Additive manufacturing最新文献

{"title":"Electrohydrodynamic jet printing of micro-structured electrode featuring 3D gold micropillar array for non-enzymatic detection of glucose","authors":"Zhaofa Zhang ,&nbsp;Li Wang ,&nbsp;Tianxue Yin ,&nbsp;Yulin Zheng ,&nbsp;Yuechen Pei ,&nbsp;Shijia Wei ,&nbsp;Yu Luo ,&nbsp;Huaying Wu ,&nbsp;Bingheng Lu","doi":"10.1016/j.addma.2025.104806","DOIUrl":"10.1016/j.addma.2025.104806","url":null,"abstract":"<div><div>Three-dimensional (3D) micro-structured gold electrodes offer remarkable advantages in electrochemical sensing, electrocatalysis and energy storage. However, conventional cleanroom fabrication methods, such as lithography and vapor deposition, rely on expensive equipment and often involve material waste. This work proposes an EHD jet printing process for fabricating a micro-structured electrode featuring a 3D gold micropillar array (GMA) using water-based gold nanoparticle ink. Through COMSOL simulations, the utilization and avoidance of the electrostatic autofocusing effect is proposed in terms of the single micropillar and micropillar array, thereby obtaining the optimal micropillar height and spacing for the GMA. To address the tilting and detachment issues, the GMA was printed on an electrochemically deposited gold particle-dendrite layer, significantly enhancing the adhesion between the micropillars and substrate. Along with the proposed stepwise sintering process, the fabricated 3D GMA electrode exhibited excellent structural integrity. Subsequently, the fabricated 3D GMA electrode was applied to non-enzymatic electrochemical glucose detection and the results show that, compared to a planar electrode, the hybrid working electrode of the sensor demonstrated a 534 % increase in electrochemical active surface area and a notably high ratio of 6.25 cm²/cm² was obtained. This work highlights the potential of EHD jet printing for fabricating robust 3D micro-structured gold electrodes, offering a reliable, cost-effective and promising solution for applications in biomedical detection and advanced healthcare technologies.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104806"},"PeriodicalIF":10.3,"publicationDate":"2025-05-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143929628","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":"Recycling nickel aluminium bronze grinding chips to feedstock for directed energy deposition via impact whirl milling: Investigation on processability, microstructure and mechanical properties","authors":"Vinzenz Müller ,&nbsp;Janek Maria Fasselt ,&nbsp;Christian Klötzer-Freese ,&nbsp;Tobias Kruse ,&nbsp;Rafael Kleba-Ehrhardt ,&nbsp;Max Biegler ,&nbsp;Michael Rethmeier","doi":"10.1016/j.addma.2025.104804","DOIUrl":"10.1016/j.addma.2025.104804","url":null,"abstract":"<div><div>During the production of ship propellers, considerable quantities of grinding chips from nickel aluminium bronze are produced. This paper examines the mechanical comminution of such chips via impact whirl milling and the utilization of two chip-powder batches as feedstock for a laser-based directed energy deposition process. The materials are characterized via digital image analysis, standardized flowability tests, scanning electron microscopy and energy dispersive X-ray spectroscopy and are compared to conventional, gas atomized powder. The specimens deposited via directed energy deposition are analyzed for density, hardness and microstructure and tensile properties for vertical and horizontal build up directions are compared. At elevated mill rotation speeds, the comminution with impact whirl milling produced rounded particles, favorable flow properties and particle size distribution, making them suitable to deposit additive specimens. The microstructure exhibited characteristic martensitic phases due to the high cooling rates of the additive manufacturing process. The presence of ceramic inclusions was observed in both the powder and on the tensile fracture surfaces, partly impairing the mechanical properties. However, specimens in the vertical build-up direction (Z) showed competitive tensile results, with 775 MPa in tensile strength, 455 MPa in yield strength and 12.6 % elongation at break. The findings of this study indicate that recycling of machining chips to additive manufacturing feedstock can be a viable option for reducing material costs and environmental impact.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104804"},"PeriodicalIF":10.3,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143906400","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":"Stiffness and strength enhancement of hierarchical TPMS-based shell lattices via inter-level conformal design","authors":"Rui Li,&nbsp;Winston Wai Shing Ma,&nbsp;Tianxiao Niu,&nbsp;Hui Liu,&nbsp;Junhao Ding,&nbsp;Xu Song","doi":"10.1016/j.addma.2025.104802","DOIUrl":"10.1016/j.addma.2025.104802","url":null,"abstract":"<div><div>Hierarchical structures in nature provide a blueprint design principle for engineering advanced lattice structures with enhanced mechanical properties and multifunctional performance. However, traditional Boolean-operation-based hierarchical lattices with incomplete second-level lattice structures at the boundaries, often suffer from localized deformation and stress concentration, limiting their stiffness and strength. Here, we introduce an inter-level conformal design for constructing hierarchical shell lattices that exhibit superior mechanical properties. By integrating a parameterized Monge patch model with iso-parametric transformation techniques, we achieve geometric conformity across multiple hierarchical levels. Numerical simulations with experimental validation reveal that inter-level conformal hierarchical triply periodic minimal surface (TPMS) shell lattices outperform their non-conformal Boolean-operation-based counterparts in stiffness, strength, and specific energy absorption by 28.4 %, 47.3 %, and 48.1 %, respectively. Such performance enhancement stems from the inter-level conformal design, which eliminates structural discontinuities and geometric truncations, prevent degrading the mechanical performance and introducing deadweight. Additionally, inter-level conformal architectures mitigate anisotropy, resulting in lower anisotropic Zener and Poisson's ratios. A statistical analysis of deformation mechanisms in hierarchical TPMS-based lattices reveals that both inter-level conformal and non-conformal designs exhibit a Weibull distribution of deformation behaviors. Notably, inter-level conformal designs are effective to reduce the stress localization, resulting in higher mechanical performance. These findings highlight the potential of inter-level conformal hierarchical design in enhancing the stiffness and strength of lattice structures, offering new opportunities for the design of high-performance lattice metamaterials across diverse engineering applications.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104802"},"PeriodicalIF":10.3,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143917780","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":"Investigating thermal strains and chemical shrinkage in tomographic volumetric additive manufacturing","authors":"Nicole Pellizzon,&nbsp;Berin Šeta,&nbsp;Carl Sander Kruse,&nbsp;Roozbeh Salajeghe,&nbsp;Jon Spangenberg","doi":"10.1016/j.addma.2025.104781","DOIUrl":"10.1016/j.addma.2025.104781","url":null,"abstract":"<div><div>Volumetric additive manufacturing provides many advantages over more traditional layer-based additive manufacturing methods by permitting support-free printing with isotropic material properties. However, accurate geometry reproduction remains a challenge. This work presents two models to investigate the contributions of thermal strains and chemical shrinkage to parts made via tomographic volumetric additive manufacturing. A thermal model, with invariant material properties and uniform cure progression, reproduces similar magnitude deformations to those seen experimentally. Through a parameter study and partial least squares regression, for a target cube geometry, deformations are found to be dominated by the heat transfer coefficient. A second model investigates non-uniform chemical shrinkage predicting smaller deformations but better capturing the deformed shape. This work concludes that a combination of primarily thermal strains and secondarily chemical shrinkage is thus required to capture this geometric infidelity paving the way to better understanding the deformation phenomena.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104781"},"PeriodicalIF":10.3,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143903418","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":"Mechanical properties of particle-bed 3D printed concrete infill patterns","authors":"Bo Zhang,&nbsp;Wouter De Corte,&nbsp;Ticho Ooms,&nbsp;Roman Wan-Wendner","doi":"10.1016/j.addma.2025.104803","DOIUrl":"10.1016/j.addma.2025.104803","url":null,"abstract":"<div><div>The particle-bed printing technique utilizes unbound material as support during the printing process, enabling the creation of complex 3D patterns that extrusion-based printing method cannot achieve. This study uses the selective paste intrusion particle-bed printing technique to produce specimens, including various prisms and cylindrical shapes with gyroid, diamond, and I-WP infill patterns, along with full cylinders, printed in various orientations. Three-point bending tests are conducted on the prisms to evaluate tensile, compressive, and fracture properties, while uniaxial compression tests are performed on the cylinders to assess the compressive properties. The compressive tests on the infill cylinders indicate that relationships between infill density and compressive properties follow a power-law function, consistent with similar patterns observed in other materials. Cracking primarily occurs at locations where the angle between unit cell faces approaches zero. These positions create an aggregation of surfaces that effectively bridge the internal structure, facilitating load transfer within the concrete. This study investigates the mechanical properties of particle-bed printed specimens, focusing on the compressive behavior of complex 3D concrete infill patterns featuring overhangs. These intricate geometries, fabricated for the first time using concrete particle-bed printing, are analyzed to evaluate how varying design parameters, such as printing direction and infill density, influence compressive performance. The relationships between infill density and compressive properties are systematically quantified across different infill patterns, providing valuable insights for structural design and topology optimization.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"106 ","pages":"Article 104803"},"PeriodicalIF":10.3,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143921780","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":"Multi-scale numerical modeling of inductively coupled plasma spheroidization of refractory tungsten powders for additive manufacturing","authors":"Shashank Sharma ,&nbsp;K.V. Mani Krishna ,&nbsp;Sameehan S. Joshi ,&nbsp;Ishtiaq Ahmed Fazle Rabbi ,&nbsp;M.S.K.K.Y. Nartu ,&nbsp;Rajarshi Banerjee ,&nbsp;Narendra B. Dahotre","doi":"10.1016/j.addma.2025.104801","DOIUrl":"10.1016/j.addma.2025.104801","url":null,"abstract":"<div><div>This study presents a multi-step, multi-scale modeling framework to address the complexities of particle spheroidization in inductively coupled plasma (ICP) processing of refractory tungsten powders, a precursor for refractory additive manufacturing. The framework integrates 2D axisymmetric and 3D non-transient multiphysics models to resolve plasma dynamics and turbulent flow fields within the ICP system. Additionally, a transient 3D Discrete Phase Model (DPM) was employed to predict particle flow behavior, heating, vaporization, and mass loss, while a 2D multiphase thermo-fluidic model at the particle scale simulated morphology evolution, including melting, vaporization, and sphericity transformations. The particle morphology evolution was governed by the interplay of surface tension, vaporization-induced recoil pressure, and non-uniform temperature distributions. Surface tension dominated the early melting phase, rapidly stabilizing smaller particles, while larger particles exhibited prolonged oscillations due to significant thermal gradients. Vaporization-induced recoil pressure dominated later stages, inducing localized deformation and altering droplet trajectories, with particles larger than 100 µm showing resistance to vaporization effects. The numerical results matched well with experimental observations, including the bimodal particle size distribution and post-spheroidization particle morphologies. The multi-scale multiphysics framework successfully predicted thermal flow, and morphological transformations providing a physics informed spheroidization pathways offering a robust platform for optimizing ICP-based spheroidization of refractory materials.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104801"},"PeriodicalIF":10.3,"publicationDate":"2025-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143898566","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":"An additive manufacturing assisted electric discharge machining technique to produce complex, thin-walled, injection mould cavities in 316 L stainless steel","authors":"Christopher O’Hara ,&nbsp;Marion McAfee ,&nbsp;Ramesh Raghavendra ,&nbsp;David Tormey","doi":"10.1016/j.addma.2025.104800","DOIUrl":"10.1016/j.addma.2025.104800","url":null,"abstract":"<div><div>This study takes a unique approach using an additively manufactured (AM) copper electric discharge machining (EDM) electrode to surface finish a 316 L Stainless Steel AM injection mould cavity. The research has a dual focus: first, to comprehend the achievable accuracy and surface finishing capabilities of a complex geometry electrode, manufactured using atomic diffusion additive manufacturing (ADAM). Second, reduce the volume of material used to manufacture electrodes and workpieces by printing the cavity geometry net shape, thereby reducing the number of electrodes and EDM process steps required to form the desired cavity geometry and surface finish. The study reveals that the ADAM electrode was subject to variable shrinkage, leading to varied results on the cavity surface finish and geometric accuracy after the EDM process. This method resulted in an average surface roughness (Ra) improvement of 56.3 %, with some surfaces seeing up to a 77 % reduction in their Ra compared to the as printed roughness. This study achieved a mean cavity accuracy of 0.07 mm, standard deviation 0.204 mm and median accuracy was 0.081. However, the maximum and minimum workpiece accuracy was + 0.442 mm / −0.24 mm. These findings indicate that an AM assisted EDM post-processing method, using a net shape AM cavity and an ADAM EDM electrode, can significantly reduce the number of electrodes in EDM post-processing from 10 to 1. Further opportunity exists to improve the accuracy obtained in this study by optimising the ADAM and EDM process parameters to better control the electrode geometry or apply alternative AM technologies for similar workflows.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104800"},"PeriodicalIF":10.3,"publicationDate":"2025-04-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143883274","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":"Cavity-induced bubbles and pore formation of laser direct energy deposited titanium alloy: Influence of powder melting degree","authors":"Mingyuan Chen ,&nbsp;Jikui Zhang ,&nbsp;Qiulin Qu ,&nbsp;Shuquan Zhang ,&nbsp;Dong Liu","doi":"10.1016/j.addma.2025.104792","DOIUrl":"10.1016/j.addma.2025.104792","url":null,"abstract":"<div><div>Porosity defects and their impact on fatigue performance have become one of the key issues in the widespread application of laser direct energy deposited titanium alloy components. The present work focuses on the cavity evolution and bubble generation process of unmelted, partially melted and fully melted powder entering the melt pool. Firstly, an equivalent experiment, ice particle with different melting degree impact water, was designed and conducted on the basis of similarity criterion in fluid mechanics. Secondly, a numerical model of powder impingement melt pool was established by using dynamic mesh method to simulate the evolution of cavity with different melting degree. Finally, a deposition processing with different melting states of the powder, by adjusting the angle and height of the powder feeding nozzle, was engaged to verify the influence of the melting states of the powder on the pore formation. The equivalent test and simulation results show that for the unmelted powder with large diameter and high velocity, the impacted cavity pinches off near the surface and induces gas entrainment and bubbles formation. For comparison, the fully melted powder enters the melt pool with a crater-shaped cavity which collapsed in a contraction mode and has not residual gas and bubbles. The surrounding liquid surface of partially melted powder changes the shape of the cavity and extended the time of collapse. With the increase of melting degree of powder, the collapse of cavity changes from the pinch-off to contraction mode, which avoids the generation of cavity-induced bubbles. The deposition experimental results show that both the pore size and porosity of the deposited specimen decrease with the increase of powder melting degree. This study is significant to clarify of the mechanism of porosity formation and decrease of porosity defects of laser direct energy deposited titanium alloy.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104792"},"PeriodicalIF":10.3,"publicationDate":"2025-04-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143883273","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":"Instrumentation of silicone liquid deposition modeling by extrusion: Introduction and evaluation of laser profilometry and associated indicators for supervision","authors":"Loïc Mosser,&nbsp;Lennart Rubbert,&nbsp;Laurent Barbé,&nbsp;Pierre Renaud","doi":"10.1016/j.addma.2025.104779","DOIUrl":"10.1016/j.addma.2025.104779","url":null,"abstract":"<div><div>While silicone printing by extrusion is a promising technique, part production is still a challenge when support-free printing is considered. In this paper, we consider three main causes of defects, namely the management of silicone flow rate during printing, the part deformation under its own weight before polymerization and the deformations due to the nozzle-layer interactions during printing. An instrumentation strategy is here proposed to monitor layer deposition. Our approach, based on laser profilometry, is detailed with open source software to control printing and scanning. The process to build point clouds and extract data is presented. More importantly, indicators are introduced to build metrics related to the current main causes of printing failure, using prior geometric information on the planned layers. Through experimental evaluation, the adequacy of the indicators and their complementarity is discussed. This introduction of new indicators opens ways to implement efficient silicone extrusion supervision.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104779"},"PeriodicalIF":10.3,"publicationDate":"2025-04-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143898567","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":"On the powder chilling effect in laser based directed energy deposition","authors":"Wei Fan ,&nbsp;Yijie Peng ,&nbsp;Siyu Zhang ,&nbsp;Zhiwei Hao ,&nbsp;Zhe Feng ,&nbsp;Hua Tan ,&nbsp;Liming Yao ,&nbsp;Fengying Zhang ,&nbsp;Xin Lin","doi":"10.1016/j.addma.2025.104789","DOIUrl":"10.1016/j.addma.2025.104789","url":null,"abstract":"<div><div>Understanding the thermal behavior during laser based directed energy deposition (LDED) is crucial for the grain structure control for superior and bespoke mechanical performance. Transient and localized chilling effect induced by the melting behavior of injected powder particles during the LDED process, plays a similar role of the cold mold surface in casting on solidification but has received little attention in the past. Here, we employ low energy density to partially retain the fine-grained powder particles during the deposition process, serving as tracers to study the influence of powder particle melting heat absorption on solidification. High-speed camera and infrared camera are used to real-time record the dynamic and thermal interactions between the powder particles and melt pool. Results show that powder particles gradually melt and absorb heat, leading to chilling effect on the melt pool at a millimeter scale. The temperature at the interaction position determines whether powder particles can penetrate the melt pool, thereby affecting the melting mode. Compared to floating powder, powder entering the melt pool can cause larger temperature drops. The collective powder chilling effect induced by multi-particle powder flow results in significant fluctuations in melt pool shape, maximum temperature, average temperature. Consequently, the powder chilling effect increases the average solidification rate at the tail of the melt pool to nearly three times, reduces the temperature gradient at the solid-liquid interface by 45 %, promoting the columnar-to-equiaxed transition during solidification. This study could be valuable in the additive manufacturing of single crystal and fine-grained components.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"105 ","pages":"Article 104789"},"PeriodicalIF":10.3,"publicationDate":"2025-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859860","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}