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Advances in Additive Manufacturing for Metallic Materials and Their Applications...
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Advances in Additive Manufacturing for Metallic Materials and Their Applications (3rd Edition)

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: 31 August 2025 | Viewed by 1716

Special Issue Editors

Prof. Dr. Petru Berce

E-Mail Website
Guest Editor
Manufacturing Engineering Department, Technical University of Cluj Napoca, 400641 Cluj-Napoca, Romania
Interests: additive manufacturing and their applications; rapid tooling; CNC manufacturing
Special Issues, Collections and Topics in MDPI journals
Dr. Razvan Ioan Pacurar

E-Mail Website
Guest Editor
Department of Manufacturing Engineering, Faculty of Industrial Engineering, Robotics and Production Management, Technical University of Cluj-Napoca, 400114 Cluj-Napoca, Romania
Interests: three-dimensional printing; bio-printing; topological optimization; computer aided design; computer aided engineering
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) is a new type of manufacturing engineering with a history of less than 35 years. The real value of additive manufacturing is in identifying those applications where reductions in lead time, manufacturing cost, weight, tooling, and so on can lead to huge benefits across a part’s lifecycle.

Additive manufacturing has evolved rapidly in the last few years and has been embraced by major industrial companies looking for ways to improve their products. The ability to deliver near-instant part production and fully custom designs that cannot be replicated with other manufacturing techniques has accelerated investment and research in this field.

A number of different metals are now available in powdered form to suit exact processes and requirements. Titanium, steel, stainless steel, and aluminum, as well as copper-, cobalt chrome-, titanium-, and nickel-based alloys are available in powdered form, as are precious metals such as gold, platinum, palladium, and silver.

This Special Issue will encompass fundamental research on existing additive manufacturing processes, optimizations, new processes, rapid tooling, and applications ranging from industry to medicine using metal powders as raw materials.

We hope that the present Special Issue will be an opportunity to create a strong network between authors and readers working in different sectors.

Prof. Dr. Petru Berce
Dr. Razvan Ioan Pacurar
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. Metals is an international peer-reviewed open access monthly 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

  • additive manufacturing process
  • optimization of AM process
  • rapid tooling
  • industrial applications
  • medical applications

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Related Special Issue

Published Papers (4 papers)

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Research

25 pages, 14859 KiB  
Article
The Effect of Drag Finishing on Additively Manufactured Customized Dental Crowns
by Cosmin Cosma, Martin Melichar, Stelian Libu, Alexandru Popan, Glad Contiu, Cristina Teusan, Petru Berce and Nicolae Balc
Metals 2025, 15(5), 471; https://doi.org/10.3390/met15050471 - 22 Apr 2025
Viewed by 212
Abstract
Cobalt–chromium (CoCr) alloys are frequently used to produce customized dental applications such as crowns, bridges, or prostheses. These medical products have anatomical forms, and can be effectively manufactured using the laser-based powder bed fusion (PBF-LB/M) technique. A major disadvantage of this approach is [...] Read more.
Cobalt–chromium (CoCr) alloys are frequently used to produce customized dental applications such as crowns, bridges, or prostheses. These medical products have anatomical forms, and can be effectively manufactured using the laser-based powder bed fusion (PBF-LB/M) technique. A major disadvantage of this approach is the extended time required to refine the resultant surface. The purpose of this research is to reduce the surface roughness of PBF-LB/M/CoCr dental crowns by adopting drag finishing (DF) technology. To evaluate the impact of this automatic post-processing, surface roughness measurements and geometrical investigations were undertaken. The microstructure was characterized using scanning electron microscopy (SEM), and the chemical composition was verified by energy-dispersive X-ray spectroscopy (EDAX). On outside surfaces, the DF post-processing decreased the initial surface roughness by 70–90%. The dental crown’s surface roughness value after DF post-processing was comparable to that of the basic form (cylinder). The lowest roughness was obtained with DF3 post-processing (Ra~0.60 μm). The inner surfaces were limitedly finished. The 3D surface texture showed that the DF method reduced the height of peaks, uniformizing the surfaces. CMM work compared the deviations between the virtual model and the printed samples before and after DF post-processing. This analysis revealed that dimensional deviations were reduced on the outside crown walls, ranging from +0.01 to +0.05 mm. The laser parameters and the heat treatment applied increased the hardness of CoCr crowns to 520 HV, but the proper DF conditions identified reduced the surface roughness and improved the accuracy. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing for Metallic Materials and Their Applications (3rd Edition))
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16 pages, 7646 KiB  
Article
Optimized and Additively Manufactured Face Mills for Enhanced Cutting Performance
by Ozgur Poyraz, Daniel Tomlinson, Anthony Molyneux, Marie E. Baxter, Evren Yasa and James Hughes
Metals 2025, 15(4), 376; https://doi.org/10.3390/met15040376 - 28 Mar 2025
Viewed by 816
Abstract
With the growing acceptance of additive manufacturing (AM) across various sectors, laser-based powder bed fusion (PBF-LB) has widely been utilized to create intricately shaped parts from a range of metals alloys. The factors contributing to this reception are limited not only to the [...] Read more.
With the growing acceptance of additive manufacturing (AM) across various sectors, laser-based powder bed fusion (PBF-LB) has widely been utilized to create intricately shaped parts from a range of metals alloys. The factors contributing to this reception are limited not only to the achievable geometrical complexity but also enhanced product functionality. Prominent sectors such as aerospace, defense, and biomedical have begun to leverage PBF-LB for a wide range of applications; its use in other industries, such as cutting tool manufacturing, remains more limited. Therefore, to address the potential of LPBF for higher performance in cutting tool applications, this study examines topology optimization and the laser powder bed fusion of face mills with experimental modal characteristics and cutting performance. The objectives in topology optimizations were to decrease the vibration magnitudes of face mills while keeping them stiff against deformation due to cutting forces. Three distinct designs were benchmarked, each with different weight reduction targets, and were fabricated using PBF-LB with M300 maraging steel. The optimized face mills demonstrated better performance with diminished vibration magnitudes and less tool wear patterns. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing for Metallic Materials and Their Applications (3rd Edition))
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24 pages, 12572 KiB  
Article
Additively Manufactured Biomedical Ti-15Mo Alloy with Triply Periodical Minimal Surfaces and Functional Surface Modification
by Zerui Li, Jingyuan Xu, Jincheng Tang, Zhuo Sang and Ming Yan
Metals 2025, 15(4), 355; https://doi.org/10.3390/met15040355 - 24 Mar 2025
Viewed by 305
Abstract
Ti and Ti alloys are being widely used as bone tissue repair materials. Progress on mechanical properties and bio-functionality is required for their applications due to the large difference in elastic modulus between bone and Ti implants and the fact that the Ti [...] Read more.
Ti and Ti alloys are being widely used as bone tissue repair materials. Progress on mechanical properties and bio-functionality is required for their applications due to the large difference in elastic modulus between bone and Ti implants and the fact that the Ti materials themselves are biologically inert. In this work, a low-modulus, β-phase Ti-15Mo alloy based on a triply periodical minimal surfaces (TPMS) structure was fabricated using a Powder Bed Fusion-Laser Beam (PBF-LB) under optimized printing parameters into implant samples with controllable porous structures. The selection of TPMS, lattice unit cell size, and relative density was based on a combination of mechanical properties and cytocompatibility. Surface modifications were used to further impart antibacterial, antioxidant, and osteogenesis properties to the implants. Broad-spectrum antibacterial Ag, antioxidant tannic acid (TA), and highly stable fluorinated hydroxyapatite ((F)HA) were applied as an advanced coating on a microporous TiO2 surface modification layer formed by micro-arc oxidation. Ultimately, porous Ti-15Mo implant samples with a biofunctional coating were obtained with Young’s modulus 15–50 GPa, a yield strength of approximately 100 MPa, and good cytocompatibility, hemocompatibility, and bactericidal effects. This study provides a systematic scheme for the preparation and surface modification of β Ti alloy implants for subsequent studies. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing for Metallic Materials and Their Applications (3rd Edition))
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15 pages, 23808 KiB  
Article
Enhanced Compressive Properties of Additively Manufactured Ti-6Al-4V Gradient Lattice Structures
by Zhengjie Guo, Yuting Ma, Tayyeb Ali, Yi Yang, Juan Hou, Shujun Li and Hao Wang
Metals 2025, 15(3), 230; https://doi.org/10.3390/met15030230 - 21 Feb 2025
Viewed by 512
Abstract
Lattice structures are widely used in the aerospace and biomedical fields, due to their lightweight, high specific strength, large specific surface area, good biocompatibility, etc. However, the balancing of the weight and the mechanical properties remains a challenge in designing lattice structures. Combining [...] Read more.
Lattice structures are widely used in the aerospace and biomedical fields, due to their lightweight, high specific strength, large specific surface area, good biocompatibility, etc. However, the balancing of the weight and the mechanical properties remains a challenge in designing lattice structures. Combining experiments and simulations, the present work first designs and evaluates the mechanical properties of uniform and gradient topology-optimized Ti-6Al-4V lattices with the same overall porosity of 84.27%, employing finite element simulations. Then, laser powder bed fusion technology is used to fabricate the uniform and gradient Ti-6Al-4V lattices, and their compressive performance is tested. The results indicate that, under longitudinal compression, the gradient lattice structure exhibits good layer-by-layer collapse deformation behavior, achieving better comprehensive performance than the uniform lattice structure. While under horizontal compression, the deformation behavior of the gradient lattice structure is similar to that of the uniform lattice structure, and the deformation is mostly randomly distributed. The cumulative energy absorption of the gradient lattice structure increased by approximately 20% compared with that of the uniform lattice structure. The results provide a technical basis for the integrated design of structural and functional components for aerospace applications. Full article
(This article belongs to the Special Issue Advances in Additive Manufacturing for Metallic Materials and Their Applications (3rd Edition))
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