Conventional Manufacturing Techniques Research Articles

Material removal and optimization of Si3N4 ceramic microgrooves with large-aspect ratio by WJALM

ABSTRACT Silicon nitride (Si3N4) ceramic is a typically difficult-to-machine material and has been one preferred material for functional microstructures like heat dissipators, reactors, mixers and so on. However, the processing capabilities of conventional manufacturing techniques are inadequate in machined quality and efficient for Si3N4 microstructures with large-aspect ratio (LAR). Waterjet-assisted laser machining (WJALM) is a method that introduces the waterjet assistance into the laser-only machining (LOM) process, thus combining the advantages of LOM with the impact and cooling effects of the waterjet. This makes WJALM become an ideal approach for fabricating LAR microstructures on silicon nitride ceramic. This research concentrates on multi-objective optimization of aspect-ratio (AR) and ablation-area ratio (AAR) of LAR microgrooves by orthogonal experiments and Grey-relational analysis (GRA). Optimal waterjet-laser composite parameters are obtained, and the optimized AR and AAR is 3.324 and 80.1%, respectively.

Multifunctional 3D food printer with quad-screw nozzle for four-color printing and dual ink mixing

This paper presents a novel multifunctional 3D food printer that significantly enhances conventional food manufacturing techniques. The printer features a quad-screw nozzle system capable of precisely mixing up to four different bioinks simultaneously, enabling the creation of complex multicolor food structures. Utilizing its four distinct functions—quad, replicator, multicolor, and mixing print—the printer facilitates a flexible design tailored for various culinary applications. Various bioinks, including polysaccharide curdlan, vegetable, and dairy powders, were tested to evaluate their mechanical properties and printability. Quantitative analyses were conducted using rheological measurements to assess apparent viscosity, while texture profile analysis (TPA) was employed to measure ink hardness, cohesiveness, and adhesiveness. The results indicated that the composition of the inks critically influenced the structural integrity and aesthetic quality of the printed food items. Computed tomography (CT) was used to investigate the accuracy of the printed structures. This technique allows a detailed evaluation of the shape and structure of printed foods, contributing to the improvement of product quality. This innovative approach expands the possibilities of food design and production and paves the way for diverse and creative culinary applications.

Choosing between additive and conventional manufacturing of spare parts: On the impact of failure rate uncertainties and the tools to reduce them

Recently, there has been great interest in using additive manufacturing (AM) to produce spare parts: allowing to produce spare parts with short lead times and close to the point of use, AM reduces the need for large inventories otherwise required by conventional manufacturing (CM) techniques to deal with intermittent spare parts demand. However, using AM to produce spare parts is limited by two main drawbacks: high production costs and uncertain failure rates arising from AM still being a relatively new production technique. While the former can be counterbalanced by inventory cost reductions, it is unclear how the latter impacts the sourcing option decision (i.e. AM or CM). We aim to fill this gap by studying a periodic review model in which spare parts demands follow a Poisson process. To make our analysis accurate and reliable, we leverage a material science approach to obtain realistic values for the failure rate uncertainties. From the results, it emerges that AM is heavily penalized by failure rate uncertainties much higher than those of CM. Consequently, we then focus on some recent tools developed to reduce AM failure rate uncertainties: porosity assessment and in-situ monitoring. We find that the failure rate uncertainty should be reduced by five and six percentage points to make it worthwhile to invest in porosity assessment and in-situ monitoring, respectively. Finally, we determine under which circumstances each tool is preferred over the other and found that porosity assessment is typically the most competitive uncertainty reduction tool.

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.

Fabrication of high-quality microlens arrays on fused silica based on combined rapid evaporative ablation and precision melting polishing of CO2 lasers

Microlens arrays (MLAs) made from fused silica possess broad applications in wavefront sensing, optical focusing, beam shaping, etc. However, it is challenging to fabricate the hard-brittle silica MLAs with high accuracy and low cost by conventional manufacturing techniques efficiently. In this work, a novel two-step method, which consists of rapid evaporative ablation and precision melting polishing by CO2 lasers, is proposed to fabricate high-quality MLAs. The first step is to rapidly ablate and engrave micro-pillar arrays (MPAs) with flat groove bottom by high-energy density CO2 lasers. The second step is to precisely polish and shape the flat-topped MPAs into the dome-topped MLAs with good surface roughness (Sa) by low-energy density CO2 lasers. The whole preparation process could be achieved through a set of machining system. Firstly, the geometric dimension (period, p and height, h) of the microlens is determined by the Monte Carlo ray tracing method. Secondly, to diminish the groove depth inconsistency caused by heat accumulation, the multiple ablation compensation strategy is developed. The MPAs (p = 200–400 μm), of which maximum height error is 7.1%, are prepared in 1 s by the proposed compensation strategy. Then, the MPAs are smoothed into the MLAs by low-energy density CO2 lasers, and the average Sa is improved from 960 nm to 32.56 nm. Finally, the optical performances of the MLAs are verified from the effectiveness of imaging, focusing and homogenization. The proposed two-step processing method paves a new way to fabricate high-performance MLAs on hard-brittle fused silica with low cost and high efficiency.

On morphology and roughness of upskin surfaces in laser powder-bed fusion additive manufacturing – Contouring strategy effects

The surface quality of inclined parts made by Laser powder-bed fusion (L-PBF) additive manufacturing is inferior to those made by conventional formative and subtractive manufacturing techniques. The inherited step edges formed during such layer-by-layer fabrications and partially melted or non-melted particles attached to the newly formed surface are the major causes of poor surface finish of L-PBF parts. This study is a part of a research framework, in which the effects of different contouring strategies and scan parameters on the surface morphology of inclined parts are investigated by both experimental and numerical methods. In particular, the effect of two different contour scan strategies, namely pre-contouring and post-contouring, on the upskin surface roughness of 30⁰ inclined parts is analyzed. The inclined specimens were fabricated with Ti6Al4V powder using an EOS M270 system and the upskin surfaces were measured by a white light interferometer. In addition, a multi-track multi-layer numerical approach using coupled discrete element method and thermo-fluid simulation was also performed to understand the inclined surface formation in L-PBF.The findings show that the pre-contouring strategy with high linear energy density (LED) (0.4 J/mm) results in average surface roughness (Sa) as low as 7.43 µm, whereas the lowest LED (0.05 J/mm) resulted in the highest Sa of 33.74 µm. Larger melt pool dimensions were obtained in the high LED pre-contouring simulations, which indicates a better material fusion resulting in a good surface finish. The numerical simulation showed that the upskin surface roughness is also affected by the raster scan, if the raster scanning LED is higher than that of pre-contour scans. For the post-contouring strategy studied, higher and lower LEDs were used in inner and outer contour scanning, respectively. It is indicated that the inner contour scanning with a high LED reduces the surface roughness because of a larger melt pool size, irrespective of outer contour scanning. The lowest Sa obtained was 8.24 µm for the highest LED inner contour (0.05 J/mm) case and the highest Sa was 19.95 µm, for the parts made with the lowest LED inner contour scan (0.075 J/mm) strategy. The coupled discrete-element and thermo-fluid-based simulations offer insights into the sloped surface formation and the results supported the experimental findings in qualitative manner.

Electrochemical additive manufacturing of interdigitated structures using a multi-anode system with independently-controlled anodes

Interdigitated parts are used across a multitude of engineering applications. The overlapping, intertwined structures pose a challenge for fabrication using conventional additive manufacturing techniques, especially at small size scales. Electrochemical additive manufacturing (ECAM) has been shown to successfully create overhanging parts at the small scale without reliance on support structures. This study extends the ECAM capabilities into demonstration of the fabrication of interdigitated parts by the use of a multi-anode electrochemical additive manufacturing system. The ECAM process is operated by a tool head consisting of multiple anodes independently controlled by individual channels on an in-house-built multipotentiostatic system. Each anode is independently switched into active (anodic) or inactive (open-circuit) mode using a predefined, coded pattern controlling the custom electronics. While each tool is in anodic mode, its current contribution into the overall deposition process is tracked independently as well. Each independent tool can deposit material extending from regions deposited by itself or neighboring tools. The entire multi-head tool is controllably moved by a 3-axis translation system. An interdigitated comb geometry relevant to practical engineering applications is fabricated using this system. This geometry is built using a parallelized voxel-by-voxel tool path with characteristic electrode activation patterns at each position of the tool head. It was found that a purely closed-loop control with no time limit yielded a qualitatively better geometry than a control system with a 10-minute time limit applied. This study overall demonstrates the working principle of a multi-anode system and its ability to fabricate parts interdigitated structures. This study therefore advances the capabilities of ECAM as a valuable additive manufacturing process that can fabricate a variety of challenging parts for relevant engineering applications.

Comparative Analysis of Mechanical Properties: Conventional vs. Additive Manufacturing for Stainless Steel 316L

This research investigates the tensile strength and microstructural properties of stainless steel 316L, comparing samples fabricated using additive manufacturing (AM) to those produced via conventional manufacturing techniques such as forging and casting using stainless steel 316L for its mechanical performance and corrosion resistance. Tensile tests revealed that AM samples had an ultimate tensile strength (UTS) of 650 MPa, a yield strength of 550 MPa and an elongation at break of 20%, and conventionally manufactured samples achieved a UTS of 580 MPa, a yield strength of 450 MPa and a higher elongation at break of 35%. The reduced ductility of AM samples is offset by their higher strength. Scanning electron microscopy (SEM) analysis showed that AM samples had a refined grain structure, with grain sizes ranging from 1 to 5 µm, whereas conventionally produced samples exhibited larger grain sizes of 10 to 20 µm, contributing to their increased ductility. This shows that while AM processes can give a rather high strength, the ductility property is simpler to attain with casting. Further work is needed to investigate post-processing techniques like hot isotropic pressing (HIP) and heat treatments for enhancing the ductility of AM parts as well as mechanical properties.

Polymer‐Sorbent Direct Air Capture Contactors with Complex Geometries 3D‐Printed via Templated Phase Inversion

AbstractLow‐cost direct air capture (DAC) systems require efficient gas–solid contactors. These contactors provide rapid rates of heat and mass transport with minimal pressure drops. Triply periodic minimal surfaces (TPMS) are a class of geometries that are shown to have heat transfer properties that exceed those of other geometries, and these benefits are expected to manifest in mass transfer as well due to the analogies between heat and mass transfer. However, creating TPMS contactors is difficult using conventional manufacturing techniques such as injection molding. Non‐solvent‐induced phase separation (NIPS) of a polymeric ink containing the adsorbent is one way to construct adsorption contactors with excellent mass transport rates, but contactors have to date only been fabricated in simple geometries (e.g., films, fibers). This study demonstrates that NIPS of polymeric inks occurs within a simultaneously‐dissolving, water‐soluble, 3D‐printed template. This templated phase inversion (TPI) technique can create seemingly unlimited macroscopic architectures, including TPMS contactors, using a variety of potential DAC adsorbents, including zeolite, silica, activated carbon, and metal–organic frameworks. SEM, micro‐computed tomography, and nitrogen adsorption experiments reveal the microscopic pore structures and macroscopic geometries of the resulting sorbent contactors. TPMS DAC contactors with poly(ethyleneimine)/silica adsorbents are shown to have CO2 capture performances that rival or exceed other contactor geometries.

Comparison of Tensile Bond Strength of Soft Denture Liner Material on Denture Base Resins

Aim: This study aims to evaluate the tensile bond strength (TBS) of a silicone-based soft denture liner material on denture bases produced via conventional, subtractive, and additive manufacturing techniques and examine the effect of aluminum oxide particle abrasion (APA) on TBS. Material and Methods: A total of 48 cylindrical denture base resin samples were manufactured using three different techniques: conventional, subtractive, and additive manufacturing. The samples were divided into two groups: control and APA. All samples were separated at the center, and the soft liner was applied to the corresponding surfaces. The specimens then underwent TBS testing. Data were analyzed using Two-way ANOVA and Bonferroni post hoc tests. Results: Two-way ANOVA results indicated a significant difference among the denture base resins, while no significant difference was found between the control and APA groups. The highest TBS was observed in the subtractive-manufactured APA group, while the lowest TBS was in the additive-manufactured APA group. Significant differences were found between the subtractive and additive-manufactured groups (p=0.022). Conclusion: This study demonstrates that TBS varies with the DB's manufacturing technique. While APA increased TBS in subtractive manufacturing, it had no statistically significant effect. Further research should explore different soft lining materials and consider in vivo conditions for more comprehensive insights.

Inkjet-Printed LSM-YSZ Thin Films for Enhanced Oxygen Electrodes in Solid Oxide Fuel Cells.

In the present work, symmetrical oxide ion conducting solid oxide single cells with inkjet-printed composite LSM-YSZ electrodes, onto commercially available YSZ dense substrates using GDC as buffer interlayer, were fabricated and characterized. Stable inkjet-printable LSM-YSZ nanoparticle inks were developed based on water solvent, after processing with high intensity ball milling. The deposition of LSM-YSZ electrodes was performed by inkjet printing, as well as a conventional additive manufacturing technique, screen printing, in order to compare the electrochemical performance of the produced cells for the reversible charge transfer reaction (O2 + 4 e- ↔ 2 O2-). The physicochemical properties of the LSM-YSZ nanoparticle ink was investigated to determine ink printability. The electrochemical performance of fabricated inkjet-printed and screen printed symmetrical cells (LSM-YSZ | GDC | YSZ | GDC | LSM-YSZ) exposed under a synthetic air atmosphere was evaluated in a single chamber cell reactor, employing the AC impedance spectroscopy and linear scan voltammetry techniques, at the temperature range of 700-850 °C. The inkjet-printed electrodes exhibited highly homogeneous and porous morphologies with the corresponding cell achieving current densities almost five times higher, up to 1 A/cm2 at 2 V cell potential and 850 °C, than those of the equivalent screen-printed one. To the best of our knowledge, this is the first successful implementation of water-based inks of LSM-YSZ electrodes in the fabrication of inkjet-printed solid oxide cells.

Design of a Robotic 3D Printing System

Abstract Additive manufacturing enables the production of complex shapes with a large degree of freedom compared to conventional manufacturing techniques such as injection molding, thermoforming or pressing. In particular, the creation of moving parts, complex structures and large-scale printing remains underexplored and research is constantly expanding. Due to design limitations related to the construction of currently available printers, 3D printing technology is increasingly being combined with robotics. Using a robot to 3D print products eliminates the need to design complex printer structures, which ultimately should simplify the process of manufacturing large-scale products and shorten the time required for preparation and production. The paper deals with the description of the designed 3D printing system and the procedure of the steps of creating a robotic simulation model with the generation of a control program for the FDM 3D printing process by an industrial robot.

A new combined fabrication process to shape small flexure hinges

This paper presents a new combined fabrication method, named 3D-PLAST, aimed at overcoming inherent limitations of conventional additive manufacturing techniques when producing small flexure hinges in compliant mechanisms. Flexure hinges play a crucial role in various applications, offering advantages such as cost reduction, increased precision, and weight reduction. However, traditional additive manufacturing proves challenging in achieving satisfactory mechanical properties when manufacturing small-size hinges. To overcome these limitations, the 3D-PLAST process combines fused filament fabrication with compressive plastic deformation. This hybrid process exploits the advantages of both techniques, i.e., flexibility, low cost, and ease of use. This process enables the fabrication of small-size mechanisms with good dimensional accuracy. Finally, the paper reports experimental tests on two materials comparing flexure hinges manufactured by 3D-PLAST versus 3D printing methods to demonstrate the effectiveness of the proposed process.

A Survey on Fused Filament Fabrication to Produce Functionally Gradient Materials.

Fused filament fabrication (FFF) is a key extrusion-based additive manufacturing (AM) process for fabricating components from polymers and their composites. Functionally gradient materials (FGMs) exhibit spatially varying properties by modulating chemical compositions, microstructures, and design attributes, offering enhanced performance over homogeneous materials and conventional composites. These materials are pivotal in aerospace, automotive, and medical applications, where the optimization of weight, cost, and functional properties is critical. Conventional FGM manufacturing techniques are hindered by complexity, high costs, and limited precision. AM, particularly FFF, presents a promising alternative for FGM production, though its application is predominantly confined to research settings. This paper conducts an in-depth review of current FFF techniques for FGMs, evaluates the limitations of traditional methods, and discusses the challenges, opportunities, and future research trajectories in this emerging field.

Geometric Benchmarking of Metal Material Extrusion Technology: A Preliminary Study

Metal additive manufacturing technologies such as powder bed fusion (PBF) and direct energy deposition (DED) are experiencing fast development, due to the growing awareness of industries. However, high energy consumption, slow production processes, and high costs of both machines and feedstocks hamper their competitiveness, compared to conventional manufacturing techniques. Metal material extrusion (metal-MEX) can represent a cost- and energy-effective alternative for metal additive manufacturing. This article aims to assess the potential of such technology by addressing uncertainties related to product design and process stability through a preliminary geometric benchmarking study. The geometric tolerances and minimum achievable sizes of some simple geometries produced in 316L stainless steel were evaluated using geometric benchmark test artifacts (GBTAs). Process maps were also proposed to forecast the feasibility of achieving acceptable values of the investigated tolerances, based on the nominal dimensions of the features.

Symmetrical dual-D and dual-core single-mode fiber surface plasmon resonance liquid sensor

A symmetrical dual-D and dual-core single-mode fiber surface plasmon resonance (SPR) liquid sensor is designed for biological detection. The dual-core design optimizes the transmission path, improves the momentum matching between free electrons and photons, and facilitates bidirectional coupling, consequently amplifying the SPR effect and enabling sensitive monitoring of the refractive index changes of biological solutions. In this structure, a gold wire is placed in the middle of the polished surface of the double-D-shaped single-mode fiber (SMF) to produce high-quality free electrons and promote the mode-coupling excitation of the SPR effect. The characteristics of the sensor are analyzed by the finite element method, and the important structural parameters are optimized systematically. The sensor can be operated in the near-infrared region for a refractive index (RI) range of 1.31–1.40 with a maximum wavelength sensitivity (WS) of 21,000 nm/RIU, amplitude sensitivity of 586.62RIU−1, as well as resolution of 4.76×10−6RIU. Small changes in the refractive index can be detected by the sensor and it can be produced easily by conventional manufacturing techniques. The sensor thus has wide application prospects in biomedical and chemical analysis and related applications.

Microhardness and Tensile Strength Analysis of SS316L/CuCrZr Interface by Laser Powder Bed Fusion.

Metallic joints within tokamak devices necessitate high interface hardness and superior bonding properties. However, conventional manufacturing techniques, specifically the hot isostatic pressing (HIP) diffusion joining process, encounter challenges, including the degradation of the SS316L/CuCrZr interface and CuCrZr hardness. To address this, we explore the potential of laser powder bed fusion (LPBF) technology. To assess its viability, we fabricated 54 SS316L/CuCrZr samples and systematically investigated the impact of varied process parameters on the microhardness and tensile strength of the dissimilar metal interfaces. Through comprehensive analysis, integrating scanning electron microscopy (SEM) imagery, we elucidated the mechanisms underlying mechanical property alterations. Notably, within a laser volumetric energy density range of 60 J/mm3 to 90 J/mm3, we achieved elevated interface hardness (around 150 HV) and commendable bonding quality. Comparative analysis against traditional methods revealed a substantial enhancement of 30% to 40% in interface hardness with additive manufacturing, effectively mitigating CuCrZr hardness degradation.

Integration of soft tooling by additive manufacturing in polymer profile extrusion process chain

Integrating additive manufacturing (AM) into polymer extrusion offers process chain flexibility and design freedom. It reduces the need for time-consuming iterations and trial-and-error in the die design process. Consequently, polymer AM of extrusion (i.e., soft tooling) allows for a shorter product development cycle and cost-effectiveness for small-scale production and highly customized products. In this study, carbon fibre (CF)-polyether-ether-ketone (PEEK) dies were manufactured using the fused filament fabrication (FFF) AM process, employing a streamlined die design achieved through freeform transition planes. Calibration slides were produced using masked stereolithography (MSLA), FFF, and conventional manufacturing techniques (i.e., machining) to preserve the final product’s cross-section during the cooling process. The dimensional and surface characteristics of these calibration slides were evaluated to assess the dimensional accuracy and surface topography of various materials and manufacturing processes. The dimensional evaluation reveals that MSLA-printed parts exhibit deviation from the nominal dimension closer to the conventionally manufactured part. The integrated soft tooling in the polymer extrusion line was tested with polypropylene (PP) and acrylonitrile butadiene styrene (ABS) as extruded materials. The surface topography of the CF-PEEK die displays distinctive ripple features resulting from the FFF process, identified by relatively flat peaks and deep valleys. The overall surface texture parameter values of CF-PEEK were higher due to the presence of deep valleys. Considering that the areas around the peaks interacted more with polymer molecules during the extrusion, the surface texture parameters of the extrudates were closer to the value observed in 90 µm region areas around the peaks. Notably, extrudates of AM calibration slides have lower surface texture parameters than extrudates of conventionally manufactured calibration slides, even though surface defects in the form of dimple sink marks were observed in extruded material of PP from extrudates using AM calibration slides.

Effects of high gravity on properties of parts fabricated using material extrusion system by additive manufacturing

Additive manufacturing (AM) has gained significant attention in recent years owing to its ability to fabricate intricate shapes and structures that are often challenging or unattainable using conventional manufacturing techniques. This high-quality development trend entails higher requirements for the structural design of 3D printers. In this study, polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) filaments were fed through a heated extrusion nozzle, which melted the material and deposited it onto a build platform. This study's objectives are high-gravitational material extrusion (HG-MEX) systems development, analyzing the high gravity influences on the flow behavior of materials during extrusion, and understanding the effects of gravitational on material flow and overall extrusion performance. HG-MEX systems have great potential for addressing various challenges in additive manufacturing, such as precise manufacturing. The highlight of the progress is that we developed an HG-MEX system and applied surface science to material extrusion in different gravity. We established a system and obtained results on different gravity, we analyzed the analogy between different gravity phenomena. We analyzed the interplay between the behavior of the fabricated parts and gravity. We analyzed high gravity effects on extrusion processes. The results confirmed the characteristics and feasibility of the developed system. The results suggest that a material extrusion line operating under 15 G conditions resulted in better printing quality compared to one operating under 1 G conditions. This observation implies that high gravity had a positive effect on the extrusion process, leading to improved material extrusion performance.

Single-Step Fabrication of Highly Tunable Blazed Gratings Using Triangular-Shaped Femtosecond Laser Pulses.

Blazed gratings are periodic surface structures of great interest for applications such as friction control, light trapping, and spectrometry. While different laser processing methods have been explored to produce these elements, they have not yet surpassed conventional surface manufacturing techniques, often based on lithography processes or mechanical ruling. This work introduces a new approach based on the combination of ultrashort pulses and triangular beam shaping, which enables the generation of asymmetrical grooves in a single step. The main advantage of this strategy is that by simply changing the laser processing direction we can induce a significant modification in the ratio of asymmetry between the sidewall angles of the machined channels. The paper includes a comprehensive study, which has been supported by statistical tools, of the effect of this and other experimental parameters on the morphology of grooves machined on stainless steel. As a result, we achieved a wide range of geometries, with asymmetry ratios spanning from 1 to 5 and channel depths between 3 and 15 µm. Furthermore, we demonstrate the validity of the approach through the successful manufacture of blazed gratings of various slopes. The results reflect the versatility and cost-efficiency of the proposed fabrication strategy, and thus its potential to streamline the production of sawtooth gratings and other devices that are based on asymmetrical features.