Additive manufacturing letters最新文献

Continuous carbon fiber 3D printing with interweaving deposition for enhanced mechanical performance in fused filament fabrication

IF 4.2

Additive manufacturing letters Pub Date : 2025-05-09 DOI: 10.1016/j.addlet.2025.100289

A. ElSherbiny, A.J. Qureshi, P. Mertiny

{"title":"Continuous carbon fiber 3D printing with interweaving deposition for enhanced mechanical performance in fused filament fabrication","authors":"A. ElSherbiny, A.J. Qureshi, P. Mertiny","doi":"10.1016/j.addlet.2025.100289","DOIUrl":"10.1016/j.addlet.2025.100289","url":null,"abstract":"<div><div>Additive manufacturing (AM) has revolutionized modern manufacturing by enabling the rapid prototyping and production of complex geometries with minimal material waste. Among AM techniques, Fused Filament Fabrication (FFF) is widely used for polymer-based manufacturing but exhibits limitations in high-performance applications due to insufficient mechanical properties. To address these shortcomings, this study focuses on advancing a standard FFF system to integrate Continuous Carbon Fiber (CCF) and implement interweaving deposition patterns, with the goal of enhancing structural performance and integrity. Representative volume element modeling and finite element analysis were conducted to evaluate the mechanical behavior, with results validated through experimental mechanical testing. The results confirm that CCF reinforcement improves the mechanical performance of printed components, particularly in the raster direction, although variations in response highlight the influence of material imperfections and non-linearities. The study demonstrates the potential of advanced CCF 3D printing in addressing the limitations of traditional FFF and provides insights for further advancements in polymer composite AM.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100289"},"PeriodicalIF":4.2,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143943283","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

An activity-based parametric cost analysis for upcycling machining chips to produce feedstock for sustainable additive friction stir deposition 基于作业的切削屑升级回收参数成本分析，以生产可持续添加剂搅拌摩擦沉积的原料

IF 4.2

Additive manufacturing letters Pub Date : 2025-05-08 DOI: 10.1016/j.addlet.2025.100288

Sweta Baruah, Joshua Hoekstra, Tony Schmitz

{"title":"An activity-based parametric cost analysis for upcycling machining chips to produce feedstock for sustainable additive friction stir deposition","authors":"Sweta Baruah, Joshua Hoekstra, Tony Schmitz","doi":"10.1016/j.addlet.2025.100288","DOIUrl":"10.1016/j.addlet.2025.100288","url":null,"abstract":"<div><div>With the growing emphasis on supply chain resilience and efficiency, manufacturers are increasingly exploring sustainable material reuse strategies. One promising approach is the upcycling of machining chips into usable feedstock for additive friction stir deposition (AFSD), a solid-state additive manufacturing process. AFSD has demonstrated potential for integrating into hybrid manufacturing workflows, offering advantages such as reduced material waste and enhanced process sustainability. However, for chip upcycling to produce AFSD feedstock to be viable, its production cost must be accurately assessed and compared to conventional feedstock options. Estimating these costs poses challenges due to the complexity of the upcycling process and its associated variables. This paper presents a cost modeling framework for the production of upcycled bars from machining chips, specifically as AFSD feedstock. The proposed model incorporates key cost factors such as material preparation, compaction, and processing efficiency. A case study is conducted to compare the cost of upcycled feedstock with commercially available AFSD feedstock, providing insights into the economic feasibility of chip upcycling for AFSD applications.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100288"},"PeriodicalIF":4.2,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143935863","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Multimaterial 3D printing of structured surfaces for increased hydrophobicity of biocomposite materials 用于增加生物复合材料疏水性的结构表面的多材料3D打印

IF 4.2

Additive manufacturing letters Pub Date : 2025-05-08 DOI: 10.1016/j.addlet.2025.100286

Kayah St. Germain , Damien Marchand , Laurence Chocinski-Arnault , Hani E. Naguib , Fabienne Touchard

{"title":"Multimaterial 3D printing of structured surfaces for increased hydrophobicity of biocomposite materials","authors":"Kayah St. Germain , Damien Marchand , Laurence Chocinski-Arnault , Hani E. Naguib , Fabienne Touchard","doi":"10.1016/j.addlet.2025.100286","DOIUrl":"10.1016/j.addlet.2025.100286","url":null,"abstract":"<div><div>Material extrusion 3D printing is an up-and-coming additive manufacturing method that is continuously being explored for its many benefits including rapid prototyping, high degree of customizability, and low material waste production, among others. One of the most widely used materials in material extrusion 3D printing is polylactic acid (PLA) due to its ease of printability and bio-origins. Recently, new biofiller reinforced PLA biocomposite filaments have begun being sold commercially, but the introduction of the biofiller creates problems of increased hydrophilicity and hygroscopicity. In this study, a possible solution to this problem was explored by using multimaterial 3D printing to add a thin, structured outer layer to the biocomposite in either pure PLA or TPU. This layer helps limit any external moisture from coming into contact with the underlying biocomposite by creating a barrier with increased hydrophobicity. A grid, triangle, and honeycomb pattern were each tested at 50 %, 75 %, and 100 % pattern densities for each material. It was found that, along with the pattern that was printed, the filament deposition process created additional roughness that influenced the way the water droplets interacted with the surface. All the patterned surfaces displayed a higher water contact angle than when the material was printed in a flat manner. Additionally, factors that influence the feasibility of using this outer structured layer to improve the surface hydrophobicity of biocomposite parts were explored, including material compatibility and adhesion.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100286"},"PeriodicalIF":4.2,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144070317","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Introduction of Cr steels to additive manufacturing using an innovative alloying approach - Challenges and Potentials 采用创新的合金化方法将Cr钢引入增材制造-挑战和潜力

IF 4.2

Additive manufacturing letters Pub Date : 2025-05-03 DOI: 10.1016/j.addlet.2025.100287

Philip König, Sebastian Weber, Jonathan Lentz

{"title":"Introduction of Cr steels to additive manufacturing using an innovative alloying approach - Challenges and Potentials","authors":"Philip König, Sebastian Weber, Jonathan Lentz","doi":"10.1016/j.addlet.2025.100287","DOIUrl":"10.1016/j.addlet.2025.100287","url":null,"abstract":"<div><div>This study introduces martensitic Cr steels into additive manufacturing (AM) and provides first important findings for its PBF-LB/M processing. The comprehensive approach covers the entire process chain, including alloy modification, powder production, additive manufacturing, and microstructural characterization. Nitrogen (N), as an interstitial element soluble in iron, plays a central role in this strategy, offering economic and sustainability benefits during powder production while improving the PBF-LB/M-processability and performance of the final components. The atomizing gas N₂ was employed in vacuum induction gas atomization (VIGA) to facilitate direct alloying with N in the powder production process. A thermodynamic calculation-based alloying adjustment of the base alloy resulted in an increased N concentration of approximately 0.17 mass% in the powder. Consequently, electron backscatter diffraction (EBSD) and X-ray diffraction (XRD) studies demonstrate a notable increase in austenite content in the PBF-LB/M state. This finding aligns with thermodynamic predictions regarding the impact of N on austenite stability, reducing the propensity for cold cracking.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100287"},"PeriodicalIF":4.2,"publicationDate":"2025-05-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143912556","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Toward an Entropy-based Method for Multi-Physics Optimization of Additively Manufactured Cellular Materials 基于熵的增材制造细胞材料多物理场优化方法研究

IF 4.2

Additive manufacturing letters Pub Date : 2025-05-02 DOI: 10.1016/j.addlet.2025.100285

Tyler D. Smith, Dhruv Bhate

引用次数: 0

Dimensionless process windows in laser-based powder bed fusion of AISI 316L using ring-shaped beam profiles 基于环形光束轮廓的aisi316l激光粉末床熔合无因次加工窗口

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-28 DOI: 10.1016/j.addlet.2025.100284

Jonas Grünewald, Katrin Wudy

{"title":"Dimensionless process windows in laser-based powder bed fusion of AISI 316L using ring-shaped beam profiles","authors":"Jonas Grünewald, Katrin Wudy","doi":"10.1016/j.addlet.2025.100284","DOIUrl":"10.1016/j.addlet.2025.100284","url":null,"abstract":"<div><div>The research trend to investigate the influence of alternative beam profiles on the process and component properties in laser-based powder bed fusion raises the question of how to compare the processes and process results generated with various beam profiles in different sizes. The current state of research mainly examines the process simplified on a single-track basis or addresses isolated aspects, such as the change in beam profile and size with constant absolute process parameters, which neglects the cross-effects of these parameters. Therefore, this paper presents a new approach to consider varied process parameters and their cross effects. The approach is based on a simple heat conduction model and allows the creation of beam shape and size-independent process maps. These dimensionless process maps are created by replacing the common dimensioned process parameters (laser power and scan speed) with combined dimensionless parameters (dimensionless enthalpy and Peclét number, each extended by a dimensionless hatch distance). This way, the parameters consider material and beam properties. Within the process maps, the process boundaries are predicted by simple geometric conditions of the calculated melt pools using the introduced heat conduction model. The model is experimentally validated by conducting a comprehensive parameter study using a multidimensional design of experiments with seven different beam profiles in various sizes and varying laser power, scanning speed, and hatch distance processing AISI 316L. The relative density and surface roughness are evaluated in the experiments. The predicted and experimentally determined process limits are in excellent agreement.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100284"},"PeriodicalIF":4.2,"publicationDate":"2025-04-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143906639","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Columnar-to-equiaxed transitions in additively manufactured face-centered cubic multi-principal element alloys 增材制造面心立方多主元素合金的柱向等轴转变

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-14 DOI: 10.1016/j.addlet.2025.100283

Mengyao Zheng , Yu Liao , Zheng Zhou , Hao Zhang , Chuanwei Li , Zhong Long , Jianfeng Gu

{"title":"Columnar-to-equiaxed transitions in additively manufactured face-centered cubic multi-principal element alloys","authors":"Mengyao Zheng , Yu Liao , Zheng Zhou , Hao Zhang , Chuanwei Li , Zhong Long , Jianfeng Gu","doi":"10.1016/j.addlet.2025.100283","DOIUrl":"10.1016/j.addlet.2025.100283","url":null,"abstract":"<div><div>Columnar-to-equiaxed transition (CET) represents a critical microstructural characteristic in additively manufactured alloys. Precise control over CET is essential for achieving high-performance metallic components through additive manufacturing. In this study, two face-centered cubic multi-principal element alloys (MPEAs), namely CoCrNi and FeCoCrNi, were fabricated via laser directed energy deposition. The influence of process parameter and alloy composition on the CET of the two MPEAs was investigated. The results demonstrated that pronounced CET phenomena were observed in both MPEAs as the laser power increased and the scanning speed decreased. However, significant variations were noted in their CET parameters, equiaxed grain fraction, and crystallographic texture. Subsequently, the impact of process parameters on temperature gradient, solidification rate, and molten pool morphology was investigated via finite element modelling, revealing the formation mechanisms of the grain morphology and texture in additively manufactured CoCrNi and FeCoCrNi alloys. Additionally, the results of thermodynamic calculation revealed significant differences in the growth restriction factors between the two MPEAs, thereby explaining the distinct CET behaviors observed in the two MPEAs.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"14 ","pages":"Article 100283"},"PeriodicalIF":4.2,"publicationDate":"2025-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143859350","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers 使用小型和大型基于颗粒的3d打印机对钕铁硼/SmFeN尼龙粘结磁铁进行综合压缩成型的材料挤压

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-01 DOI: 10.1016/j.addlet.2025.100282

Kaustubh Mungale , Vipin Kumar , Mariappan Parans Paranthaman , Brian C. Sales , Harshida Parmar , Ikenna C. Nlebedim , Brittany Rodriguez , Uday Kumar Vaidya

{"title":"Material extrusion with integrated compression molding of NdFeB/SmFeN nylon bonded magnets using small- and large-scale pellet-based 3D-printers","authors":"Kaustubh Mungale , Vipin Kumar , Mariappan Parans Paranthaman , Brian C. Sales , Harshida Parmar , Ikenna C. Nlebedim , Brittany Rodriguez , Uday Kumar Vaidya","doi":"10.1016/j.addlet.2025.100282","DOIUrl":"10.1016/j.addlet.2025.100282","url":null,"abstract":"<div><div>High-density bonded rare-earth magnets are manufactured using pellet-fed additive manufacturing (AM)/material extrusion and an integrated additive manufacturing-compression molding (AM-CM) process. Neodymium iron boron – samarium iron nitride in polyamide 12 (NdFeB-SmFeN/PA12) of 93 % weight fraction (65 % volume fraction) are used for the study. The mechanical properties (tensile strength and modulus), magnetic properties (maximum energy density, coercivity, remanence) are reported. Manufacturing parameters such as layer height, barrel temperatures, screw speed and gantry feed rate are optimized to obtain the highest possible density of the magnets using a small-scale desktop material extrusion printer. Large scale integrated additive manufacturing-compression molding (AM-CM) is then utilized to increase the density of the magnets by reducing porosity defects common in the material extrusion process. The density of as-printed magnets was 5.2 g/cm<sup>3</sup> with a <em>BH<sub>max</sub></em> value of 124.14 kJ/m<sup>3</sup>, tensile strength of 20 MPa and a modulus of 2 GPa. AM-CM increased the density of the compound by 5.5 % (5.49 g/cm<sup>3</sup>). The reduction in porosity was confirmed using X-ray tomography (XCT). Improvement in mechanical strength of the material was also observed, with an increase in tensile strength of 25 % (25.09 MPa) and increase in tensile modulus of 275 % (5.49 GPa). Scanning electron microscopy showed increased particle-matrix adhesion with the integrated AM-CM process.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100282"},"PeriodicalIF":4.2,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143838686","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

On cyber sabotage risks in automated manufacturing of advanced composites 先进复合材料自动化制造中的网络破坏风险研究

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-01 DOI: 10.1016/j.addlet.2025.100280

Saral Mittal , Hammond Pearce , Mark Yampolskiy , Ebrahim Oromiehie , B. Gangadhara Prusty

{"title":"On cyber sabotage risks in automated manufacturing of advanced composites","authors":"Saral Mittal , Hammond Pearce , Mark Yampolskiy , Ebrahim Oromiehie , B. Gangadhara Prusty","doi":"10.1016/j.addlet.2025.100280","DOIUrl":"10.1016/j.addlet.2025.100280","url":null,"abstract":"<div><div>Recent advancements in the manufacturing of layered composite structures have seen the deployment of automated control systems, with computers used for both design protocols and control of manufacturing processes. However, as digitisation and computerisation of composites manufacturing advances, so too grows the potential exposure to cyber-attacks. Given that large manufacturing companies, government organisations, and defence agencies are increasingly utilising parts made out of fibre-reinforced composite materials, this security exposure must be acknowledged and managed carefully.</div><div>From other computerised manufacturing domains, we know that adversaries may aim to steal technical data such as digital design files (for example, for espionage or to infringe on Intellectual Property, IP) or to sabotage manufactured parts. Both can have consequences reaching far beyond immediate financial or physical damage. While it can be assumed that the adversarial goals are similar for composites manufacturing, the attack methods have not been explored or studied yet. This paper seeks to address this gap in part, by providing the first holistic security analysis of potential sabotage attacks in automated composites manufacturing using modern equipment. This security analysis provides a framework for composite manufacturers to identify vulnerabilities in their production workflows that are susceptible to cyber-attacks, while also providing opportunity to design customised countermeasures to strengthen the security of their automated manufacturing processes.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100280"},"PeriodicalIF":4.2,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143823526","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Simultaneously improving strength and corrosion resistance of additively manufactured Mg-Gd-Zr alloy by in-situ alloying with Al 通过原位合金化铝，同时提高了增材制造Mg-Gd-Zr合金的强度和耐腐蚀性

IF 4.2

Additive manufacturing letters Pub Date : 2025-04-01 DOI: 10.1016/j.addlet.2025.100279

Ziyi Liu, Qingchen Deng, Yiwen Ding, Ziyan Li, Jiacheng Wang, Liming Peng

{"title":"Simultaneously improving strength and corrosion resistance of additively manufactured Mg-Gd-Zr alloy by in-situ alloying with Al","authors":"Ziyi Liu, Qingchen Deng, Yiwen Ding, Ziyan Li, Jiacheng Wang, Liming Peng","doi":"10.1016/j.addlet.2025.100279","DOIUrl":"10.1016/j.addlet.2025.100279","url":null,"abstract":"<div><div>Additive manufacturing of magnesium (Mg) alloy components with intricate geometries via laser powder bed fusion (LPBF) offers significant advantages for lightweight engineering applications. However, as a commonly issue of Mg alloys, the corrosion resistance of LPBF-Mg alloys is even worse than their cast and deformed counterparts. In-situ alloying provides a rapid pathway for composition modification tailored for the LPBF process. In this study, aluminum (Al) is introduced through in-situ alloying to prepare Mg-10Gd-xAl-Zr (GA10xK, <em>x</em> = 0.5, 1, 2 wt. %) alloys using blended Mg-10Gd-Zr and Mg-15Al powders. By employing a lower scanning speed during LPBF, a uniform distribution of Al throughout the as-built components is achieved. The increase in Al content leads to the progressive enhancement in grain refinement and the transformation of secondary phases from Mg<sub>3</sub>Gd to Al<sub>2</sub>Gd with a significant reduction in size and a notable increase in number density. These microstructural transformations yield a synchronous enhancement in strength and corrosion resistance with increasing Al content. The yield strength and ultimate tensile strength of the GA102K alloy reach 328 MPa and 350 MPa, respectively, with a minimized corrosion rate of 0.787 mm/yr., surpassing the mechanical and corrosion performance of both LPBF and semi-continuous cast G10K alloys.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"13 ","pages":"Article 100279"},"PeriodicalIF":4.2,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739518","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0