Additive manufacturing最新文献_第5页

Stereolithography 3D printing of PTFE-filled photopolymer composites with enhanced THz transparency 增强太赫兹透明度的聚四氟乙烯填充光聚合物复合材料的立体光刻3D打印

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-16 DOI: 10.1016/j.addma.2025.105057

Luke Phillips , Harry J. Godden , John Kendrick , Nathan R. Fox , Alexander Valavanis , Andrew D. Burnett , Robert Kay , Ehab Saleh

Quasi-optics are essential components of terahertz (THz) systems, used to direct and manipulate THz radiation. High-resolution additive manufacturing (AM) techniques, such as vat photopolymerization (VP), enable the low-cost production of complex quasi-optical components with optically smooth surfaces and fine geometric features with dimensions comparable to wavelengths in the THz region. However, VP-produced quasi-optics are often inefficient owing to significant absorption losses, with commercially available photopolymers exhibiting absorption coefficients ranging between 19 – 27 cm^–1 at 1 THz. Polytetrafluoroethylene (PTFE) is highly transparent in the THz region, making it a promising filler material to reduce the absorption of photopolymers. However, no previous studies have reported the development of a PTFE composite suitable for processing via VP. In this study, PTFE powder-filled composites were formulated containing PTFE-to-photocurable-resin ratios ranging from 1:10–4:10, corresponding to approximately 9.0 % and 28.5 % by weight, respectively. Samples were manufactured via VP and characterised from 0.5 to 2.0 THz using a THz time-domain spectroscopy system. The results demonstrated a correlation between higher PTFE ratios and a reduction in the absorption coefficient of the samples from 0.5 to 2.0 THz, with the 4:10 sample having an absorption coefficient of 15.3 ± 0.3 cm^–1 at 1 THz, 27.8 % lower than that of the neat resin (21.2 ± 0.4 cm^–1). Additionally, experimental results were shown to agree well with a Maxwell Garnett effective medium approximation-based calculation of the THz optical properties of AM composites. These findings highlight the potential of non-polar polymer fillers to enhance the transparency of photopolymers to THz radiation, potentially supporting the future development of more efficient VP-produced quasi-optical components.

准光学是太赫兹（THz）系统的重要组成部分，用于指导和操纵太赫兹辐射。高分辨率增材制造（AM）技术，如还原光聚合（VP），可以低成本生产具有光学光滑表面和精细几何特征的复杂准光学元件，其尺寸可与太赫兹区域的波长相媲美。然而，由于显著的吸收损失，vp产生的准光学器件通常效率低下，商业上可用的光聚合物的吸收系数在19 - 27 cm-1和1 太赫兹之间。聚四氟乙烯（PTFE）在太赫兹区是高度透明的，使其成为一种有前途的填充材料，以减少光聚合物的吸收。然而，目前还没有研究报道开发出一种适合VP加工的PTFE复合材料。在本研究中，PTFE粉末填充复合材料的配方中，PTFE与光固化树脂的比例为1:10-4:10，重量分别约为9.0 %和28.5 %。样品通过VP制造，并使用太赫兹时域光谱系统在0.5至2.0 太赫兹范围内进行表征。结果显示出更高的聚四氟乙烯比率之间的相关性,减少样品的吸收系数从0.5到2.0 太赫兹,叫样本有一个吸收系数为15.3 ±0.3  cm - 1 1 太赫兹,低27.8 %比纯树脂(21.2 ±0.4  cm - 1)。此外，实验结果与基于Maxwell Garnett有效介质近似的增材复合材料太赫兹光学特性计算结果一致。这些发现强调了非极性聚合物填料在提高光聚合物对太赫兹辐射的透明度方面的潜力，可能支持未来开发更高效的vp生产的准光学元件。

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引用次数: 0

A framework for process anomaly detection in 3D concrete printing 三维混凝土打印过程异常检测框架

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-16 DOI: 10.1016/j.addma.2025.105056

Abdallah Kamhawi , Yuxin Lin , Christopher Watson , Kira Barton , Mania Aghaei Meibodi

Extrusion-based 3D concrete printing offers a transformative opportunity for waste-free fabrication of complex and materially optimized building components. However, the current reliance on manual observation and ad-hoc parameter tuning introduces significant variability into the process and limits the scalability of 3D concrete printing. Existing systems offer no predictive insight into failure events and remain dependent on trial-and-error methods, resulting in increased material consumption, higher costs, and prolonged production times. To address this, the paper introduces a comprehensive framework for process anomaly detection tailored to two-component extrusion-based 3D concrete printing systems. The proposed framework integrates systematic sensor instrumentation, heterogeneous data acquisition, and signal feature characterization to enable real-time monitoring of system health. Non-destructive sensors are deployed to measure environmental conditions, slurry pumpability, hydration behavior, and workability. Collected signals are analyzed using a suite of processing techniques — including frequency analysis, amplitude envelope detection, curve fitting, and magnitude deviation analysis — to extract critical features indicative of emerging anomalies. The methodology presented in this paper establishes a generalizable framework for anomaly detection, using data collected from physical experiments, where the specific metric values derived from the data are tied to the feedstock used in this study for validation. The paper results demonstrate the ability of the proposed methods to detect failure modes — such as pump clogging, material segregation, and two-component mixing head clogging — ahead of human operator detection. These findings confirm the viability of the proposed framework for anomaly detection.

基于挤压的3D混凝土打印为无废物制造复杂和材料优化的建筑构件提供了一个变革性的机会。然而，目前对人工观察和临时参数调整的依赖给过程带来了显著的可变性，并限制了3D混凝土打印的可扩展性。现有的系统无法预测故障事件，仍然依赖于试错方法，导致材料消耗增加，成本增加，生产时间延长。为了解决这个问题，本文介绍了一个针对基于双组分挤出的3D混凝土打印系统的过程异常检测的综合框架。提出的框架集成了系统传感器仪器、异构数据采集和信号特征表征，以实现对系统健康状况的实时监控。非破坏性传感器可用于测量环境条件、泥浆泵送性、水化行为和可加工性。收集到的信号使用一套处理技术进行分析，包括频率分析、幅度包络检测、曲线拟合和幅度偏差分析，以提取指示新出现异常的关键特征。本文提出的方法建立了一个可推广的异常检测框架，使用从物理实验中收集的数据，其中从数据中获得的特定度量值与本研究中使用的原料相关联以进行验证。本文的结果表明，所提出的方法能够在人工操作人员检测之前检测故障模式，如泵堵塞、材料离析和双组分混合头堵塞。这些发现证实了所提出的异常检测框架的可行性。

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引用次数: 0

Towards efficient and integrated precision manufacturing of internal features by powder bed-based additive and 5-axis subtractive hybrid manufacturing 采用基于粉末床的增材制造和五轴减法混合制造技术实现内部特征的高效集成精密制造

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-13 DOI: 10.1016/j.addma.2025.105049

Yin Wang, Yukai Chen, Yu Lu, Yuxuan Jiang, Ke Huang, Xuewei Fang, Bin Han, Qi Zhang

The growing demand for complex internal structural components in the aerospace and automotive industries has highlighted significant manufacturing challenges due to tool accessibility constraints. While additive manufacturing (AM) enables the integrated fabrication of complex internal features, its inherent surface quality deficiencies restrict precision and performance. Powder bed (PB)-based additive/subtractive hybrid manufacturing (ASHM) offers a transformative approach for fabricating components with intricate internal features. However, it faces two key challenges: first, the widespread reliance on 3-axis systems limits geometric capability for curved structures, and suboptimal trade-offs between efficiency and surface quality in manual CAM-based process planning. This study presents a novel PB-based 5-axis ASHM system and a comprehensive hybrid manufacturing strategy planning method. This method comprises three key components: global toolpath planning, cutter contact point (CCP) accessibility judgment, and accessibility-driven adaptive layering. This integrated approach enables the adaptive generation of optimal AM/SM alternation strategies and collision-free 5-axis toolpaths specifically tailored for intricate internal features. Departing from conventional approaches, this method prioritizes CCP accessibility as the criterion for model segmentation, ensures global machinability of internal features while effectively reducing AM/SM alternations and generating corresponding 5-axis collision-free toolpaths. Experimental validation using two representative internal structures confirms the method's effectiveness. The proposed hybrid manufacturing strategy demonstrates 50 % fewer AM/SM alternations and over tenfold efficiency improvement compared to conventional manual planning, while achieving 40–60 % greater machinable area than 5-axis CNC. Furthermore, it achieves superior surface quality (Ra 0.5–0.8 μm, significantly better than AM-only 6.2–8.3 μm) and exceptional dimensional accuracy (within ±0.03 mm, representing an 80 % improvement compared to AM). This work establishes a novel solution for efficient and integrated precision manufacturing of intricate internal structures.

航空航天和汽车行业对复杂内部结构部件的需求不断增长，凸显了由于工具可及性限制而带来的重大制造挑战。虽然增材制造（AM）能够实现复杂内部特征的集成制造，但其固有的表面质量缺陷限制了精度和性能。基于粉末床（PB）的增/减混合制造（ASHM）为制造具有复杂内部特征的部件提供了一种变革性的方法。然而，它面临着两个关键挑战：首先，对三轴系统的广泛依赖限制了弯曲结构的几何能力，以及在基于手动cam的工艺规划中效率和表面质量之间的次优权衡。提出了一种新型的基于pb的五轴ASHM系统和一种综合混合制造策略规划方法。该方法包括三个关键部分：全局刀具路径规划、刀具接触点可及性判断和可及性驱动的自适应分层。这种集成方法能够自适应生成最佳AM/SM交替策略和专门为复杂的内部特征量身定制的无碰撞5轴刀具路径。与传统方法不同，该方法优先考虑CCP可达性作为模型分割的标准，确保内部特征的全局可加工性，同时有效地减少AM/SM交替并生成相应的五轴无碰撞刀具路径。用两个具有代表性的内部结构进行了实验验证，验证了该方法的有效性。所提出的混合制造策略表明，与传统的手动规划相比，AM/SM的更换减少了50% %，效率提高了十倍以上，同时可加工面积比5轴CNC大40 - 60% %。此外，它具有卓越的表面质量（Ra 0.5-0.8 μm，明显优于AM的6.2-8.3 μm）和卓越的尺寸精度（在±0.03 mm内，与AM相比提高了80% %）。本工作为复杂内部结构的高效集成精密制造提供了一种新的解决方案。

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引用次数: 0

Ink-based laser powder bed fusion of barium titanate 钛酸钡油墨基激光粉末床熔接

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-13 DOI: 10.1016/j.addma.2025.105052

Mingqi Shuai , Haotian Lu , Eric Stolt , Philip DePond , Brandon Lum , Juan Rivas-Davila , Xiaoyu (Rayne) Zheng , X. Wendy Gu

Barium titanate (BTO) is a lead-free functional ceramic that is widely used in sensors, transducers, and actuators. The increasing demand for complex geometries and quick design iterations motivates the use of additive manufacturing techniques. Laser powder bed fusion (L-PBF) additive manufacturing technique enables the net-shape or near-net-shape fabrication of metals and alloys. Ceramic L-PBF remains challenging due to their high melting temperature. To address this challenge, a nanoparticle ink feedstock was incorporated into the L-PBF process to allow low power melting of BTO. Key print parameters (i.e. laser power, scanning speed, and hatching spacing) were optimized to fabricate millimeter-scale BTO parts. The printed BTO samples possessed an inhomogeneous equiaxed-columnar-cellular microstructure. Semiconducting current-voltage behavior was observed in as-printed samples, which was attributed to the creation of oxygen vacancies. The piezoelectric d₃₃ coefficient was measured to be 4.6 pC/N.

钛酸钡（BTO）是一种无铅功能陶瓷，广泛应用于传感器、传感器和执行器中。对复杂几何形状和快速设计迭代的日益增长的需求促使了增材制造技术的使用。激光粉末床熔合（L-PBF）增材制造技术能够实现金属和合金的净形或近净形制造。陶瓷L-PBF由于其高熔融温度仍然具有挑战性。为了解决这一挑战，在L-PBF工艺中加入了纳米颗粒油墨原料，以实现BTO的低功率熔化。优化了关键打印参数（即激光功率，扫描速度和孵化间距）以制造毫米级BTO零件。打印的BTO样品具有不均匀的等轴-柱-细胞微观结构。在印刷样品中观察到半导体电流-电压行为，这归因于氧空位的产生。测得压电d33系数为4.6 pC/N。

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引用次数: 0

Ultralow-shrinkage ceramic fabrication via three-dimensional printing of high-solid-loading suspensions 通过高固载悬浮液的三维打印制造超低收缩陶瓷

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-13 DOI: 10.1016/j.addma.2025.105051

Wei-Cheng Chao , Yi-Hua Kao , Chien-Hua Chen , Ying-Chih Liao

Vat photopolymerization (VPP) 3D printing has opened new opportunities for fabricating ceramics with unprecedentedly intricate architectures. However, VPP 3D-printed ceramics still suffer from excessive sintering shrinkage and insufficient density, restricting their use in high-precision components. Overcoming these long-standing challenges critically depends on improving the printability of ultrahigh-solid-loading suspensions. In this study, ultrahigh-solid-loading suspensions containing silica up to 83.0 vol% were formulated with superior flowability (<50 Pa.s). A systematic optimization of suspension composition was established, integrating Hansen solubility parameters (HSP), a viscosity model, and the Scott equation. HSP guides the enhancement of particle-resin compatibility to maximize solid loading, while the viscosity model predicts optimal particle size distribution for minimized viscosity at 83.0 vol% loading. Despite the extremely limited resin matrix, TMPTA reinforcement effectively increases the tensile strength of green parts beyond the viscous peel stress. The critical issue of negative curing width and excessive curing depth in ultrahigh-solid-loading suspensions is mitigated by introducing 1.60 wt% UV-absorber, which reduces curing depth at the width-critical energy dose and enables fine-feature printing with low dimensional deviation (<6 %). The optimized 83 vol% suspension achieves the sintered ceramics with ultralow isotropic volumetric shrinkage (<6.5 %) and nearly full densification (∼100 % relative density). The resulting ceramic air penetrator retains intricate architectures with high fidelity and dense microstructures. In summary, ultralow-shrinkage ceramics are successfully fabricated through a systematic strategy for designing low-viscosity, ultrahigh-solid-loading suspensions. This work represents a significant milestone in 3D-printed ceramics and paves the way for next-generation, high-precision engineering applications.

还原光聚合（VPP） 3D打印为制造具有前所未有复杂结构的陶瓷开辟了新的机会。然而，VPP 3d打印陶瓷仍然存在烧结收缩率过高和密度不足的问题，限制了其在高精度部件中的应用。克服这些长期存在的挑战，关键取决于提高超高固载悬浮液的可打印性。在这项研究中，配制了含有高达83.0 体积%的二氧化硅的超高固体负载悬浮液，具有优异的流动性（<50 Pa.s）。综合Hansen溶解度参数（HSP）、粘度模型和Scott方程，对悬浮液的组成进行了系统优化。HSP指导颗粒-树脂相容性的增强以最大化固体负载，而粘度模型预测了在83.0 vol%加载时最小粘度的最佳粒径分布。尽管树脂基体非常有限，但TMPTA增强有效地提高了未加工零件的抗拉强度，超出了粘性剥离应力。通过引入1.60 wt%的紫外线吸收剂，可以缓解超高固载悬浮液中负固化宽度和过度固化深度的关键问题，从而降低了宽度临界能量剂量下的固化深度，并实现了低尺寸偏差（<6 %）的精细特征打印。优化后的83 vol%悬悬液实现了具有超低各向同性体积收缩率（<6.5 %）和接近完全致密化（相对密度~ 100 %）的烧结陶瓷。由此产生的陶瓷空气穿透器保留了复杂的结构，具有高保真度和致密的微结构。综上所述，通过设计低粘度、超高固载悬浮液的系统策略，成功制备了超低收缩陶瓷。这项工作代表了3d打印陶瓷的一个重要里程碑，为下一代高精度工程应用铺平了道路。

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引用次数: 0

Influence of Haynes 282 powder oxidation on powder properties and component quality in laser powder bed fusion Haynes 282粉末氧化对激光粉末床熔合粉末性能和构件质量的影响

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-13 DOI: 10.1016/j.addma.2025.105050

Rafael Kleba-Ehrhardt , Josué Dávila , Johann Geissler , Gunther Mohr , Johannes Schmidt , Christoph Heinze , Kai Hilgenberg , Aleksander Gurlo , David Karl

Reuse of powder in powder bed additive manufacturing is a common practice to enhance sustainability and reduce costs. However, the reusability of metal powder is limited by the oxidation of the powders. Even in a protective atmosphere, each build job leads to gradual oxidation of the powder, which has led to concerns about its impact on powder and part properties. Consequently, strict confidence intervals for oxygen content in nickel-based alloy feedstocks are enforced in the industry. Despite this, there is currently a lack of in-depth studies investigating the specific influence of oxygen on Haynes 282, a widely used nickel-based alloy. This study examines artificially aged Haynes 282 powder batches with oxygen content of 160 ppm, 330 ppm, 1050 ppm, and 1420 ppm. Detailed powder characterization was performed, including morphology, chemical composition, particle size, flowability, and packing behavior. Components were fabricated via PBF-LB/M to evaluate density and mechanical properties. The results showed that higher oxidation levels improved powder flowability and packing density. However, in manufactured parts, irregular melt tracks and increased surface roughness were observed, which could easily be removed by post-processing. No significant differences in density or mechanical properties at room temperature, such as tensile strength and elongation, were found. These findings indicate that H282 powder potentially remains suitable for reuse, even when the batches exhibit increased oxygen content, supporting discussions on revising the existing oxygen content confidence intervals for nickel-based alloys. The results highlight the potential for optimizing recycling strategies and reducing material waste in additive manufacturing processes.

粉末床增材制造中粉末的再利用是提高可持续性和降低成本的常见做法。然而，金属粉末的可重复使用性受到粉末氧化的限制。即使在保护气氛中，每次构建工作都会导致粉末逐渐氧化，这导致人们担心其对粉末和零件性能的影响。因此，镍基合金原料中氧含量的严格置信区间在工业中是强制执行的。尽管如此，目前还缺乏深入研究氧对Haynes 282（一种广泛使用的镍基合金）的具体影响。本研究考察了人工老化的Haynes 282粉末批次，氧含量为160 ppm， 330 ppm， 1050 ppm和1420 ppm。进行了详细的粉末表征，包括形态，化学成分，粒度，流动性和包装行为。通过PBF-LB/M制备各组件，以评估其密度和力学性能。结果表明，较高的氧化水平提高了粉末的流动性和堆积密度。然而，在制造的零件中，观察到不规则的熔化痕迹和增加的表面粗糙度，可以很容易地通过后处理去除。在室温下，密度和机械性能（如抗拉强度和伸长率）没有显著差异。这些发现表明，H282粉末可能仍然适合重复使用，即使批次表现出更高的氧含量，支持修改现有镍基合金氧含量置信区间的讨论。研究结果强调了优化回收策略和减少增材制造过程中材料浪费的潜力。

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引用次数: 0

Efficient multi-laser PBF microstructural tuning via physics-based feedforward control 基于物理前馈控制的多激光PBF微结构有效调谐

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-11 DOI: 10.1016/j.addma.2025.105036

Nathaniel Wood , Nicholas Kirschbaum , Edwin Schwalbach , Sean Donegan , Andrew Gillman , Chinedum Okwudire

In situ heat treatment is a longstanding goal of laser powder bed fusion (L-PBF) process development because it would help mitigate build defects, improve throughput, and improve the printability of crack-prone materials. A primary barrier to these efforts is the L-PBF laser speed, which cannot move fast enough to achieve heat treatment through spot welding like in electron beam PBF. The state of the art (“Benchmark”) for achieving this heat treatment in a flexible geometry-agnostic way is performing extra laser passes over the build sequentially before fusing another layer. These Benchmark treatments succeed in transforming the microstructure, but at the cost of dramatically lengthened print times. We introduce an extension of the two-laser variant of the SmartScan algorithm, which leverages parallelized two-laser scans to perform the heat treatment while the layer is fused, with movements and powers optimized by physics-based models. We compare SmartScan against Benchmark scans for 3 heat treatment regimes, and compare both heat treatments against a standard slicer-derived toolpath with heuristically-chosen parameters (the “nominal scan”) on 316L stainless steel. We observe that SmartScan produces microstructures with features that correlate with superior mechanical properties, i.e. stronger, more isotropic, and better fatigue performance, given the manufactured steel is less strongly textured, with both smaller and more equiaxed grains that have lowered dislocation densities, and a higher relative density. Additionally, printing time is reduced by 77% with respect to the Benchmarks.

原位热处理是激光粉末床熔合（L-PBF）工艺发展的长期目标，因为它有助于减轻构建缺陷，提高吞吐量，并改善易开裂材料的可打印性。这些努力的主要障碍是L-PBF激光的速度，它不能像电子束PBF那样通过点焊实现足够快的热处理。以一种灵活的几何无关的方式实现这种热处理的最新技术（“基准”）是在融合另一层之前依次在构建上执行额外的激光通道。这些基准处理成功地改变了微观结构，但代价是大大延长了打印时间。我们介绍了SmartScan算法的双激光变体的扩展，该算法利用并行双激光扫描在熔覆层时进行热处理，并通过基于物理的模型优化运动和功率。我们将SmartScan与3种热处理方案的基准扫描进行比较，并将这两种热处理与316L不锈钢上启发式选择参数（“标称扫描”）的标准切片机衍生工具路径进行比较。我们观察到，SmartScan产生的显微组织具有与优越的机械性能相关的特征，即更强、更各向同性和更好的疲劳性能，因为制造的钢的织构不那么强烈，具有更小和更等轴的晶粒，具有更低的位错密度，以及更高的相对密度。此外，与基准测试相比，打印时间减少了77%。

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引用次数: 0

Predicting fatigue failure induced by lack-of-fusion defects in additive manufacturing: A synergistic multiscale simulation-deep learning framework 预测增材制造中缺乏融合缺陷引起的疲劳失效：一个协同的多尺度模拟-深度学习框架

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-08 DOI: 10.1016/j.addma.2025.105047

Weiqin Tang , Zhenxuan Luo , Dayong Li , Yinghong Peng

Additive manufacturing (AM) technologies such as laser powder bed fusion (LPBF) enable the fabrication of complex components, yet intrinsic lack-of-fusion (LOF) defects significantly impair their fatigue performance due to their irregular morphologies. Multiscale physical-modeling struggles to predict fatigue strength scatter due to computational complexity and reliance on costly X-ray computed tomography (XCT)-based defect characterization. This study proposes a hybrid framework integrating multiscale simulation with deep learning to predict high-cycle fatigue (HCF) strength distributions in LPBF-fabricated AlSi10Mg alloys. A three-dimensional generative adversarial network (3D GAN) trained on XCT data is built to synthesize defects with real defect shapes, while a 3D convolutional neural network (3D CNN) with hybrid attention mechanisms is established to map the nonlinear relationship between defect features, loading conditions, and fatigue strengths. The multiscale simulation generates virtual datasets encompassing microstructure evolution, defect-induced stress concentrations, and fatigue responses. Results demonstrate that the CNN-GAN framework predicts fatigue strength distributions with 90 % accuracy, capturing experimental trends while exhibiting conservative deviations (≤7.7 %). The spatial-channel attention mechanism enhances feature extraction by focusing on defect edges and morphological criticalities. This work bridges the gap between LOF defects and fatigue prediction, offering a cost-effective and robust data-driven approach for reliability assessment of AM components.

激光粉末床熔融（LPBF）等增材制造（AM）技术能够制造复杂的部件，但由于其不规则的形貌，固有的熔合不足（LOF）缺陷严重影响了它们的疲劳性能。由于计算复杂性和依赖昂贵的基于x射线计算机断层扫描（XCT）的缺陷表征，多尺度物理建模难以预测疲劳强度散射。本研究提出了一种将多尺度模拟与深度学习相结合的混合框架，用于预测lpbf制造的AlSi10Mg合金的高周疲劳强度分布。建立了基于XCT数据训练的三维生成对抗网络（3D GAN）来合成具有真实缺陷形状的缺陷，建立了具有混合注意机制的三维卷积神经网络（3D CNN）来映射缺陷特征、载荷条件和疲劳强度之间的非线性关系。多尺度模拟生成包含微观结构演变、缺陷引起的应力集中和疲劳响应的虚拟数据集。结果表明，CNN-GAN框架预测疲劳强度分布的准确率为90 %，捕捉了实验趋势，同时表现出保守偏差（≤7.7 %）。空间通道注意机制通过关注缺陷边缘和形态临界来增强特征提取。这项工作弥补了LOF缺陷和疲劳预测之间的差距，为增材制造部件的可靠性评估提供了一种具有成本效益和强大的数据驱动方法。

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引用次数: 0

Binder jetting printed metallic biomaterials 粘结剂喷射打印金属生物材料

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-05 DOI: 10.1016/j.addma.2025.105045

Xuan Li , Yixuan Shi , Chengcong Huang , Shangyan Zhao , Yuzhi Wu , Yifan Song , Zhao Yang , Yiyang Sun , Peipei Li , Xiangyu Zhang , Yageng Li , Luning Wang

Metallic biomaterials, including traditional inert metals (such as titanium-based, cobalt-based, stainless steel-based alloys) and emerging biodegradable metals (such as iron-, magnesium-, and zinc-based systems), have attracted considerable attention in both research and clinical settings due to their critical roles in treating musculoskeletal diseases and extending human lifespan. One of their key applications lies in the repair of large bone defects, which often require customized implants to replicate the geometry, microarchitecture, and mechanical behavior of native bone. This personalization imposes stringent demands on manufacturing techniques. Binder jetting (BJT), a rapidly advancing powder bed-based additive manufacturing (AM) technology, offers significant advantages including a wide material compatibility, high production efficiency, and the ability to fabricate large and complex parts. Unlike laser or electron beam AM techniques, BJT enables porosity control through post-processing, allowing for tailored structural and functional performance. This review systematically examines the BJT process for metallic biomaterials, focusing on how process variables, such as powder morphology, particle size distribution, binder chemistry, layer thickness, printing speed, binder saturation, and sintering conditions, affect the final properties of printed parts. Design considerations for patient-specific implants are discussed, along with a comprehensive overview of candidate metallic systems, evaluating their mechanical properties, corrosion behavior, and biocompatibility. Finally, the current challenges in using BJT for fabricating biomedical metals, including limitations in resolution, densification, debinding, and sintering deformation, are outlined. Future research directions are also proposed to advance the clinical translation of this promising technology.

金属生物材料，包括传统的惰性金属（如钛基、钴基、不锈钢基合金）和新兴的可生物降解金属（如铁基、镁基和锌基系统），由于其在治疗肌肉骨骼疾病和延长人类寿命方面的关键作用，在研究和临床环境中都引起了相当大的关注。它们的关键应用之一是修复大型骨缺损，这通常需要定制的植入物来复制天然骨的几何形状、微结构和机械行为。这种个性化对制造技术提出了严格的要求。粘结剂喷射（BJT）是一种快速发展的基于粉末床的增材制造（AM）技术，具有显著的优势，包括广泛的材料兼容性，高生产效率以及制造大型复杂零件的能力。与激光或电子束增材制造技术不同，BJT可以通过后处理控制孔隙度，从而实现定制的结构和功能性能。本文系统地研究了金属生物材料的BJT工艺，重点研究了粉末形态、粒度分布、粘结剂化学、层厚度、打印速度、粘结剂饱和度和烧结条件等工艺变量如何影响打印部件的最终性能。讨论了患者特异性植入物的设计考虑因素，以及候选金属系统的全面概述，评估其机械性能，腐蚀行为和生物相容性。最后，概述了目前使用BJT制造生物医学金属的挑战，包括分辨率，致密化，脱脂和烧结变形方面的限制。展望了未来的研究方向，以促进该技术的临床应用。

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引用次数: 0

In situ multiscale XCT degradation study of PEO-modified WE43 scaffolds: Correlating microstructure with hydrogen evolution peo修饰的WE43支架的原位多尺度XCT降解研究：微观结构与析氢的相关性

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing

Pub Date : 2025-12-04 DOI: 10.1016/j.addma.2025.105042

M.D. Martin-Alonso , G. Dominguez , F. Benn , S. Pöstges , A. Kopp , J. Villanova , P. Lhuissier , J. Molina-Aldareguia , F. Sket

The degradation of magnesium-based implants for bone regeneration leads to hydrogen gas evolution, prompting local pH shifts, oxidative stress, and reduced mechanical integrity, factors that collectively impair cell function and tissue healing. While numerous studies aim to mitigate hydrogen release, few provide three-dimensional (3D), real-time visualization of hydrogen bubble formation in direct relation to scaffold microstructure. In this study, we present a multiscale in situ imaging approach to address this gap. Time-resolved tomography was employed to monitor hydrogen bubble nucleation and growth during magnesium scaffold degradation in simulated body fluid (SBF). Simultaneously, X-ray nano-tomography revealed scaffold microstructural features, such as intermetallic precipitates, porosity, and grain oxide inclusions, at high spatial resolution. These features not only influence degradation behavior but also play a role in the formation and uniformity of the plasma electrolytic oxidation (PEO) layer, which serves as a protective barrier. By integrating both datasets, we correlated specific microstructural characteristics with hydrogen bubble dynamics and local degradation performance. Our findings identify the degradation initiation sites and the underlying corrosion mechanisms within a 3D scaffold architecture. This combined methodology provides unprecedented insights into the interplay between microstructure, degradation and PEO layer, supporting the development of more reliable, long-lasting magnesium-based implants. Unlike previous studies that have focused on post-mortem surface characterization or overall corrosion rate measurements, this work enables in situ, time-resolved 3D observation of hydrogen evolution within additively manufactured Mg scaffolds, establishing direct correlations between LPBF-induced microstructure, PEO layer uniformity, and local degradation mechanisms.

用于骨再生的镁基植入物的降解导致氢气释放，促进局部pH值变化，氧化应激和机械完整性降低，这些因素共同损害细胞功能和组织愈合。虽然许多研究旨在减少氢的释放，但很少有研究提供与支架微观结构直接相关的氢泡形成的三维（3D）实时可视化。在这项研究中，我们提出了一种多尺度原位成像方法来解决这一差距。采用时间分辨断层成像技术监测镁支架在模拟体液（SBF）降解过程中氢泡的成核和生长。同时，x射线纳米层析成像在高空间分辨率下揭示了支架的微观结构特征，如金属间析出物、孔隙度和颗粒氧化物夹杂物。这些特征不仅影响降解行为，而且对等离子体电解氧化（PEO）层的形成和均匀性起作用，PEO层起到保护屏障的作用。通过整合这两个数据集，我们将特定的微观结构特征与氢泡动力学和局部降解性能相关联。我们的研究结果确定了降解起始位点和三维支架结构中潜在的腐蚀机制。这种综合方法为微观结构、降解和PEO层之间的相互作用提供了前所未有的见解，支持开发更可靠、更持久的镁基植入物。与之前的研究不同，该研究主要关注的是死后表面表征或整体腐蚀速率测量，而这项研究能够对增材制造的Mg支架进行现场、时间分辨的3D氢演化观察，建立lpbf诱导的微观结构、PEO层均匀性和局部降解机制之间的直接关联。

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引用次数: 0