Additive manufacturing最新文献_第2页

X-ray computed tomography investigation on the geopolymer matrix formation during the binder jetting additive manufacturing process 粘结剂喷射增材制造过程中地聚合物基质形成的x射线计算机断层扫描研究

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-06-14 DOI: 10.1016/j.addma.2025.104852

J. Adrien , H. Elsayed , F. Gobbin , A. Italiano , E. Maire , P. Colombo

{"title":"X-ray computed tomography investigation on the geopolymer matrix formation during the binder jetting additive manufacturing process","authors":"J. Adrien , H. Elsayed , F. Gobbin , A. Italiano , E. Maire , P. Colombo","doi":"10.1016/j.addma.2025.104852","DOIUrl":"10.1016/j.addma.2025.104852","url":null,"abstract":"<div><div>This study investigates the geopolymerization mechanism in a binder jetting additive manufacturing system, where a highly alkaline solution is deposited onto a powder bed comprising sand and metakaolin. Two individual alkaline solutions, sodium- and potassium-based, were systematically compared, along with tap water, to interpret processes governing the formation of the geopolymer gel and the subsequent hardening of printed components. Nondestructive volume analysis via X-ray computed tomography was employed to characterize the multiscale structure of the powder bed, while real-time monitoring of alkaline solution–powder bed interactions provided insights into the reaction kinetics as well as material consolidation, from droplet impact to formation of the geopolymer matrix. The results demonstrate successful activation of metakaolin without mechanical mixing, achieved using a large-scale 3D printer with a voxel resolution of 3.0 × 3.0 × 3.0 mm³ , facilitating the production of large-volume geopolymer components, with an appropriate compressive strength of ∼20 MPa, suitable for structural applications. Moreover, Nuclear Magnetic Resonance (NMR) spectroscopy proved the change in the coordination states of aluminium ions, shifting from mixed four-, five-, and six-coordination in metakaolin to predominantly tetrahedral coordination in the final geopolymer. These findings provide critical insights into the microstructural evolution and reaction mechanisms in binder jetting-based geopolymerization.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104852"},"PeriodicalIF":10.3,"publicationDate":"2025-06-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144322773","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Numerical and experimental investigation of laser-assisted fused filament fabrication of carbon fibre reinforced polyether-ether-ketone composites: Temperature field evolution and crystallisation behaviours 激光辅助熔丝制备碳纤维增强聚醚-醚-酮复合材料的数值与实验研究：温度场演化与结晶行为

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-06-14 DOI: 10.1016/j.addma.2025.104853

Wenhan Qiu , Yingdan Zhu , Pengcheng Shi , Xiaocheng Yu , Kok hoong Wong , Dongxi Lv , Gang Chen , Jian Yang

{"title":"Numerical and experimental investigation of laser-assisted fused filament fabrication of carbon fibre reinforced polyether-ether-ketone composites: Temperature field evolution and crystallisation behaviours","authors":"Wenhan Qiu , Yingdan Zhu , Pengcheng Shi , Xiaocheng Yu , Kok hoong Wong , Dongxi Lv , Gang Chen , Jian Yang","doi":"10.1016/j.addma.2025.104853","DOIUrl":"10.1016/j.addma.2025.104853","url":null,"abstract":"<div><div>This study presents a parameterised finite element modelling approach to predict the temperature field evolution and crystallisation behaviour of short carbon fibre reinforced polyether-ether-ketone (SCF/PEEK) during laser-assisted fused filament fabrication (LAFFF). The model innovatively integrates dynamic laser-nozzle heat sources with the melting-crystallisation kinetics of materials, which effectively addresses the longstanding issues of thermal imbalance and non-uniform crystal distribution in composites additive manufacturing. Validated through thermocouple measurements, infrared monitoring, and differential scanning calorimetry, the framework achieves predictive accuracy within ± 5 % for average relative crystallinity and ± 20 % for crystal variance. This research uncovers the crucial role of laser induced through-thickness heat transfer, a characteristic that has not been previously evident in conventional FFF. The results show that optimised auxiliary heating parameters, with ambient temperatures ranging from 75–110 °C and laser power between 2–3 W, create a process window that balances crystallinity enhancement with defect mitigation. Laser preheating generates transient temperature cycles, prolonging the exposure of the material near the crystallisation peak temperature of 235 °C. Meanwhile, elevated ambient temperatures decrease thermal gradients, together expanding the crystallisation window. This synergistic effect boosts the average relative crystallinity by 60 %–82 % compared to conventional rapid - cooling FFF, reaching values similar to those of industrial - grade 3D printing systems. These insights pave the way for the optimisation of thermal conditions in LAFFF, reducing dependence on high-temperature equipment and expanding the applicability of SCF/PEEK 3D printing technology.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104853"},"PeriodicalIF":10.3,"publicationDate":"2025-06-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330504","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Exploring the impact of volumetric additive manufacturing of photo-crosslinkable gelatin on mesenchymal stromal cell behavior and differentiation 探讨光交联明胶体积增材制造对间充质间质细胞行为和分化的影响

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-06-13 DOI: 10.1016/j.addma.2025.104850

Nele Pien , Bryan Bogaert , Marguerite Meeremans , Cezar-Stefan Popovici , Peter Dubruel , Catharina De Schauwer , Sandra Van Vlierberghe

{"title":"Exploring the impact of volumetric additive manufacturing of photo-crosslinkable gelatin on mesenchymal stromal cell behavior and differentiation","authors":"Nele Pien , Bryan Bogaert , Marguerite Meeremans , Cezar-Stefan Popovici , Peter Dubruel , Catharina De Schauwer , Sandra Van Vlierberghe","doi":"10.1016/j.addma.2025.104850","DOIUrl":"10.1016/j.addma.2025.104850","url":null,"abstract":"<div><div>This study investigates photo-crosslinkable gelatin-based hydrogels - thiolated gelatin (GelSH) and gelatin norbornene (GelNB) - for volumetric additive manufacturing (VAM). GelSH was synthesized with degrees of thiol substitution (DS) of 39 %, 54 %, and 63 %, and GelNB with a DS of 60 % (with respect to primary amine content). These were combined into GelNB-GelSH photo-resins at 5, 7.5, and 10 % (w/v) and crosslinked via thiol-ene chemistry. Physico-chemical analysis showed that increasing DS and polymer concentration reduced swelling and increased moduli. VAM enabled the fabrication of high-resolution 3D hydrogel constructs from optimized formulations, demonstrating the ability to encapsulate mesenchymal stromal cells (MSCs) within a mechanically tunable, cell-supportive hydrogel environment. Film-cast hydrogels, also with embedded MSCs, served as comparative controls. VAM-printed constructs exhibited significantly higher alkaline phosphatase activity and calcium deposition, indicating enhanced osteogenesis. In contrast, chondrogenic and adipogenic differentiation were more pronounced in film-cast samples, due to their lower crosslinking density and stiffness. These findings emphasize the importance of matrix mechanics in guiding stem cell differentiation and demonstrate the potential of VAM for producing complex, functional scaffolds for tissue engineering. This work supports further development of tunable gelatin-based bioresins for applications requiring lineage-specific differentiation, including those targeting softer tissue types.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104850"},"PeriodicalIF":10.3,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144313395","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Efficient continuum-based modelling and analysis of polymer SLS: Insights into particle sintering and densification in straight and corner scanning passes 高效的基于连续体的聚合物SLS建模和分析：直扫和角扫过程中颗粒烧结和致密化的见解

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-06-13 DOI: 10.1016/j.addma.2025.104828

J. Hesselvig, R.T. Nygaard, M.K. Budzik, M. Sandberg

{"title":"Efficient continuum-based modelling and analysis of polymer SLS: Insights into particle sintering and densification in straight and corner scanning passes","authors":"J. Hesselvig, R.T. Nygaard, M.K. Budzik, M. Sandberg","doi":"10.1016/j.addma.2025.104828","DOIUrl":"10.1016/j.addma.2025.104828","url":null,"abstract":"<div><div>Selective Laser Sintering (SLS) is a widely used additive manufacturing technique that enables the production of complex polymer components. However, the sintering process involves complex thermal and material flow interactions that influence densification, shrinkage, and hence final part quality. This study presents a novel continuum-based numerical model for polymer SLS, validated through experimental investigations using PA12 powder. The model captures key sintering characteristics, including heat accumulation, powder shrinkage, and densification, at a fraction of the computational cost of traditional Discrete Element Method (DEM) approaches. A key finding of this study is the identification of oversintering effects at sharp corners, where heat accumulation leads to increased strand width and unexpected material redistribution—an effect not previously reported in the literature. Experimental validation confirmed good agreement with numerical predictions. However, deviations in strand thickness at sharp corners suggest that capillary-driven melt redistribution may play a role, which cannot be captured without resorting to more computationally intensive particle-level models. This work demonstrates the potential of continuum-based modelling for predicting sintering behaviour in SLS while maintaining computational efficiency. The model offers a valuable tool for exploring process parameters and optimising print path strategies, ultimately contributing to industrialisation of polymer SLS.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104828"},"PeriodicalIF":10.3,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144313483","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Nano/micro-structured polymer-derived SiBCN ceramics via two-photon lithography 基于双光子光刻技术的纳米/微结构聚合物衍生的SiBCN陶瓷

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-06-13 DOI: 10.1016/j.addma.2025.104849

Yanpei Dang , Zhao Xu , Ka-Wai Yeung , Zhanchen Zhu , Jiaqi Sun , Suet To , Chak-Yin Tang , Yujie Song , Haihui Ruan

{"title":"Nano/micro-structured polymer-derived SiBCN ceramics via two-photon lithography","authors":"Yanpei Dang , Zhao Xu , Ka-Wai Yeung , Zhanchen Zhu , Jiaqi Sun , Suet To , Chak-Yin Tang , Yujie Song , Haihui Ruan","doi":"10.1016/j.addma.2025.104849","DOIUrl":"10.1016/j.addma.2025.104849","url":null,"abstract":"<div><div>Printed microstructures face challenges when their applications require excellent mechanical strength and chemical stability at high temperatures. To maximize the service temperatures of printed microstructures, this study introduces a printable ceramic precursor for deriving SiBCN microstructures. The precursor possesses a high photosensitivity and high ceramic yield (76 wt%) because of the graft of acrylate and an increase of crosslinking degree, which is achieved by functionalizing polyborosilazane with 2-Isocyanatoethyl acrylate via nucleophilic addition reaction. The composition and chemical structure of the precursor and ceramic have been meticulously characterized. Moreover, a kinetics model has been established to describe the weight loss in pyrolysis, illuminating that the polymer-to-ceramic conversion is a diffusion-mediated growth process. Through two-photon lithography and pyrolysis, the photosensitive precursor can directly lead to SiBCN nano/microstructures with complex shapes and submicron (linewidth: ∼700 nm) features, which are the smallest SiBCN structures reported to date. At these microscales, it is revealed that shrinkage during pyrolysis is anisotropic and surface-area dependent and that the printed SiBCN micropillars can have an exceptional compressive strength of 3.59 ± 0.08 GPa. The potential applications of printed SiBCN microstructures were explored, including high-temperature embossing stamps for microlens and structural-color fabrication.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104849"},"PeriodicalIF":10.3,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144298668","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Critical role of electrostatic forces in powder spreading in micro laser powder bed fusion 静电力在微激光粉末床熔合中粉末扩散中的关键作用

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-06-13 DOI: 10.1016/j.addma.2025.104848

Zongxin Hu , Hui Chen , Zeshi Yang , Wentao Yan

{"title":"Critical role of electrostatic forces in powder spreading in micro laser powder bed fusion","authors":"Zongxin Hu , Hui Chen , Zeshi Yang , Wentao Yan","doi":"10.1016/j.addma.2025.104848","DOIUrl":"10.1016/j.addma.2025.104848","url":null,"abstract":"<div><div>Micro laser powder bed fusion (micro-LPBF) is a highly precise additive manufacturing technique typically utilizing fine powder particles smaller than 20 <span><math><mrow><mi>μ</mi><mi>m</mi></mrow></math></span>. However, the small size of powder particles in micro-LPBF results in serious agglomeration, leading to poor quality of the powder layer, characterized by reduced packing density and worsened surface roughness. This is crucial as the powder layer quality directly impacts the quality of as-printed parts. In this study, we leverage experimental and numerical approaches to investigate the powder spreading mechanisms in micro-LPBF. Both rubber and metal scrapers are used in the experiments, and the rubber scraper achieves a denser powder layer with the relative packing density of ∼ 40 %, outperforming the metal scraper (∼ 30 %). Both simulation and experiments confirm the existence and critical role of the electrostatic force originating from friction, which is the first report to the best of our knowledge. Compared to the metal scraper, the rubber scraper with a larger work function and a higher surface energy density produces stronger electrostatic forces between powder particles. Consequently, the attractive effects of van der Waals forces are counteracted by the repulsive electrostatic forces, alleviating the powder agglomeration and thus resulting in a denser powder layer. On the other hand, it is also found that more powder particles adhere to the bottom of the rubber scraper, leading to a less optimal powder layer, especially when the layer thickness is very small. This study has provided new scientific understanding and can offer practical guidance on selecting scrapers according to the powder materials to achieve high-quality powder layer by adjusting the electrostatic forces between powder particles.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104848"},"PeriodicalIF":10.3,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144298678","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Fine-grained binder jetted tungsten heavy alloys with in situ nano-La2O3 addition via a novel metal salt binder 通过一种新型的金属盐粘结剂，在原位添加纳米la2o3的情况下喷射出细晶粒的重钨合金

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-06-10 DOI: 10.1016/j.addma.2025.104843

Yuhua Heng, Yiwei Mao, Kunhao Feng, Jiangtao Sun, Jianan Zheng, Yingmi Xie, Qingsong Wei

{"title":"Fine-grained binder jetted tungsten heavy alloys with in situ nano-La2O3 addition via a novel metal salt binder","authors":"Yuhua Heng, Yiwei Mao, Kunhao Feng, Jiangtao Sun, Jianan Zheng, Yingmi Xie, Qingsong Wei","doi":"10.1016/j.addma.2025.104843","DOIUrl":"10.1016/j.addma.2025.104843","url":null,"abstract":"<div><div>Binder jetting (BJ) holds immense potential for manufacturing complex tungsten heavy alloy (WHA) parts with high efficiency and low cost. However, sintered BJ WHA parts often face the challenges of coarse grains and poor mechanical performance, which can be attributed to low green density and stringent sintering conditions (e.g., high temperature or long duration). In WHA powder metallurgy, oxide nanoparticles are often introduced to pin grain boundaries, limiting grain growth during the sintering process and thereby enhancing the mechanical properties. This work introduced oxide nanoparticles through the binder, which could effectively avoid the problems of uneven mixing, process complexity and impurity introduction. La(NO<sub>3</sub>)<sub>3</sub> binder, the key component of which was La(NO<sub>3</sub>)<sub>3</sub>, a water-soluble inorganic metal salt, would generate nano-La<sub>2</sub>O<sub>3</sub> (200 nm) in situ among the base powders during pretreatment, aiming at refining W grains and enhancing mechanical performance. The effects of La(NO<sub>3</sub>)<sub>3</sub> binder on the microstructure and properties of sintered BJ WHAs were systematically investigated and compared with those printed by the commercial binder. The average W grain size of sintered samples was 26.85 μm, finer than that printed by the commercial binder (34.53 μm). The ultimate tensile strength and yield strength of sintered samples were 926.54 MPa and 661.72 MPa, which were 8.46 % and 5.86 % higher than those printed by the commercial binder, respectively. Furthermore, the contributions of fine-grained strengthening, dispersion strengthening, solid-solution strengthening, and dislocation strengthening to the yield strength of sintered WHAs printed by La(NO<sub>3</sub>)<sub>3</sub> binder were all enhanced. This work offers a promising approach for grain refinement and performance enhancement of BJ metallic materials.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104843"},"PeriodicalIF":10.3,"publicationDate":"2025-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144279436","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Enhanced geometric accuracy in directed energy deposition via closed-loop melt pool height control using real-time thermal imaging 通过实时热成像闭环熔池高度控制，提高了定向能沉积的几何精度

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-06-10 DOI: 10.1016/j.addma.2025.104846

Subin Shin , Ikgeun Jeon , Hoon Sohn

{"title":"Enhanced geometric accuracy in directed energy deposition via closed-loop melt pool height control using real-time thermal imaging","authors":"Subin Shin , Ikgeun Jeon , Hoon Sohn","doi":"10.1016/j.addma.2025.104846","DOIUrl":"10.1016/j.addma.2025.104846","url":null,"abstract":"<div><div>This study presents a closed-loop melt pool height control system based on real-time thermal imaging to enhance the geometric accuracy of directed energy deposition (DED). Geometric inaccuracies in DED-printed components arise from the inherent thermal and geometric variations during the printing process. To improve geometric conformity with a predefined digital model, the proposed system employs a long-wave infrared camera to capture real-time thermal images of the melt pool. The peak-to-boundary temperature difference (TD), defined as the difference between the peak and boundary temperatures of the melt pool, is extracted from these images. The correlation between TD, melt pool height, and laser power was analyzed under various DED conditions, and the results demonstrated a strong relationship between TD and both parameters. Using the TD as a feedback parameter, the laser power is dynamically adjusted to maintain a stable melt pool height throughout the printing process. The proposed system enables real-time estimation of the melt pool height, ensures height stability through closed-loop control, and provides detailed insights into the thermal and geometric variations that affect the accuracy of the final part. This approach reduces the geometric error relative to the predefined digital model to below 4 %, highlighting its effectiveness in enhancing the geometric accuracy in complex multi-bead, multi-layer structures.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104846"},"PeriodicalIF":10.3,"publicationDate":"2025-06-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144279437","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Impact of oxygen inhibition on (meth)acrylate photopolymerization in tomographic volumetric printing 氧抑制对层析体积印刷（甲基）丙烯酸酯光聚合的影响

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-06-09 DOI: 10.1016/j.addma.2025.104844

Yujie Zhang , Hendrick de Haan , Katherine Houlahan , Kathleen L. Sampson , Daniel Webber , Antony Orth , Thomas Lacelle , Liliana Gaburici , Rene Lam , Bhavana Deore , Chantal Paquet

{"title":"Impact of oxygen inhibition on (meth)acrylate photopolymerization in tomographic volumetric printing","authors":"Yujie Zhang , Hendrick de Haan , Katherine Houlahan , Kathleen L. Sampson , Daniel Webber , Antony Orth , Thomas Lacelle , Liliana Gaburici , Rene Lam , Bhavana Deore , Chantal Paquet","doi":"10.1016/j.addma.2025.104844","DOIUrl":"10.1016/j.addma.2025.104844","url":null,"abstract":"<div><div>Oxygen inhibition in (meth)acrylate photopolymerization gives rise to a gelation threshold by delaying polymerization until the accumulated light dose exceeds a critical value, thereby enabling 3D printing with tomographic volumetric additive manufacturing (TVAM). While this thresholding behavior is essential to TVAM, its underlying kinetics have not been thoroughly studied. In this work, we systematically examine how photoinitiator (PI) concentration and light intensity govern the time required to deplete oxygen in (meth)acrylate photoresins, and evaluate their impact on print quality. To investigate these effects, we derive theoretical results elucidating oxygen inhibition, which remain valid even at low PI concentrations typical in TVAM printing, and can be used to estimate the oxygen concentration in the photoresins. We compare these predictions with photo-rheology experiments and observe good agreement. The findings reveal that at low PI concentrations, decreasing PI concentration dramatically increases oxygen depletion times, thereby extending oxygen diffusion periods and leading to poor printing quality; a similar trend is observed with reduced light intensity. While higher PI concentrations and increased light intensity can improve print quality, they are constrained by penetration depth limits and illumination restrictions of LED-based projection sources. This study also highlights the challenges of printing larger parts in TVAM, where oxygen inhibition and limited light penetration narrow the usable PI concentration range. These insights help optimize TVAM parameters to improve print quality and expand the technology's capabilities.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104844"},"PeriodicalIF":10.3,"publicationDate":"2025-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144263634","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Synergistic physics–data-driven cross-scale optimization of dielectric properties in multimaterial inkjet printing 协同物理-数据驱动的多材料喷墨打印介质性能跨尺度优化

IF 10.3 1区工程技术

Additive manufacturing Pub Date : 2025-06-09 DOI: 10.1016/j.addma.2025.104845

Zhenghua Liu, Jin Huang, Yuji Li, Jiaying Zhang, Bu Ping, Junhao Li, Wenzhuo Liu, Delong Shi, Fanbo Meng

{"title":"Synergistic physics–data-driven cross-scale optimization of dielectric properties in multimaterial inkjet printing","authors":"Zhenghua Liu, Jin Huang, Yuji Li, Jiaying Zhang, Bu Ping, Junhao Li, Wenzhuo Liu, Delong Shi, Fanbo Meng","doi":"10.1016/j.addma.2025.104845","DOIUrl":"10.1016/j.addma.2025.104845","url":null,"abstract":"<div><div>In multimaterial inkjet printing process, variations in material properties, device dimensions, and cumulative energy effects during manufacturing significantly impact the stability of the electrical properties of printed electronics. Particularly, microscale polymerization and degradation reactions of monomers severely affect the macroscopic dielectric properties. To simultaneously ensure conductive material sintering and optimize the dielectric performance, we developed an innovative physics- and data-driven intelligent optimization approach. By combining theoretical kinetic modeling, to simulate microscale polymerization and degradation reactions, with advanced machine learning algorithms, this method accurately predicts frequency-dependent macroscale dielectric properties and enables inverse process parameter optimization. The experimental results show exceptional agreement between the predicted and measured dielectric properties, with coefficients of determination of 0.9938 and 0.9812 for the real and imaginary parts, respectively. By precise inverse tuning of the process parameters, dielectric constants were stabilized at 2.7 in the high-frequency band (8.2 GHz–12.4 GHz) and at 3.5 in the low-frequency band (20 Hz–100 kHz). Furthermore, multilayer flexible circuits and microstrip antennas fabricated using this optimized strategy exhibit excellent dielectric stability and show the effectiveness of this cross-scale optimization method for guiding integrated high-performance manufacturing of multimaterial electronic devices.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"109 ","pages":"Article 104845"},"PeriodicalIF":10.3,"publicationDate":"2025-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144254322","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0