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Processes
Special Issues
Recent Advances in Additive Manufacturing and 3D Printing
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Recent Advances in Additive Manufacturing and 3D Printing

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 31 July 2025 | Viewed by 433

Special Issue Editors

Dr. Irshad Khilji

E-Mail Website
Guest Editor
Conn Center for Renewable Energy Research, University of Louisville, Louisville, KY 40292, USA
Interests: 3D printing; advanced manufacturing; advanced materials; electrical discharge; nanotechnology; renewable; wind energy
Dr. Jagannadh Satyavolu

E-Mail Website
Guest Editor
Conn Center for Renewable Energy Research, University of Louisville, Louisville, KY 40292, USA
Interests: biomass conversion; biofuels; bioproducts; novel separations; production of biogas; biohydrogen; drop-in biocoal products
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue on ‘Recent Advances in Additive Manufacturing and 3D Printing’ aims to explore the latest innovations, materials, and methodologies in 3D printing. This Special Issue will cover a range of topics from new materials development, such as hybrid nanocomposites, biobased materials, and biocompatible polymers, to advanced printing techniques like multi-material and large-scale 3D printing. The emphasis will be on applications across various industries, including aerospace, healthcare, and sustainable manufacturing. This collection seeks to highlight the transformative impacts and emerging trends shaping the future of additive manufacturing.

Dr. Irshad Khilji
Dr. Jagannadh Satyavolu
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. Processes 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 2400 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
  • 3D printing technologies
  • hybrid nanocomposites
  • biobased materials
  • biocompatible materials
  • multi-material printing
  • aerospace applications
  • sustainable manufacturing
  • large-scale 3D printing
  • advanced manufacturing techniques

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (1 paper)

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Research

22 pages, 5474 KiB  
Article
3D Printing of Optimized Titanium Scaffold for Bone Replacement
by Parvathi Nathan, Siaw Meng Chou and Wai Yee Yeong
Processes 2025, 13(6), 1827; https://doi.org/10.3390/pr13061827 - 9 Jun 2025
Viewed by 22
Abstract
Critical-sized bone defects or CSDs result from bone loss due to trauma, tumor removal, congenital defects, or degenerative diseases. Though autologous bone transplantation is the current gold standard in treating CSDs, its limitations include donor-site morbidity, unavailability of donor bone tissues, risk of [...] Read more.
Critical-sized bone defects or CSDs result from bone loss due to trauma, tumor removal, congenital defects, or degenerative diseases. Though autologous bone transplantation is the current gold standard in treating CSDs, its limitations include donor-site morbidity, unavailability of donor bone tissues, risk of infection, and mismatch between the bone geometry and the defect site. Customized scaffolds fabricated using 3D printing and biocompatible materials can provide mechanical integrity and facilitate osseointegration. Ti-6Al-4V (Ti64) is one of the most widely used commercial alloys in orthopedics. To avoid elastic modulus mismatch between bones and Ti64, it is imperative to use porous lattice structures. Ti64 scaffolds with diamond, cubic, and triply periodic minimal surface (TPMS) gyroid lattice architectures were fabricated using selective laser melting (SLM)with pore sizes ranging from 300 to 900 μm using selective laser melting and evaluated for mechanical and biological performance. Increasing pore size led to higher porosity (up to 90.54%) and reduced mechanical properties. Young’s modulus ranged from 13.18 GPa to 1.01 GPa, while yield stress decreased from 478.16 MPa to 14.86 MPa. Diamond and cubic scaffolds with 300–600 μm pores exhibited stiffness within the cortical bone range, while the 900 μm diamond scaffold approached trabecular stiffness. Gyroid scaffolds (600–900 μm) also showed modulus and yield strength within the cortical bone range but were not suitable for trabecular applications due to their higher stiffness. Cytocompatibility was confirmed through leachate analysis and DAPI-stained osteoblast nuclei. The biological evaluation reported maximum cell adherence in lower pore sizes, with gyroid scaffolds showing a statistically significant (p < 0.01) increase in cell proliferation. These findings suggest that 300–600 μm lattice scaffolds offer an optimal balance between mechanical integrity and biological response for load-bearing bone repair. Full article
(This article belongs to the Special Issue Recent Advances in Additive Manufacturing and 3D Printing)
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