Additive Manufacturing Frontiers最新文献

{"title":"Digital light processing of hierarchically porous cerium oxide ceramics for CO2 splitting and fuel production","authors":"Qin Lian, Shuhao Qi, Yanlong Chen, Chenyun Qi, Yuqi Zhan, Xueming Feng, Annan Chen, Yangtao Wang, Bin Wu, Yinjie Ma, Changning Sun, Dichen Li, Jian R. Lu","doi":"10.1016/j.amf.2026.200299","DOIUrl":"https://doi.org/10.1016/j.amf.2026.200299","url":null,"abstract":"Solar thermochemical fuel production (STFP) utilizes a two-step oxidation–reduction cycle reaction to convert solar energy into storable and transportable carbon monoxide/hydrogen fuel, and it has attracted considerable attention. Hierarchical porous cerium oxide (CeO 2 ) materials have excellent redox properties, high-temperature thermal stability, and a large specific surface area. Thus, they are crucial components of the STFP process. However, current manufacturing methods have issues such as high process costs and difficulty in controlling pores. This study uses the digital light processing (DLP) printing method to develop a soluble starch–CeO 2 composite slurry, in which micropores are generated during the subsequent pyrolysis and sintering processes. Hierarchically porous CeO 2 ceramics are obtained with controllable millimeter-scale and micrometer-scale pores. The oxidation–reduction cycle test conducted at 1400–900°C shows that the structure has good redox ability and high temperature stability, with a cyclic CO production of 100.76 μmol/g (2.257 ml/g) and a strength above 124.21±9.49 MPa. The samples function well without collapsing over 50 redox cycles. This performance is better than that of the ceramics manufactured using conventional methods. This study develops an innovative method of utilizing DLP technology to manufacture hierarchical porous CeO 2 ceramics as redox carriers, thus providing new avenues for using the DLP process to produce solar thermal chemical fuels.","PeriodicalId":516778,"journal":{"name":"Additive Manufacturing Frontiers","volume":"1 1","pages":"200299-200299"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147917738","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Additive manufacturing of triply periodic minimal surface (TPMS) structured dual-coated diamond/copper composites for high performance","authors":"Zhenyu Jiang, Guojun Sheng, Fang Li, Yan Li, Zhikun Xu, Ju’e Guo, Zedong Yin, Jie Yin, Qinglei Sun","doi":"10.1016/j.amf.2025.200272","DOIUrl":"https://doi.org/10.1016/j.amf.2025.200272","url":null,"abstract":"Additive manufactured Diamond/copper (Dia/Cu) composites are very promising candidates for advanced thermal management because of high thermal conductivity and mechanical strength. However, significant interfacial incompatibility (e.g., poor attainability, thermal expansion mismatch, and weak bonding) between diamond and Cu hinders its further high-performance application This research proposes a dual-layer surface modification strategy via integrating salt-bath titanium coating and electroless Cu plating to improve interfacial adhesion and processability of diamond particles. The continuous Ti–Cu bi-layer enhances the wettability and chemical compatibility of Dia/Cu interface for further selective laser melting (SLM) of Dia/Cu composites. The optimized SLM parameters (180 W laser power, 350 mm/s scan speed, and 0.04 mm hatch spacing) enabled the dual-layer Ti–Cu coated composites to achieve a high relative density of 95.4%. The resulting continuous Ti–Cu bi-layer coating markedly improves the chemical compatibility and wettability at the Dia/Cu interface, enabling the successful fabrication of Dia/Cu composites and complex Triply Periodic Minimal Surface (TPMS) structures via selective laser melting (SLM). additive manufacture (AM) fabricated Dia/Cu composites improved its thermal conductivity by 21.6% (from 236 to 287 W/m·K), flexural strength by 3.6% (from 270.46 to 280.18 MPa), and Vickers hardness by 11.4% (from 86.76 to 96.68 HV) compared to uncoated reference specimens. These properties enhancements are primarily attributed to the formation of a chemically bonded and thermally compatible interfacial layer, which facilitates uniform diamond dispersion and efficient energy absorption during the SLM process. This work demonstrates that integrating rational surface engineering with precision AM enables the effective fabrication of high-performance Dia/Cu composites, particularly TPMS-based architectures, offering significant potential for thermal management and structural applications requiring enhanced thermal conductivity and mechanical robustness. Flowchart of salt-bath Ti coating and electroless Cu plating","PeriodicalId":516778,"journal":{"name":"Additive Manufacturing Frontiers","volume":"5 1","pages":"200272-200272"},"PeriodicalIF":0.0,"publicationDate":"2025-11-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147884970","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microstructure and mechanical properties of digital light processing printed AISI 316L stainless steel: Optimization of slurry and sintering process","authors":"Jincheng Wang, Jie Guo, Zhibo Liu, Xinjian Cao, Da Bian, Jun Cheng, Shanhua Qian, Jun Yang","doi":"10.1016/j.amf.2025.200245","DOIUrl":"https://doi.org/10.1016/j.amf.2025.200245","url":null,"abstract":"• A DLP-printable 316 L slurry is developed with balanced curing depth, rheology and low residue. • Ar/H 2 sintering improves the strength-ductility by reducing C and O impurities. • The formation of δ-ferrite obviously improves the density and strength-ductility. • Optimization of slurry and sintering process produces 316 L with enhanced mechanical properties. Digital light processing (DLP) is widely used in ceramic additive manufacturing. However, it remains unexplored for metals. In this study, the regulatory mechanisms of the microstructure and mechanical properties of AISI 316L stainless steel were investigated by optimizing a DLP-compatible metal slurry formulation and sintering process. A photosensitive resin system (mass ratio of 5:1:2:2 for U600, LA, ACMO, and HDDA, respectively) with 88 wt% solid content is designed to achieve a slurry with balanced rheology, photocurability, and low pyrolysis residue. Compared to vacuum sintering, which leads to brittle fracture of material, the Ar/H 2 mixed gas (5 % H 2 ) effectively reduces carbon and oxygen impurities via reduction, mitigating carbide and oxide segregation at grain boundaries and within grains, thereby enhancing strength-ductility. In addition, the prolonged high-temperature sintering induces δ-ferrite precipitation at grain boundaries, which fills residual pores to improve densification obviously. Under optimized sintering conditions (Ar/H 2 , 1380 °C, 6 h), the material achieves 96.2 % relative density with tensile strength and fracture elongation of 543.5 MPa and 58.7 %, respectively, exhibiting uniform dimple-dominated fracture morphology. This synergistic optimization of the slurry formulation and sintering parameters improves the strength-ductility balance in DLP-fabricated metal materials, offering theoretical and technical insights for the additive manufacturing of complex high-performance metal components.","PeriodicalId":516778,"journal":{"name":"Additive Manufacturing Frontiers","volume":"4 4","pages":"200245-200245"},"PeriodicalIF":0.0,"publicationDate":"2025-09-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147332727","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Anti-Gravity Electrospray Printing toward In-Space Thin-Film Fabrication: Simulation, Validation, and Device Application","authors":"Yuechen Pei, Li Wang, Yulin Zheng, Lintao Zhang, Zhaofa Zhang, Tianxue Yin, Jiaye Chen, Juntao Zhang, Yi-Qing Guo, Bingheng Lu","doi":"10.1016/j.amf.2025.200241","DOIUrl":"https://doi.org/10.1016/j.amf.2025.200241","url":null,"abstract":"To explore the feasibility of electrospray-based additive manufacturing for thin-film fabrication in zero- or microgravity environments, we conducted numerical simulations of charged droplet behavior under zero-gravity conditions, followed by ground-based experimental validation using an anti-gravity electrospray (AG-ES) strategy. First, simulations of charged droplet deposition during the electrospray process showed that the presence or absence of gravity did not significantly affect deposition behavior. Second, simulations of droplet-substrate collisions indicated that the presence of an electric field could reduce the risk of droplet splashing. Third, simulations of droplet coalescence under zero-gravity conditions demonstrated that an electric field could promote the coalescence of charged droplets. An AG-ES experimental platform featuring an inverted nozzle–substrate configuration was constructed on the ground. Comparative experiments using Rhodamine B and TiO₂ nanoparticle dispersions were performed in both AG-ES and conventional electrospray (ES) modes. The results indicated that the spray cone angle, deposition area, and film morphology were comparable between the two modes. Finally, multilayer alternating-current electroluminescent (ACEL) devices were fabricated via AG-ES using ZnS:Cu/poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP), BaTiO 3 /polyvinylpyrrolidone (PVP), and silver nanowire (AgNW) inks, achieving a maximum luminance of 66.2 cd/m². This study demonstrates the potential of the electrospray process for functional thin-film fabrication under microgravity conditions.","PeriodicalId":516778,"journal":{"name":"Additive Manufacturing Frontiers","volume":"4 3","pages":"200241-200241"},"PeriodicalIF":0.0,"publicationDate":"2025-08-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147332353","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Additive Manufacturing of Lunar Regolith via Resin-Based Binder and Material Extrusion Method for High-Performance In-Situ Manufacturing on the Moon","authors":"Tongcai Wang, Guangshuai Gu, Rihan Zhang, Qianshun Cui, Gong Wang","doi":"10.1016/j.amf.2025.200233","DOIUrl":"https://doi.org/10.1016/j.amf.2025.200233","url":null,"abstract":"The utilization of lunar regolith for construction on the lunar surface presents a critical challenge in in-situ resource utilization. This study proposes a lunar regolith manufacturing method that uses a high-performance resin binder characterized by a high regolith content and strong forming capabilities. A combined resin material with both thermosetting and photosetting properties was developed and mixed with lunar regolith to create a slurry. This slurry can be directly molded or additively extruded into green bodies with specific structures. These green bodies can self-cure under the high temperatures and ultraviolet radiation experienced during the lunar day, reducing energy consumption and fulfilling the requirements of lunar construction. The material-forming processes and effects of various additive types and concentrations, regolith mass ratios, and processing parameters on the properties of the slurry and the formed specimens were thoroughly investigated. The mechanical performance and microstructure of the fabricated samples were analyzed. The lunar regolith mass ratio reached 90 wt% (approximately 79 vol%), with the highest compressive strengths exceeding 60 MPa for cast specimens and 30 MPa for printed samples. This technology shows significant potential for enabling in-situ lunar regolith-based construction in future lunar missions.","PeriodicalId":516778,"journal":{"name":"Additive Manufacturing Frontiers","volume":"4 3","pages":"200233-200233"},"PeriodicalIF":0.0,"publicationDate":"2025-07-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147894006","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"3D Printing on Droplets by Ultrasonic Levitation","authors":"QinQin, Zhicheng Cheng, Cheng Wen, Jigang Huang","doi":"10.1016/j.amf.2025.200206","DOIUrl":"https://doi.org/10.1016/j.amf.2025.200206","url":null,"abstract":"Vat photopolymerization 3D printing creates structures by projecting patterns onto a photosensitive resin within a vat. However, the presence of resin vats limits the printing of multiscale multimaterial structures. In this context, a novel 3D printing process is presented in which a cured structure is produced from acoustically levitated droplets without a physical vat. This enables the printing process to achieve high flexibility in the printing orientation and material supply. In pursuit of the envisioned 3D acoustic levitation printing strategy, acoustic levitation technology was utilized to suspend a photosensitive resin. Objects with small features were successfully produced by projecting patterns onto levitated resin droplets. Transforming printing orientations allows the fabrication of multiscale structures. Levitating resin droplets on-demand enables the rapid replacement of materials, thereby realizing effortless multimaterial 3D printing. By exploiting the flexibility of printing on levitation resin droplets, the capability of 3D printing on existing objects was established. Finally, an interesting example was illustrated, in which an object integrating liquid, gas, and solid materials was fabricated using the proposed 3D printing strategy. The results show that 3D printing on levitated droplets is feasible for fabricating multiscale and multimaterial objects, which contributes to the development of new 3D printing methods and potential applications.","PeriodicalId":516778,"journal":{"name":"Additive Manufacturing Frontiers","volume":"4 2","pages":"200206-200206"},"PeriodicalIF":0.0,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147896806","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"3D Modelling of Layer-by-Layer Heat and Mass Transfer in Wire Arc Additive Manufacturing","authors":"Yan Li, Ze Yun, Wutong Zhang, Xun Long, Jianjun Zhu","doi":"10.1016/j.amf.2024.200159","DOIUrl":"https://doi.org/10.1016/j.amf.2024.200159","url":null,"abstract":"","PeriodicalId":516778,"journal":{"name":"Additive Manufacturing Frontiers","volume":"24 8","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141702239","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Frontiers in Laser Additive Manufacturing Technology","authors":"Yongqiang Yang, Renwu Jiang, Changjun Han, Jiaqi Chen, Haoran Li, Yan Wang, Jinrong Tang, Heng Zhou, Weinan Hu, Boyuan Zheng, Z. Liu, Changhui Song, Di Wang","doi":"10.1016/j.amf.2024.200160","DOIUrl":"https://doi.org/10.1016/j.amf.2024.200160","url":null,"abstract":"","PeriodicalId":516778,"journal":{"name":"Additive Manufacturing Frontiers","volume":"392 2","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141852549","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"3D Printing for Explosive and Propellant Applications","authors":"Bojun Tan, Jinkang Dou, Yujia Wen, B. Duan, H. Mo, Zongliang Wei, Jing Zhang, Yongfei Pan, Xiaoyong Ding, Ning Liu","doi":"10.1016/j.amf.2024.200151","DOIUrl":"https://doi.org/10.1016/j.amf.2024.200151","url":null,"abstract":"","PeriodicalId":516778,"journal":{"name":"Additive Manufacturing Frontiers","volume":"9 24","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141698248","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Development of Ceramic 3D/4D Printing in China","authors":"Xinya Lu, Guo Liu, Jian Lu","doi":"10.1016/j.amf.2024.200158","DOIUrl":"https://doi.org/10.1016/j.amf.2024.200158","url":null,"abstract":"","PeriodicalId":516778,"journal":{"name":"Additive Manufacturing Frontiers","volume":"24 43","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141699582","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}