3D Printing and Additive Manufacturing最新文献

{"title":"New Perspective of Additive Manufacturing: From Materials to Processes and Algorithms of Continuous Carbon Fiber-Reinforced Composites.","authors":"Dianming Chu, Lingxiao Lu, Yan He, Wenjuan Bai","doi":"10.1089/3dp.2022.0385","DOIUrl":"10.1089/3dp.2022.0385","url":null,"abstract":"<p><p>High-strength and lightweight products have always been the dream of human beings, especially today when energy resources are increasingly depleted. Although additive manufacturing provides us with possibilities, for now, most researchers focus on reinforcing existing printing materials, improving printing processes, and updating algorithms to improve product performance. However, in the statistical classification of this work, these are only a small range of one kind of statistics. This work reviews the key factors of additive manufacturing from materials to processes and algorithms from a new perspective, to get rid of the inherent thinking mode and provide unique ideas. With the idea of \"everything is printed,\" this article emulates nature's \"make the most of everything.\" First, anisotropic materials and the solution of the weak interfacial properties are described. Second, the energy point of view through the process, in space (points, lines, planes, etc.), to summarize the classification and time division of series and parallel printing. Finally, the classification of current hierarchical printing algorithms and the expectation of future spatial printing algorithms are indicated. This article takes the key factors of continuous carbon fiber composite 3D printing as the main line, and provides certain reference for the future development of additive manufacturing from a new perspective.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11443120/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48944678","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A Review on Residual Stress in Metal Additive Manufacturing.","authors":"Tanusree Bera, Smita Mohanty","doi":"10.1089/3dp.2023.0095","DOIUrl":"10.1089/3dp.2023.0095","url":null,"abstract":"<p><p>A new method for producing parts in the expanding sector is additive manufacturing. The appropriate name for three-dimensional (3D) printing is additive manufacturing because it produces the part layer by layer. Plastics and metals can be 3D printed in large quantities with the precise surface finish and feature quality needed in additive manufacturing. More specifically, direct metal sintering, direct energy deposition, and metal binder jetting are used in 3D printing. The computer-aided design model is completed when the powder bed has been successively scanned and lowered. The metal sintering process uses a powder bed with powder metal, and laser selectively melts a flattened bed of powder, which is done with roller with successive rolling of new layer on previous into desired shape before a new layer is pushed on top of the previous layer. As a result, the new layer has solidified on top of the earlier layer, causing the prior layer to melt back again. Because of the unique thermal cycle, this results in residual stress (RS). The unique thermal cycle of metal additive manufacturing is characterized by (1) rapid heating rate caused by high energy intensity and steep temperature gradients; (2) rapid solidification with high cooling rates because of the small volume of melt pool; and (3) melt back, which involves simultaneous melting of the top powder layer and re-melting of underlying previously solidified layers. The presence of RS in metal additive manufacturing (AM) creates difficulties that restrict the process's ability to produce parts at an industrial scale. During and after manufacturing, these forces may cause parts to distort and crack. This can be solved by heating the powder bed, which will lessen this type of issue. The causes, traits, and reduction of RS are the main topics of this review article. A number of conceptual approaches to reducing RS are addressed to provide some useful inspiration for creating a methodical RS balancing procedure for AM. These approaches are based on the state and future of the relevant techniques.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11443104/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42840873","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Physics-Informed Machine Learning for Accurate Prediction of Temperature and Melt Pool Dimension in Metal Additive Manufacturing.","authors":"Feilong Jiang, Min Xia, Yaowu Hu","doi":"10.1089/3dp.2022.0363","DOIUrl":"10.1089/3dp.2022.0363","url":null,"abstract":"<p><p>The temperature distribution and melt pool size have a great influence on the microstructure and mechanical behavior of metal additive manufacturing process. The numerical method can give relatively accurate results but is time-consuming and, therefore, unsuitable for in-process prediction. Owing to its remarkable capabilities, machine learning methods have been applied to predict melt pool size and temperature distribution. However, the success of traditional data-driven machine learning methods is highly dependent on the amount and quality of the training data, which is not always convenient to access. This article proposes a physics-informed machine learning (PIML) method, which integrates data and physics laws in the training parts, overcoming the problems of low speed and data availability. An artificial neural network constrained by the heat transfer equation and a small amount of labeled data is developed to predict the melt pool size and temperature distribution. Besides, the locally adaptive activation function is utilized to improve the prediction performance. The result shows that the developed PIML model can accurately predict the temperature and melt pool dimension under different scanning speeds with a small amount of labeled data, which shows significant potential in practical application.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11443106/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"43213013","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Coupled Computational Fluid Dynamics-Discrete Element Method Model for Investigation of Powder Effects in Nonconventional Laser Powder Bed Fusion Process.","authors":"Trong-Nhan Le, Yu-Lung Lo, Wei Hung","doi":"10.1089/3dp.2023.0014","DOIUrl":"10.1089/3dp.2023.0014","url":null,"abstract":"<p><p>The present study proposes a comprehensive 3D computational fluid dynamics-discrete element method (CFD-DEM) coupled simulation model to investigate the particle dynamics induced by SS316L metal vapor spouting during single-scan-track laser powder bed fusion (L-PBF) processing. The model provides the ability to examine the effects of nonconventional process variables such as the chamber pressure and gravitational force on the suppression of the spatter and denudation phenomena. The simulation results imply that adjusting the gravitational force provides an effective technique for suppressing both spatter formation and powder bed denudation. In addition, the chamber pressure has only a marginal effect on the denudation phenomenon. In particular, under a higher operating pressure, the metal vapor tends to spout in the upward direction, while under a lower pressure, the spouting is more radially distributed. As a result, the simulation results obtained in this study have suggested that the chamber pressure and gravitational force may both provide feasible approaches for suppressing the spattering and denudation phenomena, particularly in the L-PBF processing of light-weight materials.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11443107/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41687327","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Review on Engineering of Bone Scaffolds Using Conventional and Additive Manufacturing Technologies.","authors":"Abdullah Mohammed, Amaia Jiménez, Prveen Bidare, Amr Elshaer, Adnan Memic, Hany Hassanin, Khamis Essa","doi":"10.1089/3dp.2022.0360","DOIUrl":"10.1089/3dp.2022.0360","url":null,"abstract":"<p><p>Bone is a complex connective tissue that serves as mechanical and structural support for the human body. Bones' fractures are common, and the healing process is physiologically complex and involves both mechanical and biological aspects. Tissue engineering of bone scaffolds holds great promise for the future treatment of bone injuries. However, conventional technologies to prepare bone scaffolds cannot provide the required properties of human bones. Over the past decade, three-dimensional (3D) printing or additive manufacturing technologies have enabled control over the creation of bone scaffolds with personalized geometries, appropriate materials, and tailored pores. This article aims to review recent advances in the fabrication of bone scaffolds for bone repair and regeneration. A detailed review of bone fracture repair and an in-depth discussion on conventional manufacturing and 3D printing techniques are introduced with an emphasis on novel studies concepts, potentials, and limitations.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11443118/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44571566","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Evaluation of the Influence of Technological Parameters of Selected 3D Printing Technologies on Tribological Properties.","authors":"Tomasz Kozior, Muammel M Hanon, Paweł Zmarzły, Damian Gogolewski, Mateusz Rudnik, Wiktor Szot","doi":"10.1089/3dp.2023.0080","DOIUrl":"10.1089/3dp.2023.0080","url":null,"abstract":"<p><p>The article presents the results of tribological research of sample models manufactured using three separate 3D printing technologies: selective laser sintering-SLS, photo-curing of liquid polymer resins-PolyJet Matrix (PJM) and fused deposition modeling-FDM. The impact of process parameters (printing direction, layer thickness, and energy density for SLS) on tribological properties was assessed through linear wear and coefficient of friction. The research was carried out to assess the possibility of using 3D printing for the quick manufacturing of casting models, which has a significant impact on shortening the time of implementation for mass production of the casting process. The research results proved the possibility of controlling the technological process in a manner allowing to produce models with controlled properties, including tribological parameters. In addition, the results for three additive technologies and different materials were compared by using the same friction parameters.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11443113/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47088407","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Design Aspects in Vat Photopolymerization Additive Manufacturing of Hydrophobic Surfaces.","authors":"Anna Danielak, Aminul Islam, Nicolò Cappelletto, Diana Maria Garza Agudelo, David Bue Pedersen","doi":"10.1089/3dp.2023.0076","DOIUrl":"10.1089/3dp.2023.0076","url":null,"abstract":"<p><p>Hydrophobic surfaces require finely tuned process chains due to the scale, complexity, and patterning methods. For this purpose, vat photopolymerization (VPP) additive manufacturing is a promising method for surface generation; however, together with the fabrication process, the design phase needs to be optimized to achieve the desired surface property. This work presents the influence of the design features of hydrophobic surfaces through multiple studies on simple pillar structures, intrinsic single-unit geometries, and surface deposition on complex substrates. The results showed that depending on the dimensions of single pillar dimensions, wetting properties can extend between the contact angles (CA) of 83°-115.11°. The hydrophobicity was further increased by applying a re-entrant structure, reaching the CA of 115.24°. The surface deposition on the complex substrates significantly increased water droplet adhesion, preventing it from rolling off, which can be beneficial for manifold device protection from the hazardous influence of the environment. In addition, the influence of the surface on the acoustic properties was examined, which showed that the pattern application in the real-life device does not have a detrimental effect on the intrinsic functionality. This study showed that the design phase should be an essential part of the VPP process chain as it significantly influences the wetting properties of the surfaces.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11443108/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48385312","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Defects in Metal Additive Manufacturing: Formation, Process Parameters, Postprocessing, Challenges, Economic Aspects, and Future Research Directions.","authors":"R Haribaskar, T Sampath Kumar","doi":"10.1089/3dp.2022.0344","DOIUrl":"10.1089/3dp.2022.0344","url":null,"abstract":"<p><p>Metal additive manufacturing (AM) is a revolutionary technological advancement that has made significant inroads in a wide range of sectors, including aerospace, defense, automotive, health care, and engineering applications. It offers unprecedented design freedom, reduced material waste, and enhanced performance, in addition to significant enhancements to fabrication processes. Microstructural defects and internal stresses formed during fabrication directly affect the fabricated product's surface integrity, quality, and service life. Identification, characterization, and prediction of these defects help significant and direct production of defect-free structures with high density. This article provides detailed insights concerning the common defects, mitigation techniques, and challenges reported in both powder bed fusion-based and wire arc AM methods. Defects such as porosity may develop due to the powder sphericity, roughness of the powder, preheating, process parameters, build environment, postprocessing techniques, and environmental factors. Therefore, a critical study of the techniques, alloys, process parameter optimization, and different postprocessing techniques to tone down the defects is made from their formations.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11443127/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48889541","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Characterization of Chemically Treated Flexible Body-Centered Cubic Lattice Structures Fabricated by Fused Filament Fabrication Process.","authors":"Nidhi Dixit, Prashant K Jain","doi":"10.1089/3dp.2023.0049","DOIUrl":"10.1089/3dp.2023.0049","url":null,"abstract":"<p><p>Fused filament fabrication (FFF) has opened new opportunities for the effortless fabrication of complex structures at low cost. The additively manufactured lattice structures have been widely used in different sectors. However, the parts fabricated through FFF suffered from poor surface and dimensional characteristics. These disadvantages have been overcome by using different post-processing techniques. The present investigation has been focused on the post-processing of flexible lattice structures through chemical treatment methods. The flexible lattice structures have been fabricated by using thermoplastic polyurethane material. Body-centered cubic lattice structures have been chosen for the present study. The fabricated lattice structures have been post-processed using dimethyl sulfoxide solvent through the chemical immersion method. The response characteristics chosen for the present study were surface roughness, compressive strength, and dimensional accuracy. The measurement has been taken before and after the chemical treatment method for comparison purpose. The results of experimental studies depicted that the proposed methodology significantly enhanced the surface quality and dimensional accuracy, whereas compressive strength has been observed to be slightly reduced after the post-processing method.</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11443119/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41664610","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Cost of Using Laser Powder Bed Fusion to Fabricate a Molten Salt-to-Supercritial Carbon Dioxide Heat Exchanger for Concentrating Solar Power.","authors":"Tracey Ziev, Erfan Rasouli, Ines-Noelly Tano, Ziheng Wu, Srujana Rao Yarasi, Nicholas Lamprinakos, Junwon Seo, Vinod Narayanan, Anthony D Rollett, Parth Vaishnav","doi":"10.1089/3dp.2022.0188","DOIUrl":"10.1089/3dp.2022.0188","url":null,"abstract":"<p><p>Advances in manufacturing technologies and materials are crucial to the commercial deployment of energy technologies. We present the case of concentrating solar power (CSP) with molten salt (MS) thermal storage, where low-cost, high-efficiency heat exchangers (HXs) are needed to achieve cost competitiveness. The materials required to tolerate the extreme operating conditions in CSP systems make it difficult or infeasible to produce them using conventional manufacturing processes. Although it is technically possible to produce HXs with adequate performance using additive manufacturing, specifically laser powder bed fusion (LPBF), here we assess whether doing so is cost-effective. We describe a process-based cost model (PBCM) to estimate the cost of fabricating a MS-to-supercritical carbon dioxide HX using LPBF. The PBCM is designed to identify modifications to designs, process choices, and manufacturing innovations that have the greatest effect on manufacturing cost. Our PBCM identified HX design and LPBF process modifications that reduced projected HX cost from $750 per kilo-Watt thermal (kW-th) ($8/cm³) to $350/kW-th ($6/cm³) using currently available LPBF technology, and down to $220/kW-th ($4/cm³) with improvements in LPBF technology that are likely to be achieved in the near term. The PBCM also informed a redesign of the HX design that reduced projected costs to $140-160/kW-th ($3/cm³).</p>","PeriodicalId":54341,"journal":{"name":"3D Printing and Additive Manufacturing","volume":null,"pages":null},"PeriodicalIF":2.3,"publicationDate":"2024-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11442155/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42385031","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}