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Additive Manufacturing and 3D Printing Technologies

Works Count: 101740

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This cluster of papers focuses on additive manufacturing and 3D printing technologies, covering a wide range of materials, methods, applications, and challenges. It includes research on fused deposition modeling, polymer composites, biomedical engineering, ceramics, sustainability, and the societal impact of additive manufacturing.

Keywords

Additive Manufacturing; 3D Printing; Materials; Applications; Challenges; Fused Deposition Modeling; Biomedical Engineering; Polymer Composites; Sustainability; Ceramics

Additive manufacturing methods and modelling approaches: a critical review

2015-07-23

Harry Bikas , Panagiotis Stavropoulos , George Chryssolouris

Additive manufacturing is a technology rapidly expanding on a number of industrial sectors. It provides design freedom and environmental/ecological advantages. It transforms essentially design files to fully functional products. However, … Additive manufacturing is a technology rapidly expanding on a number of industrial sectors. It provides design freedom and environmental/ecological advantages. It transforms essentially design files to fully functional products. However, it is still hampered by low productivity, poor quality and uncertainty of final part mechanical properties. The root cause of undesired effects lies in the control aspects of the process. Optimization is difficult due to limited modelling approaches. Physical phenomena associated with additive manufacturing processes are complex, including melting/solidification and vaporization, heat and mass transfer etc. The goal of the current study is to map available additive manufacturing methods based on their process mechanisms, review modelling approaches based on modelling methods and identify research gaps. Later sections of the study review implications for closed-loop control of the process.

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3D printing with polymers: Challenges among expanding options and opportunities

2015-10-23

Jeffrey W. Stansbury , Mike J. Idacavage

Highly oriented carbon fiber–polymer composites via additive manufacturing

2014-10-16

Halil Tekinalp , Vlastimil Kunc , Gregorio M. Vélez-García +5 more

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Additive manufacturing and its societal impact: a literature review

2012-10-16

Samuel H. Huang , Peng Liu , Abhiram Mokasdar +1 more

A review of melt extrusion additive manufacturing processes: I. Process design and modeling

2014-04-14

Brian N. Turner , Robert J. Strong , Scott A. Gold

Purpose – The purpose of this paper is to systematically and critically review the literature related to process design and modeling of fused deposition modeling (FDM) and similar extrusion-based additive … Purpose – The purpose of this paper is to systematically and critically review the literature related to process design and modeling of fused deposition modeling (FDM) and similar extrusion-based additive manufacturing (AM) or rapid prototyping processes. Design/methodology/approach – A systematic review of the literature focusing on process design and mathematical process modeling was carried out. Findings – FDM and similar processes are among the most widely used rapid prototyping processes with growing application in finished part manufacturing. Key elements of the typical processes, including the material feed mechanism, liquefier and print nozzle; the build surface and environment; and approaches to part finishing are described. Approaches to estimating the motor torque and power required to achieve a desired filament feed rate are presented. Models of required heat flux, shear on the melt and pressure drop in the liquefier are reviewed. On leaving the print nozzle, die swelling and bead cooling are considered. Approaches to modeling the spread of a deposited road of material and the bonding of polymer roads to one another are also reviewed. Originality/value – To date, no other systematic review of process design and modeling research related to melt extrusion AM has been published. Understanding and improving process models will be key to improving system process controls, as well as enabling the development of advanced engineering material feedstocks for FDM processes.

Anisotropic material properties of fused deposition modeling ABS

2002-10-01

Sung‐Hoon Ahn , Michael Montero , Dan Odell +2 more

Rapid Prototyping (RP) technologies provide the ability to fabricate initial prototypes from various model materials. Stratasys Fused Deposition Modeling (FDM) is a typical RP process that can fabricate prototypes out … Rapid Prototyping (RP) technologies provide the ability to fabricate initial prototypes from various model materials. Stratasys Fused Deposition Modeling (FDM) is a typical RP process that can fabricate prototypes out of ABS plastic. To predict the mechanical behavior of FDM parts, it is critical to understand the material properties of the raw FDM process material, and the effect that FDM build parameters have on anisotropic material properties. This paper characterizes the properties of ABS parts fabricated by the FDM 1650. Using a Design of Experiment (DOE) approach, the process parameters of FDM, such as raster orientation, air gap, bead width, color, and model temperature were examined. Tensile strengths and compressive strengths of directionally fabricated specimens were measured and compared with injection molded FDM ABS P400 material. For the FDM parts made with a 0.003 inch overlap between roads, the typical tensile strength ranged between 65 and 72 percent of the strength of injection molded ABS P400. The compressive strength ranged from 80 to 90 percent of the injection molded FDM ABS. Several build rules for designing FDM parts were formulated based on experimental results.

Optimization of fused deposition modeling process parameters: a review of current research and future prospects

2015-02-24

Omar Ahmed Mohamed , Syed H. Masood , Jahar Bhowmik

A review on 3D micro-additive manufacturing technologies

2012-11-24

Mohammad Vaezi , Hermann Seitz , Shoufeng Yang

Effect of processing conditions on the bonding quality of FDM polymer filaments

2008-03-28

Q. Sun , Ghaus Rizvi , C. T. Bellehumeur +1 more

Purpose The purpose of this paper is to investigate the mechanisms controlling the bond formation among extruded polymer filaments in the fused deposition modeling (FDM) process. The bonding phenomenon is … Purpose The purpose of this paper is to investigate the mechanisms controlling the bond formation among extruded polymer filaments in the fused deposition modeling (FDM) process. The bonding phenomenon is thermally driven and ultimately determines the integrity and mechanical properties of the resultant prototypes. Design/methodology/approach The bond quality was assessed through measuring and analyzing changes in the mesostructure and the degree of healing achieved at the interfaces between the adjoining polymer filaments. Experimental measurements of the temperature profiles were carried out for specimens produced under different processing conditions, and the effects on mesostructures and mechanical properties were observed. Parallel to the experimental work, predictions of the degree of bonding achieved during the filament deposition process were made based on the thermal analysis of extruded polymer filaments. Findings Experimental results showed that the fabrication strategy, the envelope temperature and variations in the convection coefficient had strong effects on the cooling temperature profile, as well as on the mesostructure and overall quality of the bond strength between filaments. The sintering phenomenon was found to have a significant effect on bond formation, but only for the very short duration when the filament's temperature was above the critical sintering temperature. Otherwise, creep deformation was found to dominate changes in the mesostructure. Originality/value This study provides valuable information about the effect of deposition strategies and processing conditions on the mesostructure and local mechanical properties within FDM prototypes. It also brings a better understanding of phenomena controlling the integrity of FDM products. Such knowledge is essential for manufacturing functional parts and diversifying the range of application of this process. The findings are particularly relevant to work conducted on modeling of the process and for the formulation of materials new to the FDM process.

A Review of Additive Manufacturing

2012-08-16

Kaufui V. Wong , Aldo Hernandez

Additive manufacturing processes take the information from a computer-aided design (CAD) file that is later converted to a stereolithography (STL) file. In this process, the drawing made in the CAD … Additive manufacturing processes take the information from a computer-aided design (CAD) file that is later converted to a stereolithography (STL) file. In this process, the drawing made in the CAD software is approximated by triangles and sliced containing the information of each layer that is going to be printed. There is a discussion of the relevant additive manufacturing processes and their applications. The aerospace industry employs them because of the possibility of manufacturing lighter structures to reduce weight. Additive manufacturing is transforming the practice of medicine and making work easier for architects. In 2004, the Society of Manufacturing Engineers did a classification of the various technologies and there are at least four additional significant technologies in 2012. Studies are reviewed which were about the strength of products made in additive manufacturing processes. However, there is still a lot of work and research to be accomplished before additive manufacturing technologies become standard in the manufacturing industry because not every commonly used manufacturing material can be handled. The accuracy needs improvement to eliminate the necessity of a finishing process. The continuous and increasing growth experienced since the early days and the successful results up to the present time allow for optimism that additive manufacturing has a significant place in the future of manufacturing.

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Additive manufacturing: technology, applications and research needs

2013-05-08

Nannan Guo , Ming C. Leu

Materials Selection in Mechanical Design

2011-01-01

M.F. Ashby , David Cebon

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Progress in Additive Manufacturing and Rapid Prototyping

1998-01-01

J.-P. Kruth , M.C. Leu , Takeo Nakagawa

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Binding mechanisms in selective laser sintering and selective laser melting

2005-01-26

Jean‐Pierre Kruth , Peter Mercelis , Jo Van Vaerenbergh +2 more

Purpose This paper provides an overview of the different binding mechanisms in selective laser sintering (SLS) and selective laser melting (SLM), thus improving the understanding of these processes. Design/methodology/approach A … Purpose This paper provides an overview of the different binding mechanisms in selective laser sintering (SLS) and selective laser melting (SLM), thus improving the understanding of these processes. Design/methodology/approach A classification of SLS/SLM processes was developed, based on the binding mechanism occurring in the process, in contrast with traditional classifications based on the processed material or the application. A broad range of commercial and experimental SLS/SLM processes – found from recent articles as well as from own experiments – was used to explain the different binding mechanism categories. Findings SLS/SLM processes can be classified into four main binding mechanism categories, namely “solid state sintering”, “chemically induced binding”, “liquid phase sintering – partial melting” and “full melting”. Most commercial processes can be classified into the latter two categories, which are therefore subdivided. The binding mechanism largely influences the process speed and the resulting part properties. Research limitations/implications The classification presented is not claimed to be definitive. Moreover some SLM/SLM processes could be classified into more than one category, based on personal interpretation. Originality/value This paper can be a useful aid in understanding existing SLS/SLM processes. It can also serve as an aid in developing new SLS/SLM processes.

Building Skeleton Models via 3-D Medial Surface Axis Thinning Algorithms

1994-11-01

T.C. Lee , R.L. Kashyap , Chong-Nam Chu

3-D printing: The new industrial revolution

2011-12-08

B. L. Berman

The status, challenges, and future of additive manufacturing in engineering

2015-04-18

Wei Gao , Yunbo Zhang , Devarajan Ramanujan +7 more

Selective laser melting of iron-based powder

2004-05-29

J.-P. Kruth , Ludo Froyen , Jo Van Vaerenbergh +3 more

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Parametric appraisal of mechanical property of fused deposition modelling processed parts

2009-06-14

Anoop Kumar Sood , Rajkumar Ohdar , Siba Sankar Mahapatra

Metal Additive Manufacturing: A Review

2014-04-07

William E. Frazier

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Porous scaffold design for tissue engineering

2005-07-01

Scott J. Hollister

Consolidation phenomena in laser and powder-bed based layered manufacturing

2007-01-01

J.-P. Kruth , Gideon Levy , Fritz Klocke +1 more

A review on stereolithography and its applications in biomedical engineering

2010-05-18

Ferry P.W. Melchels , Jan Feijén , Dirk W. Grijpma

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Biofibres, biodegradable polymers and biocomposites: An overview

2000-03-01

Amar K. Mohanty , Manjusri Misra , G. Hinrichsen

Recently the critical discussion about the preservation of natural resources and recycling has led to the renewed interest concerning biomaterials with the focus on renewable raw materials. Because of increasing … Recently the critical discussion about the preservation of natural resources and recycling has led to the renewed interest concerning biomaterials with the focus on renewable raw materials. Because of increasing environmental consciousness and demands of legislative authorities, use and removal of traditional composite structures, usually made of glass, carbon or aramid fibers being reinforced with epoxy, unsaturated polyester, or phenolics, are considered critically. Recent advances in natural fiber development, genetic engineering and composite science offer significant opportunities for improved materials from renewable resources with enhanced support for global sustainability. The important feature of composite materials is that they can be designed and tailored to meet different requirements. Since natural fibers are cheap and biodegradable, the biodegradable composites from biofibers and biodegradable polymers will render a contribution in the 21st century due to serious environmental problem. Biodegradable polymers have offered scientists a possible solution to waste-disposal problems associated with traditional petroleum-derived plastics. For scientists the real challenge lies in finding applications which would consume sufficiently large quantities of these materials to lead price reduction, allowing biodegradable polymers to compete economically in the market. Today's much better performance of traditional plastics are the outcome of continued R&D efforts of last several years; however the existing biodegradable polymers came to public only few years back. Prices of biodegradable polymers can be reduced on mass scale production; and such mass scale production will be feasible through constant R&D efforts of scientists to improve the performance of biodegradable plastics. Manufacture of biodegradable composites from such biodegradable plastics will enhance the demand of such materials. The structural aspects and properties of several biofibers and biodegradable polymers, recent developments of different biodegradable polymers and biocomposites are discussed in this review article. Collaborative R&D efforts among material scientists and engineers as well as intensive co-operation and co-ordination among industries, research institutions and government are essential to find various commercial applications of biocomposites even beyond to our imagination.

Continuous liquid interface production of 3D objects

2015-03-16

John R. Tumbleston , David Shirvanyants , Nikita Ermoshkin +7 more

Fast, continuous, 3D printing Although three-dimensional (3D) printing is now possible using relatively small and low-cost machines, it is still a fairly slow process. This is because 3D printers require … Fast, continuous, 3D printing Although three-dimensional (3D) printing is now possible using relatively small and low-cost machines, it is still a fairly slow process. This is because 3D printers require a series of steps to cure, replenish, and reposition themselves for each additive cycle. Tumbleston et al. devised a process to effectively grow solid structures out of a liquid bath. The key to the process is the creation of an oxygen-containing “dead zone” between the solid part and the liquid precursor where solidification cannot occur. The precursor liquid is then renewed by the upward movement of the growing solid part. This approach made structures tens of centimeters in size that could contain features with a resolution below 100 µm. Science , this issue p. 1349

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Additive manufacturing of tissues and organs

2011-12-09

Ferry P.W. Melchels , Marco Domingos , Travis J. Klein +3 more

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The metallurgy and processing science of metal additive manufacturing

2016-03-07

William J. Sames , F.A. List , Sreekanth Pannala +2 more

Additive manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire or sheets in a process that proceeds layer by layer. Many … Additive manufacturing (AM), widely known as 3D printing, is a method of manufacturing that forms parts from powder, wire or sheets in a process that proceeds layer by layer. Many techniques (using many different names) have been developed to accomplish this via melting or solid-state joining. In this review, these techniques for producing metal parts are explored, with a focus on the science of metal AM: processing defects, heat transfer, solidification, solid-state precipitation, mechanical properties and post-processing metallurgy. The various metal AM techniques are compared, with analysis of the strengths and limitations of each. Only a few alloys have been developed for commercial production, but recent efforts are presented as a path for the ongoing development of new materials for AM processes.

Additive manufacturing and sustainability: an exploratory study of the advantages and challenges

2016-05-10

Simon Ford , Mélanie Despeisse

The emergence of advanced manufacturing technologies, coupled with consumer demands for more customised products and services, are causing shifts in the scale and distribution of manufacturing. In this paper, consideration … The emergence of advanced manufacturing technologies, coupled with consumer demands for more customised products and services, are causing shifts in the scale and distribution of manufacturing. In this paper, consideration is given to the role of one such advanced manufacturing process technology: additive manufacturing. The consequences of adopting this novel production technology on industrial sustainability are not well understood and this exploratory study draws on publically available data to provide insights into the impacts of additive manufacturing on sustainability. Benefits are found to exist across the product and material life cycles through product and process redesign, improvements to material input processing, make-to-order component and product manufacturing, and closing the loop. As an immature technology, there are substantial challenges to these benefits being realised at each stage of the life cycle. This paper summarises these advantages and challenges, and discusses the implications of additive manufacturing on sustainability in terms of the sources of innovation, business models, and the configuration of value chains.

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PLASTIC EMBEDDING MIXTURES FOR USE IN ELECTRON MICROSCOPY.

1964-03-01

Hilton H. Mollenhauer

Additive Manufacturing Technologies

2014-12-02

Ian Gibson , David W. Rosen , Brent Stucker

Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints

2016-01-01

Mary Kathryn Thompson , Giovanni Moroni , Thomas H.J. Vaneker +7 more

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Solid-State Technology

2014-10-09

3D printing of polymer matrix composites: A review and prospective

2016-11-17

Xin Wang , Man Jiang , Zuowan Zhou +2 more

Additive manufacturing of PLA structures using fused deposition modelling: Effect of process parameters on mechanical properties and their optimal selection

2017-03-28

J.M. Chacón , M.A. Caminero , Eustaquio García Plaza +1 more

Fundamentals and applications of 3D printing for novel materials

2017-03-21

Jian‐Yuan Lee , Jia An , Chee Kai Chua

The rise of 3-D printing: The advantages of additive manufacturing over traditional manufacturing

2017-06-28

Mohsen Attaran

Polymers for 3D Printing and Customized Additive Manufacturing

2017-07-30

Samuel Clark Ligon , Robert Liska , Jürgen Stampfl +2 more

Additive manufacturing (AM) alias 3D printing translates computer-aided design (CAD) virtual 3D models into physical objects. By digital slicing of CAD, 3D scan, or tomography data, AM builds objects layer … Additive manufacturing (AM) alias 3D printing translates computer-aided design (CAD) virtual 3D models into physical objects. By digital slicing of CAD, 3D scan, or tomography data, AM builds objects layer by layer without the need for molds or machining. AM enables decentralized fabrication of customized objects on demand by exploiting digital information storage and retrieval via the Internet. The ongoing transition from rapid prototyping to rapid manufacturing prompts new challenges for mechanical engineers and materials scientists alike. Because polymers are by far the most utilized class of materials for AM, this Review focuses on polymer processing and the development of polymers and advanced polymer systems specifically for AM. AM techniques covered include vat photopolymerization (stereolithography), powder bed fusion (SLS), material and binder jetting (inkjet and aerosol 3D printing), sheet lamination (LOM), extrusion (FDM, 3D dispensing, 3D fiber deposition, and 3D plotting), and 3D bioprinting. The range of polymers used in AM encompasses thermoplastics, thermosets, elastomers, hydrogels, functional polymers, polymer blends, composites, and biological systems. Aspects of polymer design, additives, and processing parameters as they relate to enhancing build speed and improving accuracy, functionality, surface finish, stability, mechanical properties, and porosity are addressed. Selected applications demonstrate how polymer-based AM is being exploited in lightweight engineering, architecture, food processing, optics, energy technology, dentistry, drug delivery, and personalized medicine. Unparalleled by metals and ceramics, polymer-based AM plays a key role in the emerging AM of advanced multifunctional and multimaterial systems including living biological systems as well as life-like synthetic systems.

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Additive manufacturing: scientific and technological challenges, market uptake and opportunities

2017-07-29

Syed A. M. Tofail , Elias P. Koumoulos , Amit Bandyopadhyay +3 more

Additive manufacturing (AM) is fundamentally different from traditional formative or subtractive manufacturing in that it is the closest to the ‘bottom up’ manufacturing where a structure can be built into … Additive manufacturing (AM) is fundamentally different from traditional formative or subtractive manufacturing in that it is the closest to the ‘bottom up’ manufacturing where a structure can be built into its designed shape using a ‘layer-by-layer’ approach rather than casting or forming by technologies such as forging or machining. AM is versatile, flexible, highly customizable and, as such, can suite most sectors of industrial production. Materials to make these parts/objects can be of a widely varying type. These include metallic, ceramic and polymeric materials along with combinations in the form of composites, hybrid, or functionally graded materials (FGMs). The challenge remains, however, to transfer this ‘making’ shapes and structures into obtaining objects that are functional. A great deal of work is needed in AM in addressing the challenges related to its two key enabling technologies namely ‘materials’ and ‘metrology’ to achieve this functionality in a predictive and reproductive ways. The good news is that there is a significant interest in industry for taking up AM as one of the main production engineering route. Additive Manufacturing, in our opinion, is definitely at the cross-road from where this new, much-hyped but somewhat unproven manufacturing process must move towards a technology that can demonstrate the ability to produce real, innovative, complex and robust products.

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A review on additive manufacturing of polymer-fiber composites

2017-09-02

Pedram Parandoush , Dong Lin

3D printing of high-strength aluminium alloys

2017-09-01

John H. Martin , Brennan D. Yahata , Jacob M. Hundley +3 more

Mechanical characterization of 3D-printed polymers

2017-12-08

John Ryan C. Dizon , Alejandro H. Espera , Qiyi Chen +1 more

Additive manufacturing (3D printing): A review of materials, methods, applications and challenges

2018-02-13

Tuan Ngo , Alireza Kashani , Gabriele Imbalzano +2 more

3D printing of ceramics: A review

2018-11-06

Zhangwei Chen , Ziyong Li , Junjie Li +7 more

Along with extensive research on the three-dimensional (3D) printing of polymers and metals, 3D printing of ceramics is now the latest trend to come under the spotlight. The ability to … Along with extensive research on the three-dimensional (3D) printing of polymers and metals, 3D printing of ceramics is now the latest trend to come under the spotlight. The ability to fabricate ceramic components of arbitrarily complex shapes has been extremely challenging without 3D printing. This review focuses on the latest advances in the 3D printing of ceramics and presents the historical origins and evolution of each related technique. The main technical aspects, including feedstock properties, process control, post-treatments and energy source–material interactions, are also discussed. The technical challenges and advice about how to address these are presented. Comparisons are made between the techniques to facilitate the selection of the best ones in practical use. In addition, representative applications of the 3D printing of various types of ceramics are surveyed. Future directions are pointed out on the advancement on materials and forming mechanism for the fabrication of high-performance ceramic components.

3D printing of Aluminium alloys: Additive Manufacturing of Aluminium alloys using selective laser melting

2019-07-10

Nesma T. Aboulkhair , Marco Simonelli , L. Parry +3 more

Metal Additive Manufacturing (AM) processes, such as selective laser melting (SLM), enable the fabrication of arbitrary 3D-structures with unprecedented degrees of freedom. Research is rapidly progressing in this field, with … Metal Additive Manufacturing (AM) processes, such as selective laser melting (SLM), enable the fabrication of arbitrary 3D-structures with unprecedented degrees of freedom. Research is rapidly progressing in this field, with promising results opening up a range of possible applications across both scientific and industrial sectors. Many sectors are now benefiting from fabricating complex structures using AM technologies to achieve the objectives of light-weighting, increased functionality, and part number reduction, among others. AM also lends potential in fulfilling demands for reducing the cost and design-to-manufacture time. Aluminium alloys are of the main material systems receiving attention in SLM research, being favoured in many high-value applications. However, processing them is challenging due to the difficulties associated with laser-melting aluminium where parts suffer various defects. A number of studies in recent years have developed approaches to remedy them and reported successful SLM of various Al-alloys and have gone on to explore its potential application in advanced componentry. This paper reports on recent advancements in this area and highlights some key topics requiring attention for further progression. It aims to develop a comprehensive understanding of the interrelation between the various aspects of the subject, as this is essential to demonstrate credibility for industrial needs.

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An Overview on 3D Printing Technology: Technological, Materials, and Applications

2019-01-01

N. Shahrubudin , Lee Te Chuan , Rohaizan Ramlan

Digital fabrication technology, also referred to as 3D printing or additive manufacturing, creates physical objects from a geometrical representation by successive addition of materials. 3D printing technology is a fast-emerging … Digital fabrication technology, also referred to as 3D printing or additive manufacturing, creates physical objects from a geometrical representation by successive addition of materials. 3D printing technology is a fast-emerging technology. Nowadays, 3D Printing is widely used in the world. 3D printing technology increasingly used for the mass customization, production of any types of open source designs in the field of agriculture, in healthcare, automotive industry, locomotive industry and aviation industries. 3D printing technology can print an object layer by layer deposition of material directly from a computer aided design (CAD) model. This paper presents the overview of the types of 3D printing technologies, the application of 3D printing technology and lastly, the materials used for 3D printing technology in manufacturing industry.

Additive Manufacturing Technologies

2020-11-10

Ian Gibson , David W. Rosen , Brent Stucker +1 more

Additive Manufacturing Technologies

2009-12-02

Ian Gibson , David W. Rosen , Brent Stucker

A perspective of pulsed laser deposition (PLD) in surface engineering alumina coatings and substrates

2008-01-01

Adele Carradò , H. Pelletier , Félix Sima +4 more

Additive manufacturing of carbon fiber reinforced thermoplastic composites using fused deposition modeling

2015-06-20

Fuda Ning , Weilong Cong , Jingjing Qiu +2 more

Machine learning-driven sustainable optimization of rapid prototyping via FDM: Enhancing mechanical strength, energy efficiency, and SDG contributions of thermoplastic composites

2025-06-25

S. Raja , Maher Ali Rusho , Xing Jia | Applied Chemical Engineering

Fused Deposition Modeling (FDM)-based rapid prototyping is a key technology in sustainable manufacturing, offering cost-effective solutions aligned with the United Nations Sustainable Development Goals (SDGs 1–6) by promoting affordable production, … Fused Deposition Modeling (FDM)-based rapid prototyping is a key technology in sustainable manufacturing, offering cost-effective solutions aligned with the United Nations Sustainable Development Goals (SDGs 1–6) by promoting affordable production, resource efficiency, and environmental sustainability. However, optimizing mechanical performance and energy efficiency in bio-based thermoplastic composites remains a challenge. This study explores PLA–walnut wood fiber composites, leveraging machine learning (ML) to optimize tensile, compression, and flexural properties while minimizing energy consumption. A dataset incorporating nozzle temperature, layer height, infill density, and print speed was trained using ML, achieving prediction accuracy above 95%. State-of-the-art studies highlight bio-based composite advantages, yet ML-driven multi-objective optimization for mechanical strength and sustainability remains unexplored. Experimental results indicate that an optimal nozzle temperature of 200–210°C, an infill density of 60–80%, and a layer height of 0.2 mm led to a 15% increase in tensile strength (38 MPa), a 12% improvement in flexural strength (62 MPa), and a 10% enhancement in compression strength (49 MPa). SEM analysis confirms improved fiber-matrix adhesion, enhancing structural integrity. Additionally, energy consumption was reduced by 18%, supporting cost-effective and low-carbon production. These findings contribute to poverty reduction (SDG 1), agricultural waste valorization (SDG 2), biocompatible materials for healthcare (SDG 3), STEM education accessibility (SDG 4), gender inclusivity in engineering (SDG 5), and clean water protection through reduced plastic waste (SDG 6). This study underscores the potential of ML-driven sustainable rapid prototyping to advance material efficiency, waste reduction, and resource-conscious manufacturing.

Additive Manufacturing (Fused Filament Fabrication) of Viton-Ammonium Perchlorate-Aluminum

2025-06-25

V. Ramírez , František Wald , Matthew A. Ellsworth +7 more | ACS Applied Engineering Materials

RP955 Assessment of the Application for Renewal of Finase EC Produced by Trichoderma Reesei CBS 122001 as a Feed Additive

2025-06-25

| FSA research and evidence.

The FSA/ FSS have undertaken a safety assessment of application RP 955 for the renewal of use of Finase EC produced by Trichoderma reesei CBS 122001 as a feed additive … The FSA/ FSS have undertaken a safety assessment of application RP 955 for the renewal of use of Finase EC produced by Trichoderma reesei CBS 122001 as a feed additive for pigs and poultry, from Roal Oy. FSA/FSS has reviewed the EFSA opinion (EFSA Journal 2020;18(12):6336) and confirm that it is adequate for UK considerations and therefore a full safety assessment of this application was not performed by FSA and FSS. In line with the principles for making use of EFSA opinions in their decision making on regulated products, the FSA/FSS opinion is that the conclusions of the EFSA opinion are valid for the UK and therefore Finase EC, as described in this application, is safe and is not liable to have an adverse effect on the target species, worker safety, environmental safety and human health at the intended concentrations of use.

3D Printing of Silver/Conductive Polymer Composites in Silica Gel Glass

2025-06-25

Xiaolin Fan , Shujun Hu , Ying Ye +4 more | Nano Letters

Conductive polymers, with their unique mechanical flexibility, electrical conductivity, and optoelectronic properties, have shown great potential in various fields. However, 3D patterning of conductive polymers has been limited by resolution, … Conductive polymers, with their unique mechanical flexibility, electrical conductivity, and optoelectronic properties, have shown great potential in various fields. However, 3D patterning of conductive polymers has been limited by resolution, material compatibility, and structural complexity. In this study, these challenges were addressed by fabricating three-dimensional (3D) Ag/PEDOT, Ag/PTH, and Ag/PPY structures with a resolution of 600 nm inside nanoporous silica gel glass using femtosecond laser direct writing (FsLDW) technology. Notably, these microstructures can effectively amplify the Raman signals of organic dyes. This study introduces a new strategy for 3D patterning of conductive polymers, opening up new avenues for applications in flexible electronics and sensing.

Additive Manufacturing of Novel Heat Exchanger Configurations

2025-06-25

Amit Choudhari , Ashish Kumar Gupta , Abhishek Kumar +3 more | CRC Press eBooks

Novel Tools for Analyzing Life Cycle Energy Use, Carbon Emissions, and Cost of Additive Manufacturing

2025-06-25

Christopher Price , Kristina Armstrong , Dipti Kamath +2 more | Journal of Manufacturing and Materials Processing

Decarbonizing industrial manufacturing is a significant challenge in the effort to limit the impacts of global climate change. Additive manufacturing (AM) is one pathway for reducing the impacts of manufacturing … Decarbonizing industrial manufacturing is a significant challenge in the effort to limit the impacts of global climate change. Additive manufacturing (AM) is one pathway for reducing the impacts of manufacturing as it creates parts layer-by-layer rather than by removing (i.e., subtracting) material from solid stock as with conventional techniques. This reduces material inputs and generates less waste, which can substantially lower life cycle energy consumption and greenhouse gas emissions. However, AM adoption in the manufacturing sector has been slow, partly due to challenges in making a strong business case compared with more traditional and widely available techniques. This paper highlights the need for the development of simple screening analysis tools to speed the adoption of AM in the manufacturing sector by providing decision-makers easy access to important production life cycle emissions, and cost information. Details on the development of two Microsoft Excel software tools are provided: upgrades to an existing tool on the energy and carbon impacts of AM and a new tool for analyzing the major cost components of AM. A case study applies these two tools to the production of a lightweight aerospace bracket, showing how the tools can be used to estimate the environmental benefits and production costs of AM.

Nanotechnology Inventions Geared toward Manufacturing

2025-06-24

Rajesh Kumar Thakur , Ishaq Ahmad , B. Mallick +2 more | CRC Press eBooks

Thermal Deformation Analysis in L-PBF 3D Printing Process of Front Knuckle Structure

2025-06-24

Young-Soo Yang , Seok-Chul Yun , Kyunsuk Choi +1 more | Journal of the Korean Society of Manufacturing Process Engineers

Electron Beam Bonding: a novel method for joining additively manufactured carbon fiber thermoplastic composites with aluminum to produce multi-material joints for lightweight applications

2025-06-24

Aybike Yalçınyüz , Julius Raute , Joamin González-Gutiérrez +3 more | Progress in Additive Manufacturing

Abstract In recent years, new solutions have been explored to reduce the weight of components for the automotive, railway, and aerospace industries. For this reason, Carbon Fiber Composites (CFCs) have … Abstract In recent years, new solutions have been explored to reduce the weight of components for the automotive, railway, and aerospace industries. For this reason, Carbon Fiber Composites (CFCs) have increasingly replaced metals in products that need to be lightweight. However, due to their poor thermal conductivity, CFCs have limited use in applications requiring efficient heat dissipation. In such applications, conventionally manufactured metal alloys are typically utilized. To address these limitations, a novel approach using a combination of additively manufactured aluminum and CFCs is proposed to exploit the distinct advantages of both materials. These innovative hybrid structures aim to combine good structural and thermal management properties with reduced weight compared to conventionally produced metal products. In this study, additively manufactured aluminum alloy (AlSi10Mg) and short carbon fiber Polyamide 6 composite (sCF-PA6) are utilized to produce metal–polymer pairs using electron beam energy to bond the two materials. Direct irradiation of short CFCs with electron beam leads to polymer degradation. Thus, a novel method “Electron Beam Bonding” for joining CFCs with aluminum alloy in various joint configurations using electron beam technology is demonstrated. This innovative approach presents a promising solution for creating metal–polymer multi-materials for lightweight applications.

Design of Alternatives to Stained Glass with Open-Source Distributed Additive Manufacturing for Energy Efficiency and Economic Savings

2025-06-24

Emily Bow Pearce , Joshua M. Pearce , Alessia Romani | Designs

Stained glass has played important roles in heritage building construction, however, conventional fabrication techniques have become economically prohibitive due to both capital costs and energy inefficiency, as well as high-level … Stained glass has played important roles in heritage building construction, however, conventional fabrication techniques have become economically prohibitive due to both capital costs and energy inefficiency, as well as high-level artistic and craft skills. To overcome these challenges, this study provides a new design methodology for customized 3D-printed polycarbonate (PC)-based stained-glass window alternatives using a fully open-source toolchain and methodology based on digital fabrication and hybrid crafts. Based on design thinking and open design principles, this procedure involves fabricating an additional insert made of (i) a PC substrate and (ii) custom geometries directly 3D printed on the substrate with PC-based 3D printing feedstock (iii) to be painted after the 3D printing process. This alternative is intended for customizable stained-glass design patterns to be used instead of traditional stained glass or in addition to conventional windows, making stained glass accessible and customizable according to users’ needs. Three approaches are developed and demonstrated to generate customized painted stained-glass geometries according to the different users’ skills and needs using (i) online-retrieved 3D and 2D patterns; (ii) custom patterns, i.e., hand-drawn and digital-drawn images; and (iii) AI-generated patterns. The proposed methodology shows potential for distributed applications in the building and heritage sectors, demonstrating its practical feasibility. Its use makes stained-glass-based products accessible to a broader range of end-users, especially for repairing and replicating existing conventional stained glass and designing new customizable products. The developed custom patterns are 50 times less expensive than traditional stained glass and can potentially improve thermal insulation, paving the way to energy efficiency and economic savings.

Assessing the environmental and economic performances of 3D printing processes for manufacturing printed circuit boards

2025-06-24

Yingying Ke , Фу Гу , Jingxiang Lv +1 more | Environmental Impact Assessment Review

Look-ahead stress-oriented trajectory planning to improve the strength of fused filament fabricated parts

2025-06-24

Mehrdad Sadeghieh , Jannis Saelzer , Ali Hosseini +2 more | CIRP journal of manufacturing science and technology

Recent Developments in Additively Manufactured Crash Boxes: Geometric Design Innovations, Material Behavior, and Manufacturing Techniques

2025-06-24

Ahmed Saber , A. M. Amer , Ali I. Shehata +2 more | Applied Sciences

Crash boxes play a vital role in improving vehicle safety by absorbing collision energy and reducing the forces transmitted to occupants. Additive manufacturing (AM) has become a powerful method for … Crash boxes play a vital role in improving vehicle safety by absorbing collision energy and reducing the forces transmitted to occupants. Additive manufacturing (AM) has become a powerful method for developing advanced crash boxes by enabling complex geometries. This review provides a comprehensive examination of recent progress in AM crash boxes, with a focus on three key aspects: geometric design innovations, material behavior, and manufacturing techniques. The review investigates the influence of various AM-enabled structural configurations, including tubular, origami-inspired, lattice, and bio-inspired designs, on crashworthiness performance. Among these, bio-inspired structures exhibit superior energy absorption characteristics, achieving a mean specific energy absorption (SEA) of 21.51 J/g. Material selection is also explored, covering polymers, fiber-reinforced polymers, metals, and multi-material structures. Metallic AM crash boxes demonstrate the highest energy absorption capacity, with a mean SEA of 28.65 J/g. In addition, the performance of different AM technologies is evaluated, including Stereolithography (SLA), Material Jetting (MJT), Selective Laser Melting (SLM), Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM), and hybrid manufacturing techniques. Among these, crash boxes produced by SLM show the most favorable energy absorption performance, with a mean SEA of 16.50 J/g. The findings presented in this review offer critical insights to guide future research and development in the design and manufacturing of next-generation AM crash boxes intended to enhance vehicle safety.

Inteligentna tektura falista w erze Przemysłu 5.0

2025-06-24

TOMASZ GARBOWSKI | PRZEGLĄD PAPIERNICZY

Optimization of main process control parameters of PHA bio-polymer in material extrusion additive manufacturing: experimental design and predictive models

2025-06-24

Nectarios Vidakis , Markos Petousis , Nikolaos Mountakis +3 more | The International Journal of Advanced Manufacturing Technology

Structural behaviour of polyethylene terephthalate glycol reinforced with carbon fibre through fused filament fabrication for automotive components

2025-06-24

Akash Jain , Tapish Raj , Ankit Sahai +1 more | Plastics Rubber and Composites Macromolecular Engineering

Automotive manufacturers are currently facing a range of significant challenges, including disruptions in the supply chain, heightened concerns about sustainability, and evolving customer demands. One promising solution to these issues … Automotive manufacturers are currently facing a range of significant challenges, including disruptions in the supply chain, heightened concerns about sustainability, and evolving customer demands. One promising solution to these issues is the adoption of fused filament fabrication (FFF), a popular manufacturing method. Numerous aspects affecting FFF have an influence on structural behaviour and become a key factor if such parts are designed for industrial use. This work focuses on polyethylene terephthalate glycol (PETG) specimens reinforced with carbon fibres (CFs), while also considering how nozzle hole diameter and internal filling pattern affect structural behaviour, notably flexural strength, compressive strength and impact behaviour. High-modulus CFs’ reinforcement contributes to the improved structural behaviour of PETG composites. Experimental analysis was used to assess the structural behaviour of CF-PETG specimens. Using statistical analysis of the information acquired from the structural behaviour testing of the specimens, the validity of the experimental investigation was valued. The sample's fracture mechanism was studied using high-end microscopy. The composites’ strengths enhanced from 35.31 to 48.96 MPa for compressive strength, 45.76 to 65.12 MPa for flexural strength and 23.75 to 36.54 kJ/m 2 for impact strength. Tailoring these parameters is crucial for achieving the desired performance and structural characteristics of automotive components. Fused filament fabrication parts surpass the flexibility of traditional moulded components, enhancing resilience in automotive applications.

On the Design and Development of a Conformal Sensor Using 3D Gel Printing of Polycaprolactone

2025-06-24

Ankush Mehta , Rupinder Singh , Jitendra Kumar +1 more | Journal of The Institution of Engineers (India) Series C

AMMap Tool for Additive Manufacturing Design, Alloy Discovery, and Path Planning

2025-06-23

Alexander Richter , Adam M. Krajewski , Zhening Yang +2 more | Journal of Physics Materials

Abstract Compositionally complex materials (CCMs), such as functionally graded materials (FGMs) made by additive manufacturing (AM) often form undesired phases or cracks, negatively affecting the build. Equilibrium thermodynamic calculations and … Abstract Compositionally complex materials (CCMs), such as functionally graded materials (FGMs) made by additive manufacturing (AM) often form undesired phases or cracks, negatively affecting the build. Equilibrium thermodynamic calculations and solidification simulations, such as Scheil-Gulliver, can be used to predict feasible compositions or compositional paths, acting as constraints before empirical or machine learning models are applied to predict properties of interest. In addition, additional analysis of solidification simulations can be used to predict hot-cracking using various criteria to further account for manufacturability. To define and navigate the high order chemical systems of CCMs/FGMs, the open-source tool, AMMap, has been developed utilizing open models and CALPHAD methods for thermodynamic computation. AMMap explores spaces constructed with the nimplex library, using a novel algorithm to represent high-dimensional systems as graphs that can be joined into homogenous structures and explored with graph traversal algorithms to automate the path-design process. This method allows the use of existing high-performance gradient descent, graph traversal search, and other path optimization algorithms to automate the path-design process with as little prior bias as possible.

Optical stability of 3D‐printed and milled zirconia after artificial aging and immersion in liquids: An in vitro study

2025-06-23

Athanasios E. Rigos , Matthew J. Kesterke , Jenn‐Hwan Chen +2 more | Journal of Prosthodontics

To assess the impact of artificial aging and immersion in common liquids on the optical properties of 3D-printed and milled zirconia. Monolithic zirconia discs (N = 100) were fabricated using … To assess the impact of artificial aging and immersion in common liquids on the optical properties of 3D-printed and milled zirconia. Monolithic zirconia discs (N = 100) were fabricated using two methods: 3Y-TZP for milling (e.max ZirCAD LT BL, Ivoclar Vivadent) and printable 3Y-TZP material (LithaCon 3Y 230) for 3D printing. The flat surfaces of the discs were mechanically polished. Color measurements were taken at baseline, after 10,000 thermal cycles and storage in various liquids for 20 days (T1), and after 20,000 thermal cycles and storage for 40 days (T2) using a spectrophotometer. Samples were stored in distilled water, tea, coffee, red wine, or Coca-Cola (n = 10 per group). Color differences (ΔE) were calculated between baseline and T1 as well as baseline and T2 using the CIEDE2000 formula, while contrast ratio (CR) and translucency parameter (TP) were calculated for each time point. Kruskal-Wallis nonparametric tests with Bonferroni corrections were used for comparisons between zirconia types, liquids, and time points. Shapiro-Wilk tests were applied for time-point comparisons (α ≤ 0.05). At T1 and T2, significant differences in TP and CR were observed after storage in tea, coffee, and red wine for both zirconia types. ΔE values following immersion in distilled water remained below clinically perceptible levels, while tea, wine, and coffee resulted in unacceptable ΔE at T1 and T2. 3D-printed and milled zirconia demonstrated comparable color stability after artificial aging and immersion in common liquids, with no significant differences between the materials in terms of color change (ΔE).

Some investigations on hybrid 3D printed PVDF-based functional prototypes

2025-06-23

Vinay Kumar , Gurwinder Singh , Minhaz Husain +4 more | Next Materials

Comparative Analysis of Build Direction in Stereolithography-Printed Parts Based on Optical, Quasi-Static, Fracture, and Dynamic Experiments

2025-06-23

C. P. Sandhya , R. Sujithra , Abhishek Kumar | Journal of Materials Engineering and Performance

Additive manufacturing of low environmental impact PLA-basalt/hemp biocomposites: life cycle assessment and mechanical properties

2025-06-23

Ersilia Cozzolino , Francesco Napolitano , Pietro Russo +2 more | The International Journal of Advanced Manufacturing Technology

Comprehensive analysis of heat treatment effects on PLA-wood biocomposites

2025-06-23

Altuğ Bakırcı , Mehmet Kivanc Turan , Fatih Karpat | Rapid Prototyping Journal

Purpose This study aims to investigate the effects of heat treatment on the mechanical and visual properties of PLA-wood samples. Three different heating temperatures and three different durations were applied … Purpose This study aims to investigate the effects of heat treatment on the mechanical and visual properties of PLA-wood samples. Three different heating temperatures and three different durations were applied to determine their impact on tensile strength, hardness, moisture resistance, dimensional stability, surface quality and visual appearance. Design/methodology/approach Samples were designed according to ASTM standards and produced via additive manufacturing. A full factorial experimental design was used. A total of 11 experimental groups were created: one untreated, one dried-only and nine heat-treated. Mechanical and physical evaluations included tensile testing, Shore D hardness, surface roughness, moisture absorption and visual color changes using a custom-built low-cost colorimeter developed specifically for this study. Findings Heat treatment improved mechanical strength and moisture resistance of PLA-wood. The highest tensile strength was achieved at 100 °C for 90 min, showing a 12.8% increase compared to the untreated group. Heat treatment increased hardness and brittleness while reducing elongation and moisture absorption. Dimensional changes stabilized after 100 °C for 90 min, and color generally darkened with increasing temperature. These findings indicate that heat treatment is effective for improving the performance and appearance of PLA-wood composites. Originality/value This is one of the most comprehensive heat treatment studies on PLA-wood in the literature, incorporating five distinct testing methods. A novel, low-cost colorimeter was developed for visual analysis. The results contribute significantly to the limited body of work on PLA-wood biocomposites and offer guidance for enhancing their functional and aesthetic properties through post-processing.

Fabrication of Organic/Inorganic Nanocomposites: From Traditional Synthesis to Additive Manufacturing

2025-06-23

Liwen Zhang , Xumin Huang , Liwei Liu +6 more | Advanced Materials

Abstract Nanocomposites, are materials that incorporate nanosized particles into a matrix of standard material, have emerged as a versatile class of materials with tunable properties for a wide range of … Abstract Nanocomposites, are materials that incorporate nanosized particles into a matrix of standard material, have emerged as a versatile class of materials with tunable properties for a wide range of applications. Traditional fabrication approaches, including physical blending, in situ polymerization, layer‐by‐layer assembly, and sol–gel synthetic methods, have been widely employed to develop nanocomposites with high structural homogeneity and tailored properties. This review presents a cohesive and comprehensive overview of nanocomposite fabrication methods, spanning from conventional synthetic strategies to cutting‐edge approaches such as 3D printing technologies. How 3D printing has driven innovations in nanocomposite applications, particularly in biomedicine, soft robotics, electronics, and water treatment, is explored. Additionally, key challenges in 3D‐printed nanocomposite development are discussed, and emerging advancements such as 5D printing, artificial intelligence (AI)‐assisted material optimization, nanoscale additive manufacturing, and closed‐loop recycling systems are highlighted. By bridging traditional synthesis with cutting‐edge fabrication techniques, this review aims to provide insights into the future directions of nanocomposite research and applications.

Combined effect of bio-inspired surface patterning and plasma treatment on the bonding performance of 3D-printed polycarbonate

2025-06-23

Nidhal Naat , Khalil Hajlaoui , Salah Mezlini +1 more | The International Journal of Advanced Manufacturing Technology

Indentation hardness of 3D-printed metals

2025-06-23

Gia Khanh Pham , Ruth Domes , Ümit Mavis +6 more | Rakenteiden Mekaniikka

Additive manufacturing is typically used for rapid prototyping and the production of small to medium quantities of complex parts. The quality of 3D-printed metallic parts depends on the printing process … Additive manufacturing is typically used for rapid prototyping and the production of small to medium quantities of complex parts. The quality of 3D-printed metallic parts depends on the printing process parameters and material behaviour. In order to characterize the mechanical properties of materials, the nearly non-destructive micro-indentation hardness testing of additively manufactured steel and aluminium alloy using Laser Powder Bed Fusion technology was investigated in this study. The micro-hardness and modulus of elasticity of hot work tool steel AISI H13 (1.2344) were evaluated to study the influence of printing parameters, such as laser power and laser scanning speed. While no pile-up or sink-in effects were detected in the steel samples, the pile-up effect was observed during the hardness measurement of the aluminum alloy AlMg1Si AA-6061. Since the pile-up effect leads to an overestimation of the measured hardness, a correction factor was applied to account for this deviation, resulting in an adjusted value approximately 7% lower than the initially measured hardness for the aluminum alloy. In addition, the statistical reliability of the measured hardness properties of the 3D-printed metals was evaluated using the Weibull distribution. It was demonstrated that the indentation test is highly suitable for analyzing small additively manufactured samples with relatively little effort while delivering high statistical reliability and providing meaningful insights into the mechanical properties of the materials, such as micro-hardness and indentation modulus.

Revolutionizing Healthcare: Recent Advances of Polyamide 12 in Medical Applications

2025-06-23

Logatharshiini Thanabalan , Matheel AL-Rawas , Nur Fatiha Ghazalli +2 more | Global Journal of Medical Pharmaceutical and Biomedical Update

Objectives: Polyamide 12 (PA 12), a widely used thermoplastic polymer, exhibits exceptional mechanical, thermal, and chemical properties, making it a crucial material in various industries, particularly the medical sector. With … Objectives: Polyamide 12 (PA 12), a widely used thermoplastic polymer, exhibits exceptional mechanical, thermal, and chemical properties, making it a crucial material in various industries, particularly the medical sector. With its semi-crystalline structure and low water absorption, PA 12 offers superior flexibility, impact resistance, and processability. This review explores the advancements and applications of PA 12 in medical fields. Material and Methods: Only articles published in 2013–2024 and written in English were reviewed in this study. An electronic search was conducted in databases such as Google Scholar, PubMed, PubMed Central, ScienceDirect, and Medline with the terms “polyamide,” “polyamide 12,” and “polyamide 12 in the medical field” used. Results: From a pool of 1018 articles initially identified, 211 were deemed relevant to the keywords “polyamide,” “polyamide 12,” and “PA 12 in the medical industry.” Following a screening process focusing on articles published from 2013 to 2024 and reviewing content, only 19 articles met the criteria. Conclusion: PA 12 was found to play a vital role in the medical sector, being used in catheters, tissue engineering, biomedical implants, dental prostheses, and many more.

Microgroove‐Assisted Film Patterning for the Control of Layered Microstructures in 3D‐Printed Ceramics

2025-06-23

Xiangquan Wu , Jiaqi Zhou , Shan Liu +5 more | Small

Abstract In the artificial fabrication of microstructured ceramics with platelets, precisely controlling the local alignment of microstructural units and constructing complex macroscopic geometries remain critical challenges. Herein, an inert film … Abstract In the artificial fabrication of microstructured ceramics with platelets, precisely controlling the local alignment of microstructural units and constructing complex macroscopic geometries remain critical challenges. Herein, an inert film with microgrooves is introduced into the ceramic printing process, and a novel microgroove‐assisted ceramic stereolithography approach is proposed. By combining microgroove geometry and layered printing, the local flow field generated during platform positioning through the interaction between the slurry and the microgrooves is harnessed to drive the orientation of alumina platelets and to form layered microstructures and non‐flat interfaces between layers. The flow‐driven orientation mechanism of the platelets is elucidated. After sintering, grain orientations are effectively controlled, and microgroove‐scale textured microstructures are introduced within each layer. A gradient distribution of hardness is formed along the microgroove. The warpage in the sintered samples is reduced. These layered microstructures further influence crack extension and deflection. Printing results using films with pits and letter arrays demonstrate that this mechanism can form more complex microstructures. This approach provides a fast, stable, and effective flow‐driven orientation mechanism for platelets in high‐solid‐content ceramic slurry, which controls the layered distribution of designed microstructure patterns within the 3D‐printed ceramics.

Correction to “Low‐temperature 3D printing and curing process of continuous fiber‐reinforced thermosetting polymer composites”

2025-06-23

| Polymer Composites

AddManBERT: A combinatorial triples extraction and classification task for establishing a knowledge graph to facilitate design for additive manufacturing

2025-06-23

Auwal Haruna , Khandaker Noman , Yongbo Li +3 more | Advanced Engineering Informatics

Casting Against Type

2025-06-23

Gerald W. C. Driskill , Julien C. Mirivel | Routledge eBooks

Tunable Elasto‐Viscoplastic Properties of Polymer Blends for 3D Printing Applications

2025-06-23

Ases Akas Mishra , Manoj Chandregowda , Janina Faiß +5 more | Macromolecular Rapid Communications

ABSTRACT Post‐extrusion flow dynamics of soft matter are governed by their elasto‐viscoplastic (EVP) rheological properties, which influence filament stability, die swelling, and shape fidelity in extrusion‐based 3D printing. Achieving precision … ABSTRACT Post‐extrusion flow dynamics of soft matter are governed by their elasto‐viscoplastic (EVP) rheological properties, which influence filament stability, die swelling, and shape fidelity in extrusion‐based 3D printing. Achieving precision and control in printed structures requires optimizing yield stress, viscoelasticity, and extrusion pressure to minimize excessive die swelling and material spreading, which can lead to unstable extrusion and poor print fidelity. We investigate Carbopol‐polyethylene oxide (PEO) blends as model EVP fluids, systematically varying their composition to assess die swelling, print width, and deposition accuracy. Rheo‐SAXS measurements reveal that die swelling can be directly related to characteristic nanoscale lengthscales. Parametric analysis using the Ohnesorge () and modified Bingham () numbers reveals that at high (yield stress, Pa) and , surface tension and viscoelastic effects dominate, leading to excessive die swelling and spreading upon deposition (up to 1.6 and 6 times the nozzle diameter, respectively), ultimately causing drop formation rather than stable filament extrusion. Conversely, and ensure optimal printability, high shape fidelity, and minimal die swelling. These findings guide EVP formulation and optimal extrusion pressure using dimensionless groups that capture material rheology and flow behavior.

Preparation of Functionally Graded Aluminum Alloy Composites with Alumina Dispersant under Gravity Casting

2025-06-23

Gen Sasaki , Chisato Indo , Kenjiro Sugio | Key engineering materials

By replacing the interface with sharp change properties with a functionally graded material with a gradually changing composition, a stable interface can be formed for mechanical and functional properties. In … By replacing the interface with sharp change properties with a functionally graded material with a gradually changing composition, a stable interface can be formed for mechanical and functional properties. In this study, the final goal is to functionally grade the interface between aluminum and alumina (Al 2 O 3 )/aluminum (Al) composites. First, the segmentation velocity of Al 2 O 3 particles under gravity was measured to clarify the possibility of functional grading. The starting materials used were A356.0 Al alloy and α-type Al 2 O 3 particles. The segmentation velocity obtained by the experiment was much faster than the theoretical velocity obtained by Stokes' law. It seems Stokes' law assumes that the particles are spherical and there is no interaction between particles, but the actual particle velocity was affected by the actual particle shape and interaction between particles. These factors affect the change in the segmentation velocity. The height of the mold was set to 40 mm, and an Al 2 O 3 particle/Al composite with a particle size of 6.7 μm was placed on the top and an Al alloy was placed on the bottom in the mold, melted, and rapidly solidified after 12 sec., and an Al 2 O 3 particle-dispersed Al alloy functionally graded composite was obtained under gravity.

Analysis and Testing of Infills of 3D Printed Specimens with Varying Infills

2025-06-23

Syed Musa Hassan Gillani , Gábor Balogh | Key engineering materials

The study focuses on the stress-strain behavior of 3D-printed infill patterns with two different infill densities, which are 15% and 30%, to analyze their performance. The stress-strain behavior of a … The study focuses on the stress-strain behavior of 3D-printed infill patterns with two different infill densities, which are 15% and 30%, to analyze their performance. The stress-strain behavior of a material describes how it deforms and reacts under different stress levels. The stress will be calculated in MPa and the strain in [%]; an example is the stress of gyroid in fill was 19.167 MPa while the average strain was 2.7833 % at 15% infill density. Using a tensile test machine with an optical extensometer, we would like to find out how infilled densities and parameters affect stress and strain. An Anycubic Kobra 3D printer with PLA filament from Anycubic was used for each sample. All the infills in the Ultimaker Cura software are being used.Additive manufacturing techniques are still in a process where further testing is required until we can perfectly control the results through specific instructions in the software. These tests can lead to forces of the required stress and strain, high quality where required, and products that use lower amounts of infills but still have high stress/strain. The main purpose is to further understand the forces we observe with every infill and independently analyze the stress and strain outputs. This will also lead to lower material usage in the FDM printing technology when a product is prepared.Two tests are designed to support the results and decision process, the tests have different properties such as layer height, wall layer counts, infill density, and top and bottom layer thickness. The tests with different properties were analyzed to check the best results and find the most suitable material effect and force difference due to material densities, wall thickness, and other properties. These properties show large differences in results, such as a 20% strain increase in the Quarter cubic infill. The highest strain was observed in concentric infill with 30% infill.

Optimization of Lightweight Components through Hybrid Topology Optimization and Generative Design in Additive Manufacturing

2025-06-23

Omar Lkadi , Mohammed Nassraoui , Otmane Bouksour | Key engineering materials

Generative design (GD) and topology optimization (TO) are two advanced methods that make it possible to design lightweight and high-performance structures for industrial and mechanical needs. This study offers an … Generative design (GD) and topology optimization (TO) are two advanced methods that make it possible to design lightweight and high-performance structures for industrial and mechanical needs. This study offers an approach that combines generative design and topology optimization to reach the best possible balance of material efficiency and manufacturability in complex components. By utilizing GD's capacity to provide several design options within predetermined parameters and TO's material distribution methodology, the suggested approach minimizes weight while maximizing structural integrity. To validate the methodology, a case study involving optimization of performance, weight, and manufacturability of a motorcycle triple clamp is discussed in the paper. The study uses ANSYS for TO to create a preliminary efficient design, it then uses Fusion 360's Generative Design tools to develop the design and investigate various manufacturable configurations (additive and subtractive manufacturing). The final design is confirmed by finite element analysis (FEA), which evaluates each alternative's mechanical performance, manufacturability, with significant weight reduction—up to 35%—while preserving manufacturing viability and structural integrity.

Additive Manufacturing, Building Materials and Processing of Structural Metals

2025-06-23

Hisaki Watari , Ramesh K. Agarwal , Mihály Csüllög | Trans Tech Publications Ltd. eBooks

Measurement and Testing of the Effect of Infill on Additively Manufactured TPU Part

2025-06-23

Ahnaf Tahmid , Gábor Balogh , S Gillani | Key engineering materials

Nowadays, there is a spike in 3D printing and additive manufacturing technology all over the world. Starting from the prototype state to the final production process, a high demand is … Nowadays, there is a spike in 3D printing and additive manufacturing technology all over the world. Starting from the prototype state to the final production process, a high demand is noticed due to the fact that this technology is rapid, economical and good-fit for finding out the mechanical behavior of the material and the structure. Thermoplastic polyurethane (TPU) is widely used in automotive industry, sport industry, medical industry, even in footwear industry. High abrasion resistance, shear strength, elasticity with low-temperature performance make TPU widely used and so important. In this study, we focused on the effect of infill pattern and density in mechanical behavior of 3D printed TPU part. We controlled the density and pattern both resulting in changing mechanical properties, helping us reduce the use of material, cost and production time accordingly. It is necessary to prepare a database on the test results, which can help us to understand the parameters related to internal structure or infill pattern of the material.

Integration of Machine Learning in Additive Manufacturing for Material Extrusion and Powder Bed Fusion, a Brief Literature Review

2025-06-23

Attila Debreceni , Sándor Bodzás | Key engineering materials

Today's computational capacity enables the use of advanced statistical algorithms to identify relationships between features in high-dimensional data. Additive manufacturing methods are typically complex processes with many variables in both … Today's computational capacity enables the use of advanced statistical algorithms to identify relationships between features in high-dimensional data. Additive manufacturing methods are typically complex processes with many variables in both printing parameters and material properties. Consequently, machine learning offers opportunities for process optimization, quality assurance, and innovation in both Material Extrusion and Powder Bed Fusion technologies. The paper reviews the recent findings in machine learning applications for these additive manufacturing techniques, focusing on areas like defect detection, process control, and material property prediction. Key trends reveal that, while machine learning offers promising enhancements for additive manufacturing, challenges remain in data scarcity, model generalization, real-time adaptability. Our findings underscore the potential of machine learning to improve the overall quality of additive manufacturing processes by predicting optimal manufacturing parameters.

Process Control for Direct Ink Writing of Composite Materials via Reinforcement Learning

2025-06-23

Zebin Li , Wuyang Chen , Zipeng Guo +2 more | Journal of Manufacturing Science and Engineering

Abstract Material extrusion-based additive manufacturing is a versatile technology attracting interests across multiple industries in energy, semiconductor, biomedical, and construction. It has several unique merits including material variety, the ability … Abstract Material extrusion-based additive manufacturing is a versatile technology attracting interests across multiple industries in energy, semiconductor, biomedical, and construction. It has several unique merits including material variety, the ability to produce complex and customized geometries, and cost-effectiveness. The feedstock material, commonly referred to as the feedstock ink, is a viscous elastomeric fluid (i.e., a kind of composite material). Extrusion of such feedstock inks is a dynamic process governed by multiple interdependent process parameters. The intrinsic interactions within the process often lead to ink flow heterogeneity, resulting in unpredictable under-extrusion and over-extrusion. This ultimately affects the consistency of ink deposition. Traditional control strategies rely on open-loop, empirically derived methods that are often material-specific and nontransferable. Lacking a generic control strategy poses significant challenges with composite material-based inks. In this work, a data-driven reinforcement learning (RL) based controller is developed to address the challenge. The stochastic state transition technique is adopted to generate the offline dataset for the RL-based controller training and reduce the physical experimentation needs. The RL-based controller adjusts the printing in real-time to compensate for the over-extrusion and under-extrusion when such undesired phenomena occur. Several validation material extrusion experiments demonstrate the effectiveness of the RL-based controller. Besides, the RL-based controller is transferable and can be adapted to new process conditions with limited experiments at new process conditions, showing its generalization ability and broadening the application scenarios of the RL-based controller.

Microstructural Characterization and Porosity Analysis in Sheet Lamination and Material Extrusion-Based Additively Manufactured Thermoplastic Composites

2025-06-23

Samiul Alam , Devin Young , Dae Han Sung +1 more | SAMPE JOURNAL

Additive manufacturing (AM) of fiber-reinforced composites has garnered significant interest for its versatility in creating intricate parts and rapid prototyping. Short fiber-reinforced composites are typically fabricated through fused deposition modeling … Additive manufacturing (AM) of fiber-reinforced composites has garnered significant interest for its versatility in creating intricate parts and rapid prototyping. Short fiber-reinforced composites are typically fabricated through fused deposition modeling (FDM), but they possess several challenges including limited fiber volume fraction (Vf), low printing speed, and low throughput for industry scales. Composite-based additive manufacturing (CBAM) is a novel sheet lamination-based AM process, combining non-woven fabric reinforcement with thermoplastic materials to fabricate three-dimensional objects. CBAM offers notable advantages over FDM, including the potential for achieving higher Vf and faster production rates, making it a promising technology for further investigation in composite manufacturing. This paper investigates the microstructural characteristics and porosity analyses of non-woven carbon fabric reinforced nylon composites (CF-PA12) manufactured by CBAM and FDM. Test coupons were fabricated in flatwise and edgewise printing orientations. CBAM flatwise specimens were less porous than edgewise specimens attributed to the comparatively higher number of sheets in edgewise orientation. This study highlights the microstructural characteristics of mechanical test specimens prepared using CBAM and FDM. It reveals that CBAM specimens exhibit a higher Vf, lower porosity, and smaller, more randomly distributed closed pores compared to FDM specimens, which enhance its material integrity and performance, offering a foundation for further development in composite AM technology.

A flexible decision support tool for the green selection of additive over subtractive manufacturing approaches

2025-06-23

Maria Gloria Trapani , Rosa Di Lorenzo , Livan Fratini +1 more | Journal of Cleaner Production

Circular Shear Printing of Spiral-Oriented CF-PP Components for Enhanced Mechanical Performance and Warp Mitigation

2025-06-22

Dashan Mi , Tao Yang , Jinghua Jiang +2 more | Polymers

Extrusion-based printers have attracted much attention for their simplified printing process and broader material compatibility. Carbon fibers (CF), known for their excellent mechanical properties, are incorporated into polypropylene (PP) printing … Extrusion-based printers have attracted much attention for their simplified printing process and broader material compatibility. Carbon fibers (CF), known for their excellent mechanical properties, are incorporated into polypropylene (PP) printing materials. This study presents a shear screw printer (SSP) with a modified screw design. The SSP generates torsional shear forces, enabling helical orientation of CFs within PP/CF composites. The study also compares the SSP’s performance with that of a conventional screw printer (CSP). PP/CF composite specimens containing 15% CF were printed at four different layup angles: 0°, 45°, 90°, and ±45° (net). The results show that combining CFs’ helical orientation with a net printing arrangement can effectively enhance tensile properties while reducing anisotropy. Furthermore, this approach can significantly mitigate warping in printed parts.

The Impact of MEX 3D Printing Key Control Settings on the Rheology and DMA Response of Bacteria-Derived PHA

2025-06-22

Markos Petousis , Nikolaos Michailidis , Nikolaos Mountakis +5 more | ACS Omega

3D‐Printed Architected Material for the Generation of Foam‐Based Protective Equipment

2025-06-22

Ali Zolfagharian , Gerard Bel Català , Daniel Saakes +3 more | Advanced Engineering Materials

This article explores the development of architected structures, considering both their static and dynamic performances for protective equipment and aiming to replace traditional foam materials. The study delves into the … This article explores the development of architected structures, considering both their static and dynamic performances for protective equipment and aiming to replace traditional foam materials. The study delves into the complexities of the manufacturing process for these structures, with a particular focus on 3D printing specific parameters. This technology offers unique opportunities for designing and developing highly customized products. By integrating both design and production processes, the study aims to tailor the mechanical performance of the final structures, particularly their impact strength and damping properties. A key aspect of this research involves testing samples generated using the developed structures and comparing the results to conventional nonprinted foams typically used in protective equipment. The findings demonstrate that the new methodology has significant potential for creating a new generation of protective gear with high customizability, reduced weight, and tunable performance.