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Additive Manufacturing for Novel and Advanced Materials: Characteristics, Challenges, and Applications

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

Deadline for manuscript submissions: 31 October 2025 | Viewed by 3720

Special Issue Editors

Dr. Edgar Moraru

E-Mail Website1 Website2
Guest Editor
Department of Mechatronics and Precision Mechanics, National University of Science and Technology Politehnica Bucharest, 060042 Bucharest, Romania
Interests: manufacturing technologies; additive manufacturing; 3D printing; mechanical engineering; mechatronics; materials science and technology; characterization of materials and structures; biomaterials; biomedical engineering; finite element analysis; measurement and metrology; micro- and nanotechnology
Prof. Dr. Manoj Gupta

E-Mail Website
Guest Editor
Department of Mechanical Engineering, National University of Singapore, Singapore 117576, Singapore
Interests: metal additive manufacturing; processing; characterization; lightweight materials; nanocomposites
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In recent years, additive manufacturing or 3D printing has marked a spectacular development, contributing majorly to and advancing many key fields such as medicine, the aerospace and automotive industry, robotics, and other top fields. This is due to the unbeatable advantages that it possesses compared to conventional technologies, including design flexibility, customization, rapid prototyping, and minimized waste manufacturing. However, there are some disadvantages related to these technologies such as the limited availability and compatibility of materials in relation to a certain additive process or in terms of quality and post-processing requirements. This represents a challenge and a constant concern for the scientific community to research and find viable solutions in order to improve the field of 3D printing. Nevertheless, additive manufacturing has huge potential for continuous evolution and integration with other advanced technologies through the use of novel and advanced materials and leading technological approaches, which will facilitate the improvement or even the expansion of the areas of applicability.

This Special Issue aims at bringing together the efforts of worldwide researchers and sharing their latest contributions (original research papers or highly valuable review articles) regarding 3D printing or even 4D printing with novel and advanced materials (metal, ceramic, polymer, or composite), using various technological approaches to process them and using theoretical, numerical, and/or experimental methods to characterize them. This Special Issue also welcomes scientific works and outcomes related to existing and future challenges associated with additive manufacturing methods and their impact on current applications, as well as the potential integration of these technologies into new areas of applicability.

Dr. Edgar Moraru
Prof. Dr. Manoj Gupta
Guest Editors

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. Applied Sciences 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 2400 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
  • digital manufacturing
  • metal additive manufacturing
  • ceramic additive manufacturing
  • polymer additive manufacturing
  • composite additive manufacturing
  • 3D printing
  • 4D printing
  • rapid prototyping
  • fused deposition modelling
  • vat photopolymerisation
  • selective laser melting
  • selective laser sintering
  • selective electron-beam melting
  • powder bed fusion
  • binder jetting
  • material jetting
  • laminated object manufacturing
  • direct metal deposition
  • resin-based materials
  • powder-based materials
  • filament-based materials

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Published Papers (5 papers)

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Research

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16 pages, 3584 KiB  
Article
Evaluating the Reliability of Powder Bed Fusion for Biomedical Materials: An Experimental Approach
by Danut Vasile Leordean, Cosmin Cosma, Nicolae Balc and Mircea Cristian Dudescu
Appl. Sci. 2025, 15(8), 4542; https://doi.org/10.3390/app15084542 - 20 Apr 2025
Viewed by 173
Abstract
This article provides a comprehensive, step-by-step framework that bridges the gap between the theory and engineering practical applications of Powder Bed Fusion (PBF) technology for producing high-quality metal parts suitable for end users. This proposed framework integrates multiple aspects into a coherent methodology [...] Read more.
This article provides a comprehensive, step-by-step framework that bridges the gap between the theory and engineering practical applications of Powder Bed Fusion (PBF) technology for producing high-quality metal parts suitable for end users. This proposed framework integrates multiple aspects into a coherent methodology on how to evaluate the PBF parameters and processing conditions, in order to establish a reliability scale for the PBF process on the Realizer 250 SLM machine. Experimental research, conducted over the past 10 years, reveals that the PBF process often encounters challenges related to process stability and part consistency. To address these issues, this paper introduces a novel method for evaluating the manufacturing process by considering the obtained physico-mechanical characteristics. The determined properties of PBF samples were ultimate tensile strength, Young’s modulus, the Poisson ratio, maximum elongation, hardness, and surface roughness. Test specimens were fabricated and tested without applying a stress relief heat treatment. Four bio-metal materials were studied as follows: pure Titanium, Ti6Al7Nb, CoCr, and CoCrWMo. Optimal processing parameters were established for each material focused on laser power, scanning speed, and hatch distance. To have a high chance of successfully printing, each material has its own set of PBF parameters. The results showed that the mechanical resistance can be up to 441 MPa for pure Ti (parameters 120 W, 500 mm/s, 0.12 mm) and 1159 MPa for CoCrWMo alloys (parameters 85 W, 500 mm/s, 0.10 mm). The mechanical properties of these materials are presented, offering valuable data for finite element analysis (FEA) necessary for designing medical implants. This paper provides practical guidelines beneficial for both medical application designers and manufacturers using PBF technology, contributing to enhanced reliability and efficiency in PBF-based metal part production. Full article
(This article belongs to the Special Issue Additive Manufacturing for Novel and Advanced Materials: Characteristics, Challenges, and Applications)
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33 pages, 16534 KiB  
Article
Design of 3D Scanning Technology Using a Method with No External Reference Elements and Without Repositioning of the Device Relative to the Object
by Adrián Vodilka, Marek Kočiško, Martin Pollák, Jakub Kaščak and Jozef Török
Appl. Sci. 2025, 15(8), 4533; https://doi.org/10.3390/app15084533 - 19 Apr 2025
Viewed by 198
Abstract
The use of 3D scanning technologies for surface scanning of objects is limited by environmental conditions and technology requirements based on their characteristics. Among the emerging fields is technical diagnostics in areas of hard-to-reach places with varying surface characteristics of objects of different [...] Read more.
The use of 3D scanning technologies for surface scanning of objects is limited by environmental conditions and technology requirements based on their characteristics. Among the emerging fields is technical diagnostics in areas of hard-to-reach places with varying surface characteristics of objects of different materials, where the use of commercially available 3D scanning technologies is limited by space. Furthermore, in these areas it is not convenient to use external reference elements or to move the equipment during the digitization process. This paper presents a novel markerless 3D scanning system capable of digitizing objects in confined spaces without requiring external reference elements or repositioning the device relative to the object and aims to address this challenge by designing a 3D scanning technology using the Active Shape from Stereo technique utilizing laser vertical line projection. For this purpose, a testing and prototype design and a software solution using a unique method of calculating 3D surface coordinates have been proposed. In addition to hard-to-reach places, this solution can be used as a desktop 3D scanner and for other 3D digitizing applications for objects of different materials and surface characteristics. Furthermore, the device is well suited to inspecting 3D printed objects, enabling quick, markerless checks of surface geometry and dimensions during the process of 3D printing to ensure printing accuracy and quality. Full article
(This article belongs to the Special Issue Additive Manufacturing for Novel and Advanced Materials: Characteristics, Challenges, and Applications)
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13 pages, 6715 KiB  
Article
Selective Alkali Activation of Limestone for Additive Manufacturing in Construction: Influence of Alkali Concentration on Physical and Mechanical Properties
by Mursaleen Shahid, Alexandre Pierre, Annelise Cousture and Vincenzo M. Sglavo
Appl. Sci. 2025, 15(8), 4453; https://doi.org/10.3390/app15084453 - 17 Apr 2025
Viewed by 143
Abstract
Alkali-activated binders are gaining importance in the construction industry because of their environmental and mechanical advantages. This paper focuses on selective limestone activation (SLA) using aqueous sodium hydroxide solutions to be used as a non-hydraulic binder material. This study investigates the mechanical performance [...] Read more.
Alkali-activated binders are gaining importance in the construction industry because of their environmental and mechanical advantages. This paper focuses on selective limestone activation (SLA) using aqueous sodium hydroxide solutions to be used as a non-hydraulic binder material. This study investigates the mechanical performance of 3D-printed specimens cured at 45 °C produced with different NaOH concentrations. Varying the NaOH concentration is significant for analyzing its role in optimizing the reactivity and mechanical behavior for additive manufacturing applications. The results show that mechanical strength and physical properties are influenced by the NaOH concentration, with the strength decreasing at higher sodium hydroxide loads. Although porosity and density are consistent in all concentrations, microstructure examination showed non-homogeneous grainy texture. Full article
(This article belongs to the Special Issue Additive Manufacturing for Novel and Advanced Materials: Characteristics, Challenges, and Applications)
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14 pages, 12167 KiB  
Article
Hydraulic Performance Comparison of Centrifugal Closed Impellers Fabricated by Means of Additive Manufacturing and Classical Machining for Space Active Thermal Control Systems of Satellites
by Ionut-Florian Popa, Cristian Dobromirescu, Ionut Sebastian Vintila, Iulia Tinca, Dragos Mihai, Alexa Miruna Canache and Daniel Eugeniu Crunteanu
Appl. Sci. 2024, 14(20), 9448; https://doi.org/10.3390/app14209448 - 16 Oct 2024
Cited by 1 | Viewed by 1087
Abstract
The current paper addresses the challenges in manufacturing a critical component of a centrifugal pump for space active thermal control systems of satellites, namely, the closed centrifugal impeller. Compared to the classical technologies, there is an obvious advantage of additive manufacturing of closed [...] Read more.
The current paper addresses the challenges in manufacturing a critical component of a centrifugal pump for space active thermal control systems of satellites, namely, the closed centrifugal impeller. Compared to the classical technologies, there is an obvious advantage of additive manufacturing of closed impellers, due to the possibility of creating complex geometries, which boost the hydraulic performances of the part and, implicitly, of the pump. In this regard, the authors performed a comparative analysis between a closed impeller obtained by classical machining and three manufactured by additive technology (selective laser melting) by means of dimensional inspection, non-destructive testing, and experimental evaluation. The study performed here showed that the additively manufactured closed impellers exhibited similar hydraulic performances to the classical one, without the need for performing post-processing of internal surfaces. Also, in terms of dimensional and geometrical stability, the additively manufactured closed impellers were within the imposed tolerances, demonstrating the feasibility of obtaining such complex parts by using additive manufacturing. Subsequently, the allocated time for manufacturing decreased by 75% for the closed impellers manufactured by additive technologies, and the need for using four technological processes was decreased to only two, printing and post-processing. Full article
(This article belongs to the Special Issue Additive Manufacturing for Novel and Advanced Materials: Characteristics, Challenges, and Applications)
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Review

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28 pages, 2305 KiB  
Review
Insights into Machining Techniques for Additively Manufactured Ti6Al4V Alloy: A Comprehensive Review
by Abdulkadir Mohammed Sambo, Muhammad Younas and James Njuguna
Appl. Sci. 2024, 14(22), 10340; https://doi.org/10.3390/app142210340 - 11 Nov 2024
Cited by 3 | Viewed by 1632
Abstract
Investigation into the post-processing machinability of Ti6Al4V alloy is increasingly crucial in the manufacturing industry, particularly in the machining of additively manufactured (AM) Ti6Al4V alloy to ensure effective machining parameters. This review article summarizes various AM techniques and machining processes for Ti6Al4V alloy. [...] Read more.
Investigation into the post-processing machinability of Ti6Al4V alloy is increasingly crucial in the manufacturing industry, particularly in the machining of additively manufactured (AM) Ti6Al4V alloy to ensure effective machining parameters. This review article summarizes various AM techniques and machining processes for Ti6Al4V alloy. It focuses on powder-based fusion AM techniques such as electron beam melting (EBM), selected laser melting (SLM), and direct metal deposition (DMD). The review addresses key aspects of machining Ti6Al4V alloy, including machining parameters, residual stress effects, hardness, microstructural changes, and surface defects introduced during the additive manufacturing (AM) process. Additionally, it covers the qualification process for machined components and the optimization of cutting parameters. It also examines the application of finite element analysis (FEA) in post-processing methods for Ti6Al4V alloy. The review reveals a scarcity of articles addressing the significance of post-processing methods and the qualification process for machined parts of Ti6Al4V alloy fabricated using such AM techniques. Consequently, this article focuses on the AM-based techniques for Ti6Al4V alloy parts to evaluate and understand the performance of the Johnson–Cook (J–C) model in predicting flow stress and cutting forces during machining of the alloy. Full article
(This article belongs to the Special Issue Additive Manufacturing for Novel and Advanced Materials: Characteristics, Challenges, and Applications)
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