Search Results (710)

Additive manufacturing (AM) using powder bed fusion (PBF) has been the predominant printing method used over the last decade. The capability of this approach to produce complex parts with high precision has attracted the attention of major industries as a potential tool for replacing traditional manufacturing technologies. 15-5 PH stainless steel is one of the alloys being studied as a candidate for PBF processes. Its superior strength and corrosion resistance have made it a highly attractive option in numerous industries, including the automotive, nuclear, and petrochemical industries. To enhance the properties of 15-5 PH stainless-steel AM parts following printing, one can use a thermal treatment such as age hardening. However, very little research exists regarding the functional properties of AM parts made from this alloy after heat treatment. This study aims to evaluate the effect of H1150M age hardening heat treatment following printing on the properties of 15-5 PH steel, particularly regarding its mechanical properties and environmental behavior. The microstructure was studied using both optical and electron microscopy, along with X-ray diffraction (XRD) analysis. The mechanical properties were examined by tensile testing and fracture toughness assessment. Corrosion behavior was analyzed in terms of potentiodynamic polarization and using impedance spectroscopy. The results obtained have shown that over-aging caused by H1150M heat treatment has a detrimental effect on the mechanical and environmental behavior of the tested alloy. This was primarily attributed to the formation of an austenitic phase within the inherent martensitic matrix, the generation of brittle phases (mainly carbonitrides of Cr and Nb) and a reduction in grain size. Full article

Soft magnetic composite materials have a low total loss and high magnetic conductivity and are highly desirable for high-frequency motors, semiconductors, and 5G communication technologies. However, these composites often contain a high-volume fraction of soft magnetic metallic powders and are difficult to process into complex shapes. Herein, iron-based amorphous powders were surface-modified with silane coupling agents (DTMS and KH570) and applied in 3D direct ink writing (DIW). The modified powders exhibit improved compatibility and dispersion in epoxy resin. The optimized 92.3 wt% FeSiB@3.35 wt% KH570/EP slurry shows favorable rheological properties and a dense interfacial microstructure. The printed composite achieves the best magnetic performance (M_s: 137.02 ± 1.2 emu/g, H_c: 6.63 ± 0.2 Oe) and stable permeability up to 1 GHz. The surface modification enhanced slurry fluidity, preventing nozzle blockage and increasing powder loading. Various shaped magnetic cores were successfully fabricated with excellent magnetic properties and printing quality. Our work paves a new way for realizing the high processibility of soft magnetic composites, which lays a foundation for a technique for the wide applications of these materials in various electronic devices. Full article

Surface Acoustic Wave (SAW) technology, long central to analog signal processing and RF filtering, is undergoing a major renewal. Driven by advances that decouple SAWs from traditional piezoelectric materials and fixed-function devices, the field is gaining unprecedented control over acoustic, optical, and electronic interactions at the micro and nanoscale. This review synthesizes these developments across four fronts: new physical mechanisms for SAW manipulation, emerging material platforms, ranging from thin films to 2D systems, along with reconfigurable device architectures and circuits, and the expanding landscape of applications they enable. Optical methods are reshaping how SAWs are generated and controlled, bypassing the limits of conventional electromechanical coupling. Coherent optical excitation of high-Q SAW cavities via Brillouin-like optomechanical interactions now grants access to modes in non-piezoelectric substrates such as diamond and silicon, while on-chip SAW excitation in photonic waveguides through backward stimulated Brillouin scattering opens new integrated sensing routes. In parallel, magneto-acoustic experiments have revealed nonreciprocal SAW diffraction from resonant scattering in magnetoelastic gratings. On the device side, ZnO thin-film transistors integrated on LiNbO₃ exploit acoustoelectric coupling to realize voltage-tunable phase shifters; UHF Z-shaped delay lines achieve high sensitivity in a compact footprint; and parametric synthesis of wideband, multi-stage lattice filters targets 5G-class performance. Atomistic simulations show that SAW propagation in 2D MXene films can be engineered via surface terminations, while aerosol jet printing and SAW-assisted particle patterning provide agile, cleanroom-light fabrication of microfluidic and magnetic components. These advances enable applications ranging from hybrid quantum systems and quantum links to lab-on-a-chip particle control, SBS-based and UHF sensing, reconfigurable RF front-ends, and soft robotic actuators based on patterned magnetic composites. At the same time, optical techniques offer non-contact probes of dissipation, and MXenes and other emerging materials open new regimes of acoustic control. Conclusively, they are transforming SAW technology into a versatile, programmable platform for mediating complex interactions in next-generation electronic, photonic, and quantum systems. Full article

Hybrid metal–polymer components are used in many industries, such as in aerospace, automotives, and electronics, due to the possibility of reducing the weight of the final part while maintaining mechanical properties comparable to components made entirely of metal. Conventional 3D printing processes do not enable the direct fabrication of hybrid structures consisting of solid metal and polymer parts due to the significant differences in the processing temperatures of both materials. A solution to this problem is the integration of two processes, electrodeposition and photopolymerization, which allow fabrication to be carried out at room temperature. This paper presents preparatory studies aimed at developing a new 3D printing technology that uses the simultaneous application of electrodeposition and photopolymerization to manufacture hybrid metal–polymer elements in a single, integrated 3D printing process. Here, a hybrid metal–polymer element is defined as a component composed of at least two bonded parts, including at least one metal part fabricated by electrodeposition and at least one polymer part produced by photopolymerization. Thus, it is not a polymer component merely coated with an electrodeposited metal layer, but a true hybrid structure consisting of functional metallic and polymeric parts. Such components can be manufactured using the world’s first hybrid 3D printer, which integrates electrodeposition and photopolymerization to produce metal–polymer hybrid parts within a single 3D printing process (the device has been submitted to the Polish Patent Office). However, its design and operating principle are beyond the scope of this paper. The presented research focuses on initial study of selected feedstock materials for this printer, namely photocurable resins and electroplating baths. Since the entire hybrid printing process occurs in an electroplating bath environment, studies of these materials for 3D printing under such conditions were essential. This work includes a screening study of photocurable formulations with respect to rheological properties, 3D printing tests in a model copper electroplating bath, and selection of a suitable bath brightener to maximize the quality (fine grain size, homogeneous grain distribution) of additively deposited copper layers. The study was conducted using copper electrodeposition and acrylate resin photopolymerization as model processes for evaluating the proposed hybrid metal–polymer 3D printing technology. Finally, the most suitable feedstock materials for producing metal–polymer hybrid parts via the proposed 3D printing method were selected. Full article

Background/Objectives: Bioceramic scaffolds with complex geometries and customized mechanical and biological properties can now be produced via 3D printing, revolutionizing dental and maxillofacial tissue engineering. This review discusses the recent progress in 3D printing technologies applied to bioceramic scaffolds for dental and maxillofacial reconstruction. Methods: A comprehensive literature search was conducted across major electronic databases, including Scopus, PubMed, ScienceDirect, and Web of Science. Peer-reviewed articles published between 2015 and 2026 were considered for inclusion. Several 3D printing methods can be used to create bioceramic or composite scaffolds for the regeneration of dental, oral, or maxillofacial tissues. Results: Additive manufacturing enables customization of bioceramic scaffolds. This report emphasizes the osteoconductive properties, biodegradability, and compatibility of calcium phosphate, bioactive glass, and calcium silicate ceramics. Conclusions: This review helps to determine how 3D-printed bioceramics can be optimized for dental and maxillofacial applications tailored to specific patients. Full article

Printed electronics have emerged as a versatile manufacturing platform for next-generation biosensors, enabling on-demand and low-cost fabrication of functional devices on flexible, stretchable, and unconventional substrates. One major challenge in this field lies in the sintering of printed features, as conventional high-temperature processing is incompatible with polymeric substrates and thermally sensitive biological components. Low-temperature sintering inks, typically processed below 200 °C or even at room temperature, have become a critical enabling technology for bio-integrated electronics. This review provides an overview of the current state-of-the-art and key challenges associated with low-temperature sintering inks for printed bioelectronics. We discuss inks based on metal nanoparticles, metal–organic decomposition precursors, metal oxides, chalcogenides, and hybrid material systems. The emphasis is on how ink chemistry, ligand selection, and precursor structure govern rheology, stability, and sintering behavior. In addition, key low-temperature sintering and curing strategies, including thermal, photonic, laser, plasma, microwave, and chemical sintering, are compared in terms of energy delivery, densification mechanisms, and substrate compatibility. Finally, we outline emerging directions towards low temperature and room-temperature sintering inks, and sustainable biobased ink formulations, and discuss their applications for wearable, implantable, and soft biosensing platforms. Full article

The use of additive manufacturing in structural applications has increased in industry; however, reliable material selection criteria remain limited when printed components must withstand real service loads. The following study provides a comprehensive evaluation of polymeric materials (PLA filament, ABS filament, and ABS-like resin) used in additive manufacturing technologies for the production of footwear heels. Consequently, five heel models were designed using reverse engineering based on real industry references and analyzed within a decision framework based on the Input–Transformation–Output (ITO) model. Within this framework, each material was subjected to static mechanical tests (tensile, compression, flexural and hardness), scanning electron microscopy (SEM) analysis and numerical simulations. In addition, functional tests were carried out by mounting the printed heels on real sandals, allowing for evaluation of their performance under service conditions. Significant differences in surface morphology were observed, attributable to the physical state and consolidation mechanism of each material. Uncontrolled environmental conditions during printing and testing were identified as a limitation affecting reproducibility. The ABS-like resin showed the highest compressive load capacity (10.8 kN), together with a tensile strength of 14.99 MPa and a deformation at break of 0.076 mm/mm. SEM analysis revealed a more homogeneous surface morphology and greater structural continuity after curing, consistent with the numerical simulations, which predicted stresses between 19.98 and 196.23 MPa, displacements up to 8.917 mm and unit strains up to 0.1378. The integrated interpretation of the experimental, microstructural and functional results provides technical criteria for material selection in reverse-engineered footwear components and structural elements manufactured by additive manufacturing. Full article

To meet the requirements of flexibility and high performance for energy storage devices in flexible wearable electronic equipment, the MnO₂/acetylene black composite flexible cathodes is fabricated via 3D printing technology and the aqueous manganese-based zinc-ion flexible batteries are assembled. Based on bending and torsion mechanical tests, and the electrochemical tests, the optimal 3D printing electrode structure was determined. The micromorphology of the electrode after mechanical tests shows that when the printed lines of the upper and lower layers form a 30° angle, the electrode sheet exhibits the least damage. Electrochemical tests indicated that it had an ohmic resistance of 2.052 Ω, an interfacial charge transfer resistance of 141.1 Ω, a specific capacity of 103 mAh/g at 50 mA/g, and a specific capacity of 65 mAh/g at 500 mA/g. Compared with traditional coated electrodes, the 3D-printed electrode showed significantly improved diffusion coefficient, conductivity, and cycle stability. The assembled 3D-printed flexible battery could stably power a 1.5 V LED bulb under flat, bent, and twisted states. It provides a feasible solution for the development of high-performance flexible energy storage devices. Full article

This in vitro study evaluated the fracture resistance of CAD/CAM-fabricated lithium disilicate and 3D-printed resin crowns with varying occlusal thicknesses (0.5, 1.0, and 1.5 mm) following thermomechanical aging. Sixty extracted human molars were assigned to six experimental groups (n = 10), categorized by crown material and occlusal thickness. The crowns were fabricated using CAD/CAM technology in accordance with the manufacturer’s protocol. All specimens underwent thermomechanical aging, which consisted of thermocycling between 5 and 50 °C (5500 cycles) combined with mechanical loading of 50 N at 1.6 Hz for 75,000 cycles. The fracture loads were measured using a universal testing machine, and the failure modes were assessed using scanning electron microscopy. Statistical evaluation was performed using two-way analysis of variance with Tukey’s post hoc test (α = 0.05). Both the material type and occlusal thickness had a statistically significant effect on fracture resistance (p < 0.001). Lithium disilicate crowns exhibited higher fracture loads than 3D-printed resin crowns independent of occlusal thickness. Although the fracture resistance of 3D-printed resin crowns was lower, specimens with occlusal thicknesses ≥1.0 mm exhibited fracture loads exceeding average physiological masticatory forces, suggesting that 3D-printed resin crowns may represent a clinically acceptable option for conservative posterior restorations. In contrast, crowns with an occlusal thickness of 0.5 mm demonstrated fracture resistance values below the reported functional masticatory loads. Additionally, the proportion of repairable fractures increased with increasing occlusal thickness for both materials. Overall, the findings suggest that an occlusal thickness of at least 1.0 mm may represent a reliable threshold for posterior restorations, whereas a thickness of 0.5 mm may be insufficient to withstand functional occlusal loads in molar regions. Full article

Textile materials represent a versatile class of engineering substrates widely used in apparel, domestic products, and medical protective systems. Despite their extensive application, large-scale textile production has seen limited integration of fundamentally new functionalization strategies. In recent years, however, advances in materials science have enabled the development of textiles with tailored electrical, adaptive, and biological functionalities. This review summarizes recent progress in the functionalization of textile materials with a focus on approaches relevant to engineering and industrial implementation. Particular attention is given to conductive textiles designed for operation under extreme environmental conditions, including low-temperature climates. Methods for integrating electrically conductive elements into fibrous structures are discussed, highlighting their potential for sensing, thermal regulation, and energy-related applications such as powering portable electronic devices. Inkjet printing is presented as a scalable technique for high-resolution deposition of conductive patterns while preserving the mechanical integrity and aesthetic properties of textile substrates. In addition, adaptive and stimuli-responsive textile systems are reviewed, including materials capable of responding to thermal, optical, or chemical stimuli, with applications in camouflage, wearable systems, and multifunctional surfaces. The review further addresses the development of bioactive textiles, emphasizing antibacterial functionalization using organic and inorganic agents to mitigate the spread of pathogenic microorganisms. The relevance of such materials has been underscored by recent global viral outbreaks. Overall, this work aims to provide a materials science perspective on emerging textile functionalization strategies and to facilitate the transition of these technologies from laboratory-scale research to practical engineering applications. Full article

Background/Objectives: Hand loss or severe impairment significantly reduces quality of life by restricting essential daily activities and professional tasks. Despite advances in prosthetics, challenges remain in affordability, accessibility, and usability. This study aimed to design and develop a low-cost, ergonomic bionic hand prototype that integrates sustainable fabrication, intuitive control, and modular electronics. Methods: A user-centred design process guided by iterative prototyping, anatomical modelling, and functional validation. The prototype was manufactured using 3D printing techniques and assembled with modular electronic components. The design included segmented fingers, independent thumb articulation, and a tendon-like actuation system driven by micro-motors. Control was implemented through an ESP32-based board and a Bluetooth-enabled mobile application. Durability was preliminarily assessed through 500 grasp–release cycles. Results: Experimental validation confirmed the feasibility of both precision and power grips. The pinch grip successfully lifted objects to 120 g, and the power grip up to 85 g, corresponding to effective output forces of approximately 1.2 N and 0.83 N, respectively. The final prototype weighed ~350 g and maintained reliable performance during 500 grasp–release cycles. Conclusions: The developed bionic hand demonstrates that an affordable, ergonomic, and functional prosthetic can be achieved through sustainable 3D printing and accessible electronics. Future work will focus on enhancing actuation strength, long-term durability, and integration of sensory feedback, with the long-term objective of clinical testing and scalable production. Full article

Additive manufacturing is transforming high-frequency electronics prototyping by offering a sustainable and cost-effective alternative to traditional methods. This work addresses and demonstrates two areas: the use of 3D printing for millimeter-wave (mmWave) antennas, and chip-to-chip or chip-to-PCB interconnects. Both approaches facilitate reduced material waste. A 47 GHz series-fed microstrip patch array was printed on flexible Kapton using aerosol jet technology, showing performance comparable to etched arrays on Roger’s substrates. Crucially, the Kapton film can be peeled off after testing, allowing the reuse of expensive low-loss substrates. Therefore, this method supports rapid, low-waste prototyping. To address future chip-to-chip and chip-to-PCB mmWave interconnect limitations, XTPL’s Ultra-Precise Dispensing (UPD) was used to fabricate 3D-printed micro-interconnects. At 73 GHz, these interconnect structures achieved return loss better than 10 dB and insertion loss under 1 dB—outperforming traditional bondwires. Together, these results show 3D printing’s potential to enable sustainable, high-performance mmWave RF systems. Full article

Additive Manufacturing (AM) and printing-based fabrication technologies have emerged as powerful enablers for next-generation electronic integration and packaging, addressing the growing limitations of conventional subtractive manufacturing techniques. As electronic systems continue to scale toward higher operating frequencies (10–110 GHz and beyond) and increased functional density (>10⁴ interconnects/cm²), traditional packaging approaches struggle with rigid design constraints, complex processing steps (>15–25 fabrication steps), high tooling costs ($10,000–$100,000 for mask and molds) and limited compatibility with heterogeneous integration. In this review, a comprehensive and critical overview of major additive manufacturing and printing technologies including aerosol jet printing, inkjet printing, vat polymerization, fused filament fabrication (FFF) and nScrypt printing is presented from the perspective of electronic assembly and packaging. The fundamental working mechanisms, material compatibility, resolution limits, scalability, and reliability considerations of each technique are systematically discussed. From a manufacturing standpoint, AM reduces material waste by 50–90% compared to subtractive PCB processing and eliminates tooling costs, enabling low-volume prototyping with per-unit fabrication costs reduced by 30–70% for small batches (<100 units). Production throughput varies widely, from 1 to 20 cm²/min for high-resolution direct write systems to >100 cm²/min for scalable inkjet systems. Moreover, it is discussed how these technologies enable advanced packaging architectures such as printed signal crossovers, three-dimensional interconnects, ramps, and embedded chip assemblies. Recent research efforts and reported demonstrations are analyzed to highlight the advantages and current limitations of additive manufacturing for high-frequency, RF, and system-on-package (SoP) applications. Finally, future directions and remaining challenges are discussed, including advances in materials, custom and on-demand manufacturing, enhanced design freedom, integration of multifunctionality, cost-effectiveness, and smart packaging solutions. This review aims to serve as a reference for researchers and engineers seeking to leverage additive manufacturing for high-performance electronic integration and next-generation electronic packaging solutions. Full article

Background/Objectives: 3D printing, particularly fused deposition modeling (FDM), is an emerging technology in pharmaceutical manufacturing, enabling the customization of dose or release rate to individual patient needs. However, finding the appropriate loading method to ensure the stability of the drug and achieve the targeted dose may be challenging. Furthermore, the drug utilization of most loading methods is poor, which results in considerable waste production and increased environmental burden. This study aimed to compare two post-printing drug-loading techniques: electronic syringe deposition and pan coating on FDM-printed polylactic acid (PLA) tablets. PLA is a biodegradable and biocompatible polymer that is widely used in this field due to its mechanical strength and regulatory approval. Methods: Tablets with honeycomb-shaped infill (30% and 60% infill densities) were fabricated using PLA filaments, followed by loading with a 15% paracetamol solution via either electronic syringe deposition or pan coating. The resulting tablets were assessed for drug content, weight variation, friability%, surface morphology (SEM), drug distribution (Raman mapping), solid-state characteristics (DSC and FTIR), and dissolution performance. Results: The results indicated that pan coating and electronic syringe deposition offered drug utilization up to 88% and 91.7%, respectively, which is superior to conventional soaking methods. Nevertheless, there is a significant difference in drug loading and release rate: pan coating yielded up to 10.14% drug loads and fast release (over 80% in 30 min), while electronic syringe deposition showed lower drug loading up to 4.8% and slower release (less than 80% within 60 min), which could be associated with better mechanical film integrity and higher precision. Both methods met USP standards with a weight loss of less than 1% and maintained the drug’s crystalline state and compatibility with PLA. Conclusions: FDM combined with controlled post-printing drug loading presents a rapid, cost-effective, and flexible novel approach for manufacturing personalized immediate-release tablets, with pan coating potentially being more suitable for commercial scalability and electronic syringe offering precise dosing for personalized therapies. Full article

Nowadays, Additive Manufacturing for Electronics (AME) is gaining ground in device fabrication for the numerous advantages of these types of manufacturing technologies, such as fast production processes, freeform design, and low-cost prototyping. In this scenario, the proposed research work is focused on evaluating an innovative strategy for a common issue in power electronics, which is related to the generation of hotspots. To face this problem, the 3D printing of ceramic substrates with different high surface areas was studied to improve thermal dissipation. Together with improved thermal management, the upper surface of the devices enabled the deposition of a desired conductive pattern and the bonding of bare die components for device fabrication. Finally, thermal exchange was monitored to verify the efficacy and efficiency of the devices’ dissipation capabilities. The proposed models exhibited a 70% temperature reduction upon transitioning from air to water. Furthermore, the operating temperature remained stable for 10 min, meeting the specific requirements of the intended application. Full article