Additive manufacturing最新文献

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Significant enhancement of room-temperature shape recovery properties of Ta-modified Fe-Mn-Si shape memory alloys fabricated by laser powder bed fusion 激光粉末床熔合制备的ta改性Fe-Mn-Si形状记忆合金的室温形状恢复性能显著增强
IF 11.1 1区 工程技术
Additive manufacturing Pub Date : 2025-08-05 DOI: 10.1016/j.addma.2025.104956
Zi Li , Zhuohan Cao , Qian Liu , Wenliang Chen , Zuhao Zhang , Richard F. Webster , Yu Wang , Jiawen Xu , Xiebin Wang , Michael Ferry , Jamie J. Kruzic , Xiaopeng Li
{"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}
引用次数: 0
Nozzle heating with internal channel enhanced aerosol-jet printing with ultrahigh aspect ratio and ultrafine resolution for conformal electronics 喷嘴加热与内部通道增强气溶胶喷射打印具有超高纵横比和超细分辨率的保形电子
IF 11.1 1区 工程技术
Additive manufacturing Pub Date : 2025-08-05 DOI: 10.1016/j.addma.2025.104965
Teng Ma , Yuan Li , Ao Li , Yingjie Niu , Hui Cheng , Chenglin Yi , Kaifu Zhang
{"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}
引用次数: 0
Influence of the layer thickness on the dimensional accuracy and mechanical properties of lattice structures during PBF-LB of AlSi10Mg AlSi10Mg PBF-LB过程中层厚对晶格结构尺寸精度和力学性能的影响
IF 11.1 1区 工程技术
Additive manufacturing Pub Date : 2025-08-05 DOI: 10.1016/j.addma.2025.104972
Matthias Greiner , Simon Drews , Ben Jäger , Christian Mittelstedt
{"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}
引用次数: 0
Novel 3D printed continuous fiber-reinforced composites: A strategy to realize spiral mode manipulating and support-free manufacturing 新型3D打印连续纤维增强复合材料:实现螺旋模操纵和无支撑制造的策略
IF 11.1 1区 工程技术
Additive manufacturing Pub Date : 2025-08-05 DOI: 10.1016/j.addma.2025.104975
Chang Liu , Zirui Liu , Rilong Wu , Yulong Zhang , Xuliang Lu , Kaisheng Yang , Suqian Ma , Yunhong Liang , Luquan Ren
{"title":"Novel 3D printed continuous fiber-reinforced composites: A strategy to realize spiral mode manipulating and support-free manufacturing","authors":"Chang Liu ,&nbsp;Zirui Liu ,&nbsp;Rilong Wu ,&nbsp;Yulong Zhang ,&nbsp;Xuliang Lu ,&nbsp;Kaisheng Yang ,&nbsp;Suqian Ma ,&nbsp;Yunhong Liang ,&nbsp;Luquan Ren","doi":"10.1016/j.addma.2025.104975","DOIUrl":"10.1016/j.addma.2025.104975","url":null,"abstract":"<div><div>To meet the demands of lightweight, high-strength, and multifunctionality in advanced systems, a manufacturing strategy based on helical-gradient continuous-fibers for both reinforcement and sensing is needed. We developed an integrated fabrication platform that combined a resin-coated continuous-fiber twisting extrusion process with 3D printing. This platform enables unsupported 3D printing for fabricating helical-fiber-reinforced composite specimens exhibiting multiple helical modes and graded twist levels. Compared with conventional non-twisted-fiber composites, the resulting filaments exhibited superior mechanical properties—with tensile and flexural moduli increased by 172 % and 202 %, respectively—and displayed a pronounced change in resistance under strain. Quantitative models were established that relate helical architectures to mechanical and sensing responses. We designed several sensing devices based on these composites, including a resistive strain sensor, a dual-helical resistive sensor, and a capacitance–resistance hybrid sensor. Notably, the resistive strain sensor achieved a 562 % increase in sensitivity relative to conventional materials, while the capacitance-resistance hybrid sensor simultaneously detected distance, angle, and pressing positions using two sensing interfaces for large-area applications. This study provides innovative technological support for multifunctional, high-efficient industrial applications in aerospace, automotive, health monitoring, and related fields.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104975"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262901","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
Real-time multivariable control of directed energy deposition via adaptive model predictive control 基于自适应模型预测控制的定向能沉积实时多变量控制
IF 11.1 1区 工程技术
Additive manufacturing Pub Date : 2025-08-05 DOI: 10.1016/j.addma.2025.104941
Richard H. van Blitterswijk, Lucas A. Botelho, Amir Khajepour
{"title":"Real-time multivariable control of directed energy deposition via adaptive model predictive control","authors":"Richard H. van Blitterswijk,&nbsp;Lucas A. Botelho,&nbsp;Amir Khajepour","doi":"10.1016/j.addma.2025.104941","DOIUrl":"10.1016/j.addma.2025.104941","url":null,"abstract":"<div><div>Additive manufacturing processes such as directed energy deposition (DED) enable precise material deposition and customization, but ensuring consistent material properties remains a challenge due to the complex interplay of process parameters. This research presents a novel adaptive model predictive control (AMPC) algorithm for real-time multivariable control in DED, integrating an adaptive one-dimensional thermal model for accurate prediction of both temperature distribution and spatial cooling rate. The model was experimentally validated in single-track deposition tests across four different materials, achieving temperature predictions within ±1% of infrared camera measurements and spatial cooling rate errors below 2.73%. The validated model was embedded within the control framework and evaluated in five-layer wall experiments under open-loop, single-input single-output (SISO), and multi-input multi-output (MIMO) closed-loop control configurations. Results demonstrate that the AMPC algorithm effectively stabilized melt pool dynamics through simultaneous control of laser power and traveling speed, leading to consistent layer heights and improved material uniformity. This work introduces a scalable, adaptive, physics-based framework for real-time thermal prediction and multivariable control in advanced manufacturing processes that use concentrated energy sources, improving melt pool stability, material consistency, and overall part quality.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104941"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145107671","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
Understanding fatigue of additively manufactured TPMS metallic metamaterials: Experiments and modeling 了解增材制造TPMS金属超材料的疲劳:实验和建模
IF 11.1 1区 工程技术
Additive manufacturing Pub Date : 2025-08-05 DOI: 10.1016/j.addma.2025.104966
Krista Dyer , Mohammad Amjadi , Shuai Shao , Nima Shamsaei , Reza Molaei
{"title":"Understanding fatigue of additively manufactured TPMS metallic metamaterials: Experiments and modeling","authors":"Krista Dyer ,&nbsp;Mohammad Amjadi ,&nbsp;Shuai Shao ,&nbsp;Nima Shamsaei ,&nbsp;Reza Molaei","doi":"10.1016/j.addma.2025.104966","DOIUrl":"10.1016/j.addma.2025.104966","url":null,"abstract":"<div><div>Triply periodic minimal surfaces (TPMS) are specific types of lattice structures that can only be fabricated using the geometric freedom of additive manufacturing (AM). These structures are gaining traction in fields, such as biomedical and aerospace industries, due to their reduced stress concentrations and increased surface area to volume ratio compared to traditional strut-based lattices. Prior to acceptance into industry design applications, it is vital to understand the fatigue behavior of such porous structures under various loading conditions. The purpose of this study is to characterize and predict the fatigue behavior of Ti-6Al-4V TPMS lattice structures under a variety of loading conditions. Diamond and gyroid unit cell specimens of 50 % and 70 % porosity are fabricated for testing. Finite element analysis (FEA) and X-ray computed tomography (XCT) are also conducted for stress distribution and geometrical accuracy analysis. Various modeling techniques are used to correlate fatigue data of solid specimens and the lattice structures. It is found that popular methods from literature based on monotonic properties are not successful at correlating solid and porous data. This study expands to more robust local stress models, such as fatigue notch factor, that result in significantly improved life predictions but can be computationally expensive. A new model based on nominal applied cyclic loads and stress intensity factor is also proposed that produces comparable results to local stress models with reduced computational expenses.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104966"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145107672","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
Enabling robust and energy-efficient laser powder bed fusion of Cu alloys via Mo nanoparticle decoration 通过纳米Mo颗粒修饰实现铜合金的激光粉末床熔合
IF 11.1 1区 工程技术
Additive manufacturing Pub Date : 2025-08-05 DOI: 10.1016/j.addma.2025.104988
Guichuan Li , Michel Smet , Yagnitha Kandula , Zhuangzhuang Liu , Brecht Van Hooreweder , Kim Vanmeensel
{"title":"Enabling robust and energy-efficient laser powder bed fusion of Cu alloys via Mo nanoparticle decoration","authors":"Guichuan Li ,&nbsp;Michel Smet ,&nbsp;Yagnitha Kandula ,&nbsp;Zhuangzhuang Liu ,&nbsp;Brecht Van Hooreweder ,&nbsp;Kim Vanmeensel","doi":"10.1016/j.addma.2025.104988","DOIUrl":"10.1016/j.addma.2025.104988","url":null,"abstract":"<div><div>Laser Powder Bed Fusion (PBF-LB) of copper and low-alloyed copper alloys remains challenging due to their low infrared absorptivity and high thermal conductivity. This study introduces a multi-faceted strategy integrating computational thermodynamics-guided alloy design, Mo nanoparticle surface decoration, and thermal process optimization to enable robust and energy-efficient PBF-LB processing of reflective Cu-based alloys. Surface decoration with 0.44 wt% Mo nanoparticles enhances laser energy absorption, enabling a 40–45 % reduction in the required laser volumetric energy density from 167 to 188–100–118 J/mm<sup>3</sup> to achieve &gt; 99.1 % part density. Additionally, Mo addition improves the alloy’s resistance to precipitate coarsening while maintaining low solid solubility in Cu, thereby preserving electrical conductivity. In CuCrZr alloys, baseplate preheating to 300 °C promotes densification and in-situ precipitation of Cr and Cu<sub>x</sub>Zr<sub>y</sub> phases during PBF-LB, enhancing both strength and conductivity. In contrast, Mo addition suppresses in-situ precipitation due to its sluggish diffusion in Cu and preferential partitioning into Cr and Cu<sub>x</sub>Zr<sub>y</sub> phases. After direct age-hardening (450 °C, 9 h), the CuCrZrMo alloy exhibits a fine dispersion of Mo-doped nanoprecipitates, achieving a yield strength of 598 ± 7 MPa (vs. 576 ± 7 MPa for CuCrZr) while retaining high electrical conductivity (67–68 % IACS). This work highlights a synergistic alloy and process design strategy to address key PBF-LB challenges in Cu alloys, enabling their application in high-performance components requiring combined high mechanical strength and electrical conductivity.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104988"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262939","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
Mechanism-driven process planning for continuous fiber-reinforced suspension lattice structures with complex path features via self-supporting suspension printing 基于自支撑悬浮打印的复杂路径特征连续纤维增强悬浮晶格结构工艺规划
IF 11.1 1区 工程技术
Additive manufacturing Pub Date : 2025-08-05 DOI: 10.1016/j.addma.2025.104980
Ke Dong , Ziwen Chen , Feirui Li , Kaicheng Ruan , Xueliang Xiao , Pai Zheng , Yi Xiong
{"title":"Mechanism-driven process planning for continuous fiber-reinforced suspension lattice structures with complex path features via self-supporting suspension printing","authors":"Ke Dong ,&nbsp;Ziwen Chen ,&nbsp;Feirui Li ,&nbsp;Kaicheng Ruan ,&nbsp;Xueliang Xiao ,&nbsp;Pai Zheng ,&nbsp;Yi Xiong","doi":"10.1016/j.addma.2025.104980","DOIUrl":"10.1016/j.addma.2025.104980","url":null,"abstract":"<div><div>Continuous fiber-reinforced polymer additive manufacturing (CFRP-AM) enables the creation of a novel class of composite structures known as suspension lattices, formed by stacking distinct layer patterns via self-supporting suspension printing (SSSP). With hybrid topologies and complex internal channels, these structures open new avenues for structural enhancement and multifunctional integration. However, engineering suspension lattices with intricate corner path features remains challenging due to limited understanding of printing mechanisms and a lack of effective process planning methods to address manufacturing issues, like gravity-induced sagging and fiber-tension-induced turning slippage. This study proposes a mechanism-driven process planning method for architecting geometrically accurate and mechanically robust suspension lattices. The process is categorized into two phases (i.e., fabrication of primary skeletons and secondary elements) to decouple the structural complexity. The underlying printing mechanism is revealed through experimental characterization of diverse path features, which facilitates the development of physics-informed few-shot learning (PI-FSL) models for accurate prediction of printing quality. A slip transmission mechanism for sequential corner features is introduced that leverages PI-FSL models to quantify the influence of preceding path slippage on the subsequent path accuracy. Subsequently, these models are integrated with a genetic algorithm for path planning of suspension lattices. The proposed approach achieves high efficiency in three complex target patterns, as evidenced by desirable path accuracy with geometric deviations of less than 1.0 mm. Furthermore, the effectiveness of this method is demonstrated through two potential applications in creating two-and-a-half-dimensional (2.5D) lattices for battery enclosures and three-dimensional (3D) skeletons for drone protective cages.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104980"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262936","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
Corrosion-resistant and heat-dissipative SiOC ultralight lattice for high-temperature EMI shielding 耐腐蚀和散热SiOC超轻晶格高温电磁干扰屏蔽
IF 11.1 1区 工程技术
Additive manufacturing Pub Date : 2025-08-05 DOI: 10.1016/j.addma.2025.104964
Shixiang Zhou , Yijing Zhao , Xiao Guo , Udeshwari Jamwal , Pon Janani Sugumaran , Sreekanth Ginnaram , Wentao Yan , Jun Ding , Yong Yang
{"title":"Corrosion-resistant and heat-dissipative SiOC ultralight lattice for high-temperature EMI shielding","authors":"Shixiang Zhou ,&nbsp;Yijing Zhao ,&nbsp;Xiao Guo ,&nbsp;Udeshwari Jamwal ,&nbsp;Pon Janani Sugumaran ,&nbsp;Sreekanth Ginnaram ,&nbsp;Wentao Yan ,&nbsp;Jun Ding ,&nbsp;Yong Yang","doi":"10.1016/j.addma.2025.104964","DOIUrl":"10.1016/j.addma.2025.104964","url":null,"abstract":"<div><div>High-temperature electromagnetic interference (EMI) shielding material is essential for intense thermal or electromagnetic radiation applications. Ceramics are promising candidates but are often fabricated with increased density and thickness to achieve sufficient shielding effectiveness (SE). However, we present an unconventional strategy to enhance the SE of ceramics by reducing density realized through hierarchical lattice design. 3D-printed silicon oxycarbide (SiOC) with self-arrayed and corrosion-resistant carbon nanosheets was employed to materialize this design. As the density decreases from 2.73 to 0.53 g/cm<sup>3</sup>, the SE increases from 12.53 to 27.27 dB. The combined effects of densely arrayed carbon nanosheets and hierarchical design amplify multi-reflection/scattering, enabling enhanced EMI shielding at reduced density. Furthermore, this structure is capable of operation at 600 °C and oxygen corrosion environment even at an ultralow density of 0.29 g/cm<sup>3</sup>, achieving over 99 % shielding efficiency. It exhibits a low thermal expansion coefficient of 1.41 × 10<sup>−6</sup>/K at 600 °C, along with compressive strength, Young’s modulus, and energy absorption of 6.38 MPa, 3.02 GPa, and 8.14 kJ/cm<sup>3</sup>, respectively, ensuring mechanical, dimensional, and shielding robustness. The interconnected hollow spaces and exposed surfaces facilitate both active and passive heat dissipation, preventing thermal failure and extending the operational lifespan. Under airflow, the heated structure cools to 46.6 °C within 25 s, effectively reducing the operating temperature. This strategy provides a straightforward approach for fabricating high-temperature and lightweight EMI shielding ceramics through structural optimization, underscoring its potential for performance enhancement, cost reduction, and application expansion for extreme environments.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104964"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145107673","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
Multi-material nozzle geometry design optimization for bioprinting 生物打印多材料喷嘴几何设计优化
IF 11.1 1区 工程技术
Additive manufacturing Pub Date : 2025-08-05 DOI: 10.1016/j.addma.2025.104959
Jun Sim, Wan Kyun Chung
{"title":"Multi-material nozzle geometry design optimization for bioprinting","authors":"Jun Sim,&nbsp;Wan Kyun Chung","doi":"10.1016/j.addma.2025.104959","DOIUrl":"10.1016/j.addma.2025.104959","url":null,"abstract":"<div><div>Multi-material additive manufacturing (AM) introduces complex challenges in maintaining stable and controllable flow within the printing nozzle, where flow disturbances such as backflow, excessive shear stress, and delayed material transitions can compromise print uniformity and cell viability. These issues are particularly pronounced when handling non-Newtonian, yield stress bioinks such as Herschel–Bulkley fluids. Motivated by on-the-fly material switching, we explicitly scope the optimization to a one-ink-on/one-ink-idle Y-junction in which one inlet is driven while the other remains idle. This study presents a simulation-driven optimization framework for multi-material Y-junction nozzle geometry aimed at improving backflow suppression, shear-stress minimization, and rapid material switching. A numerical model quantifies three key performance indices as backflow potential, maximum wall shear stress, and switching time index across a four dimensional design space. High fidelity CFD simulations generate training data for a Gaussian Process surrogate with a Matérn kernel, and Bayesian optimization efficiently identifies optimal geometries. The optimized designs achieve significant reductions in backflow, peak shear stress, and outlet refill time compared to baseline nozzles. Experimental validation comprising cell viability assays on high versus low shear designs, air filled backflow tests in a worst-case setup, and on-the-fly switching time measurements corroborates all three cost components. Our findings deliver a robust, scalable, and experimentally validated methodology for multi-material nozzle design, with broad implications for precision, speed, and biological functionality in extrusion-based bioprinting.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"111 ","pages":"Article 104959"},"PeriodicalIF":11.1,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145107676","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
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