Search Results (125)

Thermal wick-debinding, commonly used in low-pressure injection molding, remains challenging due to complex interactions between binder transport, capillary forces, and thermal effects. This study presents a numerical simulation of binder removal kinetics by coupling Darcy’s law with the Phase Transport in Porous Media interface in COMSOL Multiphysics. The model was validated and subsequently used to study the influence of key debinding parameters. Contrary to the Level Set method, which predicts isolated binder clusters, the Multiphase Flow in Porous Media method proposed in this work more accurately reflects the physical behavior of the process, capturing a continuous binder extraction throughout the green part and a uniform binder distribution within the wicking medium. The model successfully predicted the experimentally observed decrease in binder saturation with increasing debinding temperature or time, with deviation limited 3–10 vol. % (attributed to a mandatory brushing operation, which may underestimate the residual binder mass). The model was then used to optimize the debinding process: for a temperature of 100 °C and an inter-part gap distance of 5 mm, the debinding time was minimized to 7 h. These findings highlight the model’s practical utility for process design, offering a valuable tool for determining optimal debinding parameters and improving productivity. Full article

Compared to traditional manufacturing methods, additive manufacturing (AM) enables the production of parts with arbitrary structures, effectively addressing the challenges faced when fabricating complex geometries using conventional techniques. The dynamic development of this technology has led to the emergence of increasingly advanced materials. One of the best examples is metal–polymer composites, which allow the manufacturing of fully dense components consisting of stainless steel and titanium alloys, employing the widely available AM technology based on material extrusion (MEX). Metallic materials intended for this type of 3D printing may serve as an alternative to currently prevalent techniques including techniques like selective laser melting (SLM), owing to significantly lower equipment and material costs. Particularly applicable in low-volume production, where total costs and manufacturing time are critical factors, MEX technology of polymer–metallic composites offer relatively fast and economical AM of metal components, proving beneficial during the design of geometrically complex, and low-cost equipment. Due to the significant advancements in AM technology, this review focuses on the latest developments in the additive manufacturing of metallic components using the MEX approach. The discussion encompasses the printing process characteristics, materials tailored to this technology, and post-processing steps (debinding and sintering) necessary for obtaining fully metallic MEX components. Additionally, the article characterizes the printing process parameters and their influence on the functional characteristics of the resulting components. Finally, it presents the drawbacks of the process, identifies gaps in existing research, and outlines challenges in refining the technology. Full article

This study introduced a systematic framework to develop practical design guidelines specifically for filament-based material extrusion of metals (MEX/M), an additive manufacturing (AM) process defined by ISO/ASTM 52900. MEX/M provides a cost-efficient alternative to conventional manufacturing methods, which is particularly valuable for rapid prototyping. Although AM offers significant design flexibility, the MEX/M process imposes distinct geometric and process constraints requiring targeted optimization. The research formulates and validates design guidelines tailored for the MEX/M using an austenitic steel 316L (1.4404) alloy filament. The feedstock consists of a uniform blend of 316L stainless steel powder and polymeric binder embedded within a thermoplastic matrix, extruded and deposited layer by layer. Benchmark parts were fabricated to examine geometric feasibility, such as minimum printable wall thickness, feature inclination angles, borehole precision, overhang stability, and achievable resolution of horizontal and vertical gaps. After fabrication, the as-built (green-state) components undergo a two-step thermal post-processing treatment involving binder removal (debinding), followed by sintering at elevated temperatures to reach densification. Geometric accuracy was quantitatively assessed through a 3D scan by comparing the manufactured parts to their original CAD models, allowing the identification of deformation patterns and shrinkage rates. Finally, the practical utility of the developed guidelines was demonstrated by successfully manufacturing an impeller designed according to the established geometric constraints. These design guidelines apply specifically to the machine and filament type utilized in this study. Full article

Atomic diffusion additive manufacturing (ADAM) is a specialized extrusion-based metal additive manufacturing (MAM) process where metal parts are produced through a three-stage process of printing, de-binding and sintering. Several scientific facts, such as dimensional error, surface quality, tensile behavior and the internal structure of this process for specific materials for certain conditions, are not well explained in the existing literature. To address these issues, the present manuscript investigates the effect of infill type and shell thickness on 17-4 precipitation-hardened (PH) stainless steels on the dimensional accuracy, surface roughness and mechanical properties of the printed specimens. It was found that the strength (maximum ultimate tensile strength up to 1049.1 MPa) and hardness (290 HRB) of the specimens mainly depend on shell thickness, while infill type plays a relatively minor role. The principle of atomic diffusion may be the reason behind this pattern, as an increase in shell thickness is essentially an increase in the density of material deposited during printing, allowing more fusion during sintering and thus increasing its strength. The two different infill types (triangular and gyroid) contribute towards minimal changes, although it should be noted that triangular specimens exhibited greater ultimate tensile strength, whereas the gyroid had slightly longer elongation at break. Dimensional accuracy and surface roughness for all the specimens remain reasonably consistent. The cross-section of the tensile tested specimens revealed significant pores in the microstructure that could contribute to a reduction in the mechanical properties of the specimens. Full article

Alumina is a polycrystalline oxide ceramic with different structures. Currently, α-alumina with a hexagonal close-packed stacking structure is mainly used for a variety of industrial applications. Alumina-based ceramics and composites have been widely used in various fields due to their excellent hardness, strength, creep resistance and good biocompatibility. However, it is difficult for Al₂O₃ ceramic components based on traditional preparation methods to meet the increasing industrial requirements, especially for applications such as precise multi-walled complex structures. Al₂O₃ ceramic additive manufacturing by vat photopolymerization 3D printing stands out owing to its ability to produce complex structures and tailored shaping accuracy/properties. The vat photopolymerization 3D printing of Al₂O₃ ceramics requires multiple steps including slurry preparation, photopolymerization shaping, debinding and sintering. Therefore, many efforts mainly focus on the strategies of optimizing the ceramic slurry formulation and the debinding/sintering process. This paper provides a scoping review to present optimization strategies for the above aspects of vat photopolymerization 3D printing, which creates a strong reference for researchers to improve the accuracy and properties of alumina parts. Finally, this review also states the main applications of Al₂O₃ ceramic components based on vat photopolymerization, and highlights the opportunities and challenges associated with this technology in the future. It is beneficial to understanding the future trends and policy directions of advanced manufacturing industry. Full article

Digital light processing (DLP) is widely recognized as one of the most promising additive manufacturing technologies for ceramic fabrication. Nevertheless, during the additive manufacturing of zirconia ceramics, debinding and sintering often lead to structural defects, which severely deteriorate the material properties and hinder their broader application. In this study, we added an oligomer into the photosensitive resin and systematically investigated the effects of oligomer content on the viscosity and curing properties of ceramic suspensions. The results demonstrated that the introduction of oligomers is conducive to enhancing the crosslinking density and reducing defects. Finally, a 45 vol% solid content zirconia ceramic slurry was prepared by adding 20 wt% oligomers to the resin system. After printing, debinding, and sintering, the final zirconia ceramics exhibited a uniform microstructure without delamination or cracks, its bending strength reached 682.4 MPa. This study demonstrates that zirconia ceramics fabricated by photopolymerization with oligomer photosensitive resin exhibit excellent mechanical properties, significantly expanding the potential applications for high-performance zirconia ceramic components with additive manufacturing. Full article

As additive manufacturing technologies continue to gain ground in industrial applications, the need for the accurate metrological evaluation of parts produced with advanced materials becomes increasingly critical. In this context, non-contact metrology plays a key role. This research investigates the performance of conoscopic holography as an optical metrology technique for the inspection of ceramic parts manufactured by stereolithography. However, its reliability needs to be validated, especially as factors such as material properties, surface finish, and color can significantly affect measurement accuracy. Spherical artifacts in alumina were chosen as mathematically well-defined reference elements, and a representative series was produced with the best values for the printing, debinding, and sintering parameters. These spheres were first measured via contact with a coordinate measuring machine (CMM) to establish dimensional (diameter) and geometrical (form error) reference values. These parameters were then compared with measurements obtained via conoscopic holography and optimized by means of Gaussian filters. The results indicated significant dimensional (up to 60 µm) and geometrical (up to 280 µm) deviations from the CMM reference data. The investigation shows that conoscopic holography does not ensure an accurate measurement method for this additive process and ceramic material, making it impossible to achieve power and frequency settings that would allow signal-to-noise ratios above 50%. Full article

Additive manufacturing of metals is limited by a fundamental tradeoff between deposition rates and manufacturability of fine-scale features. To overcome this problem, a laser-ablated bound metal deposition (laBMD) process is demonstrated in which 3D-printed green-state bound metal deposition (BMD) parts are post-processed via laser ablation prior to conventional BMD debinding and sintering. The laBMD process is experimentally characterized via a full-factorial design of experiments to determine the effect of five factors—number of laser passes (one pass, three passes), laser power (25%, 75%), scanning speed (50%, 100%), direction of laser travel (perpendicular, parallel), and laser resolution (600 dpi, 1200 dpi)—on as-sintered ablated depth, surface roughness, width, and angle between ablated and non-ablated regions. The as-sintered ablation depth/pass ranged from 3 to 122 µm/pass, the ablated surface roughness ranged from 3 to 79 µm, the angle between ablated and non-ablated regions ranged from 1° to 68°, and ablated bottom widths ranged from 729 to 1254 µm. This study provides novel insights into as-manufactured ablated geometries and surface finishes produced via laser ablation of polymer–metallic composites. The ability to inexpensively and accurately manufacture fine-scale features with tailorable geometric tolerances and surface finishes is important to a variety of applications, such as manufacturing molds for microfluidic devices. Full article

Si₃N₄ ceramics and composites stand out for their exceptional mechanical and thermal properties. Compared with conventional ceramic forming processes, 3D printing via vat photopolymerization not only ensures high geometric precision but also improves the forming efficiency and strength of green body. Nevertheless, the grayish appearance of Si₃N₄ and its relatively high refractive index can adversely affect the photocuring behavior in ceramic slurries. The primary objectives focus on enhancing the curing performance and rheological properties of slurries, minimizing defects during post-processing, and improving the relative density and mechanical properties of Si₃N₄ ceramics. Key advancements include slurry optimization via refractive index matching, biomodal particle gradation and surface modification, while the integration of whisker/fiber additions or polymer-derived ceramic strategies enhances mechanical properties. In addition, controlling the atmosphere and heating rate of the post-processing innovations can achieve a relative density of more than 95%. This paper introduces the mechanisms of vat photopolymerization and then summarizes the strategies for improving Si₃N₄ ceramic slurries as well as controlling the printing and debinding/sintering processes. It further highlights the ways in which different approaches can be used to enhance the properties of Si₃N₄ slurries and ceramic parts. Finally, applications of Si₃N₄ ceramics and composites via vat photopolymerization in various fields such as aviation, aerospace, energy, electronics, chemical processes, and biomedical implants are also presented to point out future opportunities and challenges. Full article

In ceramic digital light processing (DLP) additive manufacturing, the photosensitive resin, which acts as a carrier for ceramic particles, must exhibit suitable curing performance, curing strength, and viscosity. This ensures both the bonding strength of the fabricated ceramic parts and the dimensional accuracy of the ceramic green body. In this study, various photosensitive resin monomers were investigated in depth to formulate resins containing monofunctional, bifunctional, and multifunctional groups. Their rheological and curing properties were analyzed theoretically and experimentally. Different resin slurry systems were prepared and printed using DLP technology, and their mechanical properties were tested and compared. The effect of photoinitiator content on the curing behavior of the resin was examined, and the optimal photoinitiator concentration was identified. Based on the optimized resin, a zirconia ceramic slurry with 56 vol% solid content was prepared. After DLP printing, debinding, and sintering, dense zirconia ceramic samples with a relatively uniform grain structure were obtained, exhibiting a bending strength of 766.85 MPa. These results significantly expand the potential applications for zirconia ceramic components with complex geometries. Full article

Additive manufacturing has revolutionized the production industry by enabling the fabrication of complex geometries. In recent years, significant advancements have been made in 3D printing using metal filament, particularly with materials such as 316L stainless steel. Known for its high strength, corrosion resistance, and ductility, 316L stainless steel is well suited for demanding applications in the medical, marine, and aerospace industries. However, secondary processes such as debinding and sintering can lead to changes in the dimensions and mechanical properties of the final product. This study investigates the effect of layer thickness on the mechanical properties of 316L stainless steel produced through additive manufacturing. Samples were produced with varying layer thicknesses (100, 200, 300, and 400 µm) and tested for tensile strength, hardness, and density. The results indicate that tensile strength increases with decreasing layer thickness. The highest tensile strength (432 MPa) and hardness (213 Hv) were observed at a layer thickness of 100 µm. Additionally, phase analyses and microstructural examinations were conducted. The primary phases identified in the samples were face-centered cubic (FCC) austenite and body-centered cubic (BCC) ferrite (δ). In this study, the manufacturing parameters with 316L filament have been optimized, and their impact on the mechanical properties has been examined. Full article

The objective of this study is to demonstrate the feasibility of producing SiC–aluminum composites by the binder jetting 3D printing of SiC preforms and spontaneous infiltration by aluminum. SiC preforms fabricated using binder jetting 3D printing were subjected to several post-processing steps (including curing, depowdering, debinding, and sintering). Sintering was conducted at 1700 °C, and aluminum infiltrating was conducted at 1000 °C, with both carried out in a controlled nitrogen environment under a pressure of 25 psi. The bulk density of the sintered SiC preforms was increased by 14% after infiltration. X-ray diffraction and energy-dispersive X-ray spectroscopy confirmed the presence of aluminum in the SiC matrix. This paper is the first to report fabricating SiC–aluminum composites by binder jetting and infiltrating, providing a new approach to producing these composites with potential applications in the aerospace and automotive industries. Full article

Alumina is the most widely used oxide ceramic, and its applications are widespread in engineering and in biomedical fields. Its spheroidization was performed by a prototypal direct current (DC) thermal plasma, which was designed and installed at ENEA, investigating surface morphology, particle size distribution, crystallinity, spheroidization, and reactivity. Features such as morphology and porosity significantly influence the flowability of the powder on the printer bed and, consequently, the density of the printed parts. It has been reported that spherical powder shape is highly recommended in additive manufacturing (AM) due to its superior flowability compared to other shapes whose interaction between powder particles results in poor flowability. In this paper, the spheroidization process of alumina powders using two different DC plasma powers and two kinds of secondary gas is reported. The average value of the circularity of the powders, after plasma treatment, has always been greater than or equal to 0.8 with the degree of the spheroidization over 90% at high power. The best process parameters of the thermal plasma were properly selected to produce spherical powders suitable for AM applications, and powders with high circularity were successfully obtained. Forming, debinding, and sintering tests were performed to verify the processability and the densification of produced powders, with good results in terms of density (97%). Full article

Fused filament fabrication (FFF) is the most widespread and versatile material extrusion (MEX) technique. Although powder-based systems have dominated the metal 3D printing landscape in the past, FFF’s popularity for producing metal parts (“metal FFF”) is growing. Metal FFF starts from a polymer–metal composite feedstock and proceeds through three primary stages, namely shaping (i.e., printing), debinding, and sintering. As critically discussed in the present review, the final quality of metal FFF parts is influenced by the characteristics of the composite feedstock, such as the metal loading, polymer backbone, and presence of additives, as well as by the processing conditions. The literature shows that a diverse array of metals, including steel, copper, titanium, aluminium, nickel, and their alloys, can be successfully used in metal FFF. However, the formulation of appropriate polymer binders represents a hurdle to the adoption of new material systems. Meanwhile, intricate geometries are difficult to fabricate due to FFF-related surface roughness and sintering-induced shrinkage. Nonetheless, the comparison of metal FFF with other common metal AM techniques conducted herein suggests that metal FFF represents a convenient option, especially for prototyping and small-scale production. Whilst providing insights into the functioning mechanisms of metal FFF, the present review offers valuable recommendations, facilitating the broader uptake of metal FFF across various industries. Full article

This study investigates the application of robocasting technology for fabricating high-density yttria-stabilized zirconia (8YSZ) electrolytes used in solid oxide fuel cells (SOFCs). The primary goal is to overcome the limitations of traditional manufacturing techniques, such as low density and poor microstructural control. Using a combination of hydrothermal synthesis, rheological testing, and robocasting, we achieved dense 8YSZ structures (over 95% density) with minimal porosity. The fabricated electrolytes underwent sintering and debinding processes, with thermal treatment profiles optimized for structural integrity. A microstructural analysis through SEM and XRD confirmed the formation of stable crystalline phase. This research opens new avenues for the use of additive manufacturing in electrochemical applications, particularly for producing complex ceramic components with superior characteristics. Full article