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Advances in Additive Manufacturing: Horizons of Novel Processes and Applications

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

Deadline for manuscript submissions: closed (30 January 2025) | Viewed by 3796

Special Issue Editor


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Guest Editor
Technion’s R&D Foundation, Israel Institute of Materials Manufacturing Technologies, Haifa, Israel
Interests: phase transitions; reactive diffusion; heat treating of metallic alloys; ceramic materials; composite materials; powders technologies; additive manufacturing; advanced materials characterization

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM), being one of the most common technological methods worldwide nowadays, is a modern promising approach, for which scientific and technological boundaries are still not understood clearly due to the extremely fast development that has occurred in recent years. AM is highly attractive to scientists, as well as to mechanical, materials, chemical, and biomedical engineers and technologists, and it involves not only different important issues of physics and chemistry, but also machinery, software, machine learning, process organization, control, optimization and repeatability, economics, materials characterization, failure analysis and quality assurance, etc. The main reason for its popularity is the unique possibility of combining AM with different 3D printing technologies relevant to a wide spectrum of materials (metals, ceramics, composites, polymers, organics, etc.) with processes digitalization and artificial intelligence.

This Special Issue provides a forum for researchers, engineers, and practitioners to report their latest achievements and to highlight critical issues and challenges for future investigations of the design and applications of 3D printing and additive manufacturing.

Dr. Alexander Katz-Demyanetz
Guest Editor

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Keywords

  • additive manufacturing
  • powdered raw materials
  • process parametrization
  • as-built product
  • post-treatment
  • product’s final density
  • mechanical properties
  • process simulation
  • machine learning

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Published Papers (3 papers)

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Research

18 pages, 5705 KiB  
Article
Investigation of FDM-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Cutting
by Szabolcs Szalai, Brigitta Fruzsina Szívós, Vivien Nemes, György Szabó, Dmytro Kurhan, Mykola Sysyn and Szabolcs Fischer
Appl. Sci. 2025, 15(1), 442; https://doi.org/10.3390/app15010442 - 6 Jan 2025
Viewed by 687
Abstract
Within the scope of the work, the possible use of fused deposition modeling (FDM) technology in executing rapid prototypes of cutting tools for aluminum sheets was systematically studied. Relevant investigations have thus far mainly concentrated on tools for the 3D printing of bent [...] Read more.
Within the scope of the work, the possible use of fused deposition modeling (FDM) technology in executing rapid prototypes of cutting tools for aluminum sheets was systematically studied. Relevant investigations have thus far mainly concentrated on tools for the 3D printing of bent and deep-drawn pieces, yet the implementation of FDM tools in cutting has been insufficiently covered. This study aims to determine the characteristics of FDM cutting tools, such as wear and tear, dimensional stability, and cutting efficiency. Various tool designs were tested under different wall thicknesses and orientations with respect to the feed of Al99.5 sheets with thicknesses of 0.22 mm and 0.3 mm. According to the results, in the best case, three-dimensional printed PLA tools performed six cuts with no burrs and an acceptable wear level due to the IT tolerances (IT9 and IT10). Tools with thicker walls and more appropriate orientations were found to be more robust. However, some designs failed when subjected to greater loads, revealing a deficiency in some of the strength properties of the material. These observations suggest that it is possible to create 3D printed tools for modeling and small-scale production at considerably cheaper and faster rates than conventional methods. Future work will integrate advanced materials and designs to enhance tool performance, further solidifying FDM as a transformative approach in industrial tool manufacturing. With this research, the authors wanted to demonstrate that FDM technology can also be used to produce a classic sheet cut, which, of course, is still of great importance for prototyping or setting up production processes. This research demonstrated that FDM printing can play a role in this area. Full article
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14 pages, 8157 KiB  
Article
Evaluation of Additive Manufacturing Feasibility in the Energy Sector: A Case Study of a Gas-Insulated High-Voltage Switchgear
by Elham Haghighat Naeini and Robert Sekula
Appl. Sci. 2024, 14(14), 6237; https://doi.org/10.3390/app14146237 - 17 Jul 2024
Viewed by 1266
Abstract
In recent years, additive manufacturing (AM) has made considerable progress and has spread in many industries. Despite the advantages of this technology including freedom of design, lead time reduction, material waste reduction, special tools manufacturing elimination, and sustainability, there are still a lot [...] Read more.
In recent years, additive manufacturing (AM) has made considerable progress and has spread in many industries. Despite the advantages of this technology including freedom of design, lead time reduction, material waste reduction, special tools manufacturing elimination, and sustainability, there are still a lot of challenges regarding finding the beneficial application. In this study, the feasibility of replacing traditional manufacturing methods with additive manufacturing in the energy sector is investigated, with a specific focus on gas-insulated high-voltage switchgear (GIS). All aluminum parts in one specific GIS product are analyzed and a decision flowchart is proposed. Using this flowchart, printability and the best AM technique are suggested with respect to part size, required surface roughness, requirements of electrical and mechanical properties, and additional post processes. Simple to medium complexity level of geometry, large size, high requirements for electrical and mechanical properties, threading and sealing, and lack of a standard for printed parts in the high voltage industry make AM a challenging manufacturing technology for this specific product. In total, implementing AM as a short series production method for GIS aluminum parts may not be sufficient because of the higher cost and more complex supply chain management, but it can be beneficial in R&D cases or prototyping scenarios where a limited number of parts are needed in a brief time limit. Full article
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26 pages, 4926 KiB  
Article
Residual Stress Determination with the Hole-Drilling Method on FDM 3D-Printed Precurved Specimen through Digital Image Correlation
by Ciro Santus, Paolo Neri, Luca Romoli and Marco Cococcioni
Appl. Sci. 2024, 14(10), 3992; https://doi.org/10.3390/app14103992 - 8 May 2024
Cited by 1 | Viewed by 1425
Abstract
The hole-drilling method (HDM) is a common technique used for the determination of residual stresses, especially for metal alloy components, though also for polymers. This technique is usually implemented with strain gages, though other methods for determining the fields of displacements are quite [...] Read more.
The hole-drilling method (HDM) is a common technique used for the determination of residual stresses, especially for metal alloy components, though also for polymers. This technique is usually implemented with strain gages, though other methods for determining the fields of displacements are quite mature, such as the use of digital image correlation (DIC). In the present paper, this combined methodology is applied to a 3D-printed PLA precurved specimen that is flattened in order to impose a bending distribution which can be considered known with a reasonable accuracy. The back-calculated stress distribution is in agreement with the expected (imposed) bending stress, however, a converging iterative procedure for obtaining the solution is introduced and discussed in the paper. Full article
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