Purpose The purpose of this study is to compile the successful implementation of three-dimensional (3D) printing in the space for the manufacturing of complex parts. 3D printing is an additive manufacturing (AM) technique that uses metallic powder, ceramic, or polymers to build simple/complex parts. The parts produced possess good strength, low weight, excellent mechanical properties and are cost-effective

Purpose This paper aims to summarize the influence law of hybrid deposited and micro-rolling (HDMR) technology on the shaping strain and residual stress. And the rolling parameters combination was further optimized to guide the actual production. Design/methodology/approach This paper proposed a three-dimensional coupled thermo-mechanical model of the HDMR process. The validated model is used to investigate

Purpose Human aging is becoming a common issue these days as it results in orthopaedic-related issues such as joints disorderness, bone-fracture. People with age = 60 years suffer more from these aforesaid issues. It is expected that these issues in human beings will ultimately reach 2.1 billion by 2050 worldwide. Furthermore, the increase in traffic accidents in young people throughout the world has

Purpose This paper aims to present a survey concerning the accuracy of thermoplastic polymeric parts fabricated by additive manufacturing (AM). Based on the scientific literature, the aim is to provide an updated map of trends and gaps in this relevant research field. Several technologies and investigation methods are examined, thus giving an overview and analysis of the growing body of research.

Purpose There are over 40 million amputees globally with more than 185,000 Americans losing their limbs every year. For most of the world, prosthetic devices remain too expensive and uncomfortable. This paper aims to outline advancements made by a multidisciplinary research group, interested in advancing the restoration of human motion through accessible lower limb prostheses. Design/methodology/approach

Purpose Fused filament fabrication (FFF) using tough poly lactic acid (PLA) was determined to be the most suited method to achieve low-cost prosthetic sockets. However, improvement in the material properties is desirable to strengthen these sockets. This study aims to evaluate annealing as a potential method to improve material properties by a heat treatment of the object after 3D printing. Design

Purpose This paper aims to describe a new process for suppressing the formation of orange peel, which is a polymer laser sintering (LS) process error. Design/methodology/approach The target for controlling the suppression of orange peel is securing the contact between the molten polymer and the surrounding powder. The authors set the powder bed temperature closer to the melting temperature than that

Purpose Studies on titanium implants have shown that the mechanical properties of the parts are affected by the microstructure characteristic derived from the manufacturing process. The properties of different orientations of specimens under the same process parameters will be different, which should be considered in the application of bone implants. This paper aims to understand the influence of microstructure

Purpose This study aims to develop and demonstrate a deposition framework for the implementation of a region-based adaptive slicing strategy for the Tungsten Inert Gas (TIG) welding-based additive manufacturing system. The present study demonstrates a deposition framework for implementing a novel region-based adaptive slicing strategy termed as Fast Interior and Accurate Exterior with Constant Layer

Purpose The purpose of this paper is to determine the optimum nozzle diameter for parts production with polylactic acid using a three-dimensional printer. The additive manufacturing method used was fused filament fabrication. Design/methodology/approach Designers and researchers have focused on the effects of these parameters on part strength. Additionally, production time is one of the disadvantages

Purpose Additive manufacturing (AM) of thermoplastic polymers for powder bed fusion processes typically requires each layer to be fused before the next can be deposited. The purpose of this paper is to present a volumetric AM method in the form of deeply penetrating radio frequency (RF) radiation to improve the speed of the process and the mechanical properties of the polymer parts. Design/methodology/approach

Purpose Adaptive slicing is a key step in three-dimensional (3D) printing as it is closely related to the building time and the surface quality. This study aims to develop a novel adaptive slicing method based on ameliorative area ratio and accurate cusp height for 3D printing using stereolithography (STL) models. Design/methodology/approach The proposed method consists of two stages. In the first

Purpose The evaluation of novel materials such as the acrylonitrile styrene acrylate (ASA) for tribological and mechanical conditions can provide a structural protection against the environmental and wear effects that results in the long-term integrity of the 3 D printed parts. Results of the experimental stage are intended to identify the influence of the printing conditions on the functional characteristics

Purpose The deposition of particles onto a substrate during the cold spraying (CS) process relies on severe plastic deformation, so there are various micro-defects induced by insufficient deformation and severe crushing. To solve the problems, many post-treat techniques have been used to improving the quality by eliminating the micro-defects. This paper aims to help scholars and engineers in this field

Purpose This study aims to investigate additive manufacturing of nickel-based superalloy IN718 made by powder bed fusion processes: powder bed fusion laser beam (PBF-LB) and powder bed fusion electron beam (PBF-EB). Design/methodology/approach This work has focused on the influence of building methods and post-fabrication processes on the final part properties, including microstructure, surface quality

Purpose Springs are an integral part of mechanisms and can benefit from additive manufacturing’s (AM) increased design freedom. Given the limited literature on the subject, the purpose of this paper is to develop guidelines for fabricating helical springs using three-dimensional (3D) printing. Design/methodology/approach Polylactic acid (PLA) is the main material investigated, with ULTEM™ 9085 used

Purpose Laser powder bed fusion (LPBF) provides the means to produce unique components with almost no restriction on geometry in an extremely short time. However, the high-temperature gradient and high cooling rate produced during the fabrication process result in residual stress, which may prompt part warpage, cracks or even baseplate separation. Accordingly, an appropriate selection of the LPBF processing

Purpose The purpose of this paper is to study the effects of printing strategies and processing parameters on wall thickness, microhardness and compression strength of Inconel 718 superalloy thin-walled honeycomb lattice structures manufactured by laser powder bed fusion (L-PBF). Design/methodology/approach Two printing contour strategies were applied for producing thin-walled honeycomb lattice structures

Purpose The purpose of this paper is to examine the effect of internal pores on the tensile properties of a Co–Cr–Mo alloy fabricated by selective laser melting (SLM). Design/methodology/approach The size and volume fraction of pores were controlled through high temperature annealing (HTA) and hot isostatic pressing (HIP). Findings After HTA, the size and fraction of pores decreased compared with the

Purpose A three-dimensional (3D) printing error simulation approach is proposed to analyze the influence of tilted vertical beams on the 3D printing accuracy. The purpose of this study is to analyze the influence of such errors on printing accuracy and printing quality for delta-robot 3D printer. Design/methodology/approach First, the kinematic model of a delta-robot 3D printer with an ideal geometric

Purpose This paper aims to present a series of approaches for three-related issues in multiaxis in wire and arc additive manufacturing (WAAM) as follows: how to achieve a stable and robust deposition process and maintain uniform growth of the part; how to maintain consistent formation of a melt pool on the surface of the workpiece; and how to fabricate an overhanging structure without supports. De

Purpose The purpose of this study is to validate a novel model of resting hand splint manufactured by additive manufacturing (AM) and compare it with the traditional model manufactured by high temperature thermoplastic in terms of cost, weight, volume and thermal comfort. Design/methodology/approach A novel resting hand splint model was created from the topology optimization (TO) and analyzed, by finite-element

Purpose Support structures used in laser powder bed fusion are often difficult to clean from unsintered powder at the end of the process. This issue can be significantly reduced through a proper design of these auxiliary structures. This paper aims to investigate preliminary the airflow within differently oriented support structures and to provide design guidelines to enhance their cleanability, especially

Purpose The purpose of this paper is to study the wire and arc additive manufacturing (WAAM) method and path planning algorithm of truss structure parts, to realize the collision-free rapid prototyping of truss structures with complex characteristics. Design/methodology/approach First, a point-by-point stacking strategy is proposed based on the spot-welding mode of cold metal transfer welding technology

Purpose This paper aims to focus on developing a theoretical framework for the analysis of factors influencing additive manufacturing (AM) in the health-care domain. Design/methodology/approach A total of 18 factors are considered through extensive literature review and the relationship between each factor is studied using total interpretive structural modeling (TISM) and the model is logically developed

Purpose The purpose of this study is to use the Freeform Reversible Embedding of Suspended Hydrogels (FRESH) additive manufacturing (AM) technique for manufacturing a liver phantom which can mimic the corresponding soft living tissue. One of the possible applications is surgical planning. Design/methodology/approach A thermo-reversible Pluronic® F-127-based support bath is used for the FRESH technique

Purpose This paper aims to enhance the surface finish of the fused deposition modeling (FDM) part using the vapor smoothening (VS) post-processing method and to study the combined effect of FDM and VS process parameters on the quality of the part. Design/methodology/approach Analysis of variance method is used to understand the significance of the FDM and VS process parameters. Following this, the

Purpose Additive manufacturing (AM) offers potential solutions when conventional manufacturing reaches its technological limits. These include a high degree of design freedom, lightweight design, functional integration and rapid prototyping. In this paper, the authors show how AM can be implemented not only for prototyping but also production using different optimization approaches in design including

Purpose Powder bed additive manufacturing processes are widespread due to their many technical and economic advantages. Nevertheless, the disposal of leftover powder poses a problem in terms of process sustainability. The purpose of this paper is to provide an alternative solution to recycle waste PA12 powder from HP multi jet fusion. In particular, the opportunity to use this material as a dispersion

Purpose The purpose of present paper is to enlarge the knowledge about the performance of gypsum powder to realize complex molds or cores for aluminum casting. Design/methodology/approach The research was divided into two activities: simple; and complex-part production capability. In the simple-part step, the performance of gypsum powder and the minimum mold thickness that would withstand the casting

Purpose Most support surfaces in comfort applications and sporting equipment are made from pressure-relieving foam such as viscoelastic polyurethane. However, for some users, foam is not the best material as it acts as a thermal insulator and it may not offer adequate postural support. The additive manufacturing of such surfaces and equipment may alleviate these issues, but material and design investigation

Purpose This paper aims to gain an understanding of the behaviour of iron ore when melted by a laser beam in a continuous manner. This fundamental knowledge is essential to further develop additive manufacturing routes such as production of low cost parts and in-situ reduction of the ore during processing. Design/methodology/approach Blown powder directed energy deposition was used as the processing

Purpose Laser sintering of polyamide lattice-based lightweight fairing components for subsequent racetrack testing requires a high quality and a reliable design. Hence, the purpose of this study was to develop a design methodology for such additively manufactured prototypes, considering efficient generation and structural simulation of boundary conformal non-periodic lattices, optimization of production

Purpose Powder bed-based additive manufacturing (AM) is a promising family of technologies for industrial applications. The purpose of this study is to provide a new metrics based on the analysis of the compaction behavior for the evaluation of flowability of AM powders. Design/methodology/approach In this work, a novel qualification methodology based on a camera mounted onto a commercially available

Purpose The purpose of this paper is to study the Mode I fracture behavior of polycarbonate (PC) parts produced using fused deposition modeling (FDM). The focus of this study is on samples printed along the out-of-plane direction with different raster angles. Design/methodology/approach Tensile and Mode I fracture tests were conducted. Semi-circular bend specimens were used for the fracture tests,

Purpose The surface roughness of additively manufactured parts is usually found to be high. This limits their use in industrial and biomedical applications. Therefore, these parts required post-processing to improve their surface quality. The purpose of this study is to finish three-dimensional (3D) printed acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) parts using abrasive flow machining

Purpose Depending on an experimental approach to find optimal parameters for producing fully dense (relative density > 99%) Inconel 718 (IN718) components in the selective laser melting (SLM) process is expensive and offers no guarantee of success. Accordingly, this study aims to propose a multi-scale simulation framework to guide the choice of processing parameters in a more pragmatic manner. Des

Purpose Global economic growth provides new opportunities for the development of clothing enterprises, but at the same time, the rapid growth of clothing customization demand and the gradual increase of clothing costs also pose new challenges for the development of clothing enterprises. In this context, 3D printing technology is injecting new vitality and providing a new development direction for the

Purpose This study aims to reveal that fatigue life is improved using heat treatment in the rotational bending fatigue test, which determines the fatigue behavior closest to service conditions. Design/methodology/approach It is essential to know the mechanical behavior of the parts produced by additive manufacturing under service conditions. In general, axial stress and plane bending tests are used

Purpose This paper aims to propose a suitable atomizing solidification chitosan (CS) gel liquid extrusion molding technology for the three dimensional (3D) printing method, and experiments verify the feasibility of this method. Design/methodology/approach This paper mainly uses experimental means, combined with theoretical research. The preparation method, solidification forming method and 3D printing

Purpose The manufacturability of extremely fine porous structures in the SLM process has rarely been investigated, leading to unpredicted manufacturing results and preventing steady medical or industrial application. The research objective is to find out the process limitation and key processing parameters for printing fine porous structures so as to give reference for design and manufacturing planning

Purpose Recent advances in 3D printing construction elements have focused on ordinary Portland cement (OPC) concrete using polymeric binders; herein, this study aims to produce the same using pure water. Design/methodology/approach A binder jet printer prototype was used to fabricate specimens that are used to assess geometric and mechanical properties. Two distinct water-based binder formulations

Purpose This paper aims to investigate effect of infill density, fabricated built orientation and dose of gamma radiation to mechanical tensile and compressive properties of polylactic acid (PLA) part fabricated by fused deposit modelling (FDM) technique for medical applications. Design/methodology/approach PLA specimens for tensile and compressive tests were fabricated using FDM machine. The specimens

Purpose The purpose of this study is to investigate the influences of extruder temperatures and raster orientations on the mechanical properties of polylactic-acid (PLA) material processed by using fused filament fabrication (FFF). Design/methodology/approach In this research, the PLA specimens were first printed with nozzle or extruder temperatures of 205°C, 215°C and 225°C and then evaluated in terms

Purpose This paper aims to address the problem of uncertain product quality in digital light processing (DLP) three-dimensional (3D) printing, a scheme is proposed to qualitatively estimate whether a layer is printed with the qualified quality or not cured . Design/methodology/approach A thermochromic pigment whose color fades at 45°C is prepared as the indicator and it is mixed with the resin. A visual

Purpose The purpose of this paper is to demonstrate the aerodynamic behavior of a supersonic combustion test bench (SCTB) components, as the transition piece and the combustor of a scramjet (supersonic combustion ramjet), manufactured by 3D printing or additive manufacturing (AM). Design/methodology/approach For the dimensional and structural analysis of the manufactured models, a portable 3D scanner

Purpose The purpose of this paper is to outline some key aspects such as material systems used, phenomenological and statistical process modeling, techniques applied to monitor the process and optimization approaches reported. All these need to be taken into account for the ongoing development of the SLM technique, particularly in health care applications. The outcomes from this review allow not only

Purpose Fused deposition modeling (FDM) is one of the most adopted additive manufacturing techniques to produce prototypes and/or final parts regardless of geometrical complexity restrictions. One of the most challenging aspects of this technology is the attainable roughness. The purpose of this study is to evaluate the capability of the slurry impacts to improve the surface roughness of parts fabricated

Purpose The COVID-19 pandemic emphasises the need for antiviral materials that can reduce airborne and surface-based virus transmission. This study aims to propose the use of additive manufacturing (AM) and surrogate modelling for the rapid development and deployment of novel copper-tungsten-silver (Cu-W-Ag) microporous architecture that shows strong antiviral behaviour against severe acute respiratory

Purpose This study presents a method for fabricating multi-material objects using a hybrid additive and subtractive approach. By hybridizing the material composition in addition to the fabrication process, functional requirements can be met more effectively than through homogenous material parts produced using a single manufacturing process. Development of multi-material objects consisting of dissimilar

Purpose Ultrasonic additive manufacturing (UAM) is a solid-state joining technology used for three-dimensional printing of metal foilstock. The electrical power input to the ultrasonic welder is a key driver of part quality in UAM, but under the same process parameters, it can vary widely for different build geometries and material combinations because of mechanical compliance in the system. This study

Purpose Monodisperse microfluidic emulsions – droplets in another immiscible liquid – are beneficial to various technological applications in analytical chemistry, material and chemical engineering, biology and medicine. Upscaling the mass production of micron-sized monodisperse emulsions, however, has been a challenge because of the complexity and technical difficulty of fabricating or upscaling three-dimensional

Purpose Laser cladding deposition is limited in industrial application by the micro-defects and residual tensile stress for the thermal forming process, leading to lower fatigue strength compared with that of the forging. The purpose of this paper is to develop an approach to reduce stress and defects. Design/methodology/approach A hybrid process of laser cladding deposition and shot peening is presented

Purpose The purpose of this study is focused on the mechanical properties of multi-materials porous structures manufactured by selective laser melting (SLM). Design/methodology/approach The Diamond structure was designed by the triply periodic minimal surface function in MATLAB, and multi-materials porous structures were manufactured by SLM. Compression tests were applied to analyze the anisotropy

Purpose The purpose of this study is to introduce an alternative construction for microfluidic micromixers, where the effect of the extruded filaments in the fused deposition modeling (FDM) technique is used to enhance mixing performance identified as a challenge in microfluidic micromixers. Design/methodology/approach A simple Y-shaped micromixer was designed and printed using FDM technique. Experimental

Purpose The purpose of this paper is to report the design of a lightweight tree-shaped support structure for fused deposition modeling (FDM) three-dimensional (3D) printed models when the printing path is considered as a constraint. Design/methodology/approach A hybrid of genetic algorithm (GA) and particle swarm optimization (PSO) is proposed to address the topology optimization of the tree-shaped

Purpose This study aims to identify the effects of infill patterns and infill percentages on the energy consumption (EC) of fused filament fabrication (FFF). With increasing attention on carbon-fiber-reinforced–poly-ether-ether-ketone (CFR-PEEK) for practical applications in FFF, infill pattern and infill percentage for FFF can be properly controlled to achieve better energy performance of CFR-PEEK

Purpose With a growing list of available materials and processes, the inherent mechanical and thermophysical properties of three-dimensional (3D) prints are important design targets. This paper aims to study the functionality of binder jet 3D printed objects for thermally activated building construction elements and recyclable formwork for concrete structures. Design/methodology/approach Binder jet

Purpose This study aims to develop a specialized and economically feasible educational model using a combination of conventional approach and additive technology with a precision that proves to be sufficient for educational use. With the use of computer-aided design/computer-aided manufacturing models in educational stages, the possibility of infectious diseases transmission can be significantly reduced

Purpose During post-processing of stereolithography photopolymers, the limited penetration depth of ultraviolet (UV) light can lead to inhomogeneous cross-linking. This is a major problem in part design for industrial applications as this creates uncertainty regarding the mechanical load capacity. Therefore, this paper aims to present an experimental method to measure the post-curing depth in stereolithography