Additive manufacturing最新文献_第3页

Complex shaped Al2O3/YAG/ZrO2 eutectic ceramics with excellent high temperature mechanical properties printed by vat photopolymerization

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-02-13 DOI: 10.1016/j.addma.2025.104703

Shuqi Hao , Haijun Su , Di Zhao , Xiang Li , Zhonglin Shen , Yuan Liu , Yinuo Guo , Zhuo Zhang , Min Guo

Directionally solidified oxide eutectic ceramics exhibit excellent performances at both room and high temperatures due to strong phase interface binding, which determines broad application prospects in the field of ultra-high temperature structural components. However, oxide eutectic ceramics prepared by current directional solidification techniques are unable to simultaneously possess large volumes, complex shapes, and uniformly fine eutectic structures. In this study, complex shaped Al₂O₃/YAG/ZrO₂ eutectic ceramic hollow guide blades with nearly full relative density and uniformly fine eutectic microstructure were successfully prepared for the first time, utilizing a combination of laser floating zone melting, vat photopolymerization 3D printing and hot isostatic pressing. Sintered eutectic ceramics with fully closed porosity achieving a relative density of 91.97 ± 1.25 % were obtained by pressureless sintering at 1670℃ for 2 h. Al₂O₃/YAG/ZrO₂ sintered eutectic ceramics with a relative density of 99.27 ± 0.22 % were obtained by hot isostatic pressing at 1550℃ with 200 MPa for 60 min. The sintered highly densed eutectic ceramic exhibited a bending strength of 352.99 ± 39.97 MPa at room temperature. This bending strength can remain a value of 299.38 MPa at 1500°C, which is corresponding to a high strength retention rate of 84.81 %. Additionally, the hardness was 19.10 ± 0.69 GPa and the fracture toughness was 2.22 ± 0.21 MPa·m^1/2. This work offers a novel solution for the preparation of complex shaped oxide eutectic ceramic components.

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引用次数: 0

Modulation-enabled healable and stretchable shape-memory polymer composites for digital light processing 4D printing

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-02-12 DOI: 10.1016/j.addma.2025.104699

Wei Huang , Wenqing Chen , Vikramjeet Singh , Jianhui Zhang , Yu Wang , Mohammed Alabdullatif , Eral Bele , Gary J. Lye , Helen C. Hailes , Manish K. Tiwari

4D printing provides viable pathways for 3D-printed objects that require morphological, time-dependent adaptations. Among various 4D printing materials, shape-memory polymers (SMPs) are one of the most extensively utilized morphing materials. However, most existing SMPs in 4D printing systems suffer from irreparability and low stretchability due to abundant covalently cross-linked networks. Also, their shape-programming steps typically involve stringent temperature requirements (≥90 ºC) and lack strategies for remote controllability, significantly restricting their applicability. Herein, we report a novel thermoplastic polymer system with self-healing and highly stretchable shape-memory capabilities for digital light processing (DLP)-based 4D printing. This system was attained through the integration of two distinct compositions: a polymer-based framework that acts as the reinforcing phase; and an elastic lubricant featuring hydrogen bonds that facilitates self-healing, high stretchability, and enhanced shape recovery. Additionally, light-responsive capabilities were shown to be effectively achieved by introducing a novel cross-linker functionalized with biomass lignin. The rationally selected safer set of ingredients ensures that our printed shape-memory polymer composites (SMPCs) are biocompatible. We further demonstrate their potential applications in aerospace and healthcare. This work provides a foundation for the design and facilitation of intelligent materials, showcasing excellent properties across multiple fields.

{"title":"Modulation-enabled healable and stretchable shape-memory polymer composites for digital light processing 4D printing","authors":"Wei Huang , Wenqing Chen , Vikramjeet Singh , Jianhui Zhang , Yu Wang , Mohammed Alabdullatif , Eral Bele , Gary J. Lye , Helen C. Hailes , Manish K. Tiwari","doi":"10.1016/j.addma.2025.104699","DOIUrl":"10.1016/j.addma.2025.104699","url":null,"abstract":"<div><div>4D printing provides viable pathways for 3D-printed objects that require morphological, time-dependent adaptations. Among various 4D printing materials, shape-memory polymers (SMPs) are one of the most extensively utilized morphing materials. However, most existing SMPs in 4D printing systems suffer from irreparability and low stretchability due to abundant covalently cross-linked networks. Also, their shape-programming steps typically involve stringent temperature requirements (≥90 ºC) and lack strategies for remote controllability, significantly restricting their applicability. Herein, we report a novel thermoplastic polymer system with self-healing and highly stretchable shape-memory capabilities for digital light processing (DLP)-based 4D printing. This system was attained through the integration of two distinct compositions: a polymer-based framework that acts as the reinforcing phase; and an elastic lubricant featuring hydrogen bonds that facilitates self-healing, high stretchability, and enhanced shape recovery. Additionally, light-responsive capabilities were shown to be effectively achieved by introducing a novel cross-linker functionalized with biomass lignin. The rationally selected safer set of ingredients ensures that our printed shape-memory polymer composites (SMPCs) are biocompatible. We further demonstrate their potential applications in aerospace and healthcare. This work provides a foundation for the design and facilitation of intelligent materials, showcasing excellent properties across multiple fields.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104699"},"PeriodicalIF":10.3,"publicationDate":"2025-02-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143419524","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Multiphysics optimization of additive manufacturing of hemp fiber reinforced polylactic acid composite honeycomb structures

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-02-10 DOI: 10.1016/j.addma.2025.104697

Kandy Benié , Abel Cherouat , Thierry Barrière , Vincent Placet

This paper focuses on optimizing the additive manufacturing of a hemp/PolyLactic Acid composite honeycomb structure using the pellet-based 3D printing as material extrusion process. Based on the Diffusion, Coalescence, Crystallization (DCC) model recently introduced in the literature, this study proposes an optimization of the process parameters to maximize the compression properties of the printed bio-composite honeycomb structure. During 3D printing, the deposition of new strands tends to change the temperature in the previously printed strands. Using the thermal properties of PLA-hemp bio-composite and printing parameters, the Backward Differentiation Formula implicit method was used for solving the numerical simulation of the heat transfer during the printing of successive layers in order to calculate the temperature distribution and history. The heat transfer process was modeled by the transient heat conduction equation and the boundary conditions. At the end of simulations, the temperatures at the interface of the strands were used from probes positioned at each thermal contact and measuring the average temperature of the interface to calculate the DCC parameter. The mechanical performance of bio-composite PLA/hemp honeycomb structure was evaluated discussed using different machine parameters combinations as extrusion temperature, layer height, flow speed and platform temperature. The obtained results showed that minimizing the layer height while maximizing the extrusion temperature, the build platform temperature and the printing flow speed effectively enhances the compression properties of the structure. Experimental measurements of the axial compressive modulus and strength of the honeycomb structure validated these findings and highlighted the improved interlayer adhesion achieved by employing the best process parameters.

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引用次数: 0

Optimizing the microstructural and mechanical isotropy for the twin-wire directed energy deposition-arc fabricated Ti-48Al-2Cr-2Nb alloy via interpass remelting

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-02-10 DOI: 10.1016/j.addma.2025.104696

Danqi Zhang , Chen Shen , Lin Wang , Wenlu Zhou , Ting Zhang , Ying Li , Yuelong Zhang , Fang Li , Jianwen Xin , Kanglong Wu , Gang Ruan , Xueming Hua

Twin-wire directed energy deposition-arc (TW-DED-arc) has demonstrated feasibility in fabricating TiAl alloys. Unfortunately, it is hard to simultaneously guarantee the effective product utilization, and suppress the anisotropy. To break the trade-offs, a novel depositing strategy of an interpass remelting (IR) process, a representative of low-carbon-friendly and easy-to-operate processing route, is designed to fabricate Ti-48Al-2Cr-2Nb (TiAl-4822) alloy without chemical adjustment. The results indicated that the IR process promoted high-fraction equiaxed grains of ∼90 %, much higher than that fabricated by constant process (CP). The IR process significantly increased the microstructural and mechanical isotropy of TW-DED-arc fabricated TiAl-4822 alloy. For microstructural isotropy, the IR process facilitated the growth of equiaxed grains with appropriate size, twin thickness refinement, and micro-segregation improvement. The IR process also strengthened the α₂/γ phase interface and γ/γ twinning boundaries. For mechanical isotropy, the IR process generated superior tensile properties along different directions of TW-DED-arc fabricated TiAl-4822 alloy wall compared to CP process and other fabricating techniques. Meanwhile, the exceptional strength retention of about 97 % at 650 °C was maintained. This work provides a new perspective to optimize microstructure and mechanical properties of TiAl-4822 alloys, facilitating further development of TW-DED-arc and its application in aerospace industry.

{"title":"Optimizing the microstructural and mechanical isotropy for the twin-wire directed energy deposition-arc fabricated Ti-48Al-2Cr-2Nb alloy via interpass remelting","authors":"Danqi Zhang , Chen Shen , Lin Wang , Wenlu Zhou , Ting Zhang , Ying Li , Yuelong Zhang , Fang Li , Jianwen Xin , Kanglong Wu , Gang Ruan , Xueming Hua","doi":"10.1016/j.addma.2025.104696","DOIUrl":"10.1016/j.addma.2025.104696","url":null,"abstract":"<div><div>Twin-wire directed energy deposition-arc (TW-DED-arc) has demonstrated feasibility in fabricating TiAl alloys. Unfortunately, it is hard to simultaneously guarantee the effective product utilization, and suppress the anisotropy. To break the trade-offs, a novel depositing strategy of an interpass remelting (IR) process, a representative of low-carbon-friendly and easy-to-operate processing route, is designed to fabricate Ti-48Al-2Cr-2Nb (TiAl-4822) alloy without chemical adjustment. The results indicated that the IR process promoted high-fraction equiaxed grains of ∼90 %, much higher than that fabricated by constant process (CP). The IR process significantly increased the microstructural and mechanical isotropy of TW-DED-arc fabricated TiAl-4822 alloy. For microstructural isotropy, the IR process facilitated the growth of equiaxed grains with appropriate size, twin thickness refinement, and micro-segregation improvement. The IR process also strengthened the α<sub>2</sub>/γ phase interface and γ/γ twinning boundaries. For mechanical isotropy, the IR process generated superior tensile properties along different directions of TW-DED-arc fabricated TiAl-4822 alloy wall compared to CP process and other fabricating techniques. Meanwhile, the exceptional strength retention of about 97 % at 650 °C was maintained. This work provides a new perspective to optimize microstructure and mechanical properties of TiAl-4822 alloys, facilitating further development of TW-DED-arc and its application in aerospace industry.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104696"},"PeriodicalIF":10.3,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143403383","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Construction of dual conductive networks based on material jetting for high-performance flexible strain sensors

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-02-10 DOI: 10.1016/j.addma.2025.104698

Gang Chen , Yang Li , Pan He , Yujun Wei , Jiupeng Song , Biyou Peng , Yijun Li

Flexible strain sensors convert external mechanical stimuli into corresponding electrical signals, offering broad application prospects in electronic devices. However, achieving both a wide operating range and high sensitivity remains a key challenge. Material jetting (MJ) holds significant potential for sensor fabrication due to its contactless, maskless, and high-resolution printing process. Herein, we developed a flexible strain sensor with dual conductive networks, consisting of a polyvinyl alcohol/multi-walled carbon nanotubes (PVA/MWCNT) substrate layer and an overlying poly(3,4-ethylenedioxythiophene) polystyrene sulfonate/MWCNT (PEDOT:PSS/MWCNT) layer patterned and deposited layer by layer using a typical MJ technology, aerosol jet printing (AJP). Owing to the synergistic effect between the printed circuit and the flexible substrate, the meander-shaped sensor, fabricated under optimized 16-layer printing, achieved a wide strain response range of 0.6–80 % and high sensitivity with a gauge factor (GF) of 31.2. Additionally, the strain sensor stabilized its current signal under 2000 cyclic loading conditions, demonstrating good stability. We further investigated the effect of patterned grid density on sensor sensitivity, finding that sensitivity increased with grid density initially and then decreased, reaching an impressive GF of 47.52 at a grid density of 2 × 6. Furthermore, the sensor demonstrated remarkable versatility in applications such as full-range human body motion detection, Morse code communication, and UAV flight monitoring, including real-time strain detection during takeoff and landing processes. This study highlights the potential of AJP technology for precise patterning and the fabrication of next-generation flexible strain sensors.

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引用次数: 0

User-enabled installation qualification method for laser-based powder bed fusion of metals (PBF-LB/M) machine scanner subsystem

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-02-08 DOI: 10.1016/j.addma.2025.104694

B.L. Valadez Mesta , H.C. Taylor , J. Mireles , D. Borup , R.B. Wicker

Installation qualification for laser-based powder bed fusion of metals (PBF-LB/M) machines is challenging due to the extensive labor, time, and financial costs required by current standards. These standards demand long builds, expensive equipment, and specialized expertise, primarily focusing on mechanical properties, which complicates the analysis of subsystem performance where attention may be required. Consequently, this makes machine installation qualification both inaccessible and inconsistent for typical PBF-LB/M users. This study presents a new methodology for installation qualification of PBF-LB/M scanner subsystem hardware and control software that addresses these challenges, empowering users to qualify their systems. A plate melt setup using a commercially available 25.4-millimeter square stainless-steel plate was designed to characterize scanner performance through a series of “pass” or “attention required” tests assessing laser and scanner delays, scanner acceleration, dimensional accuracy, and slicer file software interpretation. The method was then applied on four PBF-LB/M machines, with one plate scanned per laser under machine original equipment manufacturer (OEM) recommended build conditions. Laser power and scan speed parameters were specified to be the same for the four machines. The results show notable variations in scanner delays, scanner momentum control, and path planning file preparation that impact the results of the laser welding. A simple example of the machine-to-machine variability was captured when three out of the four machines tested were unable to produce dimensionally accurate 1 mm diameter circles. In addition, all machines required attention during numerous tests aimed at slicer file software interpretation, which highlights critical gaps in the physical and programmable scanner control of PBF-LB/M machines. Overall, this study demonstrates the potential of the proposed plate melt method to assess scanner subsystem performance without the challenges of current standards.

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引用次数: 0

Autonomous exploration of the PBF-LB parameter space: An uncertainty-driven algorithm for automated processing map generation

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-02-07 DOI: 10.1016/j.addma.2025.104677

Giulio Masinelli , Lucas Schlenger , Kilian Wasmer , Toni Ivas , Jamasp Jhabvala , Chang Rajani , Amirmohammad Jamili , Roland Logé , Patrik Hoffmann , David Atienza

Powder bed fusion with laser beam (PBF-LB) is a promising additive manufacturing technique that enables the production of complex geometries with fine resolution and material efficiency, offering significant design freedom and material versatility. However, its broader adoption is limited by the need for extensive parameter tuning, which is often dependent on the specific machine, as well as the material and batch of powder used. In this paper, we introduce a novel algorithm that autonomously identifies melting regimes in an unsupervised manner using optical data acquired from photodiodes — specifically optical emission and reflection. This method eliminates the need for labeled data and achieves an F1-score of 89.2% across both materials tested: Ti–6Al–4V and 316L. Additionally, we propose an uncertainty-driven iterative strategy designed to efficiently generate processing maps by performing experiments based on uncertainty. This approach enables up to a 67% reduction in the number of required experiments, significantly lowering the associated costs of parameter exploration, while sustaining a maximum performance reduction of only 8.88% compared to traditional full factorial designs. Our results demonstrate the potential of this method to streamline PBF-LB optimization, making it more feasible for industrial applications and paving the way for its broader adoption.

{"title":"Autonomous exploration of the PBF-LB parameter space: An uncertainty-driven algorithm for automated processing map generation","authors":"Giulio Masinelli , Lucas Schlenger , Kilian Wasmer , Toni Ivas , Jamasp Jhabvala , Chang Rajani , Amirmohammad Jamili , Roland Logé , Patrik Hoffmann , David Atienza","doi":"10.1016/j.addma.2025.104677","DOIUrl":"10.1016/j.addma.2025.104677","url":null,"abstract":"<div><div>Powder bed fusion with laser beam (PBF-LB) is a promising additive manufacturing technique that enables the production of complex geometries with fine resolution and material efficiency, offering significant design freedom and material versatility. However, its broader adoption is limited by the need for extensive parameter tuning, which is often dependent on the specific machine, as well as the material and batch of powder used. In this paper, we introduce a novel algorithm that autonomously identifies melting regimes in an unsupervised manner using optical data acquired from photodiodes — specifically optical emission and reflection. This method eliminates the need for labeled data and achieves an <em>F1</em>-score of 89.2% across both materials tested: Ti–6Al–4V and 316L. Additionally, we propose an uncertainty-driven iterative strategy designed to efficiently generate processing maps by performing experiments based on uncertainty. This approach enables up to a 67% reduction in the number of required experiments, significantly lowering the associated costs of parameter exploration, while sustaining a maximum performance reduction of only 8.88% compared to traditional full factorial designs. Our results demonstrate the potential of this method to streamline PBF-LB optimization, making it more feasible for industrial applications and paving the way for its broader adoption.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104677"},"PeriodicalIF":10.3,"publicationDate":"2025-02-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143394593","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Multimodal automated fabrication with concrete: Case study and structural performance of ribbed CFRP-reinforced concrete ceilings

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-02-06 DOI: 10.1016/j.addma.2025.104689

Sven Engel, Josef Hegger, Martin Classen

A significant amount of concrete in building construction can be conserved by implementing ribbed concrete ceilings. However, their fabrication remains challenging due to the extensive manual labor required for formwork production. This paper introduces a modular ribbed ceiling system that integrates topology-optimized design principles with advanced digital manufacturing techniques. The system consists of two key components: a point-supported slab-column connection module (SCCM) and an inter-column support strip module (SSM). To enable efficient production, an innovative multimodal automated fabrication approach is presented, combining robotic casting with 3D concrete printing and reinforcement integration. In this method, slender, bi-directionally oriented ribs are 3D printed onto a robotically pre-cast concrete plate, with protruding CFRP reinforcement guiding rib placement. This process enables the production of freeform, material-efficient ceilings with high geometric flexibility. Structural tests, including bending, shear, and punching shear assessments, were conducted to evaluate the load-bearing behavior of the system. The study demonstrates the feasibility of automated multimodal manufacturing techniques for producing optimized ribbed CFRP-reinforced concrete structures, paving the way for more sustainable and resource-efficient construction.

{"title":"Multimodal automated fabrication with concrete: Case study and structural performance of ribbed CFRP-reinforced concrete ceilings","authors":"Sven Engel, Josef Hegger, Martin Classen","doi":"10.1016/j.addma.2025.104689","DOIUrl":"10.1016/j.addma.2025.104689","url":null,"abstract":"<div><div>A significant amount of concrete in building construction can be conserved by implementing ribbed concrete ceilings. However, their fabrication remains challenging due to the extensive manual labor required for formwork production. This paper introduces a modular ribbed ceiling system that integrates topology-optimized design principles with advanced digital manufacturing techniques. The system consists of two key components: a point-supported slab-column connection module (SCCM) and an inter-column support strip module (SSM). To enable efficient production, an innovative multimodal automated fabrication approach is presented, combining robotic casting with 3D concrete printing and reinforcement integration. In this method, slender, bi-directionally oriented ribs are 3D printed onto a robotically pre-cast concrete plate, with protruding CFRP reinforcement guiding rib placement. This process enables the production of freeform, material-efficient ceilings with high geometric flexibility. Structural tests, including bending, shear, and punching shear assessments, were conducted to evaluate the load-bearing behavior of the system. The study demonstrates the feasibility of automated multimodal manufacturing techniques for producing optimized ribbed CFRP-reinforced concrete structures, paving the way for more sustainable and resource-efficient construction.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"101 ","pages":"Article 104689"},"PeriodicalIF":10.3,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143403382","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Expanding the print parameter window for continuous line formation in binder jet additive manufacturing through pre-wetting of the powder bed

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-02-05 DOI: 10.1016/j.addma.2025.104693

Jacob E. Lawrence, Madi P. Lawrence, Nathan B. Crane

Binder Jet (BJ) additive manufacturing creates parts by binding powder particles together with inkjet-printed droplets. BJ shows promise as an industrial process, but poor final part properties often limit applications. Prior work has shown that there is significant powder rearrangement from the kinetic impact of binder droplets that may contribute to the formation of defects in the final parts. This study builds upon previous research by studying the effects of print parameters, including droplet spacing and inter-arrival time, and droplet parameters, including droplet volume, velocity, and satellite formation, on the formation of lines. A new method, using an adhesive film, for extracting single-layer parts is described which allows for study of smaller, more sensitive primitives. The results show that pre-wetting the powder bed expands the feasible design space and allows printing with larger droplet spacings, smaller inter-arrival times, and slower droplet velocities. This enables up to 50 % faster print rates and the potential for reduced powder relocation due to droplet impact. Results from this work can be used to inform the selection of optimal process parameters and the design of new BJ systems to produce higher quality parts.

{"title":"Expanding the print parameter window for continuous line formation in binder jet additive manufacturing through pre-wetting of the powder bed","authors":"Jacob E. Lawrence, Madi P. Lawrence, Nathan B. Crane","doi":"10.1016/j.addma.2025.104693","DOIUrl":"10.1016/j.addma.2025.104693","url":null,"abstract":"<div><div>Binder Jet (BJ) additive manufacturing creates parts by binding powder particles together with inkjet-printed droplets. BJ shows promise as an industrial process, but poor final part properties often limit applications. Prior work has shown that there is significant powder rearrangement from the kinetic impact of binder droplets that may contribute to the formation of defects in the final parts. This study builds upon previous research by studying the effects of print parameters, including droplet spacing and inter-arrival time, and droplet parameters, including droplet volume, velocity, and satellite formation, on the formation of lines. A new method, using an adhesive film, for extracting single-layer parts is described which allows for study of smaller, more sensitive primitives. The results show that pre-wetting the powder bed expands the feasible design space and allows printing with larger droplet spacings, smaller inter-arrival times, and slower droplet velocities. This enables up to 50 % faster print rates and the potential for reduced powder relocation due to droplet impact. Results from this work can be used to inform the selection of optimal process parameters and the design of new BJ systems to produce higher quality parts.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"100 ","pages":"Article 104693"},"PeriodicalIF":10.3,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143270071","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

In-situ controller autotuning by Bayesian optimization for closed-loop feedback control of laser powder bed fusion process

IF 10.3 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-02-05 DOI: 10.1016/j.addma.2025.104641

Barış Kavas , Efe C. Balta , Michael R. Tucker , Raamadaas Krishnadas , Alisa Rupenyan , John Lygeros , Markus Bambach

Laser powder bed fusion (LPBF) additive manufacturing (AM) traditionally relies on static parameter assignment in an open loop, which can lead to defects when faced with complex thermal histories and process variability. Closed-loop control offers a promising alternative that can enhance stability and mitigate defects. However, controller performance relies heavily on precise parameter tuning, a process that is typically manual and system-specific. This study employs Bayesian Optimization (BO) as an automated, sample-efficient method for tuning in-layer controllers in LPBF, leveraging the repetitive nature of the process for either online (in-process) or offline (pre-process) tuning. We experimentally apply BO to tune an in-layer PI controller to modulate laser power, assessing its performance on wedge geometries prone to overheating. The results show that BO significantly reduces overheating, outperforming uncontrolled settings. Notably, this study presents the first microstructural analysis of parts produced with in-layer controlled tuning, identifying lack-of-fusion porosities caused by the controller’s corrective adjustments. In summary, BO demonstrates strong potential for automated controller tuning in LPBF, with implications for broader applications in AM, suggesting a path towards more adaptive and robust control across diverse machines and materials.

{"title":"In-situ controller autotuning by Bayesian optimization for closed-loop feedback control of laser powder bed fusion process","authors":"Barış Kavas , Efe C. Balta , Michael R. Tucker , Raamadaas Krishnadas , Alisa Rupenyan , John Lygeros , Markus Bambach","doi":"10.1016/j.addma.2025.104641","DOIUrl":"10.1016/j.addma.2025.104641","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) additive manufacturing (AM) traditionally relies on static parameter assignment in an open loop, which can lead to defects when faced with complex thermal histories and process variability. Closed-loop control offers a promising alternative that can enhance stability and mitigate defects. However, controller performance relies heavily on precise parameter tuning, a process that is typically manual and system-specific. This study employs Bayesian Optimization (BO) as an automated, sample-efficient method for tuning in-layer controllers in LPBF, leveraging the repetitive nature of the process for either online (in-process) or offline (pre-process) tuning. We experimentally apply BO to tune an in-layer PI controller to modulate laser power, assessing its performance on wedge geometries prone to overheating. The results show that BO significantly reduces overheating, outperforming uncontrolled settings. Notably, this study presents the first microstructural analysis of parts produced with in-layer controlled tuning, identifying lack-of-fusion porosities caused by the controller’s corrective adjustments. In summary, BO demonstrates strong potential for automated controller tuning in LPBF, with implications for broader applications in AM, suggesting a path towards more adaptive and robust control across diverse machines and materials.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":"99 ","pages":"Article 104641"},"PeriodicalIF":10.3,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143137308","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0