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Direct Digital Manufacturing with Additive Manufacturing/3D Printing
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Direct Digital Manufacturing with Additive Manufacturing/3D Printing

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

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 24663

Special Issue Editor

Dr. Ioannis (John) Giannatsis

E-Mail Website
Guest Editor
Department of Industrial Management & Technology, University of Piraeus, 18534 Piraeus, Greece
Interests: additive manufacturing; 3D printing; design for additive manufacturing; direct digital manufacturing; smart factories; virtual modeling

Special Issue Information

Dear Colleagues,

Direct Digital Manufacturing (DDM), i.e., the production of end-user parts, components, and products by means of Additive Manufacturing (AM) and 3D Printing (3DP), is a concept that has attracted significant scientific and business interest during recent years. This increasing interest can be attributed to the unique characteristics of AM/3DP technologies, which enable the decentralized production of highly customized/personalized parts for both industrial users and consumers, thereby providing significant cost, speed, and sustainability advantages over the established model of centralized mass production.

Despite the fact that there is growing evidence that DDM is an economically viable and technically feasible alternative, significant challenges from a technical and an organizational point of view still exist. From a technical point of view, the development of tools, systems, and processes that enable the design and production of multi-functional and multi-material parts with sufficient precision and repeatability can help in expanding the application field of DDM. From an organizational standpoint, the successful deployment of DDM requires the rethinking of several supply chain, process design, cost, and sustainability issues. Furthermore, case studies that discuss the application of DDM in specific practical settings are also valuable for understanding and defining the advantages and limitations of the DDM paradigm.

In this context, studies that address some of the aforementioned challenges or discuss some of the possible applications of DDM are particularly welcomed for this Special Issue of JMMP. A non-exclusive list of topics for contributions is below:

  • AM/3DP technologies and systems for DDM;
  • Evaluation and selection of AM/3DP technologies, processes, and/or systems for DDM;
  • Process planning for DDM (build parameters selection, part production planning, post-processing planning, etc.);
  • Supply chain design for DDM (DDM facilities location, distributed manufacturing with DDM, etc.);
  • Part design for DDM (design for AM/3DP, part consolidation methods for simplifying/eliminating assembly, methods, and tools for heterogeneous part modeling, etc.);
  • Sustainability issues of DDM (environmental impact, comparison with other manufacturing technologies/processes, life-cycle analysis of DDM products, etc.);
  • Cost analysis and life-cycle costing in DDM;
  • Real-time monitoring and control of DDM systems for improved quality;
  • Quality control of products manufactured by DDM;
  • Innovative applications of DDM and relevant case studies.

Dr. Ioannis (John) Giannatsis
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

  • direct digital manufacturing
  • additive manufacturing
  • 3D printing
  • design for additive manufacturing
  • distributed manufacturing
  • supply chain design for DDM
  • environmental impact of DDM

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Published Papers (6 papers)

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Research

25 pages, 4239 KiB  
Article
Direct Digital Manufacturing of a Customized Face Mask
by Leonardos Bilalis, Vassilios Canellidis, Theodore Papatheodorou and John Giannatsis
J. Manuf. Mater. Process. 2022, 6(5), 126; https://doi.org/10.3390/jmmp6050126 - 21 Oct 2022
Cited by 2 | Viewed by 3357
Abstract
Direct Digital Manufacturing (DDM) is considered by many as one of the most promising approaches towards cost- and time-efficient mass customization. Compared to conventional manufacturing systems, DDM systems are not as common and incorporate several distinctive features, such as higher flexibility in product [...] Read more.
Direct Digital Manufacturing (DDM) is considered by many as one of the most promising approaches towards cost- and time-efficient mass customization. Compared to conventional manufacturing systems, DDM systems are not as common and incorporate several distinctive features, such as higher flexibility in product form and structure, lower economies of scale and higher potential for decentralized production network. The initial design phase of a DDM production system, where very important in term of efficiency and quality, decisions are made, is a relatively unexplored topic in the relevant literature. In the present study, the corresponding issues are investigated through a case study involving the direct digital production of a customized reusable face mask (respirator) for medical use. Investigated system design aspects include product, process, and facility design. Based on data generated through manufacturing tests, a preliminary cost analysis is performed and several scenarios regarding production throughput and facility planning are examined. According to the results, DDM of custom-made face masks is, to a large extent, technically and economically feasible. Interestingly, considering the whole process, a large part of production cost is associated with labor and materials. Finally, evidence for a fundamental trade-off between manufacturing cost and speed/flexibility is identified, implying that different implementations of DDM systems can be realized depending on strategic operational objectives. Full article
(This article belongs to the Special Issue Direct Digital Manufacturing with Additive Manufacturing/3D Printing)
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24 pages, 7205 KiB  
Article
Systematic Development of a Powder Deposition System for an Open Selective Laser Sintering Machine Using Analytic Hierarchy Process
by Foivos Psarommatis and George-Christopher Vosniakos
J. Manuf. Mater. Process. 2022, 6(1), 22; https://doi.org/10.3390/jmmp6010022 - 8 Feb 2022
Cited by 7 | Viewed by 3410
Abstract
This work reports on the design and manufacture of an efficient system for powder deposition into layers in an open Selective Laser Sintering machine. The system comprises mainly two subsystems, i.e., one that deposits a dose of powder onto the worktable and another [...] Read more.
This work reports on the design and manufacture of an efficient system for powder deposition into layers in an open Selective Laser Sintering machine. The system comprises mainly two subsystems, i.e., one that deposits a dose of powder onto the worktable and another that levels the powder upon its deposition. The design was conducted in two phases, namely conceptualization of the system and its detailed design. The conceptualization phase exploited the Analytic Hierarchy Process to evaluate alternative mechanical systems and determine the most suitable one. This was subsequently detail-designed using a CAD software package and then followed by selection of the necessary electronics for imparting and controlling motion of the individual mechanisms comprising the system. As regards manufacturing, custom designed components were obtained by CNC machining and the entire mechanism was assembled on an open Selective Laser Sintering machine. Functionality testing of the system was performed with satisfactory results. Full article
(This article belongs to the Special Issue Direct Digital Manufacturing with Additive Manufacturing/3D Printing)
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17 pages, 4140 KiB  
Article
Experimental and Computational Investigation of Lattice Sandwich Structures Constructed by Additive Manufacturing Technologies
by Nikolaos Kladovasilakis, Paschalis Charalampous, Konstantinos Tsongas, Ioannis Kostavelis, Dimitrios Tzetzis and Dimitrios Tzovaras
J. Manuf. Mater. Process. 2021, 5(3), 95; https://doi.org/10.3390/jmmp5030095 - 31 Aug 2021
Cited by 38 | Viewed by 5710
Abstract
Additive Manufacturing (AM) technologies offer the ability to construct complex geometrical structures in short manufacturing lead time coupled with a relatively low production cost when compared to traditional manufacturing processes. The next trend in mechanical engineering design is the adaption of design strategies [...] Read more.
Additive Manufacturing (AM) technologies offer the ability to construct complex geometrical structures in short manufacturing lead time coupled with a relatively low production cost when compared to traditional manufacturing processes. The next trend in mechanical engineering design is the adaption of design strategies that build products with lightweight lattice geometries like sandwich structures. These structures possess low mass, large surface area to volume ratio, high porosity, and adequate mechanical behavior, which are properties of great importance in scientific fields such as bioengineering, automotive, and aerospace engineering. The present work is focused on producing sandwich structures with complex lattice patterns like the Triply Periodic Minimal Surface (TPMS) Schwarz diamond structure. The specimens were manufactured with two different Additive Manufacturing procedures employing various relative densities. More specifically, Material Jetting Printing (MJP) and Fused Filament Fabrication (FFF) processes were employed to investigate the performance of Acrylonitrile Butadiene Styrene (ABS) lightweight lattice structures. These structures were examined using digital microscopy in order to measure the dimensional accuracy and the surface characteristics of the utilized AM technologies. Furthermore, three-point bending tests and finite elements analyses have been applied to investigate the mechanical performance of the proposed technologies and designs as well as the influence of the relative density on the Schwarz diamond TPMS structure. The experimental results demonstrate that the investigated structure possesses a remarkable performance in respect to its weight due to the specific distribution of its material in space. Full article
(This article belongs to the Special Issue Direct Digital Manufacturing with Additive Manufacturing/3D Printing)
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16 pages, 3094 KiB  
Article
Surface Qualification Toolpath Optimization for Hybrid Manufacturing
by Austen Thien, Christopher Saldana and Thomas Kurfess
J. Manuf. Mater. Process. 2021, 5(3), 94; https://doi.org/10.3390/jmmp5030094 - 27 Aug 2021
Cited by 4 | Viewed by 3217
Abstract
Hybrid manufacturing machine tools have great potential to revolutionize manufacturing by combining both additive manufacturing (AM) and subtractive manufacturing (SM) processes on the same machine tool. A prominent issue that can occur when going from AM to SM is that the SM process [...] Read more.
Hybrid manufacturing machine tools have great potential to revolutionize manufacturing by combining both additive manufacturing (AM) and subtractive manufacturing (SM) processes on the same machine tool. A prominent issue that can occur when going from AM to SM is that the SM process toolpath does not account for geometric discrepancies caused by the previous AM step, which leads to increased production times and tool wear, particularly when wire-based directed energy deposition (DED) is used as the AM process. This work discusses a methodology for approximating a part’s surface topology using on-machine contact probing and formulating an optimized SM toolpath using the surface topology approximation. Three different geometric surface approximations were used: triangular, trapezoidal, and a hybrid of both. SM toolpaths were created using each geometric approximation and assessed according to three objectives: reducing total machining time, reducing surface roughness, and reducing cutting force. Different prioritization scenarios of the optimization goals were also investigated. The optimal surface approximation that yielded the most improvement in the optimization was determined to be the hybrid surface topology approximation. Furthermore, it was shown that when the machining time or cutting force optimization goals were prioritized, there was little improvement in the other optimization goals. Full article
(This article belongs to the Special Issue Direct Digital Manufacturing with Additive Manufacturing/3D Printing)
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19 pages, 47539 KiB  
Article
Numerical-Experimental Plastic-Damage Characterisation of Additively Manufactured 18Ni300 Maraging Steel by Means of Multiaxial Double-Notched Specimens
by Tiago Silva, Afonso Gregório, Filipe Silva, José Xavier, Ana Reis, Pedro Rosa and Abílio de Jesus
J. Manuf. Mater. Process. 2021, 5(3), 84; https://doi.org/10.3390/jmmp5030084 - 2 Aug 2021
Cited by 3 | Viewed by 2824
Abstract
Additive manufacturing (AM) has become a viable option for producing structural parts with a high degree of geometrical complexity. Despite such trend, accurate material properties, under diversified testing conditions, are scarce or practically non-existent for the most recent additively manufactured (AMed) materials. Such [...] Read more.
Additive manufacturing (AM) has become a viable option for producing structural parts with a high degree of geometrical complexity. Despite such trend, accurate material properties, under diversified testing conditions, are scarce or practically non-existent for the most recent additively manufactured (AMed) materials. Such data gap may compromise component performance design, through numerical simulation, especially enhanced by topological optimisation of AMed components. This study aimed at a comprehensive characterisation of laser powder bed fusion as-built 18Ni300 maraging steel and its systematic comparison to the conventional counterpart. Multiaxial double-notched specimens demonstrated a successful depiction of both plastic and damage behaviour under different stress states. Tensile specimens with distinct notch configurations were also used for high stress triaxiality range characterisation. This study demonstrates that the multiaxial double-notched specimens constitute a viable option towards the inverse plastic behaviour calibration of high-strength additively manufactured steels in distinct state of stress conditions. AMed maraging steel exhibited higher strength and lower ductility than the conventional material. Full article
(This article belongs to the Special Issue Direct Digital Manufacturing with Additive Manufacturing/3D Printing)
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15 pages, 14647 KiB  
Article
Improving Geometric Accuracy of 3D Printed Parts Using 3D Metrology Feedback and Mesh Morphing
by Moustapha Jadayel and Farbod Khameneifar
J. Manuf. Mater. Process. 2020, 4(4), 112; https://doi.org/10.3390/jmmp4040112 - 29 Nov 2020
Cited by 21 | Viewed by 4728
Abstract
Additive manufacturing (AM), also known as 3D printing, has gained significant interest due to the freedom it offers in creating complex-shaped and highly customized parts with little lead time. However, a current challenge of AM is the lack of geometric accuracy of fabricated [...] Read more.
Additive manufacturing (AM), also known as 3D printing, has gained significant interest due to the freedom it offers in creating complex-shaped and highly customized parts with little lead time. However, a current challenge of AM is the lack of geometric accuracy of fabricated parts. To improve the geometric accuracy of 3D printed parts, this paper presents a three-dimensional geometric compensation method that allows for eliminating systematic deviations by morphing the original surface mesh model of the part by the inverse of the systematic deviations. These systematic deviations are measured by 3D scanning multiple sacrificial printed parts and computing an average deviation vector field throughout the model. We demonstrate the necessity to filter out the random deviations from the measurement data used for compensation. Case studies demonstrate that printing the compensated mesh model based on the average deviation of five sacrificial parts produces a part with deviations about three times smaller than measured on the uncompensated parts. The deviation values of this compensated part based on the average deviation vector field are less than half of the deviation values of the compensated part based on only one sacrificial part. Full article
(This article belongs to the Special Issue Direct Digital Manufacturing with Additive Manufacturing/3D Printing)
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