Additive manufacturing最新文献

{"title":"Erosion-free penalty minimization optimization for high-fidelity computed axial lithography","authors":"Jia-Qi Lü ,&nbsp;Jian-Su Sun ,&nbsp;Rui-Ping Jia ,&nbsp;Di Wang ,&nbsp;Ze-Kuo Zhang ,&nbsp;Ling-Fei Zheng ,&nbsp;Haiyue Jiang","doi":"10.1016/j.addma.2025.104990","DOIUrl":"10.1016/j.addma.2025.104990","url":null,"abstract":"<div><div>Inspired by the idea of tomography, computed axial lithography (CAL) which is a photopolymerization-based volumetric additive manufacturing process, providing a promising 3D printing approach with fast manufacturing speed and isotropic mechanical properties. The structured light projections which laterally illuminate a synchronously rotating container are critical for CAL, whose optimizations are necessary for high-fidelity 3D printing. Here, the erosion-free penalty minimization (EFPM) method is proposed. The whole object space is optimized without losing the edge information of the target geometry. The kinetic model of CAL is demonstrated to reveal the optimization mechanism, where balanced curing processes are found. The CAL based on EFPM method is quantitatively evaluated, where the fidelity can be found significantly enhanced comparing with traditional method.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104990"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145263058","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}

{"title":"3D printing of biodegradable polymer vascular stents to treat cardiovascular diseases: A review","authors":"Yi Huang ,&nbsp;Yan Xu ,&nbsp;Xiaolong Chen ,&nbsp;James P.K. Armstrong ,&nbsp;Massimo Caputo ,&nbsp;Qunfen Qi ,&nbsp;Ben Hicks ,&nbsp;Cian Vyas ,&nbsp;Paulo Bartolo ,&nbsp;Giovanni Biglino ,&nbsp;Fengyuan Liu","doi":"10.1016/j.addma.2025.104984","DOIUrl":"10.1016/j.addma.2025.104984","url":null,"abstract":"<div><div>Cardiovascular diseases (CVDs), the leading cause of mortality worldwide, stem from structural and functional abnormalities in the heart and blood vessels. Although advancements in treatments such as percutaneous coronary intervention and vascular stent implantation have reduced complications, challenges such as restenosis, late thrombosis, and limited customisation remain. Biodegradable polymer vascular stents (BPVSs) have emerged as promising alternatives to traditional metallic stents, offering advantages such as controlled degradation, improved biocompatibility, and reduced late-stage complications. This review examines the integration of 3D printing (3DP) techniques, including material extrusion, vat photopolymerisation, powder bed fusion, material jetting, and binder jetting into BPVS fabrication, highlighting their potential to enhance material properties, manufacturing processes, and clinical applicability. Key topics include material selection, structural design optimisation, and mechanical characterisation of 3DP BPVSs. The review also discusses preclinical evaluations and updated clinical insights, concluding with future research directions, including advanced materials development, innovative structural designs, breakthroughs in high-resolution 3DP techniques, and challenges in regulatory approval and clinical translation. These advancements underscore the potential of 3DP BPVSs to revolutionize personalised CVD treatment.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104984"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145263059","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}

{"title":"Solvent- and binder-free additive manufacturing of polymer-derived ceramics: Rheological tuning and structural performance","authors":"Laxmi Sai Viswanadha ,&nbsp;Jeremy Watts ,&nbsp;Mohammad Naraghi","doi":"10.1016/j.addma.2025.104962","DOIUrl":"10.1016/j.addma.2025.104962","url":null,"abstract":"<div><div>Silicon carbide (SiC) ceramic matrix composites are widely used in aerospace applications due to their high strength, heat resistance, and corrosion resistance. However, traditional machining methods make it challenging to fabricate complex shapes. This study presents a solvent-free and binder-free direct ink writing (DIW) method for producing SiC/SiOC composites using polycarbosilane SMP-10, a preceramic polymer that acts as both the ceramic precursor and the liquid phase, thereby eliminating the need for volatile solvents and sacrificial binders. By adjusting the SiC content, printable ink formulations were developed, and their flow properties were analyzed. The influence of geometric factors, such as inter-wall spacing and base layer width, on structural stability was also examined. Wider base layers provided greater support, increasing the maximum printable height before failure, while structures with larger inter-wall spacing were more prone to collapse due to reduced lateral support. These findings highlight the importance of structural design in achieving stable and precise prints. The printed lattice structures exhibited compressive strength of 5.62 ± 1.75 MPa – 9.62 ± 1.10 MPa and density of 2.05 – 2.34 g/cm³, alongside exceptional thermal insulation and stability. This approach offers an easy and efficient method for fabricating complex ceramic structures with excellent mechanical and thermal performance, making it highly relevant for advanced aerospace and high-temperature applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104962"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145047678","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}

{"title":"Enabling non-planar load oriented deposition of carbon fiber reinforced polymers by varying layer height","authors":"Johann Kipping,&nbsp;Thorsten Schüppstuhl","doi":"10.1016/j.addma.2025.104974","DOIUrl":"10.1016/j.addma.2025.104974","url":null,"abstract":"<div><div>A common research goal for printing carbon fiber reinforced polymers (CFRP) using fused filament fabrication (FFF) has been the deposition along load paths to fully utilize the potential of the highly anisotropic material. Yet, the state-of-the-art solutions for load oriented non-planar slicing and path planning for neat polymers involve the dynamic variation of layer height. This variation is not possible in a single layer for the most commonly used process variant for printing CFRP, towpreg extrusion, because of the fixed ratio of matrix to fiber. This problem can be solved by printing interlayers which roughly double the layer count, introduce weak points, decrease the fiber volume fraction (FVF), and increase manufacturing time. Continuous fiber coextrusion (CFC) offers a possible solution to this problem, as the amount of polymer co-matrix can be controlled. This is possible because of the pre-impregnation of the fiber material, which allows active feed of both fiber and co-matrix. This study aims to investigate the possibility of using continuous fiber coextrusion to dynamically vary layer height during the printing process to enable the load oriented non-planar printing of CFRP. To this end, the process is described, a custom control scheme is mathematically derived, and an experimental plan is presented. The experiments include the printing of coupons to evaluate the minimum and maximum layer heights and the possibility to vary the layer height dynamically. A pipe and a bracket are printed to establish the applicability to manufacturing real-life parts. Micrographs are taken to assess the void content and fiber distribution. Surface roughness is evaluated with white light interferometry. To evaluate the impact of layer height variation on stiffness and strength, a mechanical investigation is performed involving tensile and compressive tests. In conclusion of this study, the possibility of dynamic layer height variation to continuous fiber coextrusion can be confirmed and its application for load oriented non-planar printing is enabled.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104974"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262900","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}

{"title":"Microstructure and shape memory behavior of additively manufactured Ti-30Ta high-temperature shape memory alloy fabricated by laser beam powder bed fusion","authors":"C. Lauhoff ,&nbsp;M. Nobach ,&nbsp;A.E. Medvedev ,&nbsp;M. Bönisch ,&nbsp;Z. Bowen ,&nbsp;X. Shen ,&nbsp;A. Bolender ,&nbsp;A. Liehr ,&nbsp;S. Brudler ,&nbsp;A. Stark ,&nbsp;M. Stenzel ,&nbsp;M. Weinmann ,&nbsp;W. Song ,&nbsp;W. Xu ,&nbsp;A. Molotnikov ,&nbsp;T. Niendorf","doi":"10.1016/j.addma.2025.104973","DOIUrl":"10.1016/j.addma.2025.104973","url":null,"abstract":"<div><div>Titanium-tantalum (Ti-Ta) based alloys can show a reversible martensitic transformation well above 100 °C, which renders them attractive for actuator applications at elevated temperatures. The present study reports on additive manufacturing of a binary Ti-Ta high-temperature shape memory alloy (HT-SMA) by laser beam powder bed fusion (PBF-LB/M). Cuboids with near-full density of 99.99 % have been processed from pre-alloyed Ti-30Ta (at%) powder feedstock. While ω-phase formation during processing causes a β-phase stabilized solidification microstructure, an adequate post-process solution-annealing (1200 °C / 0.5 h) followed by water quenching promotes the formation of a non-equilibrium phase constitution consisting of the martensitic α″-phase. For this heat-treated material state, superior functional properties with fully reversible strains of 2.7 % at a bias stress of 350 MPa are shown. However, poor functional stability is observed. In line with findings previously reported for conventionally processed material, formation of ω-phase is found to dominate functional fatigue and eventually results in a complete loss of the shape memory effect under cyclic loading conditions. By employing detailed microstructure analysis and thermo-mechanical testing accompanied by high-energy <em>in situ</em> synchrotron diffraction, the fundamental interrelationships between processing, microstructure evolution and shape memory behavior are explored and rationalized.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104973"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262898","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}

{"title":"A skeletal line-based printing path planning method for continuous fiber reinforced composite structures","authors":"Yamin Li ,&nbsp;Xiaobao Zhi ,&nbsp;Xin Yan ,&nbsp;Jiancheng Hao ,&nbsp;Shangqin Yuan ,&nbsp;Tong Gao ,&nbsp;Jihong Zhu ,&nbsp;Weihong Zhang","doi":"10.1016/j.addma.2025.104960","DOIUrl":"10.1016/j.addma.2025.104960","url":null,"abstract":"<div><div>Continuous fiber-reinforced composite (CFRC) 3D printing integrates the benefits of additive manufacturing and advanced composites, enabling the fabrication of complex geometries with enhanced mechanical performance. However, CFRC printing faces significant path planning challenges. Conventional path generation methods frequently introduce printing defects such as voids and fiber misalignment, which substantially compromise the structural integrity of printed components. This paper proposes a novel skeletal line-based continuous path planning methodology that optimizes both manufacturability and mechanical strength, which is especially suitable for beam-like structures. The approach begins with extraction of the part's medial axis skeleton, followed by strategic decomposition into simplified sub-curves through skeleton node disconnection. Each sub-curve undergoes offset-based sub-path planning, after which the generated sub-paths are intelligently reconnected to form continuous loops. The process culminates in global path continuity through systematic loop interconnection. Experimental validation was performed to evaluate the efficacy of the proposed methodology. Comparative analysis demonstrates that our approach significantly reduces printing-induced defects while improving mechanical performance relative to conventional path planning techniques, including the Connected Fermat Spiral (CFS) method.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104960"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145027573","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}

{"title":"Machine learning-assisted multiscale optimization for continuous fiber reinforced composites","authors":"Shengya Li ,&nbsp;Huanlong Chen ,&nbsp;Zheyi Zhang ,&nbsp;Wenyang Liu ,&nbsp;Yiqi Mao ,&nbsp;Shujuan Hou ,&nbsp;Xu Han","doi":"10.1016/j.addma.2025.104968","DOIUrl":"10.1016/j.addma.2025.104968","url":null,"abstract":"<div><div>Continuous fiber reinforced composites (CFRCs) are key material systems in fields such as automotive and aerospace. Recently, additive manufacturing technology has provided a new methods for the controlled preparation of CFRCs. However, the material anisotropy and nonlinear properties caused by the non-uniform spatial distribution of fiber orientation and microstructural features pose significant challenges in multiscale modeling and concurrent optimization. In this paper, a neural network-assisted multiscale concurrent optimization (NNMCO) algorithm for the continuous fiber orientation and macrostructure topology of anisotropic composites is proposed. In order to do this, firstly, a mapping relationship between the micro fiber orientation and effective material properties of representative volume element (RVE) is constructed using fully-connected neural network (FCNN). Then, at the macroscale, the density-based Solid Isotropic Material with Penalization (SIMP) method is used to optimize the macrostructure topology by penalizing the stiffness of intermediate-density elements. Meanwhile, at the microscale, the fiber orientation is optimized during the iteration process according to the principal strain alignment (PSA) method to maximize local stiffness. The Gaussian filtering smoothing technique was used to smooth the local fiber distribution and avoid getting trapped in local optima, and the streamline algorithms were employed to generate smooth, continuous fiber paths. Finally, the efficiency and applicability of the developed method are further confirmed via 2D/3D numerical examples, 3D printing preparation, load-displacement experiment, and digital image correlation (DIC) testing. A concurrent multiscale optimization strategy is introduced for CFRCs fabricated via 3D printing.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104968"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145107674","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}

{"title":"Significant enhancement of room-temperature shape recovery properties of Ta-modified Fe-Mn-Si shape memory alloys fabricated by laser powder bed fusion","authors":"Zi Li ,&nbsp;Zhuohan Cao ,&nbsp;Qian Liu ,&nbsp;Wenliang Chen ,&nbsp;Zuhao Zhang ,&nbsp;Richard F. Webster ,&nbsp;Yu Wang ,&nbsp;Jiawen Xu ,&nbsp;Xiebin Wang ,&nbsp;Michael Ferry ,&nbsp;Jamie J. Kruzic ,&nbsp;Xiaopeng Li","doi":"10.1016/j.addma.2025.104956","DOIUrl":"10.1016/j.addma.2025.104956","url":null,"abstract":"<div><div>In this study, fully dense and crack-free Fe-30Mn-6Si-xTa (x = 0, 0.5, 1.0, 2.0 wt%) shape memory alloys (SMAs) were manufactured by laser powder bed fusion (LPBF). The effects of tantalum (Ta) addition and post-heat treatment (600 °C for 30 min) on microstructure and shape memory properties were systematically investigated. It was found that Ta effectively leads to the grain refinement in the Fe-based SMAs, which is mainly attributed to solute redistribution and the formation of Ta precipitate during rapid solidification. Post-heat treatment further improved room-temperature (RT) shape recovery properties of the Fe-30Mn-6Si-0.5Ta (wt%) alloy, achieving a recovery strain of ∼2.84 % and a shape recovery ratio of ∼71 %, which is 70 % higher than previously reported LPBF-fabricated Fe-based SMAs (i.e., ∼1.64 % recovery strain and ∼41 % shape recovery ratio). This enhancement is attributed to the increased stacking fault (SF) density facilitated by Ta precipitates and the positive influence of heat treatment, both of which promote the phase transformation from γ-austenite to ε-martensite. The research demonstrates that the Fe-based SMAs with enhanced shape memory properties can be fabricated by the LPBF technique, which provides new insights and practical guidance for designing high-performance SMAs via additive manufacturing techniques.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104956"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145047674","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}

{"title":"Nozzle heating with internal channel enhanced aerosol-jet printing with ultrahigh aspect ratio and ultrafine resolution for conformal electronics","authors":"Teng Ma ,&nbsp;Yuan Li ,&nbsp;Ao Li ,&nbsp;Yingjie Niu ,&nbsp;Hui Cheng ,&nbsp;Chenglin Yi ,&nbsp;Kaifu Zhang","doi":"10.1016/j.addma.2025.104965","DOIUrl":"10.1016/j.addma.2025.104965","url":null,"abstract":"<div><div>Aerosol jet (AJ) printing enables conformal feature fabrication but struggles with limiting aspect ratio and resolution due to insufficient focus of aerosol ink particles. Here, we introduce an efficient method for AJ printing called nozzle heating with internal channel (NHIC), which incorporates a spiral flow channel into the nozzle, facilitating a continuous and temperature-controlled water bath through the channel to establish an auxiliary annular thermal field around the aerosolized ink particles (AIPs) flow, thereby modifying the flow field dynamics and enhancing the aerodynamic focusing of AIPs By raising up NHIC temperature to 90℃, a 7 μm wide deposited trace with a thickness of 2.1 μm was achieved. Above all, we increased the maximum aspect ratio of the printed deposits up to approximately 0.3, and improved the conductivity by 25 %. NHIC-enabled AJ printing successfully fabricated high-precision and high-density circuits, resistors, and conformal electrodes, demonstrating superior aspect ratio, resolution, thickness, and conductivity compared to conventional AJ methods for uneven conformal surfaces.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104965"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145047679","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}

{"title":"Influence of the layer thickness on the dimensional accuracy and mechanical properties of lattice structures during PBF-LB of AlSi10Mg","authors":"Matthias Greiner ,&nbsp;Simon Drews ,&nbsp;Ben Jäger ,&nbsp;Christian Mittelstedt","doi":"10.1016/j.addma.2025.104972","DOIUrl":"10.1016/j.addma.2025.104972","url":null,"abstract":"<div><div>Laser powder bed fusion has emerged as a key additive manufacturing technology for manufacturing complex high-performance structures. However, a downside of the technology is the productivity of large-scale manufacturing in comparison to conventional manufacturing technologies. One of the critical parameters influencing the quality, productivity, and performance of PBF-LB-manufactured components is the layer thickness. A higher layer thickness accelerates manufacturing and reduces costs due to lower process times. On the downside, higher layer thicknesses may introduce dimensional inaccuracies, porosity due to incomplete fusion and increased surface roughness which ultimately compromises the component performance. While there are several studies about the influence of the layer thickness on bulk material, cellular materials like strut-based lattice structures are less investigated. By analyzing the strut morphology, dimensional accuracy, surface roughness and mechanical performance in relation with the productivity across different layer thicknesses, this work provides insights into process optimization for lattice structures using AlSi10Mg. Understanding the correlation between layer thickness, lattice quality, and manufacturing efficiency is essential for enhancing structural reliability, functional performance, and cost-effectiveness in PBF-LB applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104972"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145119969","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}