primary focus of this paper is to highlight the evolution and incentives for cross-disciplinary AM applications, particularly in the realm of healthcare by considering their principle, materials and applications. It is designed for a diverse audience, including manufacturing professionals and researchers, seeking insights into this transformative technology's medical dimensions.

Additive manufacturing of functionalised atomic vapour cells for next-generation quantum technologies

Abstract Atomic vapour cells are an indispensable tool for quantum technologies (QT), but potential improvements are limited by the capacities of conventional manufacturing techniques. Using an additive manufacturing (AM) technique – vat polymerisation by digital light processing - we demonstrate, for the first time, a 3D-printed glass vapour cell. The exploitation of AM capacities allows intricate internal architectures, overprinting of 2D optoelectronical materials to create integrated sensors and surface functionalisation, while also showing the ability to tailor the optical properties of the AM glass by in-situ growth of gold nanoparticles. The produced cells achieve ultra-high vacuum of 2 x 10-9 mbar and enable Doppler-free spectroscopy; we demonstrate laser frequency stabilisation as a QT application. These results highlight the transformative role that AM can play for QT in enabling compact, optimised and integrated multi-material components and devices.

State of art on evaluation of three- to six-dimensional novel additive manufacturing technology for biomedical applications

Additive manufacturing has evolved over the last few decades. Three-dimensional printing is a digital manufacturing technology that provides nearly endless options for the creation of an accessible instrument for all parts of various medical practices, including tissue engineering, through meticulous optimization of material, processing, and geometry for every point in an object. Three-dimensional printing has opened up a new, faster, and safer manufacturing process, despite its incapability to fabricate complex structures and objects. Recently, novel four-dimensional printing techniques have been developed for the transformation of typical stable three-dimensional printed parts into smart objects. The limitations of three-dimensional printing could be remedied with four-dimensional printing, by applying time as the fourth dimension. Self-repairing and speedy printing are two additional benefits of this technology's by using smart materials. By adapting this technology, numerous medical domains could be profited. Four-dimensional printing does not have the ability to produce curved complicated forms. However, five-dimensional printing overcomes the flaws seems in four-dimensional printing. Five-dimensional additive manufacturing relies on the rotation of both the print bed and the extruder head. Five-dimensional printing outlasts in terms of durability than three- and four-dimensional printing. Currently, a combination of the principles of four- and five-dimensional printing into a single process is called six-dimensional printing. In six-dimensional printing, the form changes over time due to the reaction of environmental factors, which is primarily used in biomedical applications. This paper summarizes extensive research on biomaterials in the field of biomedical science and discusses the present implications of three-, four-, five-, and six-dimensional printing techniques.

Mechanical properties of lander bionic buffer structure based on additive manufacturing

In order to meet the energy absorption requirements of the landing buffer, this paper starts with the buffer filling material of the buffer, draws on the Kelvin structure and spiral structure, and applies the engineering bionics principle to design and establish two structural models: a soccerball-like bionic structure and a multi-spiral bionic structure. Considering the energy absorption and reusability requirements of the lander buffer structure, the bionic structure sample is prepared by additive manufacturing technology and NiTi alloy with shape memory effect. The mechanical properties, energy absorption and recoverability of the sample are analyzed and verified by simulation and experiment. The results show that the accuracy of the numerical simulation is verified by comparing the force-displacement curves of the simulation test and the isometric static pressure test; the multi-spiral bionic structure has better mechanical properties, and its maximum energy absorption is 3096.23 J; the recovery rates of the two structures are as high as 98.02%and respectively 97.12%, and the recovery rate of the soccerball-like bionic structure is slightly higher. This study uses additive manufacturing to prepare the leg-type lander buffer bionic structure, which provides a reference for the bionic design of the lander buffer structure.

Modification of the Surface Topography of Additive Materials under Ar+ Ion Irradiation

Additive manufacturing (AM) is a modern developing group of technologies based not on the removal of material, but on the layer-by-layer growth and synthesis of an object according to a CAD (Computer-Aided Design) model. The main disadvantages of objects manufactured using AM technologies are a high degree of porosity and surface roughness. This work examines the possibility of modifying the surface of additive materials Ti6Al4V and AlSi10Mg using irradiation with Ar+ ions with energies in the range from 2 to 9 keV. Using SEM, the surface topography was obtained before and after irradiation and mechanical polishing. A reduction in surface porosity and roughness was demonstrated, as well as the influence of beam energy on the final surface topography.

Impact of Iron Contamination on Liquid Properties and Microstructural Evolution in AlSi20

Additive manufacturing processes enable highly flexible and scalable shaping while maintaining rapid solidification processing conditions. This combination makes additive manufacturing particularly attractive for recycling contaminated alloys, as it allows critical brittle phases to be refined and utilized as alloying elements. However, little is known about the impact of contaminants on the fluid properties of liquid metals. Herein, thermodynamic modeling and experimental methods are combined to investigate the properties of AlSi20 and its contaminated variant, (AlSi20)95Fe5. The oscillating droplet method is used to experimentally determine surface tension and analyze solidified droplets to evaluate microstructure for different cooling rates. The findings indicate that while contaminants have a minor effect on fluid properties, they significantly influence microstructural properties.