Additive manufacturing letters最新文献

{"title":"Corrigendum to “A new approach to laser DED as a repair technology with Laser Mesh Deposition” [Additive Manufacturing Letters, Volume 14, (2025) 100301]","authors":"Thomas Girerd , Richard Adamson , Andres Gameros , Marco Simonelli , Andy Norton , Adam Thomas Clare","doi":"10.1016/j.addlet.2026.100358","DOIUrl":"10.1016/j.addlet.2026.100358","url":null,"abstract":"","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"17 ","pages":"Article 100358"},"PeriodicalIF":4.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147740092","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}

{"title":"Future foundries: A convergent manufacturing platform","authors":"Shramana Ghosh ,&nbsp;Miguel Hoffmann ,&nbsp;Lauren Heinrich ,&nbsp;Kenton B. Fillingim ,&nbsp;Joshua Vaughan ,&nbsp;Brian K. Post ,&nbsp;Thomas Feldhausen","doi":"10.1016/j.addlet.2026.100364","DOIUrl":"10.1016/j.addlet.2026.100364","url":null,"abstract":"<div><div>This article introduces the Future Foundries platform developed at Oak Ridge National Laboratory, a first-generation research system designed to demonstrate convergent manufacturing. Convergent manufacturing brings together additive, subtractive, and transformative processes in a digitally interconnected environment to enable end-to-end production workflows. By linking traditionally discrete steps, convergent platforms accelerate production, improve repeatability, and support high-mix, low-volume manufacturing.</div><div>The Future Foundries platform exemplifies this vision in practice by combining four modular, vendor-agnostic process cells that include robotic WAAM, induction heating, optical metrology, and machining, coordinated through an automated pallet handler and a ROS 2-based digital thread. This architecture provides the flexibility and scalability needed for agile production in small and medium-sized manufacturing enterprises and for field deployable manufacturing.</div><div>Two case studies illustrate the platform’s capabilities. The first presents an integrated workflow for fabricating, transforming, and repairing critical replacement components, showing how consolidated thermal, additive, inspection, and machining operations reduce manual part handling and streamline process flow. The second case study highlights coordinated multi-part production enabled by automated pallet logistics and multi-cell scheduling. Together, these examples showcase convergent manufacturing as a practical and scalable strategy for strengthening domestic casting and forging capacity, improving supply-chain resilience, and enabling rapid, adaptable production of mission-critical components.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"17 ","pages":"Article 100364"},"PeriodicalIF":4.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384994","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}

{"title":"Printing multifunctional high-performance polymer parts via the hybridization of high temperature material extrusion thermal and chemical reactive bonding","authors":"Ian Y. Ho ,&nbsp;Jacob Viar ,&nbsp;Hutchison Peter ,&nbsp;Henry Claesson ,&nbsp;Christopher Williams","doi":"10.1016/j.addlet.2026.100367","DOIUrl":"10.1016/j.addlet.2026.100367","url":null,"abstract":"<div><div>Direct fabrication of multifunctional, high-performance components integrating structural dielectric and conductive materials remains a key challenge in advanced manufacturing. Additive manufacturing (AM) enables embedding functional elements layer-by-layer into structural parts. Hybrid material extrusion (MEX) systems have combined thermal reaction bonding (MEX-TRB, or fused filament fabrication, FFF) and chemical reaction bonding (MEX-CRB, or direct ink writing, DIW) modalities within the same system to directly produce multifunctional parts. However, these systems have been limited to depositing conductive traces within commodity polymers (e.g., PLA, ABS, PETG) at ambient conditions to prevent premature ink curing. These polymers lack the thermal stability to withstand high-performance ink sintering temperatures (often &gt;250 °C), limiting conductivity of the dispensed functional inks and resulting applications.</div><div>This work introduces a novel hybrid MEX-CRB/MEX-TRB system with an actively cooled MEX-CRB head to prevent ink curing while operating in chamber temperatures up to 110 °C, enabling the printing of high-performance polymers. In-situ characterization using embedded thermocouples confirmed that the cooling system maintains ink below critical curing thresholds. Conductivity measurements demonstrated successful in-situ sintering and conductive network formation of silver conductive traces within the heated chamber. Polyphenylene sulfide (PPS) parts with embedded silver traces were fabricated, leveraging the chamber for both polymer printing and trace sintering. Compared to traditional hybrid approaches requiring part shuttling between modalities, this integrated system reduces interlayer cooling and improves polymer interlayer adhesion. These results show that the high-temperature hybrid MEX system effectively balances conflicting thermal requirements of high-performance polymers and conductive inks, enabling efficient multimodality printing for advanced electrical applications.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"17 ","pages":"Article 100367"},"PeriodicalIF":4.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384999","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}

{"title":"Multi-camera fault detection in fused filament fabrication printing","authors":"Shanthalakshmi Kilambi ,&nbsp;Aster Tournoy ,&nbsp;Muhamad Amani ,&nbsp;Jovana Jovanova ,&nbsp;Baris Caglar ,&nbsp;Kunal Masania","doi":"10.1016/j.addlet.2026.100360","DOIUrl":"10.1016/j.addlet.2026.100360","url":null,"abstract":"<div><div>Fused filament fabrication is a popular extrusion 3D printing technology because of its affordability and accessibility. However, the approach often suffers from printing errors that result in wasted time, materials and energy. Convolutional neural networks can be trained to recognise a wide spectrum of printing anomalies from image data in real time, but past work has been limited to a few defect classifications at a time. Here, we introduce a fault detection system, designed to identify a range of errors without interrupting the printing process. Real-time detection is achieved using a pre-trained image recognition and pattern recognition convolutional neural network (CNN) with two mounted cameras on the print bed and a nozzle camera. Two CNN models are developed to classify images into common 3D printing errors for the two camera systems. The nozzle camera model achieves a high validation accuracy of 97.7%. The side camera model achieves comparable performance with a validation accuracy of 97.6%. To integrate the two CNNs into one unified system, a logic-based priority framework was used to improve reliability beyond individual model accuracies by resolving conflicting predictions and leveraging complementary viewing angles from both camera types to detect a broader range of defects. The data fusion framework identifies 12 common errors and has significantly improved the robustness of error classification, in-situ and in real-time, with inference times as small as 220 milliseconds. The results demonstrate the feasibility of a robust multi-input fault detection system to advance the reliability of extrusion 3D printing.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"17 ","pages":"Article 100360"},"PeriodicalIF":4.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146078659","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}

{"title":"Towards next-generation cutting tools: Laser powder bed fusion of topology-optimized WC-Co endmills","authors":"Mahmoud Seyam,&nbsp;Luke Rimac,&nbsp;Philip Koshy,&nbsp;Mohamed Elbestawi","doi":"10.1016/j.addlet.2026.100375","DOIUrl":"10.1016/j.addlet.2026.100375","url":null,"abstract":"<div><div>Additive manufacturing offers a transformative approach to reducing material waste and energy consumption by enabling the fabrication of complex, high-performance structures with greater sustainability. This study harnesses that potential in the context of cutting tool production, presenting a topology-optimized WC-Co endmill. The design was realized using a 3D finite element model based on the Solid Isotropic Material with Penalization (SIMP) method. The tool was subsequently produced via Laser Powder Bed Fusion, finish-ground, and experimentally tested. Results show that the mass of the endmill can be reduced by up to 63% without compromising its function when milling 6061 Al. Moreover, this hybrid manufacturing approach cuts energy consumption during fabrication by 89% compared to conventional methods. Modal tap testing further revealed an 18% increase in the limiting depth of cut, indicating improved dynamic stability. These findings validate the effectiveness of hybrid manufacturing for topology-optimized WC-Co rotating tools, demonstrating significant gains in both sustainability and operational performance.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"17 ","pages":"Article 100375"},"PeriodicalIF":4.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147600294","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}

{"title":"Advances in Additive Manufacturing for Architectural Acoustics: Design, Materials, Validation, and Implementation Challenges in Building Construction","authors":"Taiwo Martins Esan,&nbsp;Williams Kehinde Kupolati,&nbsp;Chris Ackerman","doi":"10.1016/j.addlet.2026.100368","DOIUrl":"10.1016/j.addlet.2026.100368","url":null,"abstract":"<div><div>Additive Manufacturing (AM), commonly referred to as 3D printing, has emerged as a transformative technology in the construction sector, enabling unprecedented geometric freedom, automation, and material efficiency. While its adoption for structural applications has accelerated, its integration into building acoustics remains limited and fragmented. This systematic review synthesizes findings from 79 peer-reviewed studies to evaluate the current state of AM for architectural acoustic applications, with emphasis on materials, design strategies, validation methods, and implementation challenges. Four dominant constraint categories are identified: material limitations (≈38%), structural and design constraints (≈19%), modeling and prediction inaccuracies (≈16%), and acoustic performance limitations, particularly narrow operational bandwidths (≈27%). The review highlights the critical role of geometry-driven design, including acoustic metamaterials and micro-perforated panels, enabled by AM processes such as material extrusion, vat photopolymerization, and powder bed fusion. However, persistent challenges related to sustainability, process scalability, surface quality, and limited field-scale validation restrict broader adoption. Emerging solutions, including AI-assisted material formulation, generative acoustic design, and hybrid computational–experimental workflows, are identified as key enablers for progress. The findings provide actionable insights for engineers and designers seeking to deploy AM-based acoustic components in buildings and establish a roadmap for advancing scalable, sustainable, and high-performance architectural acoustics.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"17 ","pages":"Article 100368"},"PeriodicalIF":4.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384997","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}

{"title":"COLD: Control and optimization of layer deposition in large-scale additive manufacturing","authors":"Diana Martins ,&nbsp;João R. Matos ,&nbsp;Diogo Sousa ,&nbsp;Fernando Gomes de Almeida","doi":"10.1016/j.addlet.2026.100371","DOIUrl":"10.1016/j.addlet.2026.100371","url":null,"abstract":"<div><div>Large-scale thermoplastic 3D printing is an emerging technology that enables cheaper and faster real-scale prototyping and rapid tooling. However, it still presents limitations that can lead to deformations in printed parts due to inadequate cooling conditions during the process. This study proposes COLD: a control and optimization of layer deposition system, based on temperature monitoring, to prevent print failures caused by excessive heat accumulation resulting from insufficient layer cooling time. A thermal camera was attached to a robotic printing system, and, after each layer is deposited, the average temperature of the regions where the next layer will be deposited is evaluated until it reaches a defined threshold. Conical thin wall parts were printed with and without COLD using Polypropylene 30% Glass Fiber, and the results show that it can contribute significantly to the success of large-scale additive manufacturing.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"17 ","pages":"Article 100371"},"PeriodicalIF":4.7,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384998","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}

{"title":"Comparing geometry and mechanical performance of as built and Hirtisation® treated Al-Cu-Mg-Ag-Ti-B-Si-Fe rhombic dodecahedron lattices manufactured by laser powder bed fusion","authors":"Ira Papamalama ,&nbsp;Emilie Beevers ,&nbsp;Berk Baris Celik ,&nbsp;Michael Doppler ,&nbsp;Selma Hansal ,&nbsp;Brecht Van Hooreweder","doi":"10.1016/j.addlet.2025.100350","DOIUrl":"10.1016/j.addlet.2025.100350","url":null,"abstract":"<div><div>This study investigates the morphological, geometrical, and mechanical characteristics of Al-Cu-Mg-Ag-Ti-B-Si-Fe aluminum alloy lattice structures fabricated via Laser Powder Bed Fusion (LPBF), with emphasis on quasi-static and fatigue mechanical performance. Using the Gibson–Ashby model as a framework, three relative lattice densities (RLDs) were examined in both as-built (AB) and Hirtisation® surface treated (HIRT) conditions. Results confirm that geometric strut waviness is inherent to the LPBF process, affecting both AB and HIRT samples. However, the Hirtisation® treatment notably reduces surface roughness and dross, enhancing fatigue life and surface uniformity. While strut length remains unchanged after post-treatment, a reduced strut diameter (thickness) alters the final density, directly impacting RLD and strength. Quasi-static tests validate the predicted strength–density relationship, with denser lattices exhibiting higher compressive strength. Fatigue testing reveals combined stretch and bending-dominated response, marked by crush bands and hybrid brittle-ductile failure mode. These findings deepen understanding of LPBF lattice structures and demonstrate the effectiveness of surface treatment in enhancing fatigue resistance and mechanical performance.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"16 ","pages":"Article 100350"},"PeriodicalIF":4.7,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145798694","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}

{"title":"Friction-induced distortion in binder jetted 316 L stainless steel: Experimental analysis, simulation, and compensation strategy","authors":"Marco Zago ,&nbsp;Thomas Grippi ,&nbsp;Elisa Torresani ,&nbsp;Matteo Perina ,&nbsp;Eugene A. Olevsky ,&nbsp;Ilaria Cristofolini","doi":"10.1016/j.addlet.2025.100352","DOIUrl":"10.1016/j.addlet.2025.100352","url":null,"abstract":"<div><div>This study investigates the origin of distortion during sintering of 316 L stainless steel components produced by binder jetting, focusing on friction between the sample and the support surface and on density inhomogeneity in the green state. A design of experiments (DoE) approach evaluates the influence of key printing parameters on the sintering behavior of two geometries with different through-hole sizes. Dimensional measurements, and density profiling, are performed in both green and sintered states. Sintering simulations use the Skorokhod-Olevsky viscous sintering (SOVS) model and include experimentally measured density gradients and frictional effects.</div><div>Results show that green density varies significantly (52% to 58%) depending on printing parameters, especially binder saturation, and exhibits directional dependence. These variations lead to measurable distortions during sintering. Simulations that include both friction and density gradients match experimental deformations with deviations below 4%. A compensation strategy that places parts on co-sintered 316 L support plates with interposed refractory particles reduces distortion to &lt;1.5%.</div><div>This work demonstrates the combined role of friction and density gradients in sintering distortion and presents a practical method to improve dimensional accuracy in binder jetting.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"16 ","pages":"Article 100352"},"PeriodicalIF":4.7,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145939218","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}

{"title":"Influence of deposition strategy on the microstructure of volumetric WADED-fabricated AZ61 magnesium alloy components","authors":"Filip Seidler,&nbsp;Jakub Slavíček,&nbsp;Daniel Koutný","doi":"10.1016/j.addlet.2025.100348","DOIUrl":"10.1016/j.addlet.2025.100348","url":null,"abstract":"<div><div>This study investigates the impact of various deposition strategies on the microstructure of volumetric components fabricated from AZ61 magnesium alloy using Wire Arc Direct Energy Deposition (WADED), also referred to as Wire Arc Additive Manufacturing (WAAM). Because coarse grains can significantly reduce mechanical performance, thermal simulations were performed to identify low-cooling-rate regions associated with different deposition trajectories. Three deposition strategies were analysed: ZigZag, Spiral, and S-pattern. The simulated thermal profiles were validated by optical grain size analysis and hardness measurements. In the selected critical regions, where the largest grains are expected, the S-pattern achieved the narrowest range in grain size and hardness distribution. This trajectory also exhibited the finest microstructure in most critical region, with the smallest average grain size. Additionally, it maintained good geometrical accuracy, indicating that it offers a promising route for producing high-quality magnesium-alloy components via WADED.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"16 ","pages":"Article 100348"},"PeriodicalIF":4.7,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145712242","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}