Additive manufacturing最新文献

{"title":"Pioneering techniques for achieving high-resolution, ultrasmooth surfaces via LCD 3D printing technology","authors":"Jui-Fu Tang,&nbsp;Kuan-Wu Lin,&nbsp;Tsung-Hsien Lin,&nbsp;Wei-Chun Lin","doi":"10.1016/j.addma.2025.104764","DOIUrl":"10.1016/j.addma.2025.104764","url":null,"abstract":"<div><div>Recently, the photocured polymerization method in 3D printing technology has gained popularity on the market due to its advantages of high resolution, low cost, and easy operation. However, the presence of surface texture defects resulting from the LCD panel's pixel array has limited the smoothness of the printed models, rendering the array unsuitable for optical component fabrication. These texture defects are attributed to the black matrix area created by the pixel array, which becomes an apparent voxel defect in the SEM image and leads to an uneven printing surface. To overcome this challenge, a novel design with hybrid LCD films has been developed to eliminate voxel defects. The upper LCD panel is designed to control the direction of light by the voltage-modulated liquid crystal. The scattered light covers the black matrix, achieving a continuous and uniform printed surface. In this research, it is confirmed that the hybrid LCD system significantly alleviates texture defects caused by the black matrix among pixels. The results successfully revealed an ultrasmooth surface, achieving an 80 % reduction in roughness through this modified LCD system without compromising printing resolution. The ultrasmooth surface also reduced the shrinkage by up to 95 % and improved the mechanical properties of the printed material due to the dense adhesion of each layer.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104764"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143767499","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":"Alternate projection optimization in ceramic vat photopolymerization","authors":"Yuzhen Zhang ,&nbsp;Wenyan Duan ,&nbsp;Xingyao Sun ,&nbsp;Shuyu Zhou ,&nbsp;Kaixiang Zhang ,&nbsp;Shan Li ,&nbsp;Bingshan Liu ,&nbsp;Gong Wang","doi":"10.1016/j.addma.2025.104777","DOIUrl":"10.1016/j.addma.2025.104777","url":null,"abstract":"<div><div>The stresses generated during ceramic vat photopolymerization can lead to significant dimensional deformation of the ceramic green body, severely limiting the practical application of this technology. In this work, the alternate projection method was successfully applied to ceramic vat photopolymerization for the first time. The effects of different alternate projection parameters on the accuracy and properties of the ceramic green bodies were compared. By optimizing the parameters and lattice skeleton, the low-deformation ceramic green bodies were successfully prepared. In addition, ceramic parts with complex structures were fabricated after thermal binder removal and sintering. Alternate projection optimization enables the preparation of high-precision ceramic parts without requiring modifications to the ceramic material or printing equipment. This method is highly practical and cost-effective, especially suitable for rapid iteration of high-precision complex structural parts, and can be widely used in semiconductor, aerospace, and other technical fields.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104777"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143783794","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":"Going against the grain: Porous defects in polymer-zeolite composite extrusion to enhance contaminant adsorption","authors":"Alan J. Kennedy ,&nbsp;Christopher B. Williams ,&nbsp;Stephen M. Martin ,&nbsp;Chris S. Griggs ,&nbsp;Travis L. Thornell ,&nbsp;Lauren R. May ,&nbsp;Michael J. Bortner","doi":"10.1016/j.addma.2025.104762","DOIUrl":"10.1016/j.addma.2025.104762","url":null,"abstract":"<div><div>While engineers seek to reduce voids and mechanical anisotropies to match injection molding properties, this investigation embraces voids inherent to polymer melt Additive Manufacturing (AM) to enable innovative water treatment solutions. Extrusion of polymer-zeolite micro-composite filaments was exploited to increase structural porosity to enhance contaminant adsorption through print parameter selection, correlating process physics and material physical properties to printed structure performance. Zeolite (32 % w/w) was immobilized in polylactic acid (PLA) filament by twin screw extrusion. Since increasing zeolite loading in dense printed structures did not improve adsorption, we hypothesized that applying print parameters to enhance voids would. While high surface area geometries are an obvious choice for water treatment, this research isolated how print parameters alone affect porous deposition and adsorptive performance at smaller dimensional scales than intentionally printed infill. Experiments determined printing PLA-zeolite faster (80 mm/s) at lower temperature (190 °C) through larger nozzles (0.8 mm) and layer heights (0.3 mm) improved porous structure-adsorptive property relationships, promoting faster ammonia adsorption. Impactful findings include: (1) dense PLA-zeolite injection molds performed poorly, emphasizing layered structure is imperative to allow voids; (2) evidence that controlling physical (roadway spacing) and rheological (extrusion/deposition/solidification) considerations are critical for functional porous structures; and (3) zeolite presence alters rheological controls to achieve printed porosity relative to neat PLA. This work catalyzes new thinking in application-specific success metrics in printed hierarchical structures for both designed and actual deposited structures and an expansion of research avenues in novel environmental applications to optimize printing away from fully dense structures.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104762"},"PeriodicalIF":10.3,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143767497","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":"Residual stress prediction in machining of parts fabricated by directed energy deposition","authors":"Shenliang Yang ,&nbsp;Alistair Speidel ,&nbsp;Adam T. Clare ,&nbsp;Chris Bennett ,&nbsp;Xiaoliang Jin","doi":"10.1016/j.addma.2025.104765","DOIUrl":"10.1016/j.addma.2025.104765","url":null,"abstract":"<div><div>The residual stress exhibited in post-machined metallic components fabricated by directed energy deposition (DED) determines their final mechanical performance and reliability in mission-critical applications. This study develops a numerical model to predict the final surface residual stress after the orthogonal cutting of DED-produced IN718, which integrates two critical factors: DED-induced initial residual stress states and microstructure properties. Using the developed modeling procedure, the penetration depth of post-machining into the initial residual stress distribution can be effectively quantified, which aligns with residual stress measurements through X-ray diffraction. The developed model is further employed to quantify the cumulative effects of initial residual stress states and grain size on cutting forces and final surface residual stress profiles. The results suggest that, under the given orthogonal cutting conditions of DED parts, variations in the initial residual stress states of the chip formation region have negligible effects on cutting forces. However, magnitudes of surface compressive residual stress in the longitudinal direction reduce by 21.8 %-52.3 % as the initial residual stress states shift from compressive-dominant to tensile-dominant, and decrease by 23.8 %-54.0 % as the built-in grain size (<em>d</em>_{<em>g</em>_<em>x</em>}) increases from 10 μm to 100 μm. With a comprehensive understanding of post-machining DED processes using this numerical modeling procedure, post-treatment techniques can now be tailored to achieve surface residual stress profiles on DED-generated or other additively manufactured metallic components to meet various industrial requirements.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"104 ","pages":"Article 104765"},"PeriodicalIF":10.3,"publicationDate":"2025-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143792433","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"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":"Designing curing layer structures to manage the anisotropies of alumina ceramics manufactured by vat photopolymerization","authors":"Xuehua Yu ,&nbsp;Yuhui Zhao ,&nbsp;Zhiguo Wang ,&nbsp;Ke Zhong ,&nbsp;Mingtao Zhang ,&nbsp;Jibin Zhao","doi":"10.1016/j.addma.2025.104763","DOIUrl":"10.1016/j.addma.2025.104763","url":null,"abstract":"<div><div>Controlling for anisotropic dimensional shrinkage, three-point bending strength, and fracture toughness are significant scientific issues in the fields of ceramic cores and bioceramics and are primarily influenced by oriented lamellar structures. For this purpose, this work designs some micro-sized hollow rectangular structures to transform lamellar structures into T-shaped dislocation layer structures which improve the section factor, thus controlling the anisotropic properties. Starting from the theoretical equation of curing depth, a novel photopolymerization profile curve equation is established to accurately predict the actual curing profile curve, guiding microstructural design. The photopolymerization state of the green body with a microstructural design is consistent with that of normal printing. This experiment investigates the control benefits of microstructural design parameters (the length, width, and area percentage of the rectangle) and sintering temperature on dimensional shrinkage, bending strength, and fracture toughness. The microstructural design method provides a dimension shrinkage control benefit of −4.02–7.22 % for the <em>x</em> direction, −3.59–9.53 % for the <em>y</em> direction, and −5.54–8.48 % for the <em>z</em> direction, a bending strength enhancement effect of −12.97–25.73 % in the <em>x</em> direction and −17.64–16.88 % in the <em>z</em> direction, and a fracture toughness reinforcement effect of 2.5–36.67 % in the <em>x</em> direction and 6.47–82.86 % in the <em>z</em> direction, which results in a reduction rate of anisotropic dimensional shrinkage and strength ranging from −175.90–32.85 % and 4.34–75.49 %, respectively. The maximum bending strength and fracture toughness reach 331.40 MPa and 6.14 MPa∙m^1/2, respectively. This provides a common control method for the dimension and mechanical properties of any material via VPP additive manufacturing.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"104 ","pages":"Article 104763"},"PeriodicalIF":10.3,"publicationDate":"2025-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143792444","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":"Vat photopolymerization 3D printed SiOC-based metamaterials with triply periodic minimal surface: Microwave absorption and load-bearing properties","authors":"Cunxian Wang ,&nbsp;Haodong Wang ,&nbsp;Lu Tang ,&nbsp;Jimei Xue ,&nbsp;Zhijun Wang ,&nbsp;Hanjun Wei","doi":"10.1016/j.addma.2025.104776","DOIUrl":"10.1016/j.addma.2025.104776","url":null,"abstract":"<div><div>Microwave absorbing structures are important for addressing challenges in complex electromagnetic (EM) and physical environments because they offer broadband absorption, a lightweight design, and mechanical load-bearing capabilities. Herein, this work employed vat photopolymerization 3D printing and polymer-derived ceramics (PDCs) technology to manufacture Re₂O₃-modified SiOC metamaterials, where Re refers to holmium (Ho), neodymium (Nd), and yttrium (Y). The materials feature a triply periodic minimal surface (TPMS) meta-structure inspired by the gyroid structure. The effects of different Re elements on the dielectric, magnetic, microwave absorption, and compression properties were investigated. Compared with the original SiOC, Ho₂O₃<img>SiOC, and Y₂O₃<img>SiOC ceramics, the Nd₂O₃<img>SiOC ceramic demonstrated excellent absorption characteristics within the X<img>band. It achieves a minimum reflection loss (RL_min) of <img>45.12 dB at 4.15 mm and an effective absorption bandwidth (EAB) spanning 4.2 GHz from 3.5 to 3.7 mm. This performance is attributed mainly to the TPMS meta-structure, which improves impedance matching. The Nd₂O₃ particles enhance the dielectric and magnetic losses. The Nd₂O₃<img>SiOC ceramic also demonstrated strong mechanical properties, with a maximum failure strength of 11.3 MPa and a Young’s modulus of 1.72 GPa. These results arise from the uniform dispersion and fine-scale distribution of Nd₂O₃ within the SiOC matrix. The CST simulations indicate that the Nd₂O₃<img>SiOC metamaterials cover the entire C-band (4–8.2 GHz), which is particularly effective within thicknesses ranging from 2.9 to 5.0 mm. Consequently, Nd₂O₃<img>SiOC ceramics display substantial promise in both their low-frequency and broadband absorption capabilities, as well as in their mechanical load-bearing properties.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"104 ","pages":"Article 104776"},"PeriodicalIF":10.3,"publicationDate":"2025-04-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143792432","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":"Identifying melt pool behavior in ceramics PBF-LB via operando synchrotron tomographic microscopy and high-fidelity process modeling","authors":"A. Muther ,&nbsp;M.G. Makowska ,&nbsp;Z.L. Zhang ,&nbsp;F. Verga ,&nbsp;F. Marone ,&nbsp;N. Garrivier ,&nbsp;A. Cretton ,&nbsp;S. Van Petegem ,&nbsp;M. Bambach ,&nbsp;M. Afrasiabi","doi":"10.1016/j.addma.2025.104756","DOIUrl":"10.1016/j.addma.2025.104756","url":null,"abstract":"<div><div>Recent advancements in high-fidelity process simulations have significantly enhanced the understanding of melt pool behavior during laser-based powder bed fusion (PBF-LB) of metals. However, for ceramics, their unique material properties and complex thermophysical behavior present significant challenges in developing detailed models that effectively complement limited experimental observations. In this work, we integrate operando synchrotron X-ray tomographic microscopy with computational fluid dynamics-discrete element method (CFD-DEM) simulations to investigate the melt pool dynamics of alumina during PBF-LB. In-situ observations reveal a shallow and wide melt pool, distinct from that of metals. This behavior is linked to alumina’s low thermal conductivity, high laser absorption, and negative surface tension gradients, as confirmed through high-fidelity process simulations. Key mechanisms identified include limited heat penetration, enhanced surface-oriented convection, and surface vortices driven by heat exchange with the surrounding gas environment. The influence of laser power and scanning speed on melt pool geometry is systematically analyzed, leading to the first virtual process map and parameter windows for stable PBF-LB of alumina. These findings provide critical insights for optimizing process parameters and advancing ceramic additive manufacturing.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"103 ","pages":"Article 104756"},"PeriodicalIF":10.3,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143760753","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":"Simultaneous topology and toolpath optimization for layer-free multi-axis additive manufacturing of 3D composite structures","authors":"Joseph R. Kubalak,&nbsp;Alfred L. Wicks,&nbsp;Christopher B. Williams","doi":"10.1016/j.addma.2025.104774","DOIUrl":"10.1016/j.addma.2025.104774","url":null,"abstract":"<div><div>Composite materials are extremely common in nature, with organic structures freely distributing and orienting anisotropic material properties in 3D to achieve a high degree of efficiency and functionality. Human-made composite structures do not leverage the same design thinking; they are frequently designed specifically for isotropic performance and with little geometric complexity due to limitations imposed by the manufacturing processes. While additive manufacturing (AM) provides unprecedented geometric flexibility, it typically deposits material in a series of stacked 2D layers (despite the moniker of “3D printing”); it does not enable the same freedoms of material placement and orientation seen in nature. Multi-axis (e.g., robotically-enabled) AM enables true 3D part fabrication such that material anisotropy can be advantageously oriented to enhance part performance (e.g., aligning fiber reinforcement to anticipated load paths), but existing methodologies separate the design of part geometry from its multi-axis printing toolpath. This paper presents a novel design and manufacturing workflow that integrates design optimization and multi-axis AM to algorithmically create optimal part topologies concurrently with their printing toolpaths. The workflow is aware of manufacturing and design considerations to maximize part performance while simultaneously guaranteeing multi-axis printability. Material is placed through an optimized, layer-free process to significantly improve the performance of additively manufactured composite structures. The design workflow is validated by optimizing, fabricating, and mechanically evaluating multi-axis structures and demonstrated a 56.9 % improvement in structural efficiency relative to a conventional, layer-wise AM process.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"104 ","pages":"Article 104774"},"PeriodicalIF":10.3,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829176","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":"Control of spatter due to liquid metal expulsion in additive manufacturing","authors":"Yang Du ,&nbsp;Stephanie A. Pestka ,&nbsp;Alaa Elwany","doi":"10.1016/j.addma.2025.104773","DOIUrl":"10.1016/j.addma.2025.104773","url":null,"abstract":"<div><div>The undesired, unpreventable, liquid metallic spatters can significantly degrade the surface quality, dimension accuracy, and mechanical properties of the manufactured parts of the laser powder bed fusion (LPBF). However, the control and prediction for spatter formation are still challenging because additive manufacturing involves many simultaneously occurring physical processes. Among the various influencing factors, vapor recoil and surface tension forces are the primary contributors to metallic spatter formation. In this work, we present a novel spatter index that captures the synthetic influence of vapor recoil and surface tension forces on the periphery of the melt pool and the metallic spatter’s formation and behavior. An analytical model, considering the influence of various process conditions (such as shielding gas, powder bed, and alloy properties), is applied to calculate the temperature field of the LPBF process, and the computed results have been rigorously tested by three alloys under various process conditions. The calculated temperature field and the alloy’s chemical composition are applied to compute the surface tension force, vapor recoil force, and spatter index. This derived dimensionless spatter index reveals insights into the formation mechanism and shows a linear relationship with the spatter’s amount and initial ejection speed for various alloys. In addition, we generate a spatter index process map for AF9629 under different process conditions. The proposed easy-to-calculate and easy-to-apply spatter index and process map offer significant potential for optimizing process conditions, mitigating metallic spatter formation, and enhancing printed components' surface quality and mechanical properties.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"104 ","pages":"Article 104773"},"PeriodicalIF":10.3,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143792431","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":"Harnessing on-machine metrology data for prints with a surrogate model for laser powder directed energy deposition","authors":"Michael Juhasz,&nbsp;Eric Chin,&nbsp;Youngsoo Choi,&nbsp;Joseph T. McKeown,&nbsp;Saad Khairallah","doi":"10.1016/j.addma.2025.104745","DOIUrl":"10.1016/j.addma.2025.104745","url":null,"abstract":"<div><div>In this study, we leverage the massive amount of multi-modal on-machine metrology data generated from Laser Powder Directed Energy Deposition (LP-DED) to construct a comprehensive surrogate model of the 3D printing process. By employing Dynamic Mode Decomposition with Control (DMDc), a data-driven technique, we capture the complex physics inherent in this extensive dataset. This physics-based surrogate model emphasizes thermodynamically significant quantities, enabling us to accurately predict key process outcomes. The model ingests 21 process parameters, including laser power, scan rate, and position, while providing outputs such as melt pool temperature, melt pool size, and other essential observables. Furthermore, it incorporates uncertainty quantification to provide bounds on these predictions, enhancing reliability and confidence in the results. We then deploy the surrogate model on a new, unseen part and monitor the printing process as validation of the method. Our experimental results demonstrate that the predictions align with actual measurements with high accuracy, confirming the effectiveness of our approach. This methodology not only facilitates real-time predictions but also operates at process-relevant speeds, establishing a basis for implementing feedback control in LP-DED.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104745"},"PeriodicalIF":10.3,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143847377","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}