Journal articles: 'AM material development'

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Roberson, David, Corey M. Shemelya, Eric MacDonald, and Ryan Wicker. "Expanding the applicability of FDM-type technologies through materials development." Rapid Prototyping Journal 21, no. 2 (March 16, 2015): 137–43. http://dx.doi.org/10.1108/rpj-12-2014-0165.

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Purpose – The purpose of this paper is to demonstrate the strategy for increasing the applicability of material extrusion additive manufacturing (AM) technologies, based on fused deposition modeling (FDM), through the development of materials with targeted physical properties. Here, the authors demonstrate materials specifically developed for the manufacture of electromechanical and electromagnetic applications, the use of FDM-type processes in austere environments and the application of material extrusion AM. Design/methodology/approach – Using a twin screw polymeric extrusion process, novel polymer matrix composites and blends were created where the base material was a material commonly used in FDM-type processes, namely, acrylonitrile butadiene styrene (ABS) or polycarbonate (PC). Findings – The work presented here demonstrates that, through targeted materials development, the applicability of AM platforms based on FDM technology can be increased. Here, the authors demonstrate that that the physical properties of ABS and PC can be manipulated to be used in several applications such as electromagnetic and X-ray shielding. Other instances of the development of new materials for FDM led to mitigation of problems associated with the process such as surface finish and mechanical property anisotropy based on build orientation. Originality/value – This paper is an overview of a research effort dedicated to increasing the amount of material systems available to material extrusion AM. Here materials development is shown to not only increase the number of suitable applications for FDM-type processes, but to be a pathway toward solving inherent problems associated with FDM such as surface finish and build orientation-caused mechanical property anisotropy.

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Koptioug, Andrey, Lars Erik Rännar, Mikael Bäckström, and Zhi Jian Shen. "New Metallurgy of Additive Manufacturing in Metal: Experiences from the Material and Process Development with Electron Beam Melting Technology (EBM)." Materials Science Forum 879 (November 2016): 996–1001. http://dx.doi.org/10.4028/www.scientific.net/msf.879.996.

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Additive manufacturing (AM) is becoming one of the most discussed modern technologies. Significant achievements of the AM in metals today are mainly connected to the unprecedented freedom of component shapes this technology allows. But full potential of these methods lies in the development of new materials designed to be used specifically with AM. Proper understanding of the AM process will open up new possibilities, where material and component properties can be specifically tailored by controlling the parameters throughout the whole manufacturing process. Present paper discusses the issues related to the beam melting technologies AM and electron beam welding (EBW). We are speaking of new direction in material science that can be termed “non-stationary metallurgy”, using the examples from material and process development for EBW, electron beam melting (EBM®) and other additive manufacturing methods.

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Mohan, Denesh, Zee Khai Teong, Afifah Nabilah Bakir, Mohd Shaiful Sajab, and Hatika Kaco. "Extending Cellulose-Based Polymers Application in Additive Manufacturing Technology: A Review of Recent Approaches." Polymers 12, no. 9 (August 20, 2020): 1876. http://dx.doi.org/10.3390/polym12091876.

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The materials for additive manufacturing (AM) technology have grown substantially over the last few years to fulfill industrial needs. Despite that, the use of bio-based composites for improved mechanical properties and biodegradation is still not fully explored. This limits the universal expansion of AM-fabricated products due to the incompatibility of the products made from petroleum-derived resources. The development of naturally-derived polymers for AM materials is promising with the increasing number of studies in recent years owing to their biodegradation and biocompatibility. Cellulose is the most abundant biopolymer that possesses many favorable properties to be incorporated into AM materials, which have been continuously focused on in recent years. This critical review discusses the development of AM technologies and materials, cellulose-based polymers, cellulose-based three-dimensional (3D) printing filaments, liquid deposition modeling of cellulose, and four-dimensional (4D) printing of cellulose-based materials. Cellulose-based AM material applications and the limitations with future developments are also reviewed.

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Gu, Dongdong, Xinyu Shi, Reinhart Poprawe, David L. Bourell, Rossitza Setchi, and Jihong Zhu. "Material-structure-performance integrated laser-metal additive manufacturing." Science 372, no. 6545 (May 27, 2021): eabg1487. http://dx.doi.org/10.1126/science.abg1487.

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Laser-metal additive manufacturing capabilities have advanced from single-material printing to multimaterial/multifunctional design and manufacturing. Material-structure-performance integrated additive manufacturing (MSPI-AM) represents a path toward the integral manufacturing of end-use components with innovative structures and multimaterial layouts to meet the increasing demand from industries such as aviation, aerospace, automobile manufacturing, and energy production. We highlight two methodological ideas for MSPI-AM—“the right materials printed in the right positions” and “unique structures printed for unique functions”—to realize major improvements in performance and function. We establish how cross-scale mechanisms to coordinate nano/microscale material development, mesoscale process monitoring, and macroscale structure and performance control can be used proactively to achieve high performance with multifunctionality. MSPI-AM exemplifies the revolution of design and manufacturing strategies for AM and its technological enhancement and sustainable development.

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Fu, Wentao, Christoph Haberland, Eva Verena Klapdor, David Rule, and Sebastian Piegert. "Streamlined frameworks for advancing metal based additive manufacturing technologies." Journal of the Global Power and Propulsion Society 2 (January 29, 2018): QJLS4L. http://dx.doi.org/10.22261/jgpps.qjls4l.

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Abstract Metal-based additive manufacturing (AM) technologies such as selective laser melting (SLM) have seen successful applications in the gas turbine industry over the past years. The rapidly growing demand in AM requires in-depth knowledge of the process, materials and design for additive manufacturing (DFAM). However, the material characterization and process development are highly specific to a particular AM system, even for a number of standard alloys such as IN718 that are suitable for gas turbine applications. When the AM system changes or a new material becomes available, the whole development workflow needs to start almost “from scratch,” which consumes considerable time and effort. To address these issues, Siemens Power & Gas has established cross-divisional competence centers for AM to enhance collaborative material and process development. The article describes this framework and its effectiveness in streamlining the AM process and materials development. To close the design and manufacturing process chain, it is also critical to ensure that the full AM potential is accessible in design stages. In this article, a DFAM framework is proposed to drive the design paradigm shift to AM. In the framework, a complete DFAM process is defined based on existing studies of Siemens gas turbine applications. By integrating a set of DFAM methods, tools and considerations into the current gas turbine design processes, the AM-driven product design is enabled. We use Siemens large gas turbine applications to demonstrate the development and industrialization of AM using the frameworks. The benefits in reducing cost, expediting time to market, improving component performance and enabling new design freedom will be highlighted.

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Rimkus, Arvydas, Mahmoud M. Farh, and Viktor Gribniak. "Continuously Reinforced Polymeric Composite for Additive Manufacturing—Development and Efficiency Analysis." Polymers 14, no. 17 (August 25, 2022): 3471. http://dx.doi.org/10.3390/polym14173471.

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Additive manufacturing (AM) is a rapidly growing technology, referring to a 3D design process by which digital data builds a physical object in layers by depositing the printed material. The AM has evolved in the aviation, automotive, and medical industries. The AM development for fiber-reinforced composites is the point of current interest, with most research focused on using short fibers. However, notwithstanding particular technological complexities, continuous filaments have superior tensile properties compared to short fibers. Therefore, this manuscript develops an adaptive continuous reinforcement approach for AM based on polymeric material extrusion (ME) technology. It combines the raw material production process, including the ability to varying constituents (e.g., filament materials, reinforcement percentage, and recycled plastic replacement ratio), and the reinforcement efficiency analysis regarding the experimentally verified numerical model. The literature review has identified compatible materials for ensuring sustainable and high-performance plastic composites reinforced with continuous fibers. In addition, it identified the applicability of recycled polymers in developing ME processes. Thus, the study includes an experimental program to investigate the mechanical performance of 3D printed samples (polylactic acid, PLA, matrix reinforced with continuous aramid filament) through a tensile test. Recycled polymer replaced 40% of the virgin PLA. The test results do not demonstrate the recycled polymer’s negative effect on the mechanical performance of the printed samples. Moreover, the recycled material reduced the PLA cost by almost twice. However, together with the potential efficiency of the developed adaptive manufacturing technology, the mechanical characteristics of the printed material revealed room for printing technology improvement, including the aligned reinforcement distribution in the printed product and printing parameters’ setup.

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Arenas, Maria Alejandra Ardila, Dirk Gutkelch, Olaf Kosch, Rüdiger Brühl, Frank Wiekhorst, and Norbert Löwa. "Development of Phantoms for Multimodal Magnetic Resonance Imaging and Magnetic Particle Imaging." Polymers 14, no. 19 (September 20, 2022): 3925. http://dx.doi.org/10.3390/polym14193925.

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Phantoms are crucial for the development of imaging techniques based on magnetic nanoparticles (MNP). They serve as test objects to simulate application scenarios but are also used for quality assurance and interlaboratory comparisons. Magnetic particle imaging (MPI) is excellent for specifically detecting magnetic nanoparticles (MNP) without any background signals. To obtain information about the surrounding soft tissue, MPI is often used in combination with magnetic resonance imaging (MRI). For such application scenarios, this poses a challenge for phantom fabrication, as they need to accommodate MNP as well as provide MR visibility. Recently, layer-by-layer fabrication of parts using Additive Manufacturing (AM) has emerged as a powerful tool for creating complex and patient-specific phantoms, but these are characterized by poor MR visibility of the AM material. We present the systematic screening of AM materials as candidates for multimodal MRI/MPI imaging. Of all investigated materials, silicone (Dreve, Biotec) exhibited the best properties with sufficient MR-signal performance and the lowest absorption of MNP at the interface of AM materials. With the help of AM and the selection of appropriate materials, we have been able to produce suitable MRI/MPI phantoms.

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Schneck, Matthias, Max Horn, Maik Schindler, and Christian Seidel. "Capability of Multi-Material Laser-Based Powder Bed Fusion—Development and Analysis of a Prototype Large Bore Engine Component." Metals 12, no. 1 (December 25, 2021): 44. http://dx.doi.org/10.3390/met12010044.

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Additive Manufacturing (AM) allows the manufacturing of functionally graded materials (FGM). This includes compositional grading, which enables the allocation of desired materials corresponding to local product requirements. An upcoming AM process for the creation of metal-based FGMs is laser-based powder bed fusion (PBF-LB/M) utilized for multi-material manufacturing (MM). Three-dimensional multi-material approaches for PBF-LB/M are stated to have a manufacturing readiness level (MRL) of 4 to 5. In this paper, an advancement of multi-material technology is presented by realizing an industry-relevant complex part as a prototype made by PBF-LB/M. Hence, a multi-material injection nozzle consisting of tool steel and a copper alloy was manufactured in a continuous PBF-LB/M process. Single material regions showed qualities similar to the ones resulting from mono-material processes. A geometrically defined transition zone between the two materials was achieved that showed slightly higher porosity than mono-material regions. Nevertheless, defects such as porosity, cracks, and material cross-contamination were detected and must be overcome in further MM technology development.

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Junio, Raí Felipe Pereira, Pedro Henrique Poubel Mendonça da Silveira, Lucas de Mendonça Neuba, Sergio Neves Monteiro, and Lucio Fabio Cassiano Nascimento. "Development and Applications of 3D Printing-Processed Auxetic Structures for High-Velocity Impact Protection: A Review." Eng 4, no. 1 (March 8, 2023): 903–40. http://dx.doi.org/10.3390/eng4010054.

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Auxetic structures (AXSs) are a novel class of materials with unique mechanical deformation behavior associated with negative Poisson ratio. The combination of AXS configurations with various types of materials has unveiled a wide field of applications, including military high-velocity protection against explosions and ballistic projectiles. However, the characteristic geometric re-entrant model of AXSs imposes limitations and difficulties when using conventional manufacturing methods to assemble the structure lattice. Additive manufacturing (AM) has recently been explored as a more efficient and cost-effective method to fabricate AXSs, regardless of the type of material. This review paper focuses on the development and applications of AM processed AXSs. The review highlights the significance and great potential for this class of materials that can be produced relatively fast and at a low cost. The advantages of AXS/AM are expected to extend to important industrial sectors, particularly for military ballistic armor, where the feasibility for products with improved properties is critical. The use of AM offers a viable solution to overcome the difficulties associated with the conventional manufacturing methods, and thus offers greater design flexibility, cost efficiency, and reduced material waste. This review paper aims to contribute to the understanding of the current state-of-the-art and future research prospects for the production and applications of AXS/AM.

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Watschke, Hagen, Lennart Waalkes, Christian Schumacher, and Thomas Vietor. "Development of Novel Test Specimens for Characterization of Multi-Material Parts Manufactured by Material Extrusion." Applied Sciences 8, no. 8 (July 25, 2018): 1220. http://dx.doi.org/10.3390/app8081220.

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Multi-material additive manufacturing (AM) offers new design opportunities for functional integration and opens new possibilities in innovative part design, for example, regarding the integration of damping or conductive structures. However, there are no standardized test methods, and thus test specimens that provide information about the bonding quality of two materials printed together. As a result, a consideration of these new design potentials in conceptual design is hardly possible. As material extrusion (ME) allows easily combination of multiple polymeric materials in one part, it is chosen as an AM technique for this contribution. Based on a literature review of commonly used standards for polymer testing, novel test specimens are developed for the characterization of the bonding quality of two ME standard materials printed together. The proposed specimen geometries are manufactured without a variation of process parameters. The load types investigated in the course of this study were selected as examples and are tensile, lap-shear, and compression-shear. The conducted tests show that the proposed test specimens enable a quantification of the bonding quality in the material transition. Moreover, by analyzing the fracture pattern of the interface zone, influencing factors that probably affect the interface strength are identified, which can be further used for its optimization.

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Dams, Barrie, Binling Chen, Paul Shepherd, and Richard J. Ball. "Development of Cementitious Mortars for Aerial Additive Manufacturing." Applied Sciences 13, no. 1 (January 3, 2023): 641. http://dx.doi.org/10.3390/app13010641.

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Additive Manufacturing (AM) methods in the construction industry typically employ ground-based deposition methods. An alternative to transform the role of AM in construction is to introduce an aerial capability. A recent project titled Aerial Additive Manufacturing (AAM), the first AM system to use untethered, unmanned aerial vehicles (or ‘drones’), has demonstrated the 3D-printing of cementitious materials during flight. An autonomous aerial system would minimise requirements for working at height, thus reducing safety risks and release AM from ground-based constraints. This study investigates viscous cementitious mortars for AAM. To assess workability and buildability, a robotic arm representing UAV movement in three-dimensional space moved a lightweight deposition device to extrude multiple layers. Constituents such as Pulverised Fuel-Ash, Silica fume, polyol resin, limeX70 and Polypropylene fibres were added to cement-based material mixes. Sand:binder ratios were a maximum of 1.00 and Water:binder ratios ranged from 0.33–0.47. Workability and buildability of mixes were evaluated using performance parameters such as power required for extrusion, number of layers successfully extruded, the extent of deformation of extruded layers and evaluation of mechanical and rheological properties. Rheology tests revealed mortars with a suitable workability-buildability balance possessed a Complex modulus of 3–6 MPa. Mechanical tests showed that resistance to deformation and buildability positively correlate and indicate compressive strengths in excess of 25 MPa. This study has demonstrated that structural cementitious material can be processed by a device light enough to be carried by a UAV to produce an unsupported, coherent multiple-layered object and further demonstrated the feasibility of untethered AAM as an alternative to ground-based AM applications in construction.

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Cavalcanti, D. K. K., M. D. Banea, and H. F. M. de Queiroz. "Effect of Material on the Mechanical Properties of Additive Manufactured Thermoplastic Parts." Annals of Dunarea de Jos University of Galati Fascicle XII Welding Equipment and Technology 31 (December 28, 2020): 5–12. http://dx.doi.org/10.35219/awet.2020.01.

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Additive manufacturing (AM) also called 3D printing, is an emerging process in the manufacturing sector with increasing new applications in aerospace, prototyping, medical devices and product development, among others. The resistance of the AM part is determined by the chosen material and the printing parameters. As novel materials and AM methods are continuously being developed, there is a need for the development and mechanical characterization of suitable materials for 3D printing. In this study, the influence of the material and the 3D-printing parameters on the mechanical properties of additive manufactured thermoplastic parts was investigated. Three different filaments that are commercially available: Polylactic acid (PLA), acrylonitrile butadiene styrene (ABS) and Tritan were used. Tensile and flexural tests were carried out, in accordance to ASTM standards, to investigate and compare the mechanical properties of the AM parts as a function of material used. The results showed that the type of filaments had the greatest influence on the mechanical properties of the AM parts. The maximum strength and stiffness were obtained for the PLA specimens. Tritan displayed the highest deformation, while the PLA manifested the lowest deformation capacity. The mechanical properties of the printed parts also depend on the printing parameters. The parameters used in this work are a good compromise between the printing time and the mechanical properties.

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Reza, Arif, Soomin Shim, Seungsoo Kim, Naveed Ahmed, Seunggun Won, and Changsix Ra. "Nutrient Leaching Loss of Pre-Treated Struvite and Its Application in Sudan Grass Cultivation as an Eco-Friendly and Sustainable Fertilizer Source." Sustainability 11, no. 15 (August 3, 2019): 4204. http://dx.doi.org/10.3390/su11154204.

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Struvite recovered from waste streams is considered as a sustainable alternative to commercial phosphate (P) fertilizers manufactured from P rock. In this study, struvite was recovered from swine wastewater and pre-treated as air-dried material (AM), microwave irradiated material (MM), oven-dried material (OM), and incinerated material (IM) to reduce the moisture content. Based on their solubility and crystalline nature, AM and IM were selected for further experiments. The nutrient leaching loss and fertilizing value of AM and IM were evaluated in comparison to commercial fused superphosphate (FSP) fertilizer. Soil columns were used to quantify ortho-phosphate (O-P) and ammonium nitrogen (NH4-N) leaching in soil from the test materials. Among the test materials, the average leaching rate of O-P for FSP and AM was significantly different from the control and IM (p < 0.05). The average leaching rate of NH4-N among the test materials did not show any significant difference (p > 0.05). Sudan grass growth was examined with standard (urea supplemented) and high (20x, without urea) application of test materials in pot and soil box trials, respectively, to study the fertilizing value AM and IM. There were no significant differences among the test materials, except for the control, in terms of growth rate and fresh and dry matter yield in the pot trials (p > 0.05). When AM, IM, and FSP were applied in increasing amounts (20x) without urea supplement, Sudan grass growth was 50% lower in IM and was found to be significantly different from AM and FSP (p < 0.05). The results suggest that struvite pre-treated as AM could be an effective sustainable and eco-friendly alternative to commercial P fertilizers and thus helps to ensure agricultural sustainability.

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Deneault, James R., Jorge Chang, Jay Myung, Daylond Hooper, Andrew Armstrong, Mark Pitt, and Benji Maruyama. "Toward autonomous additive manufacturing: Bayesian optimization on a 3D printer." MRS Bulletin 46, no. 7 (April 19, 2021): 566–75. http://dx.doi.org/10.1557/s43577-021-00051-1.

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Abstract Materials exploration and development for three-dimensional (3D) printing technologies is slow and labor-intensive. Each 3D printing material developed requires unique print parameters be learned for successful part fabrication, and sub-optimal settings often result in defects or fabrication failure. To address this, we developed the Additive Manufacturing Autonomous Research System (AM ARES). As a preliminary test, we tasked AM ARES with autonomously modulating four print parameters to direct-write single-layer print features that matched target specifications. AM ARES employed automated image analysis as closed-loop feedback to an online Bayesian optimizer and learned to print target features in fewer than 100 experiments. In due course, this first-of-its-kind research robot will be tasked with autonomous multi-dimensional optimization of print parameters to accelerate materials discovery and development in the field of AM. The combining of open-source ARES OS software with low-cost hardware makes autonomous AM highly accessible, promoting mainstream adoption and rapid technological advancement. Impact statement The discovery and development of new materials and processes for three-dimensional (3D) printing is hindered by slow and labor-intensive trial-and-error optimization processes. Coupled with a pervasive lack of feedback mechanisms in 3D printers, this has inhibited the advancement and adoption of additive manufacturing (AM) technologies as a mainstream manufacturing approach. To accelerate new materials development and streamline the print optimization process for AM, we have developed a low-cost and accessible research robot that employs online machine learning planners, together with our ARES OS software, which we will release to the community as open-source, to rapidly and effectively optimize the complex, high-dimensional parameter sets associated with 3D printing. In preliminary trials, the first-of-its-kind research robot, the Additive Manufacturing Autonomous Research System (AM ARES), learned to print single-layer material extrusion specimens that closely matched targeted feature specifications in under 100 iterations. Delegating repetitive and high-dimensional cognitive labor to research robots such as AM ARES frees researchers to focus on more creative, insightful, and fundamental scientific work and reduces the cost and time required to develop new AM materials and processes. The teaming of human and robot researchers begets a synergy that will exponentially propel technological progress in AM.

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Essien, U. A., and S. Vaudreuil. "In-situ metal matrix composites development for additive manufacturing: a perspective." Journal of Achievements in Materials and Manufacturing Engineering 111, no. 2 (April 1, 2022): 78–85. http://dx.doi.org/10.5604/01.3001.0015.9997.

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This paper presents an overview on some ceramic materials capable of achieving in-situ reinforcements in Al/Al-alloy metal matrix composites (MMCs) during laser processing. It also presents perspective on further exploitation of the in-situ reinforcement capabilities for high quality MMCs feedstock material development. The approach utilized in writing this paper encompasses the review of relevant literature on additive manufacturing (AM) of MMCs. It is widely accepted that the in-situ reinforcement approach has proven to be more advantageous than the ex-situ approach. Though there are still some challenges like the formation of detremental phases and the evaporation of low melting temperature elements, the in-situ reinforcement approach can be used to tailor design composite powder feedstock materials for the AM of MMCs. The preprocessing or tailor-designing in-situ metal matrix composite powder before laser melting into desired components holds more promises for metal additive manufacturing. The need for the development of MMCs powder feedstock that can be directly fabricated using suitable AM technique without prior powder processing like blending or mechanical alloying has not yet been addressed Therefore, having a pre-processed in-situ reinforced MMC feedstock powder can encourage easy fabrication of MMC and other advantages of AM technologies powder recycling. The idea explained in this article is relevant to materials development for AM processing of metal matrix composite. This paper has pointed out future trends for MMCs materials feedstock powder development and new ideas for further exploitation of MMCs and AM technologies. The advantages of tailor-designing composite powders other than merely mixing them has been emphasized.

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Palousek, David, Martin Kocica, Libor Pantelejev, Lenka Klakurkova, Ladislav Celko, Daniel Koutny, and Jozef Kaiser. "SLM process parameters development of Cu-alloy Cu7.2Ni1.8Si1Cr." Rapid Prototyping Journal 25, no. 2 (March 4, 2019): 266–76. http://dx.doi.org/10.1108/rpj-06-2017-0116.

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Purpose Materials with a high thermal conductivity, such as Cu-alloys hold the most interest to the plastic moulding industry. Additive manufacturing (AM), especially selective laser melting (SLM) of metals, allows the production of parts with complicated internal cooling and increased production efficiency. The portfolio of alloys for metal AM is limited and still missing process parameters for the processing of copper alloys. This paper aims to preview the process parameters of high-strength alloy Cu7.2Ni1.8Si1Cr processed by SLM. Design/methodology/approach An experimental approach is adopted to investigate porosity and mechanical properties of SLM specimens and its comparison with standard material AMPCOLOY 944. Optimization of porosity was performed using line and cube specimens; mechanical properties and microstructure were evaluated by tensile testing and metallography. Findings Optimum processing parameters for fabrication of Cu-alloy specimens with a relative density of 99.95 per cent were identified, and no cracks were detected. Mechanical testing of SLM specimens showed the ultimate tensile strength, proof stress of 0.2 and elongation of 380, 545 MPa and 16.9 per cent. The alloy is suitable for laser AM, thanks to its processability at a relatively high laser scanning speeds and thus its promising price of part/costs ratio. Research limitations/implications The paper describes the initial state of research – the follow-up tests focussed on mechanical testing, fatigue and statistical evaluation need to be conducted. The process parameters are developed only for bulk geometry – optimal setup for lattice structures and thin walls has not been explored yet. Practical implications The research findings in this work could be used for production of 3D printed parts and after the tuning of additional parameters, e.g. for up- and down-skin zones, could be used for special application such as energy exchange. Originality/value This work produces the processing of new material suitable for laser AM. Cu7.2Ni1.8Si1Cr alloy could be the prospective material from the group of Cu alloys suitable for moulds manufacturing and thermal applications.

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Hong, Myoung-Pyo, Jin-Jae Kim, Woo-Sung Kim, Min-Kyu Lee, Ki-Man Bae, Young-Suk Kim, and Ji-Hyun Sung. "Heterogeneous Material Additive Manufacturing for Hot-Stamping Die." Metals 10, no. 9 (September 9, 2020): 1210. http://dx.doi.org/10.3390/met10091210.

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Additive manufacturing (AM) has recently been receiving global attention. As an innovative alternative to existing manufacturing technologies, AM can produce three-dimensional objects from various materials. In the manufacturing industry, AM improves production cost, time, and quality in comparison to existing methods. In addition, AM is applied in the fabrication and production of objects in diverse fields. In particular, metal AM has been continuously commercialized in high value-added industries such as aerospace and health care by many research and development projects. However, the applicability of metal AM to the mold and die industry and other low value-added industries is limited because AM is not as economical as current manufacturing technologies. Therefore, this paper proposes an effective solution to the problem. This study examines a method for using direct energy deposition and heterogeneous materials, a heterogeneous material additive-manufacturing process for metals used to optimize the cooling channels and a key process in manufacturing hot-stamping dies. The improvements in the cooling performances and uniform cooling were evaluated by heat-flow analysis in a continuous process. Finally, trial products were fabricated using the proposed method, and a trial for hot stamping was conducted to examine the possibility of it being used in commercial applications.

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Francis, Vishal, and Prashant K. Jain. "Effect of stage-dependent addition of nanoparticles in additive manufacturing." Journal of Thermoplastic Composite Materials 33, no. 3 (November 27, 2018): 357–76. http://dx.doi.org/10.1177/0892705718805528.

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Recent advancements in the additive manufacturing (AM) technology have increased its utilization in various engineering sectors for the development of end-use products. However, the limited choice of available materials tends to limit its application domain. Addition of nanoparticles can significantly improve the material properties of the AM parts. Moreover, nanoparticles can be added in different stages of the process which will play an important role in determining the increase in material properties. This aspect of the stage-dependent addition of nanoparticles in AM process has not been fully explored. The present work discusses the effect of adding nanoclay in three stages of AM process namely preprocessing, on-site and post-processing stage. It has been found that the nanoparticles interact in a different way with the polymer and result in different structure, morphology and mesostructure of the nanocomposites. The approach can be utilized for achieving improved material properties of AM-fabricated parts.

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Kumar, Parichit, Saksham Malik, Ehsan Toyserkani, and Mir Behrad Khamesee. "Development of an Electromagnetic Micromanipulator Levitation System for Metal Additive Manufacturing Applications." Micromachines 13, no. 4 (April 9, 2022): 585. http://dx.doi.org/10.3390/mi13040585.

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Magnetism and magnetic levitation has found significant interest within the field of micromanipulation of objects. Additive manufacturing (AM), which is the computer-controlled process for creating 3D objects through the deposition of materials, has also been relevant within the academic environment. Despite the research conducted individually within the two fields, there has been minimal overlapping research. The non-contact nature of magnetic micromanipulator levitation systems makes it a prime candidate within AM environments. The feasibility of integrating magnetic micromanipulator levitation system, which includes two concentric coils embedded within a high permeability material and carrying currents in opposite directions, for additive manufacturing applications is presented in this article. The working principle, the optimization and relevant design decisions pertaining to the micromanipulator levitation system are discussed. The optimized dimensions of the system allow for 920 turns in the inner coil and 800 turns in the outer coil resulting in a Ninnercoil:Noutercoil ratio of 1.15. Use of principles of free levitation, which is production of levitation and restoration forces with the coils, to levitate non-magnetic conductive materials with compatibility and applications within the AM environment are discussed. The Magnetomotive Force (MMF) ratio of the coils are adjusted by incorporation of an resistor in parallel to the outer coil to facilitate sufficient levitation forces in the axial axis while producing satisfactory restoration forces in the lateral axes resulting in the levitation of an aluminum disc with a levitation height of 4.5 mm. An additional payload of up to 15.2 g (59% of mass of levitated disc) was added to a levitated aluminum disk of 26 g showing the system capability coping with payload variations, which is crucial in AM process to gradually deploy masses. The final envisioned system is expected to have positional stability within the tolerance range of a few μm. The system performance is verified through the use of simulations (ANSYS Maxwell) and experimental analyses. A novel method of using the ratio of conductivity (σ) of the material to density (ρ) of the material to determine the compatibility of the levitation ability of non-magnetic materials with magnetic levitation application is also formulated. The key advantage of this method is that it does not rely on experimental analyses to determine the levitation ability of materials.

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Salmi, Mika. "Additive Manufacturing Processes in Medical Applications." Materials 14, no. 1 (January 3, 2021): 191. http://dx.doi.org/10.3390/ma14010191.

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Additive manufacturing (AM, 3D printing) is used in many fields and different industries. In the medical and dental field, every patient is unique and, therefore, AM has significant potential in personalized and customized solutions. This review explores what additive manufacturing processes and materials are utilized in medical and dental applications, especially focusing on processes that are less commonly used. The processes are categorized in ISO/ASTM process classes: powder bed fusion, material extrusion, VAT photopolymerization, material jetting, binder jetting, sheet lamination and directed energy deposition combined with classification of medical applications of AM. Based on the findings, it seems that directed energy deposition is utilized rarely only in implants and sheet lamination rarely for medical models or phantoms. Powder bed fusion, material extrusion and VAT photopolymerization are utilized in all categories. Material jetting is not used for implants and biomanufacturing, and binder jetting is not utilized for tools, instruments and parts for medical devices. The most common materials are thermoplastics, photopolymers and metals such as titanium alloys. If standard terminology of AM would be followed, this would allow a more systematic review of the utilization of different AM processes. Current development in binder jetting would allow more possibilities in the future.

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Kim, Sujin, Byung Shin, Chungmo Yang, Soohyun Jeong, Jung Shim, Min Park, Young Choy, Chan Heo, and Kangwon Lee. "Development of Poly(HEMA-Am) Polymer Hydrogel Filler for Soft Tissue Reconstruction by Facile Polymerization." Polymers 10, no. 7 (July 13, 2018): 772. http://dx.doi.org/10.3390/polym10070772.

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The number of breast reconstruction surgeries has been increasing due to the increase in mastectomies. Surgical implants (the standard polydimethylsiloxane (PDMS) implants) are widely used to reconstruct breast tissues, however, it can cause problems such as adverse immune reactions, fibrosis, rupture, and additional surgery. Hence, polymeric fillers have recently garnered increasing attention as strong alternatives for breast reconstruction materials. Polymeric fillers offer noninvasive methods of reconstruction, thereby reducing the possible adverse effects and simplifying the treatment. In this study, we synthesized a 2-hydroxylethylmethacrylate (HEMA) and acrylamide (Am) copolymer (Poly(HEMA-Am)) by redox polymerization to be used as a biocompatible filler material for breast reconstruction. The synthesized hydrogel swelled in phosphate buffered saline (PBS) shows an average modulus of 50 Pa, which is a characteristic similar to that of the standard dermal acrylamide filler. To investigate the biocompatibility and cytotoxicity of the Poly(HEMA-Am) hydrogel, we evaluated an in vitro cytotoxicity assay on human fibroblasts (hFBs) and human adipose-derived stem cells (hADSCs) with the hydrogel eluate, and confirmed a cell viability of over 80% of the cell viability with the Poly(HEMA-Am) hydrogel. These results suggest our polymeric hydrogel is a promising filler material in soft tissue augmentation including breast reconstruction.

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Katz-Demyanetz, Alexander, Vladimir V. Popov, Aleksey Kovalevsky, Daniel Safranchik, and Andrey Koptyug. "Powder-bed additive manufacturing for aerospace application: Techniques, metallic and metal/ceramic composite materials and trends." Manufacturing Review 6 (2019): 5. http://dx.doi.org/10.1051/mfreview/2019003.

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The current paper is devoted to classification of powder-bed additive manufacturing (PB-AM) techniques and description of specific features, advantages and limitation of different PB-AM techniques in aerospace applications. The common principle of “powder-bed” means that the used feedstock material is a powder, which forms “bed-like” platform of homogeneous layer that is fused according to cross-section of the manufactured object. After that, a new powder layer is distributed with the same thickness and the “printing” process continues. This approach is used in selective laser sintering/melting process, electron beam melting, and binder jetting printing. Additionally, relevant issues related to powder raw materials (metals, ceramics, multi-material composites, etc.) and their impact on the properties of as-manufactured components are discussed. Special attention is paid to discussion on additive manufacturing (AM) of aerospace critical parts made of Titanium alloys, Nickel-based superalloys, metal matrix composites (MMCs), ceramic matrix composites (CMCs) and high entropy alloys. Additional discussion is related to the quality control of the PB-AM materials, and to the prospects of new approaches in material development for PB-AM aiming at aerospace applications.

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Zhang, Ruiying, Fan Jiang, Long Xue, and Junyu Yu. "Review of Additive Manufacturing Techniques for Large-Scale Metal Functionally Graded Materials." Crystals 12, no. 6 (June 17, 2022): 858. http://dx.doi.org/10.3390/cryst12060858.

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Functionally graded materials (FGMs), which constitute a new type of composite material, have received considerable attention in industry because of the spatial gradient of their composition and the microstructure-induced gradient in their material performance, which make them better suited for high-performance multifunctional applications. Additive manufacturing (AM) has become one of the most promising techniques for the manufacture of materials and structures because of its high flexibility. The combination of advanced materials (FGMs) and advanced manufacturing methods (AM) is expected to facilitate the further development of such engineering materials. In this paper, the definition, historical development and material gradient types of FGMs are introduced. The classification, process principle and typical research results of the AM of metal FGMs are summarized and discussed. In particular, the research status of wire and arc additive manufacture (WAAM), which is more suitable for the preparation of large-scale metal FGMs, is reviewed in detail according to the types of FGMs, and a double-wire bypass plasma arc additive manufacturing technique, which is suitable for inducing a gradient along the direction of single-pass cladding, is proposed. On the basis of this summary of the important achievements made to date, future research is proposed.

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Pires, J. Norberto, Amin S. Azar, Filipe Nogueira, Carlos Ye Zhu, Ricardo Branco, and Trayana Tankova. "The role of robotics in additive manufacturing: review of the AM processes and introduction of an intelligent system." Industrial Robot: the international journal of robotics research and application 49, no. 2 (December 28, 2021): 311–31. http://dx.doi.org/10.1108/ir-06-2021-0110.

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Purpose Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components. AM technologies have received an enormous attention from both academia and industry, and they are being successfully used in various applications, such as rapid prototyping, tooling, direct manufacturing and repair, among others. AM does not necessarily imply building parts, as it also refers to innovation in materials, system and part designs, novel combination of properties and interplay between systems and materials. The most exciting features of AM are related to the development of radically new systems and materials that can be used in advanced products with the aim of reducing costs, manufacturing difficulties, weight, waste and energy consumption. It is essential to develop an advanced production system that assists the user through the process, from the computer-aided design model to functional components. The challenges faced in the research and development and operational phase of producing those parts include requiring the capacity to simulate and observe the building process and, more importantly, being able to introduce the production changes in a real-time fashion. This paper aims to review the role of robotics in various AM technologies to underline its importance, followed by an introduction of a novel and intelligent system for directed energy deposition (DED) technology. Design/methodology/approach AM presents intrinsic advantages when compared to the conventional processes. Nevertheless, its industrial integration remains as a challenge due to equipment and process complexities. DED technologies are among the most sophisticated concepts that have the potential of transforming the current material processing practices. Findings The objective of this paper is identifying the fundamental features of an intelligent DED platform, capable of handling the science and operational aspects of the advanced AM applications. Consequently, we introduce and discuss a novel robotic AM system, designed for processing metals and alloys such as aluminium alloys, high-strength steels, stainless steels, titanium alloys, magnesium alloys, nickel-based superalloys and other metallic alloys for various applications. A few demonstrators are presented and briefly discussed, to present the usefulness of the introduced system and underlying concept. The main design objective of the presented intelligent robotic AM system is to implement a design-and-produce strategy. This means that the system should allow the user to focus on the knowledge-based tasks, e.g. the tasks of designing the part, material selection, simulating the deposition process and anticipating the metallurgical properties of the final part, as the rest would be handled automatically. Research limitations/implications This paper reviews a few AM technologies, where robotics is a central part of the process, such as vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, DED and sheet lamination. This paper aims to influence the development of robot-based AM systems for industrial applications such as part production, automotive, medical, aerospace and defence sectors. Originality/value The presented intelligent system is an original development that is designed and built by the co-authors J. Norberto Pires, Amin S. Azar and Trayana Tankova.

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Łacicowa, Barbara. "Interaction between some fungi living on cereal seeding material." Acta Mycologica 9, no. 1 (November 21, 2014): 7–10. http://dx.doi.org/10.5586/am.1973.002.

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The biotic relations were evaluated between saprophytic fungi genera Fusarium and Helmithosporium. Most of the saprophytic fungi restricted the development of Helmihthosporium sativum and H. triseptatum more than that of Fusarium nivale and F. avenaceum. Sordaria fimicola was the only fungus which restricted the growth of Helminthosporium sativum, H. triseptatum, Fusarium nivale and F. avenaceum.

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Ahn, Jaeseung, Jaehyeok Doh, Samyeon Kim, and Sang-in Park. "Knowledge-Based Design Algorithm for Support Reduction in Material Extrusion Additive Manufacturing." Micromachines 13, no. 10 (October 4, 2022): 1672. http://dx.doi.org/10.3390/mi13101672.

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Although additive manufacturing (AM) enables designers to develop products with a high degree of design freedom, the manufacturing constraints of AM restrict design freedom. One of the key manufacturing constraints is the use of support structures for overhang features, which are indispensable in AM processes, but increase material consumption, manufacturing costs, and build time. Therefore, controlling support structure generation is a significant issue in fabricating functional products directly using AM. The goal of this paper is to propose a knowledge-based design algorithm for reducing support structures whilst considering printability and as-printed quality. The proposed method consists of three steps: (1) AM ontology development, for characterizing a target AM process, (2) Surrogate model construction, for quantifying the impact of the AM parameters on as-printed quality, (3) Design and process modification, for reducing support structures and optimizing the AM parameters. The significance of the proposed method is to not only optimize process parameters, but to also control local geometric features for a better surface roughness and build time reduction. To validate the proposed algorithm, case studies with curve-based (1D), surface-based (2D), and volume (3D) models were carried out to prove the reduction of support generation and build time while maintaining surface quality.

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Topcu, Okan, and Yigit Tascioglu. "A Virtual Prototyping System for Additive Manufacturing Process Development." Advanced Materials Research 445 (January 2012): 971–75. http://dx.doi.org/10.4028/www.scientific.net/amr.445.971.

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This paper describes a virtual prototyping (VP) system which is a part of an open source software package for an additive manufacturing (AM) process under development. The VP system facilitates the product development by uniting the AM process and virtual reality in order to produce digital prototypes. Moreover, it combines particle based and layer based processes by including powder-like particles as its basic material. These particles are used as color codes in the VP system. This coding enables obtaining basic building blocks in homogeneous state or in heterogeneous state by mixing with other particles. These blocks or bricks are collated side by side to obtain the heterogeneous material property all over the solid body. The thin layers obtained by these bricks are then subsequently stacked up to fabricate a virtual prototype. Construction of multiple material prototypes is possible due to selective-additive nature of this process. The effectiveness of the proposed system is demonstrated by processing a model of The Maidens Tower.

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Abdi, Frank, Parviz Yavari, Vasyl Harik, and Cody Godines. "Material Allowable Generation and AM Process Parameters Effect on Porosity." Coatings 10, no. 7 (June 30, 2020): 625. http://dx.doi.org/10.3390/coatings10070625.

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Additive manufacturing (AM) process methods such as powder bed fusion (LPBF) of metal powder layers can produce layered material systems with designed microstructures, which may exhibit scatter in mechanical properties (e.g., lower yield and lower failure strain), corrosion due to porosity and print anomalies. This study shows the development of AM process simulation to predict As-built material characteristic and their scatter comparing with experimental test data. ICME (Integrated Computational Materials Engineering) was used to simulate yield, ultimate, strain, and reduction of the area of sample AM. The method was extended to predict oxidation and damage of as-built parts. The samples were fabricated horizontally and vertically in multiple and scatter directions to find the effect on the mechanical properties such as ultimate tensile strength (UTS) and yield strength (YS). The probabilistic sensitivities show that in order for the next-generation technology to improve the strength of 3D printed materials, they must control the void volume fraction (trapped gas) and orientation of voids. The studied 3D print modality processes: (a) LPBF of AlSi10Mg, and (b) Electron Beam (EBM) of Ti-6Al-4V materials are shown to be over 99.99% reliable. The statistics of 3D printed Ti-6Al-4V have been observed for room and high temperature (RT/HT). The ICME Material Characterization and Qualification (MCQ) software material model prediction capabilities were used to predict (a) Material Allowable, a variation in Stress Strain Curves Characteristic Points and Residual Stress due to air particle (void/defect) shape and size and orientation. The probabilistic simulation computes Cumulative Distribution Function (CDF) and probabilistic sensitivities for YS, UTS, and %Elongation as well as A and B basis allowable of the As-Built 3D printed material and; and (b) Fracture Control Plan fracture toughness determination, and fatigue crack growth vs. stress intensity.

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Khrushchev, E. G., and A. I. Levchenko. "Historical and legal concept of development of food security: experience of the NEP." Alma mater. Vestnik Vysshey Shkoly, no. 5 (May 2021): 123–27. http://dx.doi.org/10.20339/am.05-21.123.

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Examined is the current legal issues of what is today called food security. The process of formation of this institution in the 1920s is considered through the prism of regulatory material. Such a retrospective analysis helps to prevent the dynamics of problems in modern state development. The purpose of the study is to identify the methodological, material and legal foundations for the emergence of food security during the New Economic Policy (NEP). Objectives to study the course of state and legal development during the NEP period are to analyze legal sources and archival materials of the Soviet policy in the 1920s in the field of food security. In the process of working on the study, a number of special methods were used, in particular, historical-legal, formal-legal, comparative-legal. The implementation of research tasks was achieved on the basis of a historical and legal analysis of the main sources and archival materials of the state and legal development of the NEP period, which enshrined the legal aspects of food security. An abstract review of the legal framework of the normative sources of the NEP allows to assert, that already in the 1920s, the issue of food security was formed. In addition, attempts were actively made to resolve it in corresponding legislative base formed. The experience of the NEP showed that the state agricultural food policy requires a very clear and clear legislative structure. These contradictions are more or less obvious in modern state of legal policy. This must be taken into account when making decisions. It is important to understand that the tasks of agricultural food policy do not have simple and complex solutions.

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Fujimoto, Kiyo T., Lance A. Hone, Kory D. Manning, Robert D. Seifert, Kurt L. Davis, James N. Milloway, Richard S. Skifton, Yaqiao Wu, Malwina Wilding, and David Estrada. "Additive Manufacturing of Miniaturized Peak Temperature Monitors for In-Pile Applications." Sensors 21, no. 22 (November 19, 2021): 7688. http://dx.doi.org/10.3390/s21227688.

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Passive monitoring techniques have been used for peak temperature measurements during irradiation tests by exploiting the melting point of well-characterized materials. Recent efforts to expand the capabilities of such peak temperature detection instrumentation include the development and testing of additively manufactured (AM) melt wires. In an effort to demonstrate and benchmark the performance and reliability of AM melt wires, we conducted a study to compare prototypical standard melt wires to an AM melt wire capsule, composed of printed aluminum, zinc, and tin melt wires. The lowest melting-point material used was Sn, with a melting point of approximately 230 °C, Zn melts at approximately 420 °C, and the high melting-point material was aluminum, with an approximate melting point of 660 °C. Through differential scanning calorimetry and furnace testing we show that the performance of our AM melt wire capsule was consistent with that of the standard melt-wire capsule, highlighting a path towards miniaturized peak-temperature sensors for in-pile sensor applications.

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Cabrera, Isaac A., Parker J. Hill, Win-Ying Zhao, Trinity C. Pike, Marc A. Meyers, Ramesh R. Rao, and Albert Y. M. Lin. "Prosthetic Sockets: Tensile Behavior of Vacuum Infiltrated Fused Deposition Modeling Sandwich Structure Composites." Prosthesis 4, no. 3 (June 22, 2022): 317–37. http://dx.doi.org/10.3390/prosthesis4030027.

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The development of novel materials will enable a new generation of prosthetic devices to be built with additive manufacturing (AM). Vacuum infiltrated sandwich structure composites are a promising approach for building prosthetic sockets via AM. In this paper, we test the tensile properties of 18 different composite material configurations using ASTM D638. These composites were manufactured using a custom vacuum infiltration method and had varying filament materials, infiltrated matrix materials, and print directions. Several material-matrix-print composites showed higher ultimate tensile strengths and reduced anisotropy compared to full-infill control samples. However, the mechanical properties of these composites were limited by a large degree of porosity due to the manufacturing method. Still, the results were sufficiently promising to create a proof of concept prosthetic socket via the vacuum infiltration method. Future research should focus on reducing porosity defects and investigating additional material-matrix-print combinations.

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Tassa, Oriana, Laura Alleva, and Roberto Sorci. "Powders for Additive Manufacturing: From Design to Certification." Materials Science Forum 1016 (January 2021): 1473–78. http://dx.doi.org/10.4028/www.scientific.net/msf.1016.1473.

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Rina Consulting Centro Sviluppo Materiali (CSM) has been involved in the study and development of powder metallurgy for different applications, thanks to its participation in many research industrial and funded projects. The entire metal powder production chain takes place within the company's own researcher and facilities. This allows to produce high quality powders starting from alloy design, VIGA atomization and chemical, rheological and particle size analysis. In recent years, the development has mainly concerned manufacturing processes. Currently only a limited number of metal alloys can be processed by AM. For that reason, the alloy design becomes a really important topic to enlarge AM capabilities to other materials and applications. Starting from commercial Thermodynamic and Kinetic codes and proprietary models on solidification and micro-segregation, the alloy chemical composition can be fine-tuned to optimize the microstructure, considering the target properties of the material and the relevant AM processing windows, taking into account also the post process treatment conditions. Moreover, the knowledge of the production plants allows CSM to have a wide vision on the realization and the characterization of the metal powders focusing to achieve the best powder quality suitable for AM applications. Finally, AM is a relatively “new” process, standardization is still an ongoing activity involving several communities and organizations like ASTM, AWS and ISO; in this contest CSM has already designed the guidelines for qualification and certification processes and has created a dedicated laboratory to qualify powders of AM players.

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Watschke, Hagen, Sebastian Kuschmitz, Julius Heubach, Guido Lehne, and Thomas Vietor. "A Methodical Approach to Support Conceptual Design for Multi-Material Additive Manufacturing." Proceedings of the Design Society: International Conference on Engineering Design 1, no. 1 (July 2019): 659–68. http://dx.doi.org/10.1017/dsi.2019.70.

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AbstractAdditive manufacturing (AM) opens new possibilities for innovative product designs. However, due to a lack of knowledge and restrained creativity because of design fixations, design engineers do not take advantage of AM's design freedom. Especially multi-material AM provides new opportunities for functional integration that hardly considered in ideation. To overcome barriers in the development of solution ideas and utilizing such new design potentials, new design methods and tools are needed. Therefore, in this contribution, a methodological approach for a function-oriented provision of solution principles specific to material extrusion is presented. A tool is developed to facilitate effective guidance in developing solution ideas and to foster a realistic concretization by providing a combination of opportunistic and restrictive AM knowledge. Besides general levers of AM, process-specific design opportunities support the design engineers in exploiting AM's potentials, especially those who are not familiar with Design for AM. Finally, the applicability of the methodological approach is evaluated in an academic study by means of redesigning a hand prosthesis with a grab function.

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Buranská, Eva, Ivan Buranský, Ladislav Morovič, and Katarína Líška. "Environment and Safety Impacts of Additive Manufacturing: A Review." Research Papers Faculty of Materials Science and Technology Slovak University of Technology 27, no. 44 (June 1, 2019): 9–20. http://dx.doi.org/10.2478/rput-2019-0001.

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Abstract The paper is focused on additive manufacturing (AM) which is the process of producing objects from a three-dimensional (3D) model by joining materials layer by layer, as opposed to the subtractive manufacturing methodologies [1], directly from raw material in powder, liquid, sheet, or a filament form without the need for moulds, tools, or dies. The article demonstrates potential environmental implications of additive manufacturing related to the key issues including energy use, occupational health, waste and lifecycle impact. AM provides a cost-effective and time-efficient way to fabricating products with complicated geometries, advanced material properties and functionality. Based on this review, we identified that additive manufacturing will have a significant societal impact in the near future. A critical technical review of the promises and potential issues of AM is beneficial for advancing its further development.

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Koptyug, Andrey, Mikael Bäckström, Carlos Alberto Botero Vega, Vladimir Popov, and Ekaterina Chudinova. "Developing New Materials for Electron Beam Melting: Experiences and Challenges." Materials Science Forum 941 (December 2018): 2190–95. http://dx.doi.org/10.4028/www.scientific.net/msf.941.2190.

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Lack of industrially available materials for additive manufacturing (AM) of metallic materials along with the promises of materials with improved or unique properties provides a strong drive for developing new process/material combinations. As powder bed technologies for metallic materials are relatively new to the market, and to some extent are only maturing, developers of new process/material combinations have certain challenges to overcome. Firstly, basic knowledge on the behavior of materials (even those well established for other applications) under extreme conditions of melting/solidification with beam-based AM methods is far from being adequate. Secondly, manufacturing of the equipment is up to date driven by industrial application, thus optimization of the AM machines for small test batches of powders is still belongs to research and development projects. Also, majority of the powder manufacturers are primarily driven by the market development, and even they are well aware of the demands imposed by the powder bed AM machines, availability of small test batches of adequate powders may be problematic or at least quite costly for the R&D oriented users. Present paper describes the experiences in developing new materials for EBM A2 machine by Arcam EBM, modified for operating with powder batches of 100-200 ml and less. In particular it discusses achievements and challenges of working with powders from different materials with specifications far beyond the range suggested by machine manufacturer. Also it discusses the possibility of using blended rather than pre-alloyed powders for achieving both composite-like and alloyed materials in the same part by steering electron beam energy deposition strategy.

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Alfaify, Abdullah, Mustafa Saleh, Fawaz M. Abdullah, and Abdulrahman M. Al-Ahmari. "Design for Additive Manufacturing: A Systematic Review." Sustainability 12, no. 19 (September 25, 2020): 7936. http://dx.doi.org/10.3390/su12197936.

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The last few decades have seen rapid growth in additive manufacturing (AM) technologies. AM has implemented a novel method of production in design, manufacture, and delivery to end-users. Accordingly, AM technologies have given great flexibility in design for building complex components, highly customized products, effective waste minimization, high material variety, and sustainable products. This review paper addresses the evolution of engineering design to take advantage of the opportunities provided by AM and its applications. It discusses issues related to the design of cellular and support structures, build orientation, part consolidation and assembly, materials, part complexity, and product sustainability.

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Castellví, A., L. Poudelet, A. Tejo, L. Calvo, R. Uceda, P. Lustig, J. Minguella, et al. "The commissioning of a hybrid multi-material 3D printer." IOP Conference Series: Materials Science and Engineering 1193, no. 1 (October 1, 2021): 012044. http://dx.doi.org/10.1088/1757-899x/1193/1/012044.

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Abstract Additive Manufacturing (AM) has rapidly become an important technology in both research and industry. This development has allowed the evolution of 3D printers which are able to print complex geometries at low costs and faster than traditional methods. Despite this, most of these printers are either only for using one material or one technology. This limits a lot its use in different sectors such as aeronautics, automotive or health, because multi-material prototypes are needed. For example, surgeons need surgical planning prototypes for preoperative planning. These 3D printed prototypes have mainly been manufactured using just one technology. As a result, the prototypes have some main limitations: (1) do not actually mimic the anatomical structures of the human body, (2) high costs specially for Material Jetting and Powder Bed Fusion AM technologies. Therefore, the aim of present manuscript is the design, development, and commissioning of a hybrid multi-material 3D printer.

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Tao, Yubo, Qing Yin, and Peng Li. "An Additive Manufacturing Method Using Large-Scale Wood Inspired by Laminated Object Manufacturing and Plywood Technology." Polymers 13, no. 1 (December 31, 2020): 144. http://dx.doi.org/10.3390/polym13010144.

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Wood-based materials in current additive manufacturing (AM) feedstocks are primarily restricted to the micron scale. Utilizing large-scale wood in existing AM techniques remains a challenge. This paper proposes an AM method—laser-cut veneer lamination (LcVL)—for wood-based product fabrication. Inspired by laminated object manufacturing (LOM) and plywood technology, LcVL bonds wood veneers in a layer-upon-layer manner. As demonstrated by printed samples, LcVL was able to retain the advantageous qualities of AM, specifically, the ability to manufacture products with complex geometries which would otherwise be impossible using subtractive manufacturing techniques. Furthermore, LcVL-product structures designed through adjusting internal voids and wood-texture directionality could serve as material templates or matrices for functional wood-based materials. Numerical analyses established relations between the processing resolution of LcVL and proportional veneer thickness (layer height). LcVL could serve as a basis for the further development of large-scale wood usage in AM.

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Koptioug, Andrey, Lars Erik Rännar, Mikael Bäckström, and Marie Cronskär. "Additive Manufacturing for Medical and Biomedical Applications: Advances and Challenges." Materials Science Forum 783-786 (May 2014): 1286–91. http://dx.doi.org/10.4028/www.scientific.net/msf.783-786.1286.

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Additive Manufacturing (AM) has solidly established itself not only in rapid prototyping but also in industrial manufacturing. Its success is mainly determined by a possibility of manufacturing components with extremely complex shapes with minimal material waste. Rapid development of AM technologies includes processes using unique new materials, which in some cases is very hard or impossible to process any other way. Along with traditional industrial applications AM methods are becoming quite successful in biomedical applications, in particular in implant and special tools manufacturing. Here the capacity of AM technologies in producing components with complex geometric shapes is often brought to extreme. Certain issues today are preventing the AM methods taking its deserved place in medical and biomedical applications. Present work reports on the advances in further developing of AM technology, as well as in related post-processing, necessary to address the challenges presented by biomedical applications. Particular examples used are from Electron Beam Melting (EBM), one of the methods from the AM family.

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Olivier, Djamila, Salvador Borros, and Guillermo Reyes. "Application-driven methodology for new additive manufacturing materials development." Rapid Prototyping Journal 20, no. 1 (January 14, 2014): 50–58. http://dx.doi.org/10.1108/rpj-01-2012-0002.

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Purpose – A structured customer-driven and integrative methodology to develop materials is described. The proposed methodology is aimed to drive analysis and prioritization of the multiple variables involved in a new application case for 3D printing, which involves the development of a new alumina-starch-based powder. Design/methodology/approach – The development of new powder mixture designed for 3D printing of refractory supports for metal casting moulds is presented. The quality function deployment (QFD) method was applied. Inputs for QFD analysis were found using total quality management tools. Using this approach, six process and material variables were considered to drive a prioritization analysis using a Plackett-Burman Design of Experiment (DOE) array. As performance parameter, compressive resistance was measured and assessed. Findings – QFD analysis delivered standardized procedures, irrelevant factors and target values for intermediate step parameters. Sintering parameters were found to be the most influencing over compressive resistance. Research limitations/implications – The methodology was based upon a materials development case for 3D printing. Practical implications – Knowing in advance the influence of every affecting factor of the process provides a closer control on variability of final part properties, which is a key issue to launch parts into industrial applications. Quality planning and documentation in advanced is the basis for all the quality system of the new additive manufacturing (AM) process to be created. Originality/value – Procedures for quality planning and control were proposed. This study, as methodological research, intends to introduce industrial engineering practices and quality management routines for AM material/process developers.

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Omiyale, Babatunde Olamide, and Peter Kayode Farayibi. "Additive manufacturing in the oil and gas industries." Analecta Technica Szegedinensia 14, no. 1 (June 8, 2020): 9–18. http://dx.doi.org/10.14232/analecta.2020.1.9-18.

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Additive manufacturing (AM), also known as 3D printing, is a process for creating prototypes and functional components achieved by consolidation of material layer upon layer. Applications of AM technologies have been witnessed in the healthcare, automotive, architecture, power generation, electronics and aviation industries. Some of the main benefits of AM include effective material utilisation, new design possibilities, improved functionality of the products and flexible production. The opportunities for the applications of additive manufacturing in the oil and gas industries are only just being explored. In this study, a review of the potential opportunities of AM technologies in oil and gas industries was reported. The adoption of the AM technologies necessitated the need for a rethink on design for manufacture and assembly of oil and gas component parts such as high-tech end burners, metal fuel nozzles, and submersible pump components amongst others. The possibility of employing AM technologies on-site for the production of spare parts for replacement of damage components in oil and gas equipment and facilities is commendable, as this brings about reduction in production downtime and replacement cost. The future of AM in the oil and gas industries is highly promising, however before AM can actualize its full-fledged potentials in these industries, further research is required in the area of new materials development and processing, improved surface finish of AM fabricated parts, enhanced fabrication speed and parametric optimisation to improve the mechanical properties of the fabricated components.

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Paterson, Abby Megan, Richard Bibb, R. Ian Campbell, and Guy Bingham. "Comparing additive manufacturing technologies for customised wrist splints." Rapid Prototyping Journal 21, no. 3 (April 20, 2015): 230–43. http://dx.doi.org/10.1108/rpj-10-2013-0099.

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Purpose – The purpose of this paper is to compare four different additive manufacturing (AM) processes to assess their suitability in the context of upper extremity splinting. Design/methodology/approach – This paper describes the design characteristics and subsequent fabrication of six different wrist splints using four different AM processes: laser sintering (LS), fused deposition modelling (FDM), stereolithography (SLA) and polyjet material jetting via Objet Connex. The suitability of each process was then compared against competing designs and processes from traditional splinting. The splints were created using a digital design workflow that combined recognised clinical best practice with design for AM principles. Findings – Research concluded that, based on currently available technology, FDM was considered the least suitable AM process for upper extremity splinting. LS, SLA and material jetting show promise for future applications, but further research and development into AM processes, materials and splint design optimisation is required if the full potential is to be realised. Originality/value – Unlike previous work that has applied AM processes to replicate traditional splint designs, the splints described are based on a digital design for AM workflow, incorporating novel features and physical properties not previously possible in clinical splinting. The benefits of AM for customised splint fabrication have been summarised. A range of AM processes have also been evaluated for splinting, exposing the limitations of existing technology, demonstrating novel and advantageous design features and opportunities for future research.

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Li, Xianfa, Yongjun Shi, and Shuyao Wang. "Investigation of the phase transformation characteristics of Fe-Co elastrocalaric refrigeration alloy." Journal of Physics: Conference Series 2076, no. 1 (November 1, 2021): 012033. http://dx.doi.org/10.1088/1742-6596/2076/1/012033.

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Abstract Mechanical alloying (AM) and powder metallurgy(PM) have been widely used in many fields especially in the development of new alloy materials due to the advantages of simple process, high material utilization rate and accurate material ratio. In this investigation, experimental procedures were proposed to explore the phase transformation characteristics, elastrocalaric refrigeration effect of Fe-Co alloys synthesized by AM and PM. The samples of Fe-Co elastrocalaric refrigeration alloy with different phase transformation temperatures and different enthalpy changes have been successfully prepared by changing the initial ratio of Co element. The results show that the phase transformation characteristics have changed with the increase of Co content and showed different changing trends.

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Rusicka, Magdalena, and Grażyna Lipowczan. "Potentially pathogenic fungi in the material collected by the Specialist Regional Hospital, Łódź." Acta Mycologica 45, no. 2 (December 23, 2013): 197–205. http://dx.doi.org/10.5586/am.2010.025.

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The mycobiota responsible for the development of pathological changes of the skin and its adnexa in patients presenting at the Specialist Regional Hospital, Łódź, with suspected superficial mycosis between 01 May 2003 and 30 April 2005 is analyzed. In total of 2144 isolations 39.96% were dermatophytes, 39.39% were yeast-like fungi and 20.65% were moulds. Candida albicans was the most frequently diagnosed species in fallowed by Trichophyton rubrum.

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Oliveira, Carolina, Mariana Maia, and José Costa. "Production of an Office Stapler by Material Extrusion Process, using DfAM as Optimization Strategy." U.Porto Journal of Engineering 9, no. 1 (January 23, 2023): 28–41. http://dx.doi.org/10.24840/2183-6493_009-001_001635.

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For the last few decades, the rapid growth of Additive Manufacturing (AM) technologies has been seeable. It is expected to keep maturing continuously due to its advantages compared to conventional manufacturing technologies: flexibility, reliability, energy consumption, and material efficiency. This research article addresses the development and production of a stapler using the Material Extrusion AM process. It is intended to show the development steps to redesign an everyday stapler, into an added-value tool, from the selection and fixture of the CAD model and generative design through Fusion 360 to its optimization on nTopology, simulation, and plot of the part in Eiger.

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Yao, Xiling, Seung Ki Moon, and Guijun Bi. "Multidisciplinary design optimization to identify additive manufacturing resources in customized product development." Journal of Computational Design and Engineering 4, no. 2 (October 26, 2016): 131–42. http://dx.doi.org/10.1016/j.jcde.2016.10.001.

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Abstract Additive manufacturing (AM) techniques are ideal for producing customized products due to their high design flexibility. Despite the previous studies on specific additive manufactured customized products such as biomedical implants and prostheses, the simultaneous optimization of components, materials, AM processes, and dimensions remains a challenge. Multidisciplinary design optimization (MDO) is a research area of solving complex design problems involving multiple disciplines which usually interact with each other. The objective of this research is to formulate and solve an MDO problem in the development of additive manufactured products customized for various customers in different market segments. Three disciplines, i.e. the customer preference modeling, AM production costing, and structural mechanics are incorporated in the MDO problem. The optimal selections of components, materials, AM processes, and dimensional parameters are searched with the objectives to maximize the functionality utility, match individual customers' personal performance requirements, and minimize the total cost. A multi-objective genetic algorithm with the proposed chromosome encoding pattern is applied to solve the MDO problem. A case study of designing customized trans-tibial prostheses with additive manufactured components is presented to illustrate the proposed MDO method. Clusters of multi-dimensional Pareto-optimal design solutions are obtained from the MDO, showing trade-offs among the objectives. Appropriate design decision can be chosen from the clusters based on the manufacturer's market strategy. Highlights An optimization problem for additive manufactured customized products is solved. Three disciplines are incorporated in multidisciplinary design optimization (MDO). The selection of component, material, additive manufacturing process and dimensions are optimized. A multiobjective genetic algorithm is applied to solve the MDO problem. Pareto-optimal solutions with different utilities and costs are obtained.

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Li, Hui, Xiaolong Fu, Liping Zhang, Yixiong Zhang, Lu Jiang, and Zhuo Pu. "A Review of the Latest Developments in the Field of Additive Manufacturing Techniques for Nuclear Reactors." Crystals 12, no. 7 (June 28, 2022): 918. http://dx.doi.org/10.3390/cryst12070918.

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This review paper provides insights the into current developments in additive manufacturing (AM) techniques. The comprehensive presentations about AM methods, material properties (i.e., irradiation damage, as-built defects, residual stresses and fatigue fracture), experiments, numerical simulations and standards are discussed as well as their advantages and shortages for the application in the field of nuclear reactor. Meanwhile, some recommendations that need to be focused on are presented to advance the development and application of AM techniques in nuclear reactors. The knowledge included in this paper can serve as a baseline to tailor the limitations, utilize the superiorities and promote the wide feasibilities of the AM techniques for wide application in the field of nuclear reactors.

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Keresztes, Zoltan, David Pammer, and Peter Janos Szabo. "EBSD Examination of Argon Ion Bombarded Ti-6Al-4V Samples Produced with DMLS Technology." Periodica Polytechnica Mechanical Engineering 63, no. 3 (May 31, 2019): 195–200. http://dx.doi.org/10.3311/ppme.13821.

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Additive manufacturing (AM) indicated great technological increase in the last years. Primarily development of new methods, new computer softwares and more useable materials are responsible for this progression. AM has numerous advantages that cause the appearance of it in almost every field of industry. However this widely spread technology has many under examined properties, especially those, that uses metal as raw material. One of these less understood properties is the behavior of grains during the melting phase and the microstructure after production. The main aim of this study is to examine the microstructure of ion bombarded – using argon - AM produced Ti-6Al-4V samples applying EBDS investigation, measuring the grain size, and the orientation of the grains.

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Shah, Raj, Nikhil Pai, Andreas Rosenkranz, Khosro Shirvani, and Max Marian. "Tribological Behavior of Additively Manufactured Metal Components." Journal of Manufacturing and Materials Processing 6, no. 6 (November 11, 2022): 138. http://dx.doi.org/10.3390/jmmp6060138.

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Additive manufacturing (AM) has recently become an increasingly popular form of production due to its advantages over traditional manufacturing methods, such as accessibility, the potential to produce parts with complex geometry, and reduced waste. For the widespread industry adoption of AM components, metal AM has the most potential. The most popular methods of metal AM are powder-based manufacturing techniques. Due to the layer-by-layer nature of AM, the mechanical and tribological properties of an additive manufactured part differs from those of traditionally manufactured components. For the technology to develop and grow further, the tribological properties of AM components must be fully explored and characterized. The choice of material, surface textures, and post-processing methods are shown to have significant impact on friction and wear. Therefore, this paper focuses on reviewing the existing literature with an emphasis on the development of advanced materials for AM applications as well as the optimization of the resulting surface quality via post-processing and presents areas of interest for further examination in this prospective technology.

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Torres, Jonathan, and Ali P. Gordon. "Mechanics of the small punch test: a review and qualification of additive manufacturing materials." Journal of Materials Science 56, no. 18 (March 17, 2021): 10707–44. http://dx.doi.org/10.1007/s10853-021-05929-8.

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AbstractThe small punch test (SPT) was developed for situations where source material is scarce, costly or otherwise difficult to acquire, and has been used for assessing components with variable, location-dependent material properties. Although lacking standardization, the SPT has been employed to assess material properties and verified using traditional testing. Several methods exist for equating SPT results with traditional stress–strain data. There are, however, areas of weakness, such as fracture and fatigue approaches. This document outlines the history and methodologies of SPT, reviewing the body of contemporary literature and presenting relevant findings and formulations for correlating SPT results with conventional tests. Analysis of literature is extended to evaluating the suitability of the SPT for use with additively manufactured (AM) materials. The suitability of this approach is shown through a parametric study using an approximation of the SPT via FEA, varying material properties as would be seen with varying AM process parameters. Equations describing the relationship between SPT results and conventional testing data are presented. Correlation constants dictating these relationships are determined using an accumulation of data from the literature reviewed here, along with novel experimental data. This includes AM materials to assess the fit of these and provide context for a wider view of the methodology and its interest to materials science and additive manufacturing. A case is made for the continued development of the small punch test, identifying strengths and knowledge gaps, showing need for standardization of this simple yet highly versatile method for expediting studies of material properties and optimization.

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Journal articles on the topic 'AM material development'

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