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Special Issues
Design, Processes and Materials for Additive Manufacturing
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Design, Processes and Materials for Additive Manufacturing

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 July 2024 | Viewed by 4178

Special Issue Editor

Dr. Panagiotis Stavropoulos

E-Mail Website
Guest Editor
Laboratory for Manufacturing Systems & Automation (LMS), Department of Mechanical Engineering and Aeronautics, University of Patras, 26504 Patras, Greece
Interests: conventional/non-conventional/micro manufacturing processes; machine tool design; CAD/CAM and RP/RM systems
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) has several advantages over traditional manufacturing technologies and has grown very quickly in recent years. However, there are still technological issues preventing the industry from utilizing its full potential, which can be categorized under three pillars, namely design, processes, and materials.

Such challenges include design and redesign for AM aiming to improve manufacturability, productivity, and quality, and the encapsulation of post-processing for AM into the design phase. These can be expanded towards techniques for the utilization of AI towards AM design optimization, as well as design aspects/considerations for multi-material AM and 4D printing.

Regarding process-related AM challenges, there is still a need for methodologies to mitigate the quality issues with AM parts and the optimization of process parameters for the improvement in specific key performance indicators (KPIs) related to quality and productivity, either experimentally or through simulation. Another aspect is connected to strategies and applications for in situ monitoring, defect detection, and process control, especially for metal-based AM, as well as decision support systems for AM process selection. Additionally, there is an exigency of practical and innovative modeling/simulation approaches for AM (nano-, micro-, macro-, multi-scale), as well as digital twins for AM, utilizing a holistic solution approach. Process optimization for improved surface quality and reduced post-processing is another important challenge, which will reduce the costs of AM and further increase its appeal for many industrial applications. Finally, other important topics include innovative AM processes allowing for higher productivity and a minimized need for post-processing and the design and validation of innovative hybrid AM systems.

As far as the materials pillar is concerned, there is still a need to further investigate the impact of process parameters on microstructure and mechanical properties, both experimentally and through simulations, as well as for the development of efficient quality assessment applications of mechanical properties of metal AM components. Additionally, material-related aspects of 4D printing, such as the testing and validation of 4D printing materials and methodologies for 4D printing using conventional AM equipment and materials, should be further investigated. Additional challenges include the development of techniques and methodologies for the utilization of multi-material AM for high-added-value products, as well as new materials for AM, including their testing and validation (metals, polymers, ceramics, composites, cement-based, biomaterials).

The focus and goal of this Special Issue is to address the design-, process-, and material-related challenges of AM, which include, but are not limited to, the aforementioned ones, and to propose improvements in aspects related to those three pillars to avail the wider industrial adoption of AM.

Dr. Panagiotis Stavropoulos
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing
  • AM design optimization
  • post-processing for AM
  • process optimization
  • in situ monitoring, defect detection, and process control for metal-based AM
  • material-related aspects of 4D printing
  • utilization of multi-material AM
  • new materials for AM

Published Papers (4 papers)

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Research

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18 pages, 22575 KiB  
Article
Improving the Mechanical Properties of GlassFibre-Reinforced Laser-Sintered Parts Based on Degree of Crystallinity and Porosity Content Using a Warm Isostatic Pressing (WIP) Process
by Hellen De Coninck, Jae Won Choi, Jeroen Soete, Sebastian Meyers and Brecht Van Hooreweder
J. Manuf. Mater. Process. 2024, 8(2), 64; https://doi.org/10.3390/jmmp8020064 - 25 Mar 2024
Viewed by 664
Abstract
Additively manufactured fibre-reinforced polymers are gaining traction. After the development and optimisation of a novel fibre-deposition system in a laser sintering (LS) setup, polyamide 12 specimens were produced with and without glass fibres. In this study, the relation between the crystallinity, porosity, and [...] Read more.
Additively manufactured fibre-reinforced polymers are gaining traction. After the development and optimisation of a novel fibre-deposition system in a laser sintering (LS) setup, polyamide 12 specimens were produced with and without glass fibres. In this study, the relation between the crystallinity, porosity, and mechanical properties of LS specimens with and without fibres is investigated. After testing as-built LS specimens, a detrimental effect of the fibres on the specimens’ performance was observed with a decrease in UTS of 6%. The degree of crystallinity remained the same; however, a porosity content of 2.6% was observed in specimens with fibres. These pores can have a negative influence on the bonding between the fibres and the matrix. To investigate the influence of the pores, warm isostatic pressing (WIP) was performed on LS specimens with and without fibres. The WIP process shows a positive influence on the specimens without fibres, resulting in an increase in UTS of 8.5%. The influence of the WIP process on specimens with fibres, however, is much less pronounced, with an increase in UTS of only 2%. Neither the crystallinity nor the porosity are the cause of the less-than-expected increase in UTS in LS specimens with fibres. A number of hypotheses and mitigation strategies are provided. Full article
(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing)
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17 pages, 10373 KiB  
Article
Advances in Additive Friction Extrusion Deposition (AFED): Process and Tool Design
by Max Hossfeld and Arnold Wright
J. Manuf. Mater. Process. 2024, 8(2), 57; https://doi.org/10.3390/jmmp8020057 - 05 Mar 2024
Viewed by 1427
Abstract
Additive friction extrusion deposition (AFED) is a recently developed additive manufacturing technique that promises high deposition rates at low forces. Due to the novelty of the process, the underlying phenomena and their interactions are not fully understood, and in particular, the processing strategy [...] Read more.
Additive friction extrusion deposition (AFED) is a recently developed additive manufacturing technique that promises high deposition rates at low forces. Due to the novelty of the process, the underlying phenomena and their interactions are not fully understood, and in particular, the processing strategy and tool design are still in their infancy. This work contributes to the state-of-the-art of AFED through a comprehensive analysis of its working principles and an experimental program, including a representative sample component. The working principle and process mechanics of AFED are broken down into their individual components. The forces and their origins and effects on the process are described, and measures of process efficiency and theoretical minimum energy consumption are derived. Three geometrical features of the extrusion die were identified as most relevant to the active material flow, process forces, and deposition quality: the topography of the inner and outer circular surfaces and the geometry of its extrusion channels. Based on this, the experimental program investigated seven different tool designs in terms of efficiency, force reduction, and throughput. The experiments using AA 6061-T6 as feedstock show that AFED is capable of both high material throughput (close to 550 mm3/s) and reduced substrate forces, for example, the forces for a run at 100 mm3/s remained continuously below 500 N and for a run at 400 mm3/s below 3500 N. The material flow and microstructure of AFED were assessed from macro-sections. Significant differences were found between the advancing and retracting sides for both process effects and material flow. Banded structures in the microstructure show strong similarities to other solid-state processes. The manufacturing of the sample components demonstrates that AFED is already capable of producing industrial-grade components. In mechanical tests, interlayer bonding defects resulted in more brittle failure behavior in the build direction of the structure, whereas in the horizontal direction, mechanical properties corresponding to a T4 temper were achieved. Full article
(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing)
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17 pages, 5631 KiB  
Article
Characterization of the Dimensional Precision, Physical Bonding, and Tensile Performance of 3D-Printed PLA Parts with Different Printing Temperature
by Rayson Pang, Mun Kou Lai, Khairul Izwan Ismail and Tze Chuen Yap
J. Manuf. Mater. Process. 2024, 8(2), 56; https://doi.org/10.3390/jmmp8020056 - 05 Mar 2024
Viewed by 1404
Abstract
In this study, tensile test specimens were fabricated using a material extrusion 3D-printer at various printing temperatures to evaluate the development of physical bonds within the same layer as well as in between previous layers. The tensile test specimens were fabricated using PLA [...] Read more.
In this study, tensile test specimens were fabricated using a material extrusion 3D-printer at various printing temperatures to evaluate the development of physical bonds within the same layer as well as in between previous layers. The tensile test specimens were fabricated using PLA material, with printing temperatures ranging from 180 °C to 260 °C. Experimental investigations were conducted to investigate the dimensional accuracy and physical appearance of the parts across printing temperatures. Uniaxial tensile tests were conducted at a strain rate of 1 mm/min and repeated five times for each variable in accordance with the ASTM D638-14 standard. Results showed that increasing the printing temperatures yielded parts with better tensile properties. An approximate difference of 40% in tensile strength was observed between specimens fabricated under the two most extreme conditions (180 °C and 260 °C). The changes in tensile properties were attributed to bonding mechanisms related to interlayer bonding strength and a reduction in voids within the internal geometry. Analysis of the fracture surface using scanning electron microscopy (SEM) revealed fewer and smaller voids within the internal geometry for parts printed at higher temperature. The percentage area of voids reduced significantly when the printing temperature was increased from 180 °C to 220 °C. The tensile properties continuously improved with the printing temperature, with parts printed at 220 °C exhibiting the highest dimensional accuracy. The findings offer insight into the impact of the printing temperature on both the external physical bonds between printed roads, affecting the physical appearance and dimensional accuracy, and the internal bonds, affecting the tensile properties of the fabricated parts. Full article
(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing)
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Review

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20 pages, 305 KiB  
Review
Computer-Aided Optimisation in Additive Manufacturing Processes: A State of the Art Survey
by Tanja Emilie Henriksen, Tanita Fossli Brustad, Rune Dalmo and Aleksander Pedersen
J. Manuf. Mater. Process. 2024, 8(2), 76; https://doi.org/10.3390/jmmp8020076 - 15 Apr 2024
Viewed by 323
Abstract
Additive manufacturing (AM) is a field with both industrial and academic significance. Computer-aided optimisation has brought advances to this field over the years, but challenges and areas of improvement still remain. Design to execution inaccuracies, void formation, material anisotropy, and surface quality are [...] Read more.
Additive manufacturing (AM) is a field with both industrial and academic significance. Computer-aided optimisation has brought advances to this field over the years, but challenges and areas of improvement still remain. Design to execution inaccuracies, void formation, material anisotropy, and surface quality are examples of remaining challenges. These challenges can be improved via some of the trending optimisation topics, such as artificial intelligence (AI) and machine learning (ML); STL correction, replacement, or removal; slicing algorithms; and simulations. This paper reviews AM and its history with a special focus on the printing process and how it can be optimised using computer software. The most important new contribution is a survey of the present challenges connected with the prevailing optimisation topics. This can be seen as a foundation for future research. In addition, we suggest how certain challenges can be improved and show how such changes affect the printing process. Full article
(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing)
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