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Advanced Additive Manufacturing and Its Application—2nd Edition

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 August 2026 | Viewed by 1940

Special Issue Editor

Special Issue Information

Dear Colleagues,

By definition, additive manufacturing (AM) is a technology that constructs 3D complex geometries by adding layer-upon-layer of material based on the digital computer-aided design model. The nature of this construction has brought several advantages for this production method compared to conventional subtractive manufacturing (CSM). The ability to produce complex structures, tailoring properties, as well as sustainability and ecological issues, such as less energy consumption and material waste, are taken into account as benefits of AM compared to CSM. However, the nature of this production has its own drawbacks like the formation of rough surfaces and porosities on the surface and beneath layers, which is detrimental for the lifetime of AM components. On the other hand, as a result of the complicated physical phenomena taking place during fusion and deposition, the AM material exhibits inadvertent anomalies and lacks certifiable structural integrity and/or sufficient quality for engineering applications. Therefore, prior to extending the range of applications of such promising technology and being replaced by conventional CSM, certifications regarding mechanical and tribological properties, surface integrity, and fatigue strength are required.

This Special Issue welcomes articles addressing surface integrity, fatigue life, corrosion, and wear resistance of AM material by optimizing the process window or by applying a post-processing plan. The submitted articles should outline the structural integrity of metallic materials (as well as other types of materials) that are produced using different variants of AM technologies. 

We look forward to your submissions.

Dr. Reza Teimouri
Guest Editor

Manuscript Submission Information

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Keywords

  • additive manufacturing
  • postprocessing
  • surface integrity
  • fatigue
  • wear
  • corrosion

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Related Special Issue

Published Papers (2 papers)

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Research

24 pages, 9895 KB  
Article
Role of Laser Powder Bed Fusion Process Factors in Determining the Porosity Formation in 3D Printing of Stainless Steel 316L: Theoretical Modeling and Experimental Verification
by Andrzej Stwora, Reza Teimouri and Jacek Habel
Materials 2025, 18(24), 5490; https://doi.org/10.3390/ma18245490 - 5 Dec 2025
Cited by 1 | Viewed by 880
Abstract
In this study, an analytical model was developed to evaluate the influence of laser powder bed fusion (LPBF) process parameters on process-induced porosity during the 3D printing of stainless steel 316L. First, the temperature distribution, governed by a moving point heat source model [...] Read more.
In this study, an analytical model was developed to evaluate the influence of laser powder bed fusion (LPBF) process parameters on process-induced porosity during the 3D printing of stainless steel 316L. First, the temperature distribution, governed by a moving point heat source model of the laser, was used to predict the melt pool geometry during the melting stage. This prediction was then refined to account for the formation of the solidified cap. By analyzing the interaction between melt pool size and other process parameters, such as hatch spacing and layer thickness, criteria were established to distinguish between porosity caused by lack of fusion, porosity due to keyhole formation, and defect-free samples. A series of experiments were conducted, and porosity was measured using micro-CT analysis. The results showed that the porosity predicted by the model remained within an acceptable error range compared with the experimental measurements, with errors ranging from 10.5% to 24.78% and a mean error of 16.48%, demonstrating the accuracy of the developed model. Full article
(This article belongs to the Special Issue Advanced Additive Manufacturing and Its Application—2nd Edition)
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18 pages, 3056 KB  
Article
Impact of Autoclaving on the Material Properties of Vat-Photopolymerization-Produced Components Intended for Bioprocess Engineering
by Lauri Hoffmann, Bruno Gallace, Clara Herr, Kai Scherer, Adrian Huwer, Percy Kampeis, Roland Ulber and Michael Wahl
Materials 2025, 18(20), 4720; https://doi.org/10.3390/ma18204720 - 15 Oct 2025
Viewed by 792
Abstract
Due to a lack of investigated materials for the additive manufacturing of multi-use functional parts in bioprocess engineering, this study aimed to evaluate the influence of multiple autoclaving cycles on the properties of a heat-resistant material (xPeek147) printed with vat photopolymerization. Sample bodies [...] Read more.
Due to a lack of investigated materials for the additive manufacturing of multi-use functional parts in bioprocess engineering, this study aimed to evaluate the influence of multiple autoclaving cycles on the properties of a heat-resistant material (xPeek147) printed with vat photopolymerization. Sample bodies were tested regarding their mechanical properties of tensile strength, elongation at break, and Charpy impact, as well as surface properties of roughness and wettability after up to 50 autoclaving cycles (121 °C, 2 bars, 15 min). The tightness was checked after up to 20 cycles, and accuracy was inspected for manufactured benchmark bodies after up to 10 autoclaving cycles. The reported results showed no significant changes in tensile strength, elongation at break and Charpy impact after 20 cycles, but a significant decrease after 50 autoclaving cycles, accompanied by microcracks in the structure. Regarding the surface properties the material retained its hydrophilicity, and the surface roughness was not affected significantly. No changes in tightness occurred, and the benchmark bodies for dimensional changes showed no process-relevant deviations. Through the investigations, a material for the additive manufacturing of multi-use functional parts for bioprocess engineering was identified. Additionally, a testing method for materials with the same intended application was provided. Full article
(This article belongs to the Special Issue Advanced Additive Manufacturing and Its Application—2nd Edition)
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