Advances In Additive Manufacturing Research Articles

Design and performance evaluation of a 3D printed aerostatic bearing concept with high number of micro-orifices

This study suggests a 3D printed aerostatic bearing concept. The design has a high number of orifices distributed around the bearing to obtain smoother pressure distribution for performance. Inner channels are formed to connect and feed air to each orifice using the advantage of additive manufacturing. The concept is investigated numerically to determine the performance gain of the high number of orifices by calculating bearing stiffness and load carrying capacity. In order to validate the simulation and performance gain an experimental study is conducted by testing Stereolithography (SLA) type 3D printed bearings with various orifice numbers. The bearing stiffnesses and mass flow rates of the specimens are measured, and results are discussed in terms of performance by comparing numerical results. The 3D printed bearings concept has shown promising results in terms of performance while keeping air consumption limited compared to conventional air bearings.

Artificial hearing systems based on functional cochlea models

Abstract The cochlea is one of the most complex organs in the human body, exhibiting a complex interplay of characteristics in acoustic, mechanical, electrical, and biological functions. Functional cochlea models are an essential platform for studying hearing mechanics and are crucial for developing next-generation auditory prostheses and artificial hearing systems for sensorineural hearing restoration. Recent advances in additive manufacturing, organ-on-a-chip models, drug delivery platforms, and artificial intelligence have provided valuable insights into how to manufacture artificial cochlea models that more accurately replicate the complex anatomy and physiology of the inner ear. This paper reviews recent advancements in the applications of advanced manufacturing techniques in reproducing the physical, biological, and intelligent functions of the cochlea. It also outlines the current challenges to developing mechanically, electrically, and anatomically accurate functional models of the inner ear. Finally, this review identifies the major requirements and outlook for impactful research in this field going forward. Through interdisciplinary collaboration and innovation, these functional cochlea models are poised to drive significant advancements in hearing treatments, and ultimately enhance the quality of life for individuals with hearing loss.

Permanent magnets with embedded phase changing material for electric motor thermal management

The magnetic performance of NdFeB permanent magnets rapidly decreases as their operation temperature increases. This limits the power output of electric motors as their internal temperature quickly increases with the power demand. This is particularly problematic for applications where high peak power is required for a short period of time, for example during automobile highway acceleration or during an airplane lift-off. With the advances in additive manufacturing, one can envision to fabricate more complex motor geometries and magnetic structures, without additional costs, allowing for enhanced functionalities such as better thermal management. In this context, this paper investigates the feasibility of using phase changing materials (PCMs) to mitigate the temperature rise in permanent magnets (PMs) fabricated by additive manufacturing. The potential of PCM and its relevance was validated by modeling the thermal response of an electric motor during a representative electric vehicle driving scenario. It was found that segmented magnets with embedded phase changing materials would allow to efficiently control temperature rise. To validate the simulation results, PM test pieces with and without embedded PCMs were fabricated using cold spray additive manufacturing and tested using a custom laser thermal cycling setup.

Recent Advances in Additive Manufacturing of Fibre-Reinforced Materials: A Comprehensive Review

Additive manufacturing (AM) plays a significant role in the 4th Industrial Revolution due to its flexibility, allowing AM equipment to be connected, monitored, and controlled in real time. In advance, the minimum waste of material, the agility of manufacturing complex geometries, and the ability to use recycled materials can provide an advantage to this manufacturing method. On the other hand, the poor strength and durability of the thermoplastics used in the manufacturing process are the major drawback that keeps AM behind common production methods such as casting and machining. Fibre-reinforced polymers can enhance mechanical properties, advance AM from the commonly used polymers, and make AM competitive against conventional production methods. The main focus of the current review is to examine the work conducted in the field of reinforced additively manufactured technologies in the literature of recent years. More specifically, this review discusses the conducted research in the composite fibre coextrusion (CFC) additive manufacturing techniques developed over the past years and the materials that can be used. In addition, this study includes an up-to-date comprehensive review of the evaluation of fibre-reinforced 3D printing along with its benefits in terms of mechanical response, namely tensile, flexural, compression and energy absorption, anisotropy, and dynamic properties. Finally, this review highlights possible research gaps regarding fibre-reinforced AM and proposes future directions, such as deeper investigations into energy absorption and anisotropy, to position fibre-reinforced AM as a preferred fabrication method for ready-to-use parts in cutting-edge industries, including automotive, aerospace, and biomedical sectors.

Numerical Modelling and Experimental Validation of Selective Laser Melting Processes Using a Custom Argon Chamber Setup for 316L Stainless Steel and Ti6AI4V

Selective Laser Melting (SLM) is an advanced additive manufacturing technique that demands meticulous control over thermal dynamics to maintain the integrity and performance of manufactured parts. This study presents the development and validation of a thermal model designed to enhance the SLM process for 316L stainless steel (316L SS) and titanium alloy Ti6Al4V. A specially constructed Argon Chamber Setup, equipped with a 200 W continuous-wave (CW) fibre laser system, was used to create an SLM-representative environment for 316L SS, enabling precise experimental validation of the model. This validation serves as a robust baseline, facilitating the model’s extension to more complex materials like Ti6Al4V, thereby supporting a cost-efficient and safe approach to initial testing. The rigorously validated thermal model offers a comprehensive link between experimental data and numerical simulations in SLM. It supports process optimisation by accurately predicting thermal behaviours, contributing significantly to additive manufacturing advancements. By fine-tuning processing parameters, this model enhances material characteristics, thereby providing practical insights applicable to industrial production and improving the consistency and quality of SLM-manufactured parts.

Three-dimensional honeycomb structured BaTiO3-based piezoelectric ceramics via texturing and vat photopolymerization

Textured piezoelectric ceramics have attracted significant attention due to their ability to achieve ultra-high piezoelectric properties comparable to single crystals at a lower cost. Traditional processing techniques, such as tape casting, can efficiently produce textured piezoelectric ceramics with simple structures but are inadequate for fabricating three-dimensional structures with high complexity, thereby limiting their applications in specific fields. Vat photopolymerization (VPP), an advanced additive manufacturing technology, can rapidly and accurately create intricate three-dimensional structures. Crucially, VPP can provide the necessary shear force to align the templates, resulting in the highly-textured piezoelectric ceramics. In this study, BaTiO3-based piezoelectric ceramics with a high degree of texture (97.2 %) were produced using VPP technology. These ceramics exhibited a large piezoelectric coefficient (d33 = 511 pC/N), which was 66 % higher than that of non-textured ceramics. Furthermore, textured ceramics with a honeycomb structure were fabricated, demonstrating their potential in sensing applications. This work confirms the feasibility of using VPP technology to prepare high-performance, complex-structured textured ceramics, thereby promoting the development and application of textured piezoelectric ceramics.

Soft-templating of biomass derivatives into edge-N doped 3D-interconnected hierarchical porous carbon for multi-scenario supercapacitive energy storage

Rational design of the pore structure for carbon materials is of great significance for solving the low specific capacitance and poor rate capability of supercapacitors. A novel soft-templating strategy is proposed by using biomass-derived sodium lignosulphonate as a carbon precursor and sublimable hexamethylenetetramine as a soft template. The hexamethylenetetramine nanoparticles are formed in the confined spaces of the precursor, and then these templates sublime to leave mesopores after the lignosulfonate transformed from linear structure to bulk structure by thermostabilization treatment. A high nitrogen content of 40 wt% in hexamethylenetetramine is also beneficial for the subsequent in-situ N-doping. The as-obtained nitrogen-doped hierarchical porous carbon microspheres possess a high specific surface area of 1416 m2 g−1 with an N-doping content of 4.32 % (86.26 % edge-N). In a two-electrode system, the soft-templating carbon exhibits a decent specific capacitance of 234 F g−1 at 0.1 A g−1, an excellent rate capability of 62.4 % at 50 A g−1, and a high energy density of 8.1 Wh kg−1 at 15.0 kW kg−1 in 6 M KOH aqueous electrolyte. Moreover, advanced additive manufacturing technology of direct ink writing was applied to construct a quasi-solid-state in-plane interdigital microsupercapacitor by using the soft-templating carbon, and it presents a superior areal/volumetric capacitance, rate performance, mechanical stability, and flexibility with PVA/H2SO4 gel electrolyte. This work broadens the pore structure engineering methodology by novel soft-templating biocarbon for multi-functional and multi-scenario energy storage systems.

3D-printed microfluidic and millifluidic devices for cell culture and mechanotransduction studies: A review

The practice of conventional cell culture techniques affects the quality of biological research in mechanobiology by not replicating the cell’s microenvironment adequately. Microfluidic devices resembling 3D in vivo cell culture offer viable alternatives for mechanobiology studies and other applications including cell screening, cell separation, and point-of-care diagnostics. This review highlights recent advances in additive manufacturing (AM) to fabricate microfluidic and millifluidic devices through fast design iterations and cost reduction compared with conventional device manufacturing. Key advances in AM technologies such as fused deposition modeling (FDM), stereolithography apparatus (SLA), and digital light processing (DLP) have allowed the direct manufacture of complex microfluidic devices with master molds and sacrificial structures using multiple material components. Currently, available 3D printed devices for the precise fabrication of milli- and microfluidic devices, essential to mimicking the cellular microenvironment, while economically reducing production costs by eliminating expensive clean-room environments and reducing material waste are highlighted.

Recent advances in additive manufacturing of refractory high entropy alloys (RHEAs): A critical review

Refractory High Entropy alloys (RHEAs) have evolved as a superior multicomponent material having a unique combination of microstructures and mechanical properties. RHEAs are a particular grade of high entropy alloys (HEAs) known for their outstanding high-temperature properties achieved thorough their constituent refractory elements. To date, majority of the RHEAs have been manufactured through several conventional methods, but are limited by certain limitations. Additive manufacturing (AM) has the potential to revolutionize the manufacturing industry by providing excellent opportunities to fabricate RHEAs while providing opportunities for enhancing the design freedom and complex geometrical shapes. As the field is rapidly evolving, a systematic examination of our comprehension is beneficial, and this article attempts to address this issue. To find the right place in industrial markets, additively manufactured RHEAs require further advancements. The present review provides a comprehensive overview of the additively manufactured RHEAs in terms of microstructural characterization, mechanical behaviour and other environmental properties published so far. This review article is presented lucidly with an aim of better understanding for the readers in this domain. To this end, future works and current challenges are also included and discussed briefly.

Investigation of scalable chiral metamaterial beams for combined stiffness and supplemental energy dissipation

Abstract Metamaterials have gained important interest in the research community attributable to advances in additive manufacturing enabling their fabrication at reasonable costs. The vast majority of their applications and demonstrations are at micro- and nano-scales, and challenges remained regarding the larger scale applications. In this paper, we are interested by the scalability of metamaterials, targeting structural engineering applications. To do so, we explore mechanisms capable of providing both bending stiffness and high-performance energy dissipation. Our study includes beams constructed with chiral topologies of different structural hierarchy orders, and we also explore three new topologies that we termed chiral friction, chiral-rectangular and chiral-hexagonal design to engineer the beams and the use of friction rods with tunable post-stress that inserted longitudinally through the beams to provide enhanced friction. The mechanical performance of the metamaterial beams is characterized through a series three-point bending tests. Of interest is to evaluate the bending stiffness, shape recoverability, and energy dissipation capabilities. We find that the chiral-hexagonal topology equipped with a non-stressed friction rod exhibit excellent energy dissipation capabilities, showing an improved loss factor by 11.9 times compared to the control beam using 68% of its materials density. Moreover, the use of the post-stress mechanism shows that it is possible to augment both its shape recovery and bending stiffness up to 99.3% and 47.1%, respectively. Overall, our investigation shows that it is possible to engineer scalable metamaterial beams targeting structural engineering applications, and that the use of topology optimization and strategically designed post-tensioning mechanism can allow tuning of mechanical performance.

Optimization of Triply Periodic Minimal Surface Heat Exchanger to Achieve Compactness, High Efficiency, and Low-Pressure Drop

With advancements in additive manufacturing (AM) techniques, high-quality triply periodic minimal surface (TPMS) structures can now be produced. TPMS walled heat exchangers (HX) hold significant potential for industrial applications and are receiving increasing attention. This paper explores the impact of various TPMS design variables on flow and thermal performance to optimize TPMS heat exchangers for compactness, high efficiency, and low pressure drop. The design variables examined include the type of TPMS lattice, unit cell size, wall thickness, aspect ratio, TPMS orientation, and equivalent thickness. The study reveals that the flow and heat transfer performance of TPMS structures are significantly affected by these design variables. For the Gyroid, Diamond, and SplitP lattices, performance is nearly identical when the surface-to-volume ratio is kept constant. The average velocity of the fluid in the TPMS HX should be 0.3 m/s. The corresponding Re is between 300~800. Thin wall thickness, small equivalent thickness, and flat lattice configurations can significantly reduce pressure drop while maintaining the overall heat transfer coefficient. Additionally, the angle between the flow direction and TPMS orientation can increase pressure drop. Three aluminum heat exchangers were successfully printed using an AM machine, and testing results are comparable with theoretical prediction.

Enabling tailored microstructures by hybrid directed energy deposition processing of a nickel-based superalloy

The technological advances in additive manufacturing, particularly laser based directed energy deposition (DED), revolutionized the production of complex metal components. Despite this progress, the oriented heat flux and several reheating thermal cycles can induce a strongly textured microstructure, which induces an anisotropic mechanical behavior. In addition, considerable residual stresses typically require additional post-processing. Therefore, hybrid process chains for additive manufacturing (AM) are being developed, which aim at integrating conventional post-processing into the AM process. However, a detailed investigation of thermal and mechanical effects of such hybrid processes on the mechanical properties and their interrelation is lacking. In an experimental study, we explore the integration of thermal and mechanical processing steps within the DED process chain to locally tailor microstructures and mechanical properties. Through electron backscatter diffraction measurements, we demonstrate significant microstructural changes of DED-manufactured nickel-based superalloy samples using deep rolling and laser heat treatment. A mechanical surface deformation induces microstructural misorientation leading to an increase in hardness down to substantial depth of several hundred micrometers. Additionally, the targeted management of heat input during laser heat treatment results in different grain morphologies and sizes, affecting average microhardness within a significant depth. The results demonstrate the potential for microstructural tailoring using hybrid AM process chains, while a substantial sensitivity of the microstructure to thermal and mechanical load emphasizes the importance of a precise process control. This work provides an understanding of the process-microstructure-property relationship required for developing new process pathways in hybrid AM that integrate thermal and mechanical processes into DED manufacturing.

Versatility of patient specific implants in reconstruction of maxillofacial defect: a case report of central giant cell granuloma

Reconstructing maxillofacial defects is challenging due to its complex anatomy and cosmetic and functional effects on patients. From a functional and esthetic view, it is imperative for surgeons to accurately restore the defect in a way that will ensure patient satisfaction and well-being. Here, a case of large lytic lesion of anterior mandible, causing extensive bony resorption, in a young female patient is reported. Incisional biopsy was performed and the histopathological features were suggestive of Central giant cell granuloma (CGCG). Surgical treatment by en-bloc resection of the lesion was done. Several reconstruction options are available in the literature are available for the residual bony defect including iliac crest graft, costochondral graft, submental island flaps and more. However, the advent of additive manufacturing, 3–dimensional (3D) printing, and the recent advances in those technologies has positively influenced the biomedical field, leading to the utilization of patient-specific implants (PSIs) in the surgical repair of maxillofacial defects. This report highlights the advantages of using Patient Specific Implant and describes our experience with it.

Image-Based Auto-Focus Microscope System with Visual Servo Control for Micro-Stereolithography.

Micro-stereolithography (μSL) is an advanced additive manufacturing technique that enables the fabrication of highly precise microstructures with fine feature resolution. One of the primary challenges in μSL is achieving and maintaining precise focus throughout the fabrication process. For the successful application of μSL, it is essential to maintain the sample surface within a focal depth of several microns. Despite the growing interest in auto-focus devices, limited attention has been directed towards auto-focus systems in image-based auto-focus microscope systems for precision μSL. To address this challenge, we propose an image-based auto-focus microscope system incorporating visual servo control. In the optical design, a transflective beam splitter is employed, allowing the laser beam to pass through for fabrication while reflecting the focused beam on the sample surface to the microscope and camera. Utilizing captured spot images and the Foucault knife-edge test, a deep learning-based laser spot image processing algorithm is developed to determine the focus position based on spot size and the number of spot pixels on both sides. Experimental results demonstrate that the proposed auto-focus system effectively determines the relative position of the focal point using the laser spot image and achieves auto-focusing through visual servo control.

FreeTO - Freeform 3D topology optimization using a structured mesh with smooth boundaries in Matlab

Topology optimization has revolutionized the design of structures for various applications, particularly with the advancement of additive manufacturing. However, existing open-source codes for topology optimization have limitations, such as restricted domain initialization and lack of a CAD output after optimization. A novel open-source Matlab code, FreeTO, is presented, and it addresses these limitations by enabling the initialization of 3D arbitrary geometries and providing an STL file post-optimization. FreeTO utilizes a structured mesh and a smooth-edge (boundary) algorithm to generate smooth topological boundaries. The code is demonstrated through six practical design cases, showcasing its effectiveness in compliance minimization, compliant mechanisms, and self-supporting problems. FreeTO offers a user-friendly, all-in-one topology optimization package, making it an invaluable tool for educators, researchers, and practitioners. Future developments will focus on eliminating a few geometrical deviations in the optimized topologies, incorporating speedups, and extending the code to apply to more applications.

Evaluating productivity characteristics of laser engineered net shaping titanium alloy

Advances in Additive Manufacturing (AM) technologies have made it possible to reduce the design and prototyping costs to a minimum especially for a low-productivity material like titanium. Titanium alloys are commonly and widely used alloys in the aerospace and biomedical sector due to their advantageous material properties. This paper is an evaluation study of factors affecting the productivity characteristics of Laser Engineered Net Shaping (LENS) titanium alloy (Ti-6Al-4 V) using face milling. Some of the productivity challenges associated with titanium such as rapid tool wear, poor surface finish, and high-power consumption are explored in this paper. All materials processed using AM face the same critical problem that the manufactured part requires a post machining since AM produces relatively poor surface finish. Machining trials are conducted using the combinations of machining parameters such as spindle speed of 800 and 1600 rev/min; feed rate of 50 and 100 mm/min; and a constant depth of cut of 1 mm, respectively. Titanium being a poor thermal conductivity material, the effect of coolant was investigated using wet/dry machining. Data related to the productivity factors and material behavior under a milling trial was recorded and analyzed. The obtained data from the trials include productivity factors such as Metal Removal Rate (MRR), power consumed, and the surface finish for each plate/trial. The power consumed in dry milling was observed to be lower than that in wet milling which is contrary to the observations from conventional wet milling. The paper concludes the trends observed for LENS titanium are opposed to the trends in conventional machining such as increasing cutting speed will result in lower cutting force and power consumed.

Identification of ultrasound characteristics in viscoelastic architectured materials by angular measurements in double through-transmission

Recent advances in additive manufacturing of viscoelastic materials have paved the way towards the design of increasingly complex multi-material structures with heterogeneities from the micro- to the macroscale. However, the measurement of ultrasound characteristics in such viscoelastic structures is a challenging problem, due to the strong attenuation related to both the constituent materials and the architecture. We propose here a methodological framework to identify the phase velocity and attenuation in viscoelastic multi-material quasi-heterogeneous samples. The proposed approach relies on measurements achieved in double through-transmission at various incidence angles, referred as theta-scan. The forward modeling of the wave propagation in such media allows then to identify the ultrasound characteristics based on an inverse approach. Experiments were performed on multi-material samples made of a random pattern of inclusions of a soft elastomer inside a rigid glassy polymer. The effects of the volume fraction of the constituent materials on the ultrasound characteristics was evaluated. This methodology open the path towards ultrasonic measurements in highly attenuating architectures

Unveiling the mechanical and microstructural properties of SiC reinforced aluminum wires recycled from scraps by friction stir extrusion

Friction Stir Extrusion (FSE) has been proven as an effective solid-state process to directly recycle metal chips into high-quality wires/rods/tubes. However, the demand for Al-based composite wires with enhanced properties is substantial, and achieving a uniform distribution of the strengthening phase within the composite wire by establishing a robust metal/ceramic interface remains a significant challenge. In this study, AA6082 Aluminum alloy wires reinforced with 12.5 vol% SiC particles, exhibiting homogeneous particle distribution and superior mechanical properties, were successfully produced through the FSE technique. The investigation focused on examining the influence of processing parameters and the addition of SiC reinforcement on the microstructure and mechanical characteristics of the extruded wires. Scanning electron microscopy (SEM), Electron Backscatter Diffraction (EBSD), together with microhardness, bending, and tensile tests, were used to comprehensively analyze the resulting properties. The findings demonstrate a substantial enhancement in the wires' mechanical properties due to the SiC particles. Both tool rotation and tool force were varied during the experimental campaign. Notably, the reduction in porosity and grain refinement resulted in a 12.78 % increase in tensile strength and an 18.6 % improvement in microhardness compared to Al 6082 alloy extruded wires. Grain orientation analysis revealed a fully recrystallized microstructure with a weak texture. Furthermore, the study evaluated power consumption and surface roughness while assessing the feasibility of deposition, thereby highlighting the potential application of this technique in advanced additive manufacturing processes.

SonoPrint: Acoustically Assisted Volumetric 3D Printing for Composites.

Advances in additive manufacturing in composites have transformed aerospace, medical devices, tissue engineering, and electronics. A key aspect of enhancing properties of 3D-printed objects involves fine-tuning the material by embedding and orienting reinforcement within the structure. Existing methods for orienting these reinforcements are limited by pattern types, alignment, and particle characteristics. Acoustics offers a versatile method to control the particles independent of their size, geometry, and charge, enabling intricate pattern formations. However, integrating acoustics into 3D printing has been challenging due to the scattering of the acoustic field between polymerized layers and unpolymerized resin, resulting in unwanted patterns. To address this challenge, SonoPrint, an innovative acoustically assisted volumetric 3D printer is developed that enables simultaneous reinforcement patterning and printing of the entire structure. SonoPrint generates mechanically tunable composite geometries by embedding reinforcement particles, such as microscopic glass, metal, and polystyrene, within the fabricated structure. This printer employs a standing wave field to create targeted particle motifs-including parallel lines, radial lines, circles, rhombuses, hexagons, and polygons-directly in the photosensitive resin, completing the print in just a few minutes. SonoPrint enhances structural properties and promises to advance volumetric printing, unlocking applications in tissue engineering, biohybrid robots, and composite fabrication.

Tiling-based lattice generation for structural property exploration

Advancements in additive manufacturing enable the development of artificial lattice structures with unique properties not found in natural materials. Specifically, filament-based lattices are known for having a lightweight yet strong nature, exhibiting auxetic behavior and excellent energy absorption capabilities. Recent research has focused on developing algorithms and frameworks to manipulate cell geometry and material properties to achieve unusual properties. However, the exploration of the full design space is hampered in practice primarily due to restrictions on cell tiling variation. Here, for the first time, a Tiling-Based Lattice Generation (TBLatGen) framework is presented that relies on various tiling operations and stochastic changes in internal cell geometry. By utilizing reflections, rotations, glide reflections, translations, and combinations of these operations, lattice structures are tiled to achieve an extensive range of properties. For instance, achieving Poisson's ratios ranging over at least ±20 using a minimal set of design parameters is demonstrated, a range unprecedented in prior studies. Experimental testing of a physical prototype validates the auxetic behavior of one newly proposed tiled lattice structure. Beyond this, the proposed TBLatGen framework is anticipated to be applicable to general periodic metamaterials, enabling the design and discovery of new structures exhibiting exceptional mechanical, thermal, electrical, or magnetic properties.