Printing Speed Research Articles

Volumetric printing and non-destructive drug quantification of water-soluble supramolecular hydrogels.

Vat photopolymerisation 3D printing is being actively explored for manufacturing personalised medicines due to its high dimensional accuracy and lack of heat application. However, several challenges have hindered its clinical translation, including the inadequate printing speeds, the lack of resins that give soluble matrices, and the need for non-destructive quality control measures. In this study, for the first time, a rapid approach to producing water-soluble vat photopolymerised matrices and a means of non-destructively verifying their drug content were investigated. Volumetric printing, a novel form of vat photopolymerisation, was used to fabricate personalised warfarin-loaded 3D-printed tablets (printlets). Eight different formulations containing varying amounts of warfarin (0.5-6.0% w/w) were used to print two different sized torus-shaped printlets within 6.5 to 11.1s. Nuclear magnetic resonance (NMR) spectroscopy revealed the presence of only trace amounts of unreacted acrylate monomers, suggesting that the photopolymerisation reaction had occurred to near completion. All printlets completely solubilised and released their entire drug load within 2.5 to 7h. NIR spectroscopy (NIRS) was used to non-destructively verify the dose of warfarin loaded into the vat photopolymerised printlets. The partial least square regression model built showed strong linearity (R2 = 0.980), and high accuracy in predicting the drug loading of the test sample (RMSEP = 0.205%). Therefore, this study advances pharmaceutical vat photopolymerisation by demonstrating the feasibility of producing water-soluble printlets via volumetric printing and quantifying the drug load of vat photopolymerised printlets with NIRS.

3D printing of metal parts using a highly-filled thermoplastic filament

Purpose This study aims to develop a highly loaded filament with spherical metallic particles for fused filament fabrication (FFF) technology. The research focuses on optimizing powder loading, printing parameters and final processes, including debinding and sintering, to produce successful metal parts. Design/methodology/approach The optimal powder loading was identified by measuring mixing torque and viscosity at various temperatures. The filament was extruded, and printing parameters − particularly printing speed to ensure proper material flow − were optimized. Different filling patterns were also examined. After printing, the polymeric binder was removed and the parts were sintered to form the final metal components. Findings The optimal powder loading was determined to be 55 vol.%. The best surface quality was achieved with an optimized printing speed of 5 mm/s. Parts printed with various infill patterns were studied for differences in open, closed and total porosity, showing a strong link between porosity and infill pattern. Originality/value This comprehensive study provides new insights into manufacturing metal parts using FFF technology. It fills a gap in the literature regarding feedstock viscosity and shear rate in highly loaded metal filaments during FFF. Additionally, it uniquely examines the open, closed and total porosity of metal parts printed with different infill patterns.

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.

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.

Characterization of three-dimensional printed hydroxyapatite/collagen composite slurry

Nowadays, biomaterial composites for bone tissue engineering are developing rapidly. Many research studies have been done on hydroxyapatite (HA) and collagen because these materials are biomimetic and can be used in human bones. This study aimed to characterize a three-dimensional (3D) printed hydroxyapatite/collagen composite slurry material with a ratio of 99.84 % (w/v) and 0.16 % (w/v). The composite material was printed using 3D printing with a print speed of 10 mm/min and a layer height of 0.5 mm. Characterization layers were investigated using a scanning electron microscope (SEM), Fourier transform infrared (FTIR) spectroscopy, X-ray diffraction (XRD), energy dispersive X-ray (EDX), and thermogravimetric analysis (TGA). SEM showed the occurrence of overlapping between layers, which was investigated by the reduction in layer dimensions after printing (layer size 432 μm). Moreover, there were no boundaries between layers; the connection between layers occurred, and porosity and the rough surface were presented. FTIR analyses showed spectrum peaks at 559.36, 628.79, 1022.27, 1562.34, and 1639.49 cm−1 which was confirmed as hydroxyapatite and amide (indicates the presence of spectrum collagen). The XRD pattern peaks show the crystallinity of HA/collagen composite (41 %) and HA (42 %). The Ca/P ratio of the material composite was 1.77. The ratio was osteoconductive, and this characteristic was the main requirement for bone grafts. From TGA, the weight loss occurred between temperatures of 25 °C and 1000 °C with three stages: water absorption (1.844 %), removal of organic content (2.854 %), and decomposition of inorganic compounds (3.517 %).

In vitro assessment of corrosion, antibacterial properties, and degradation behavior of zirconia-coated polyetheretherketone (PEEK)

The medical industry often uses ceramic and polymeric coatings to safeguard metal substrates. However, more investigation is required to explore the implementation of ceramic coatings on polymer substrates and to determine their degradation and in vitro characteristics. This work involves applying zirconia coating onto the 3D-printed PEEK polymer substrate using the RF magnetron sputtering technique. With varying layer thickness and printing speed parameters, PEEK samples (S1, S2, S3, and S4) were 3D printed and coated with zirconia. The coated and uncoated samples were immersed in Fusayama artificial saliva solution for 30 days. Following immersion in artificial saliva, this study examined the corrosion of 3D-printed PEEK samples with and without coatings. Elemental mapping, field emission scanning electron microscopy, and X-ray photoelectron spectroscopy were employed to evaluate sample morphology and estimate the binding energy of possible compounds generated in the artificial saliva solution. In vitro assessments such as antibacterial studies were performed against E. coli and S. aureus, and cytotoxic analysis was performed using Human Wharton’s jelly-derived mesenchymal stem cells (WJ-MSCs) to determine cell proliferation. The results indicated that sample S3, printed with 0.15 mm layer thickness and 20 mm/s print speed coated with zirconia showed a better degradation rate of 9.01% whereas the other three samples S1, S2, and S4 coated with zirconia showed deterioration rates of 36.4%, 33% and 16% respectively. Sample S3 showed a better antibacterial activity as biofilm formation was absent and also showed cell viability of about 79% and hence can be considered as a viable option for dental applications.

Laser Sintering by Spot and Linear Optics for Inkjet-Printed Thin-Film Conductive Silver Patterns with the Focus on Ink-Sets and Process Parameters

The implementation of the laser sintering for inkjet-printed nanoparticles and metal organic decomposition (MOD) inks on a flexible polymeric film has been analyzed in detail. A novel approach by implementing, next to a commonly 3.2 mm diameter spot laser optic, a line laser optic with a laser beam area of 2 mm × 80 mm, demonstrates the high potential of selective laser sintering to proceed towards a fast and efficient sintering methodology in printed electronics. In this work, a multiplicity of laser parameters, primary the laser speed and the laser power, have been altered systematically to identify an optimal process window for each ink and to convert the dried and non-conductive patterns into conductive and functional silver structures. For each ink, as well as for the two laser optics, a suitable laser parameter set has been found, where a conductivity without any damage to the substrate or silver layer could be achieved. In doing so, the margin of the laser speed for both optics is ranging in between 50 mm/s and 100 mm/s, which is compatible with common inkjet printing speeds and facilitates an in-line laser sintering approach. Considering the laser power, the typical parameter range for the spot laser lays in between 10 W and 50 W, whereas for the line optics the full laser power of 200 W had to be applied. One of the nanoparticle silver inks exhibits, especially for the line laser optic, a conductivity of up to 2.22 × 107 S‧m−1, corresponding to 36% of bulk silver within a few seconds of sintering duration. Both laser sintering approaches together present a remarkable facility to use the laser either as a digital tool for sintering of defined areas by means of a spot beam or to efficiently sinter larger areas by means of a line beam. With this, the utilization of a laser sintering methodology was successfully validated as a promising approach for converting a variety of inkjet-printed silver patterns on a flexible polymeric substrate into functionalized conductive silver layers for` applications in the field of printed electronics.

Dispense Printing of Silver Flake Inks on Hydrophilic and Hydrophobic Surfaces

In printed electronics, achieving precise deposition of conductive materials on challenging substrates like Teflon is critical. This study delves into dispense printing, a technique that offers precision and versatility for creating electronic patterns. The deposition of high‐viscosity silver flake inks on both hydrophobic surfaces is investigated, such as Teflon, and hydrophilic ones, highlighting the significant interplay between ink viscosity and substrate wettability. This interaction is key to controlling ink spreading, drying behavior, and, ultimately, printing success. Research explores the relationships between critical parameters such as nozzle height, dispense pressure, and print speed, aiming to enhance the quality and functionality of printed electronics. The printing process is analyzed through its distinct phases: extrusion from the nozzle, spreading on the substrate, and line shrinking during drying. This methodological approach allows one to pinpoint how each parameter specifically influences the printing outcome, particularly on challenging substrates like Teflon. By advancing the understanding of these dynamics, the study offers valuable theoretical insights and practical advancements for fabricating high‐quality, flexible electronics across diverse substrates. The findings underscore dispense printing's potential to meet the growing demand for flexible electronics.

Challenges on extrusion-based additive manufacturing of thermoplastic polyurethane

Fused filament fabrication (FFF) offers rapid production with user-friendly operation and cost-effectiveness, yet challenges in printing with thermoplastic polyurethane (TPU) persist. This study identifies causes of print defects in FFF-TPUs and their relation to process parameters, by visually analysing samples produced with various TPU materials. Extrusion temperature, printing speeds, filament cooling, overlap, and extrusion flow are subject to evaluation. Common issues include filament entanglements, under-extrusion, stringing, or geometric deviations. Among other approaches, results highlight the importance of slow, constant print speeds and careful optimization of extrusion temperature.

Applications of Newer Technologies in Enhancement of Pharmaceutical Industry

Computerized disruption in the drug industry refers to a revolutionary shift in customary processes in drug discovery, assembly, and patient consideration, spurred by emerging technologies. The unification of artificial intelligence (AI) and machine learning (ML) accelerates the development of new drugs by analysing large datasets to identify potential rivals for existing medications and predict patient responses. Digital therapies (DTx) are evidence-based programming interventions that improve medication adherence and chronic illness management while providing accessible and personalized medical service arrangements. Cloud computing and enormous information examination smooth out information reconciliation and investigation, empowering more productive innovative work processes. These innovations support the improvement of customized medication by utilizing genomic and clinical information, cultivating the making of designated treatments. The Internet of Things (IoT) upgrades the drug production network by checking ecological circumstances and guaranteeing the respectability of medication conveyance, while blockchain innovation guarantees information trustworthiness and straightforwardness, especially in clinical preliminaries and production network the executives. Regulatory Technology (RegTech) computerizes consistence processes, decreasing expenses and guaranteeing adherence to administrative norms. Furthermore, additive manufacturing (3D printing) speeds up drug prototyping and the creation of customized measurements structures, while supportability drives driven by advanced development lessen the natural effect of drug tasks. As computerized advances keep on developing, they offer uncommon chances to further develop effectiveness, lessen expenses, and improve patient results in the drug area. The fruitful coordination of these advancements presents difficulties however vows to alter the business by making medical services more customized, productive, and available.

Experimental investigation of FDM manufacturing of 316 l stainless steel

Continuous research in the field of metal additive manufacturing has led to the need for constant improvement of manufacturing parameters especially in the case of FDM (Fused Deposition Modeling) manufacturing. In recent years, the main directions outlined for productivity and quality improvement were related to higher printing speed and the use of ironing-type processes. This article aims to study the manufacturing parameters of the dimensional accuracy and surface quality of FDM-manufactured 316L stainless steel. The degree of novelty is given by the application of the ironing process for the green part. A full factorial 33 experimental design was designed for this study, in which the factors studied were ironing angle, ironing speed, and layer spacing during ironing. The dimensional accuracy and surface roughness were analyzed by means of deviation measurement from CAD to the green part and final part after the sintering process. Using the design of experiments offers the possibility of applying the analysis of variance (ANOVA) which provides information about the degree of influence of each of the studied factors. The results obtained for the dimensional accuracy showed that the ironing direction had the biggest influence on the Z-axis shrinkage. Overall, approximately 6% shrinkage in the Z and Y directions was obtained while in the X directions, the shrinkage percentage was around 20%. Surface roughness showed an improvement with higher ironing speeds for the green part while for the sintered part the most significant factor was ironing spacing.

Translucent zirconia dental prosthesis processed by Direct Ink Writing: Updates and challenges

Direct ink writing (DIW) is an extrusion-based additive manufacturing technique, which uses a layer-by-layer deposition of an ink, usually containing high solid loads and low concentration of additives, to provide plasticity and structural stability for the construction of near-net-shaped pieces. In this work, a zirconia stabilized with 5 mol% Y2O3 colloidal ink was developed aiming to obtain dense prototypes, partially translucent, with potential for making dental prostheses. Cylindrical pieces (Ø 20 mm × 2.5 mm), prismatic bars (55 × 5 × 4 mm) and 3-element dental prostheses were printed based on Computer-aided design (CAD) models, using a printing speed of 10 mm.s−1 and a nozzle with Ø 0.25 mm. The printed samples were dried at strictly controlled conditions, debinded using an optimized thermal cycle, and sintered at 1600 °C-2 h. The sintered parts were characterized by X-ray diffraction, scanning electron microscopy, Vickers hardness, fracture toughness and bending strength. Concerning dental prosthesis, a post-processing finishing strategy was performed on pre-sintered bodies to highlight the anatomical details. After sintering, samples presented relative density around 94–95 %, Vickers hardness, fracture toughness and Young Modulus of 12.7 ± 0.3GPa, 5.31 ± 0.21 MPa.m1/2 and 195.4 ± 45 GPa, respectively. A characteristic strength (σ0) of 303 MPa was attained, which is above the requirements for its application as ceramic single-unit dental prostheses. A critical analysis of the technological difficulties of this 3D printing technique for manufacturing dental prostheses is presented, while future directions are addressed.

Robust design optimization of Critical Quality Indicators (CQIs) of medical-graded polycaprolactone (PCL) in bioplotting

Polycaprolactone (PCL), either in its pure grade or as a polymeric matrix for bio-composites, plays a key role in the biomedical and bioengineering industries. It is also considered a multifunctional and versatile polymer for bioprinting and bioplotting purposes, especially in tissue engineering. Herein, an undiscovered yet valuable aspect of PCL extrusion-based bioprinting, such as the predictability of Critical Quality Indicators (CQIs), is investigated in depth. With the aid of the robust L25 orthogonal matrix design, the six most generic and device-independent control factors proved their impact on quality metrics such as global porosity, dimensional conformity, and surface roughness, determined with the aid of highly evolved Nondestructive Testing (NDT) and algorithms. To this end, 25 experimental runs were set, and 125 specimens were fabricated using an industrial-scale bio-plotter and medical-graded polycaprolactone. Various infill densities (ID), layer thicknesses (LT), raster deposition angles (RDA), printing speeds (PS), nozzle temperatures (NT), and bed temperatures (BT) were applied. CQIs were determined using optical profilometry and microscopy, and micro-computed tomography. Quadratic predictive equations were compiled and verified using two additional, well-chosen experimental runs. These generally applicable predictive models carry a massive amount of research and industrial merit, as they ensure visibility in bioprinting with PCL.

A comprehensive study on the effects of printing parameters on the mechanical properties of PLA

Purpose This study aims to investigate the effects of five different printing parameters, namely, printing speed (PS), printing temperature/nozzle temperature/extrusion temperature, heated-bed temperature, raster angle (RA) and layer height (LT), on mechanical properties. Design/methodology/approach American Society for Testing and Materials (ASTM) standards were used for the specimen design. Then, the Taguchi method was used for the design of the experiment and an L16 orthogonal array was preferred. Tensile, Shore D and surface roughness tests were conducted on polylactic acid test specimens. The test results were analyzed using the signal-to-noise ratio and analysis of variance (ANOVA). Findings As a result of the study, it was seen that RA is the most important parameter for the tensile strength, PS is for the hardness and LT is for the surface roughness. According to the ANOVA results, the effects of the RA, PS and LT on the maximum tensile strength, hardness and surface roughness were 41.59%, 69.51% and 44.6%, respectively. Originality/value To the best of the authors’ knowledge, this study is one of the most comprehensive parameter optimization studies for additive manufacturing in the literature because it includes five different printing parameters and three mechanical test procedures.

High-throughput in-situ mechanical evaluation and parameter optimization for 3D printing of continuous carbon fiber composites

The mechanical properties of carbon fiber reinforced thermoplastic (CFRTP) molded parts produced by thermal fusion lamination 3D printing vary with printing conditions. This study assesses the influence of the 3D printing parameters on the mechanical properties of resulting CFRTP products through parameter evaluation testing. An in-situ three-point bending test mechanism was developed to enhance the efficiency of these tests, allowing the same 3D printer to handle all processes from printing multiple CFRTP specimens simultaneously to conducting a bending test, reducing manual handling time to about one minute. Using this modified 3D printer, 700 specimens with varying printing conditions were produced, and their flexural strength was measured semi-automatically. Results revealed that the flexural strength of the 3D-printed CFRTP object varied with nozzle temperature, printing pitch, and stacking pitch, but not with printing speed. Machine learning was then employed to predict the maximum flexural strength and determine optimal printing parameters using the collected data as training data.

An investigation of prototype development using 3D printer: A digital fabrication approach

Abstract Additive manufacturing (AM) is a widely used technique in several industries for rapid prototyping and layer-by-layer fabrication of a new product. The influence of printer settings and print quality is essential for the performance of products in a variety of applications. The popularity of manufacturing using 3D printing is growing rapidly. In view of this, an investigation is carried out on the 3D printing techniques, their applications, and prototype materials for complex mechanical parts such as an impeller. The present study thoroughly considers the fundamental techniques in 3D printing technology, materials, and recent advancements applied to the current application and accepted trends. The 3D printing technology is advantageous as it accepts a wide range of designs, allows customized manufacturing, minimizes waste, builds intricate structures, and creates prototypes rapidly. Layer height of 0.2 mm, speed of 90 mm/s, and infill density of 80% were determined as the optimal print settings considering time, material cost, and properties. Considering the flexural qualities, the optimized values of layer height, print speed, and infill density were 0.15 mm, 70 mm/s, and 50%, respectively. It was observed that the uniform elongation (UEL) and ultimate stress (UTS) of a component increase as the layer thickness increases for the considered layers.

Melt flow analysis in rotational nozzle fused filament fabrication process

Fused filament fabrication (FFF) is a widely used processing method; however, heat transfer limitations within a conventional nozzle result in relatively low flow rates, leading to lengthy production times, compared to traditional processing methods, ultimately restricting its industrial application. Recently, a novel rotational nozzle FFF three-dimensional (3 D) printer has been patented and developed to enhance processing efficiency. Despite this achievement, the fundamental mechanisms behind this novel process remain unclear. In this study, both analytical analysis and numerical simulations were conducted based on a force-controlled scaled-down experimental setup. This setup, designed according to the pressure-induced melt removal theory, provided melt throughput data under varying heater temperatures, extrusion forces, and rotational speeds. Agreement between the modeling and experimental results confirms the generalizability of the models. Modeling predictions of temperature and velocity distributions indicate that viscous dissipation affects the average temperature and filament velocity. To simulate the real-world working conditions of FFF 3 D printing, a velocity-controlled simulation was introduced. It was observed that the average melt film thickness increases with nozzle rotational speed due to viscous dissipation. Additionally, the extrusion force required for the same printing speed decreases with increasing nozzle rotational speed, primarily due to the higher shear rate reducing melt viscosity.

Chaotic dynamics of flexible graphene electronic membranes with variable density in motion

With advancements in artificial intelligence and wearable technology, flexible electronic devices characterized by their flexibility and extensibility have found widespread applications in fields such as information technology, healthcare, and military. Printing technology can accurately print a circuit diagram onto a flexible membrane substrate by the pressure transfer of a conductive ink, which makes the large-scale printing of flexible graphene electronic membranes possible. However, during the roll-to-roll printing process used to prepare flexible graphene electron membranes, the density of electron membranes is variable due to the uneven distribution of inkjet-printed circuits, which limits the printing speed of flexible graphene electron membranes. Hence, investigating the dynamic properties of flexible graphene electron materials with different densities is of paramount importance to improve the production efficiency and quality of flexible graphene electron membranes. This paper takes roll-to-roll intelligent graphene electronic membranes as the research object. According to Hamilton’s principle, nonlinear vibration partial differential equations for the motion of flexible graphene electron membranes with varying densities were established and subsequently discretized using the assumed displacement function and the Bubnov–Galerkin method. Through numerical calculations, the simulation results obtained based on the fourth-order Runge–Kutta method and the multiscale algorithm were compared, and the multiscale algorithm was verified to be more correct and effective. The primary resonance amplitude–parameter characteristic curve, along with phase-plane portraits, Poincaré maps, power spectrum, time history plots, and bifurcation diagrams, for the nonlinear behavior of the membrane was obtained. The impacts of the density coefficient, velocity, damping ratio, excitation force, and detuning parameters on the nonlinear primary resonance and chaotic behavior of the moving graphene electron membrane were determined, and the stable operational region was identified, laying a theoretical foundation for the development of flexible graphene electronic membranes.

Experimental investigation of material extrusion additive manufacturing of copper with high powder loading rate

Beam-based additive manufacturing has challenges in fabricating pure copper due to high reflectivity. Material extrusion additive manufacturing (MEAM) avoids these issues with low costs, making it suitable to fabricate complex structures in pure copper. In this work, the effects of several printing parameters on the geometry of the samples are studied from single line, thin wall to cube using homemade copper feedstocks with high powder loading rate (65 vol%). The results show that the single line is most affected by layer thickness, while the thin wall has stricter requirements for printing temperature and printing speed. The geometric accuracy of the cube demonstrates large parametric tolerance due to the overlap and support between the lines. Central composite face-centered (CCF) design and central composite design (CCD) are used to analyze and optimize process parameters for densification. The measured porosity at the optimized printing (printing temperature = 177 °C, air gap = −0.05 mm, layer thickness = 0.3 mm) and sintering parameters (sintering temperature = 1045 °C, holding time = 4 h) is in good agreement with the predicted values. Air gap and sintering temperature have the greatest influence on the porosity, and other parameters within a certain range of on-demand adjustments do not have a significant effect. The ultimate tensile strength and elongation of the sintered samples under the optimal parameters are 153.9 ± 6.1 MPa and 31.36 ± 3.24%, respectively. No printing defects are found at the fracture and the elongation is good, showing the effectiveness of the parameter optimization.

Artificial Intelligence‐Augmented Additive Manufacturing: Insights on Closed‐Loop 3D Printing

The advent of 3D printing has transformed manufacturing. However, extending the library of materials to improve 3D printing quality remains a challenge. Defects can occur when printing parameters like print speed and temperature are chosen incorrectly. These can cause structural or dimensional issues in the final product. This review investigates closed‐loop artificial intelligence‐augmented additive manufacturing (AI2AM) technology that integrates AI‐based monitoring, automation, and optimization of printing parameters and processes. AI2AM uses AI to improve defect detection and prevention, improving additive manufacturing quality and efficiency. This article explores generic 3D printing processes and issues using existing research and developments. Next, it focuses on fused deposition modeling (FDM) printers and reviews their parameters and issues. The current remedies developed for defect detection and monitoring in FDM 3D printers are presented. Then, the article investigates AI‐based 3D printing monitoring, closed‐loop feedback systems, and parameter optimization development. Finally, closed‐loop 3D printing challenges and future directions are discussed. AI‐based systems detect and correct 3D printing failures, enabling current printers to operate within optimal conditions and minimizing the risk of defects or failures, which in turn leads to more sustainable manufacturing with minimum waste and extending the library of materials.