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Advances and Applications of 3D Printing and Additive Manufacturing

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

Deadline for manuscript submissions: 20 May 2026 | Viewed by 10577

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Special Issue Editors

Dr. Derui Jiang

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Guest Editor

Commonwealth Scientific and Industrial Research Organisation, Melbourne, VIC, Australia
Interests: additive manufacturing; biomedical; oil & gas; aerospace; surface postprocessing

Prof. Dr. Aijun Huang

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Guest Editor

Department of Materials Science and Engineering, Monash University, Melbourne, VIC, Australia
Interests: metal additive manufacturing; metal powder manufacturing technology; component design for AM; AM process optimization; post-AM process development

Dr. Haopeng Shen

E-Mail Website
Guest Editor

Commonwealth Scientific and Industrial Research Organisation, Melbourne, VIC, Australia
Interests: additive manufacturing; subtractive–additive hybrid manufacturing; material engineering; powder technology; aerospace engineering

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) is rapidly transforming a wide array of industries, including the medical, automotive, aerospace, and oil and gas sectors, among others. Its growing adoption is driven by significant advancements in near-net-shape fabrication, particularly for components with intricate geometries customized for specific applications which are difficult to produce using traditional manufacturing methods.

This Special Issue invites original research articles and high-quality, comprehensive reviews on the latest developments and applications of 3D printing and additive manufacturing. Our goal is to highlight the innovative capabilities of AM and its extensive applicability, providing an overview of current trends and future directions in the field.

We encourage submissions in the following areas:

Specialized applications in medical devices, aerospace, corrosion protection, and energy utilization;
Design and modeling focused on enhancing functionality for specialized applications;
Additive manufacturing processes and advancements, including hybrid systems and process optimization for improved performance and efficiency;
Development of novel materials with a focus on characterizing their performance in microstructural, mechanical, electrical, chemical, or biological contexts;
Surface postprocessing of additive-manufactured components for improved functionality in specialized applications.

Dr. Derui Jiang
Prof. Dr. Aijun Huang
Dr. Haopeng Shen
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 250 words) can be sent to the Editorial Office for assessment.

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. Materials 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 2600 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

powder bed fusion
direct energy deposition
electron beam melting
binder jetting
fused deposition modeling
finite element analysis
microstructure
mechanical properties
process optimization
surface treatment

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Published Papers (5 papers)

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Research

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14 pages, 3045 KB

Open AccessArticle

Effectiveness of Ozone Treatment, Ultrasonic Treatment, and Ultraviolet Irradiation in Removing Candida albicans Adhered to Acrylic Resins Fabricated by Different Manufacturing Methods

by Chihiro Kaneko, Tomofumi Sawada, Taichi Ishikawa, Toshitaka Miura, Takuya Kobayashi and Shinji Takemoto

Materials 2026, 19(1), 53; https://doi.org/10.3390/ma19010053 - 23 Dec 2025

Viewed by 342

Abstract

Acrylic resins are commonly used for denture bases due to ease of molding but are prone to water absorption and microbial contamination. This study aimed to evaluate the effects of ozonated water immersion (OZ), ultrasonic cleaning (US), and ultraviolet (UV) irradiation on the removal of Candida albicans from acrylic resins produced by heat curing and additive manufacturing. The resin specimens were then subjected to treatment with OZ, US, UV irradiation, and commercial denture cleansers. Following treatment, the number of viable C. albicans cells was quantified and statistically analyzed (α = 0.05), morphology was observed under a scanning electron microscope (SEM) and fluorescence imaging. OZ, US, and UV irradiation significantly reduced the viable C. albicans count. Notably, the combination of the three treatments achieved a reduction exceeding 99.9% of viable cells. Although SEM revealed that C. albicans remained on the specimens, fluorescence imaging demonstrated a progressive decrease in viable cells and an increase in dead cells with each treatment, with the greatest effect observed when the three treatments were combined. The difference of removal behaviors of C. albicans among fabrication methods was not observed, comparable to denture cleaners. The combined application of all three treatments was the most effective strategy for microbial removal. Full article

(This article belongs to the Special Issue Advances and Applications of 3D Printing and Additive Manufacturing)

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21 pages, 6306 KB

Open AccessArticle

Mechanical Properties Analysis of Nickel-Based Composite Coatings Prepared by Laser Cladding

by Shaoping Hu, Longfeng Sun, Yanchong Gao, Chao Zhang and Tianbiao Yu

Materials 2025, 18(23), 5381; https://doi.org/10.3390/ma18235381 - 28 Nov 2025

Viewed by 267

Abstract

During the laser cladding process for composite coatings, significant differences exist in the physical and mechanical properties between the substrate and the composite coating materials. Therefore, a systematic analysis of the mechanical properties is necessary to mitigate issues such as cracking and deformation caused by performance mismatch. This study investigated the mechanical properties (microhardness, wear resistance, tensile strength) of composite coatings formed by laser cladding IN718 alloy onto an EA4T steel substrate. Given the critical influence of scanning strategies on cladding layer quality, this study also examined the relationship between the tensile direction and scanning direction. By analyzing mechanical responses under different orientations, it revealed the patterns of influence on tensile properties and anisotropy characteristics of the cladding layer, providing a theoretical basis and process guidance for achieving high-performance cladding layers. Tensile tests conducted at different angles on the IN718 cladding layer indicate that when a thin cladding layer is required, selecting a scanning speed direction parallel to the primary tensile direction yields superior results. Conversely, for applications demanding a thicker cladding layer, aligning the scanning direction perpendicular to the tensile direction better leverages the cladding layer’s performance. Full article

(This article belongs to the Special Issue Advances and Applications of 3D Printing and Additive Manufacturing)

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17 pages, 8581 KB

Open AccessArticle

Slip Risk on Surfaces Made with 3D Printing Technology

by Bartosz Wieczorek, Łukasz Gierz, Łukasz Warguła, Grzegorz Kinal, Boris Kostov and Konrd Jan Waluś

Materials 2025, 18(3), 573; https://doi.org/10.3390/ma18030573 - 27 Jan 2025

Cited by 1 | Viewed by 1515

Abstract

Slip risk on surfaces used by humans or active in mechanisms is studied to mitigate its effects or harness its beneficial outcomes. This article presents pioneering research on the risk of surfaces created using 3D printing technology. The study examines three materials (Polylactic Acid, PLA; Polyethylene Terephthalate Glycol, PET-G; and Thermoplastic Polyurethane, TPU), considering three print head movement directions relative to the British Portable Skid Resistance Tester (BSRT) measurement direction. In addition, surface roughness tests were performed. Dry tests showed that the structure created by the printing direction perpendicular to the movement direction is the safest in terms of slip risk. The SRVs of the measured samples on a qualitative scale were classified on this scale as materials with low or extremely low slip risk (ranging from 55 to 90 SRV dry and 35 to 60 SRV wet). Referring to the influence of the type of material on the SRV, it was found that the safest material in terms of reducing the risk of slipping in dry conditions is TPU and, in wet conditions, PLA. During wet tests, the best properties that reduce the risk of slippage in most cases are shown by the printing direction on a horizontal plane at an angle of 45° to the direction of movement. Statistical analysis showed that the printing direction and roughness do not have a statistically significant effect on the SRV, but the type of material and the type of method (dry and wet) and their interaction have a significant effect. Full article

(This article belongs to the Special Issue Advances and Applications of 3D Printing and Additive Manufacturing)

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Review

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46 pages, 10017 KB

Open AccessReview

The 3D Printing of Flexible Materials: Technologies, Materials, and Challenges

by Suyun Li, Zengqin Shi, Yixuan Wang, Wenqing Wang and Rujie He

Materials 2025, 18(23), 5428; https://doi.org/10.3390/ma18235428 - 2 Dec 2025

Viewed by 1456

Abstract

Due to their unique functional properties, such as deformability, bendability, stretchability, and even biocompatibility, sensing, or actuation, flexible materials have become an indispensable and crucial component in electronic systems such as wearable electronic devices and soft robots. Facing the complex demands of various application scenarios, 3D printing technology can be utilized to customize the preparation of various flexible materials into desired shapes. However, compared to rigid materials, flexible materials still face printing issues such as pore defects and weak interlayer bonding during the 3D printing process. Therefore, this paper focuses on analyzing the key bottleneck issues and technical challenges currently existing in flexible material 3D printing technology, and provides an overview of the progress in preparing flexible materials using 3D printing technologies, such as Material Extrusion and Vat Polymerization. Finally, it looks forward to the technical challenges and future development of 3D printing with flexible materials. Full article

(This article belongs to the Special Issue Advances and Applications of 3D Printing and Additive Manufacturing)

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58 pages, 23645 KB

Open AccessReview

Reviewing Additive Manufacturing Techniques: Material Trends and Weight Optimization Possibilities Through Innovative Printing Patterns

by Arturo Ramos, Virginia G. Angel, Miriam Siqueiros, Thaily Sahagun, Luis Gonzalez and Rogelio Ballesteros

Materials 2025, 18(6), 1377; https://doi.org/10.3390/ma18061377 - 20 Mar 2025

Cited by 26 | Viewed by 6167

Abstract

Additive manufacturing is transforming modern industries by enabling the production of lightweight, complex structures while minimizing material waste and energy consumption. This review explores its evolution, covering historical developments, key technologies, and emerging trends. It highlights advancements in material innovations, including metals, polymers, composites, and ceramics, tailored to enhance mechanical properties and expand functional applications. Special emphasis is given to bioinspired designs and their contribution to enhancing structural efficiency. Additionally, the potential of these techniques for sustainable manufacturing and industrial scalability is discussed. The findings contribute to a broader understanding of Additive Manufacturing’s impact on design optimization and material performance, offering insights into future research and industrial applications. Full article

(This article belongs to the Special Issue Advances and Applications of 3D Printing and Additive Manufacturing)

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