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A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Additive Manufacturing Technologies".

Deadline for manuscript submissions: closed (20 April 2025) | Viewed by 14012

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Dr. Thang Quyet Tran

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Additive Manufacturing Group, Manufacturing Process Division, Singapore Institute of Manufacturing Technology, Singapore, Singapore
Interests: 3D printing technology; composites; carbon nanomaterials; material extrusion additive manufacturing; composite fibers; aerogels
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Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) technologies, also known as 3D printing, have been growing rapidly in recent years. These advanced technologies offer new capabilities to process materials with unique structures and properties that can hardly be achieved by conventional manufacturing techniques. Due to their layer-by-layer approaches, complex 3D parts made of metals, polymers, ceramics, and composites can be additively manufactured for a wide range of applications, including aerospace, automobiles, medical applications, machinery, electronics, food, textile, construction, and architecture.

This Special Issue focuses on state-of-the-art additive manufacturing methods, novel materials, together with advanced pre- and post-processing techniques. Potential topics include, but are not limited to, the following:

Recent development of new materials;
Novel approaches to improve established additive manufacturing methods;
Four-dimensional printing and multi-material printing;
Pre- and post-processing of additively manufactured parts;
Process monitoring and quality control methods for additive manufacturing;
Characterization methods for additively manufactured parts;
Novel and emerging applications for additive manufacturing.

It is our pleasure to invite you to submit full length research papers, review papers, perspectives as well as communications and letters for this Special Issue on, titled “Recent Advances in 3D Printing and Additive Manufacturing Technology”.

Dr. Thang Quyet Tran
Guest Editor

Manuscript Submission Information

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Keywords

additive manufacturing
hybrid additive manufacturing
3D printing
4D printing
multi-material printing
post-processing methods
non-destructive characterization
in-process monitoring
advanced materials

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Published Papers (11 papers)

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25 pages, 11648 KiB

Open AccessArticle

Analysis of Building Platform Inhomogeneities in PBF-LB/M Process on Alloy 718

by Niccolò Baldi, Lokesh Chandrabalan, Marco Manetti, Alessandro Giorgetti, Gabriele Arcidiacono, Paolo Citti and Marco Palladino

Appl. Sci. 2025, 15(7), 4042; https://doi.org/10.3390/app15074042 - 7 Apr 2025

Viewed by 299

Abstract

Additive Manufacturing (AM) processes, particularly PBF-LB/M, are considered advantageous due to their flexibility, which allows process engineers to design and fabricate intricate structures both in the prototyping and component manufacturing phases. It is well known that the behavior of the process directly impacts the quality of the materials and thereby induces inhomogeneities on the powder bed on the building platform. Several parameters can be tuned to keep the process under control, getting rid of process uncertainty and distinguishing aspects of a specific machine model. Such behavior requires an extended analysis of the powder bed inhomogeneities and the definition of limits in the printing process. In this work, carried out on Alloy 718 specimens printed using an EOS M290 machine, the inhomogeneities of the melt pool stability, density, and material properties were investigated based on three main factors: the amount of area melted or fused, the gas flow speed setpoint, and the location on the building platform. The test results for Track Stability, melt-pool shape, and porosity analysis show that criticality occurs when more than 50% of the building platform is exposed. This can be partly fixed by raising the differential pressure value. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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22 pages, 2439 KiB

Open AccessArticle

Evaluation of UV-Curable Solid Rocket Propellants’ Properties for Advanced 3D Printing Technologies

by Filippo Masseni, Giacomo Tetti, Alessandra Zumbo, Camilla Noé, Giovanni Polizzi, Leonardo Stumpo, Andrea Ferrero and Dario Pastrone

Appl. Sci. 2025, 15(6), 2933; https://doi.org/10.3390/app15062933 - 8 Mar 2025

Viewed by 733

Abstract

Challenges in the traditional cast-and-cure manufacturing of composite solid propellants, such as the use of mandrels and the toxicity of curing agents, are being addressed through new propellant formulations and additive manufacturing techniques. Within this framework, this study aimed to investigate the properties of UV-curable composite solid rocket propellants, focusing on their compatibility with advanced 3D printing technologies. Polybutadiene-based propellants incorporating a specific photoinitiator were examined. Key rheological properties, including the pseudoplasticity and pot-life, were assessed to evaluate the material’s behavior during the printing process. Furthermore, photopolymerization tests were performed using a customized delta illuminator to evaluate the conversion efficiency under UVA and UVC light sources. Concurrently, a modular Cartesian 3D printer was developed and preliminary tests were performed. Rheological tests also revealed a flow index n of 0.32 at 60 °C and 0.46 at 80 °C, indicating significant pseudoplastic behavior. The pot-life tests showed that the viscosity of the propellant reached the upper limit of

10^{6}

cP more quickly at higher temperatures, indicating a shorter time range of printability. UVA irradiation resulted in a polymerization conversion rate of about 90%, while UVC exposure did not significantly enhance the conversion rate beyond this value. Finally, the 3D printing tests confirmed the feasibility of producing solid propellant, though challenges related to material segregation and the extrusion consistency were observed. Material separation resulted in a significant impact on the printability, causing underextrusion and nozzle clogging, particularly with smaller nozzle diameters and higher extrusion pressures. Overall, this research represents a significant step forward in the development of UV-curable propellants for additive manufacturing, building on previous advancements by the research group. It demonstrates tangible progress in addressing key challenges such as the printability, material performance, and curing efficiency, while also highlighting areas requiring further refinement. These findings underscore the continuous evolution of this technology toward higher readiness levels, paving the way for its broader application in composite solid propellant manufacturing. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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16 pages, 2367 KiB

Open AccessArticle

Effect of Filament Material and Printing Temperature on 3D Printing Extrusion Force

by Daša Krapež, Muhammed Jusufagić, Murčo Obućina, Manja Kitek Kuzman and Mirko Kariž

Appl. Sci. 2025, 15(4), 2046; https://doi.org/10.3390/app15042046 - 15 Feb 2025

Cited by 1 | Viewed by 835

Abstract

In this study, a modified 3D printer hotend equipped with a load cell, attached to the feeding system, was used to evaluate the effects of filament material composition and printing parameters on the extrusion force required. Four different materials (commercial PLA, pure PLA, wood-PLA with different ratios of wood particles, and wood-PLA with different ratios of thermally modified wood particles) were used for 3D printing, and the feeding resistance was measured. The filament feeder was connected to the extruder hotend via a load cell, which measured the forces required to push the filament through the extruder and the nozzle. Three printing nozzle temperatures of 200, 210, and 220 °C were used. The results show that the printing temperature and the material influence the required extrusion forces, which varied between 1 and 8 N, but the variation was high. With proper optimization and integration into the printer firmware, this setup could also be used to detect nozzle clogging during printing, modify printing parameters during the process, and prevent the uneven extrusion of composite filaments. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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29 pages, 24103 KiB

Open AccessArticle

Research on Basic Properties of Polymers for Fused Deposition Modelling Technology

by Dariusz Pyka, Jakub J. Słowiński, Adam Kurzawa, Maciej Roszak, Mateusz Stachowicz, Mikołaj Kazimierczak, Maksymilian Stępczak and Dominika Grygier

Appl. Sci. 2024, 14(23), 11151; https://doi.org/10.3390/app142311151 - 29 Nov 2024

Cited by 2 | Viewed by 907

Abstract

This study investigates the mechanical properties and biocompatibility of eight commercially available filaments tailored for Fused Deposition Modeling (FDM) additive manufacturing. Test specimens were fabricated using original PRUSA MK4 printers, with ten samples from each selected polymer. Mechanical evaluations through static tensile and three-point bending tests revealed that PETG Carbon and PA+15CF exhibited superior tensile and flexural strengths, making them highly suitable for applications requiring high mechanical resilience. Biocompatibility assessments in line with the ISO 10993-5:2009 and ISO 10993-12:2021 standards indicated that all materials except FiberFlex 40D Fiberlogy were non-cytotoxic, supporting their potential in biomedical applications. The experimental data established material constants within the Johnson–Cook strength model, which effectively predicted the mechanical behaviors of monotonic materials like FiberFlex 40D, PETG, HIPS, TPU, and PA+15CF Rosa 3D, with maximum fitting errors not exceeding 2.6%. However, the model was inadequate for non-monotonic materials like PLA and PETG, resulting in higher errors and less accurate simulations. Scanning electron microscope (SEM) analyses provided insights into fracture mechanisms, correlating fracture surface characteristics with mechanical performance. This comprehensive study advances the understanding of mechanical properties in thermoplastic materials for 3D printing, validates numerical models for certain materials, and confirms material suitability for biomedical use. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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11 pages, 8637 KiB

Open AccessArticle

Study of Various Process Parameters on Bead Penetration and Porosity in Wire Arc Additive Manufacturing (WAAM) of Copper Alloy Cu1897

by Abid Shah, Neel Kamal Gupta, Rezo Aliyev and Henning Zeidler

Appl. Sci. 2024, 14(20), 9188; https://doi.org/10.3390/app14209188 - 10 Oct 2024

Viewed by 1616

Abstract

Copper-based alloys are widely known for their high thermal and electrical conductivity. Although the use of these alloys in powder-based additive manufacturing (AM) shows significant promise, applying this method in wire arc additive manufacturing (WAAM) processes poses various considerable challenges, including porosity, delamination, surface oxidation, etc. The limited research on WAAM of copper alloys, especially Cu1897, highlights the need for a more in-depth investigation. This study addresses the effects of process parameters in pulse cold metal transfer (CMT)-based WAAM of Cu1897, i.e., pulse correction (PC) and arc length correction (ALC), on bead penetration and porosity. The results showed that as PC was increased from −5 to +5, weld bead penetration increased from 2.38 mm to 3.87 mm. To further enhance penetration and reduce the porosity, the ALC was varied from +30% to −30% with a step size of 15%. The results showed that weld bead penetration increased to 4.47 mm by altering the ALC from +30% to −30%. Additionally, as the ALC varied within this range, porosity decreased significantly from 3.98% to 0.28%. Overall, it is concluded that a lower value of ALC is recommended to improve bead penetration and reduce porosity in WAAM of Cu1897. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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19 pages, 7576 KiB

Open AccessArticle

Effect of the Printing Scenario on the Dimensional Accuracy and the Tensile Strength of Different Colored PLA Specimens Produced by Fused Deposition Modeling

by Vasile Cojocaru, Raul Rusalin Turiac, Doina Frunzaverde, Gelu Trisca, Nicoleta Bacescu and Gabriela Marginean

Appl. Sci. 2024, 14(17), 7642; https://doi.org/10.3390/app14177642 - 29 Aug 2024

Viewed by 884

Abstract

Dimensional accuracy and mechanical properties of components printed by fused deposition modeling (FDM) are influenced by several process parameters. In this paper, the authors targeted the effect of the printing scenario and the PLA (polylactic acid) color on parts’ quality. Three scenarios were analyzed: individually printing, simultaneously printing of three, respective five specimens of natural (transparent), red, grey, and black PLA. The temperature variations of successive deposited layers were recorded for the black PLA. The dimensional accuracy of tensile specimens was evaluated, tensile tests were performed, and the results were correlated with the mesostructure of the prints. The effect of the independent variables on the measured parameters was analyzed by ANOVA. The experiments revealed differences for the same printing scenario regarding cross-section area (up to 5.71%) and tensile strength (up to 10.45%) determined by the material color. The number of specimens printed simultaneously and the position of the specimens on the build plate were found to influence too, but less than the color. Thus, increasing from one to five the number of specimens printed at a time altered both the dimensional accuracy (up to 3.93% increase of the cross-section area) and the tensile strength (up to 3.63% reduction). Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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14 pages, 8775 KiB

Open AccessArticle

Enhancement of Mechanical Properties of PCL/PLA/DMSO₂ Composites for Bone Tissue Engineering

by Kyung-Eun Min, Jae-Won Jang, Cheolhee Kim and Sung Yi

Appl. Sci. 2024, 14(14), 6190; https://doi.org/10.3390/app14146190 - 16 Jul 2024

Cited by 1 | Viewed by 1524

Abstract

Bone tissue engineering shows potential for regenerating or replacing damaged bone tissues by utilizing biomaterials renowned for their biocompatibility and structural support capabilities. Among these biomaterials, polycaprolactone (PCL) and polylactic acid (PLA) have gained attention due to their biodegradability and versatile applications. However, challenges such as low degradation rates and poor mechanical properties limit their effectiveness. Dimethyl sulfone (DMSO₂) has emerged as a potential additive to address these limitations, offering benefits such as reduced viscosity, increased degradation time, and enhanced surface tension. In this study, we investigate tailored composites comprising PLA, PCL, and DMSO₂ to enhance mechanical properties and hydrophilicity. Through material characterization and mechanical testing, we found that the addition of DMSO₂ led to improvements in the yield strength, modulus, and hydrophilicity of the composites. PCL and DMSO₂ 10, 20, and 30 wt% were premixed, and 20 wt% PCL + 10, 20, and 30 wt% DMSO₂ were mixed with PLA. Specifically, PLA/PCL/DMSO₂ composites exhibited higher yield strengths and moduli compared to pure PLA, pure PCL, and PLA/PCL composites. Moreover, the hydrophilicity of the composites increased with DMSO₂ concentration, facilitating cell attachment. Fourier-transform infrared spectroscopy (FTIR) confirmed the presence of –COOH and –COH bands in PLA/PCL/DMSO₂ composites, indicating chemical interactions between DMSO₂ and the polymer matrix. Fractography analysis revealed enhanced interface adhesion in PLA/PCL/DMSO₂ composites due to the hydrogen bonding. Overall, this study demonstrates the potential of PLA/PCL/DMSO₂ composites in bone tissue engineering applications, offering improved mechanical properties and enhanced cell compatibility. The findings contribute to the advancement of biomaterials for additive manufacturing in tissue engineering and regenerative medicine. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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17 pages, 33133 KiB

Open AccessArticle

Assessment of the Development Performance of Additive Manufacturing VPP Parts Using Digital Light Processing (DLP) and Liquid Crystal Display (LCD) Technologies

by Moises Batista, Jairo Mora-Jimenez, Jorge Salguero and Juan Manuel Vazquez-Martinez

Appl. Sci. 2024, 14(9), 3607; https://doi.org/10.3390/app14093607 - 24 Apr 2024

Cited by 1 | Viewed by 1286

Abstract

Non-metallic additive manufacturing technology has seen a substantial improvement in the precision of the parts it produces. Its capability to achieve complex geometries and very small dimensions makes it suitable for integration into strategic industrial sectors, such as aeronautics and medicine. Among additive manufacturing technologies, resin development processes demonstrate enhanced precision when compared to other methods, like filament printing. This study conducts a comparative analysis between digital light processing (DLP) and liquid crystal display (LCD) photopolymerization processes to assess the performance of the technologies and how process parameters affect the accuracy of the resulting parts. The research evaluates the impact of the discretization process used during the digital model export, determining the optimal mesh size and then analyzing the geometric deviations that occur by altering various operating parameters of the process. Statistical methods will be employed to identify the most significant parameters in the manufacturing process. Among other aspects, the precision of manufacturing technologies regarding the movement axis has also been evaluated. Regarding the minimum size of the features that can be fabricated, DLP technology has surpassed LCD technology, successfully producing features as small as 200 µm, compared to 500 µm for LCD technology. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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16 pages, 2750 KiB

Open AccessArticle

Raster Angle Prediction of Additive Manufacturing Process Using Machine Learning Algorithm

by Osman Ulkir, Mehmet Said Bayraklılar and Melih Kuncan

Appl. Sci. 2024, 14(5), 2046; https://doi.org/10.3390/app14052046 - 29 Feb 2024

Cited by 9 | Viewed by 1582

Abstract

As additive manufacturing (AM) processes become integrated with artificial intelligence systems, the time and cost of the fabrication process decrease. In this study, the raster angle, an important parameter in the manufacturing process, was examined using fused deposition modeling (FDM), an AM method. The optimal value of this parameter varies depending on the designed product geometry. By changing the raster angle, the distribution of stresses and strains within the printed object can be modified, potentially influencing the mechanical behavior of the object. Thus, the correct estimation of the raster angle is essential for obtaining parts with high mechanical properties. The focus of this study is to reduce the fabrication time and cost of products by intertwining machine learning (ML) systems with mechanical systems. Its novelty is that ML has never been applied for FDM raster angle estimation. The estimation and modeling of the raster angle were performed using five different ML algorithms. These algorithms include a support vector machine (SVM), Gaussian process regression (GPR), an artificial neural network (ANN), decision tree regression (DTR), and random forest regression (RFR). Data for training were generated using various shapes and geometries, then trained in the MATLAB software, and a prediction model between the input parameters and the raster angle was created. The predicted model was evaluated using five performance criteria. The RFR model predicts the raster angle in the FDM test data with R-squared (R²) = 0.92, an explained variance score (EVS) = 0.92, a mean absolute error (MAE) = 0.012, a root mean square error (RMSE) = 0.056, and a mean squared error (MSE) = 0.0032. These values are R² = 0.93, EVS = 0.93, MAE = 0.010, RMSE = 0.051, and MSE0.0025 for the training data. RFR is significantly superior to the other prediction algorithms. The proposed model predicts the optimum raster angle for any geometry. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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15 pages, 993 KiB

Open AccessArticle

Design of Viscosity and Nozzle Path Using Food 3D Printer and Pneumatic Pressure Syringe-Type Dispensing System

by Changuk Ji, Areum Cha and Dongbin Shin

Appl. Sci. 2023, 13(22), 12234; https://doi.org/10.3390/app132212234 - 11 Nov 2023

Viewed by 1821

Abstract

Recent advancements in 3D printing technology have integrated with Fourth Industrial Revolution technologies such as robotics and artificial intelligence, aiming to overcome the limitations of conventional manufacturing methods. In the field of functional foods, solvent casting, a common manufacturing technique, has been adopted to produce film-like structures with desired sizes and uniform thickness. However, the typical method of coating or injection on a conventional continuous film is difficult to produce in small amounts. To address this limitation, in the study, we developed a pneumatic pressure syringe-type dispensing system integrated with a food 3D printer utilizing fused deposition modeling (FDM) technology. A syringe type is needed to discharge crude liquid manufactured in the food field in a hygienic environment, and a 3D printing method that is easy to manufacture in small quantities or on demand was utilized. Through simulation and experiment, we wanted to confirm whether stable ejection results are generated according to the selected nozzle-based viscosity, inflow conditions, and the nozzle movement path of the food 3D printer. Based on the nozzle selected through simulation, it was confirmed that the fluid and flow velocity distribution of the viscous material were uniformly distributed and discharged under the conditions of 30,000 cps and inflow rate. By setting the parameters of the food 3D printer and preparing a coenzyme Q10 (CoQ10) sample, we achieved a stable oral dissolving film (ODF) extrusion shape through the design of viscosity and 3D printer nozzle path. The optimal viscosity range for the ODF solution was found to be 25,000 to 35,000 cps, exhibiting precise dimensions and shapes without distortion and yielding the most stable extrusion results. We defined four different nozzle path designs based on minimizing the movement of the 3D printer nozzle. Among them, a 16-step path design demonstrated a stable extrusion method, showing no tailing phenomenon under the conditions of 0.2 MPa pressure and −15.4 KPa vacuum pressure. In future research, we plan to conduct additional research to determine whether the discharge results vary depending on conditions such as viscosity of the crude liquid, nozzle path combination, and ODF thickness. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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13 pages, 698 KiB

Open AccessSystematic Review

Three-Dimensional Scaffolds Designed and Printed Using CAD/CAM Technology: A Systematic Review

by Beatriz Pardal-Peláez, Cristina Gómez-Polo, Javier Flores-Fraile, Norberto Quispe-López, Ildefonso Serrano-Belmonte and Javier Montero

Appl. Sci. 2024, 14(21), 9877; https://doi.org/10.3390/app14219877 - 29 Oct 2024

Viewed by 1170

Abstract

The objective of this work is to review the literature on the use of three-dimensional scaffolds obtained by printing for the regeneration of bone defects in the maxillofacial area. The research question asked was: what clinical experiences exist on the use of bone biomaterials manufactured by CAD/CAM in the maxillofacial area? Prospective and retrospective studies and randomized clinical trials in humans with reconstruction area in the maxillofacial and intraoral area were included. The articles had to obtain scaffolds for bone reconstruction that were designed by computer processing and printed in different materials. Clinical cases, case series, in vitro studies and those that were not performed in humans were excluded. Six clinical studies were selected that met the established inclusion criteria. The selected studies showed heterogeneity in their objectives, materials used and types of regenerated bone defects. A high survival rate was found for dental implants placed on 3D-printed scaffolds, with rates ranging from 94.3% to 98%. The materials used included polycaprolactone, coral-derived hydroxyapatite, biphasic calcium phosphate (BCP) and bioceramics. The use of CAD/CAM technology is seen as key for satisfying variations in the shapes and requirements of different fabrics and size variations between different individuals. Furthermore, the possibility of using the patient’s own stem cells could revolutionize the way bone defects are currently treated in oral surgery. The results indicate a high survival rate of dental implants placed on 3D-printed scaffolds, suggesting the potential of this technology for bone regeneration in the maxillofacial mass. Full article

(This article belongs to the Special Issue Recent Advances in 3D Printing and Additive Manufacturing Technology)

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