Pub Date : 2025-12-01Epub Date: 2025-11-11DOI: 10.1016/j.addlet.2025.100339
Sean Gip Lim , Junghyun Lee , Nuran Khalid A. Bawarith , Suvash Chandra Paul , Jihye Jhun , Issam T. Amr , Bandar A. Fadhel , Ming Jen Tan
Construction industry, responsible for a substantial portion of global carbon emissions, faces an urgent demand to adopt sustainable practices. Traditional concrete manufacturing processes contribute significantly to these emissions, underscoring a pressing need for innovative technologies that not only reduce carbon footprint but also improve material performances. This study presents an extension of CO2-steam integrated 3D construction printing by incorporating functional self-curing agents, specifically Polyethylene Glycol (PEG-6000), to enhance both early-age carbonation reactions and mechanical strength developments of 3D printed cementitious materials. The presented method aims to suppress moisture loss that delays hydration and carbonation activities during unconfined atmospheric curing, which would otherwise hinder strength developments. The combined usage of in-situ CO2-steam printing with PEG-6000 demonstrated improvements in early-age carbon uptake up to 137 %, along with substantial developments in compressive, flexural, and interlayer bond strengths of up to 29.4 %, 51.9 %, and 36.5 %, respectively.
{"title":"The efficacy of self-curing agents on enhanced internal curing and accelerated carbonation with CO2-steam integrated 3D concrete printing","authors":"Sean Gip Lim , Junghyun Lee , Nuran Khalid A. Bawarith , Suvash Chandra Paul , Jihye Jhun , Issam T. Amr , Bandar A. Fadhel , Ming Jen Tan","doi":"10.1016/j.addlet.2025.100339","DOIUrl":"10.1016/j.addlet.2025.100339","url":null,"abstract":"<div><div>Construction industry, responsible for a substantial portion of global carbon emissions, faces an urgent demand to adopt sustainable practices. Traditional concrete manufacturing processes contribute significantly to these emissions, underscoring a pressing need for innovative technologies that not only reduce carbon footprint but also improve material performances. This study presents an extension of CO<sub>2</sub>-steam integrated 3D construction printing by incorporating functional self-curing agents, specifically Polyethylene Glycol (PEG-6000), to enhance both early-age carbonation reactions and mechanical strength developments of 3D printed cementitious materials. The presented method aims to suppress moisture loss that delays hydration and carbonation activities during unconfined atmospheric curing, which would otherwise hinder strength developments. The combined usage of in-situ CO<sub>2</sub>-steam printing with PEG-6000 demonstrated improvements in early-age carbon uptake up to 137 %, along with substantial developments in compressive, flexural, and interlayer bond strengths of up to 29.4 %, 51.9 %, and 36.5 %, respectively.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100339"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145623555","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-11-29DOI: 10.1016/j.addlet.2025.100346
Derui Jiang , Darren Fraser , Sherman Wong , Timothy C. Hughes , Robert Wilson , Anthony B. Murphy , Vu Nguyen
Lattice structures made by additive manufacturing (AM) are being widely studied in the field of biomedical applications. Their strength and dimensional accuracy are critical to their performance. This study explores how different strut shapes affect the as-built quality and mechanical performance of Grade 23 titanium (Ti64) simple cubic lattices made by electron beam melting (EBM). Three strut cross-section geometries, square, octagonal, and round, were evaluated. Micro-computed tomography (CT) was used to assess dimensional deviations. Finite-element stress analysis predicted the mechanical response. Compression tests were conducted in two orientations to validate the models. Square struts showed the highest geometric accuracy and the best compressive strength, followed by the octagonal and round struts. These geometric deviations translated into mechanical trends: the square-strut lattices showed ∼10 – 20 % higher stiffness and yielding load compared with the round-strut equivalents, with the octagonal struts performing intermediately. These results suggest that square struts are better suited for load-bearing implants. The findings provide guidance for designing more reliable and effective lattice-based medical devices.
{"title":"Influence of Strut Shape on the As-Built Quality and Mechanical Performance of Additively Manufactured Simple Cubic Lattices","authors":"Derui Jiang , Darren Fraser , Sherman Wong , Timothy C. Hughes , Robert Wilson , Anthony B. Murphy , Vu Nguyen","doi":"10.1016/j.addlet.2025.100346","DOIUrl":"10.1016/j.addlet.2025.100346","url":null,"abstract":"<div><div>Lattice structures made by additive manufacturing (AM) are being widely studied in the field of biomedical applications. Their strength and dimensional accuracy are critical to their performance. This study explores how different strut shapes affect the as-built quality and mechanical performance of Grade 23 titanium (Ti64) simple cubic lattices made by electron beam melting (EBM). Three strut cross-section geometries, square, octagonal, and round, were evaluated. Micro-computed tomography (CT) was used to assess dimensional deviations. Finite-element stress analysis predicted the mechanical response. Compression tests were conducted in two orientations to validate the models. Square struts showed the highest geometric accuracy and the best compressive strength, followed by the octagonal and round struts. These geometric deviations translated into mechanical trends: the square-strut lattices showed ∼10 – 20 % higher stiffness and yielding load compared with the round-strut equivalents, with the octagonal struts performing intermediately. These results suggest that square struts are better suited for load-bearing implants. The findings provide guidance for designing more reliable and effective lattice-based medical devices.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100346"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693143","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-10-04DOI: 10.1016/j.addlet.2025.100328
Leo Körber , Thomas Wettemann , Margarita Etchegaray Bello , Isabell Petri , Gabriel Rojas , Daniela Schreil , Klaus Drechsler , Satoshi Enzaki , Yuichiro Tsuda , Jun Inagaki
Polymer Additive Manufacturing (AM) processes are a means of producing complex parts in small numbers. Short fibers are frequently added to enhance the parts’ mechanical properties. Alignment along the extrusion path during printing results in highly anisotropic material behavior. In this study, a novel resin-based AM process (“Core-Shell Method”, developed by Toray Engineering) is investigated consisting of a vat photopolymerization printing of a non-reinforced mold (“shell”) that is subsequently filled with a short fiber filled thermally cured resin (“core”). Thermal and chemical analyses were performed and recommendations for process adjustments derived. Mechanical, microscopic and CT analyses were performed on samples produced using the Core-Shell Method and manual variants of the process as reference. The Core-Shell samples show an only slightly anisotropic material behavior. From these findings, potentials for the printing process are derived, including further modification of the fiber alignment towards either improving isotropy or selectively introducing load-path adjusted fiber orientation and reinforcement within a homogenous material mixture.
{"title":"Investigation and potentials of a novel resin-based additive manufacturing process","authors":"Leo Körber , Thomas Wettemann , Margarita Etchegaray Bello , Isabell Petri , Gabriel Rojas , Daniela Schreil , Klaus Drechsler , Satoshi Enzaki , Yuichiro Tsuda , Jun Inagaki","doi":"10.1016/j.addlet.2025.100328","DOIUrl":"10.1016/j.addlet.2025.100328","url":null,"abstract":"<div><div>Polymer Additive Manufacturing (AM) processes are a means of producing complex parts in small numbers. Short fibers are frequently added to enhance the parts’ mechanical properties. Alignment along the extrusion path during printing results in highly anisotropic material behavior. In this study, a novel resin-based AM process (“Core-Shell Method”, developed by Toray Engineering) is investigated consisting of a vat photopolymerization printing of a non-reinforced mold (“shell”) that is subsequently filled with a short fiber filled thermally cured resin (“core”). Thermal and chemical analyses were performed and recommendations for process adjustments derived. Mechanical, microscopic and CT analyses were performed on samples produced using the Core-Shell Method and manual variants of the process as reference. The Core-Shell samples show an only slightly anisotropic material behavior. From these findings, potentials for the printing process are derived, including further modification of the fiber alignment towards either improving isotropy or selectively introducing load-path adjusted fiber orientation and reinforcement within a homogenous material mixture.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100328"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145362094","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-09-30DOI: 10.1016/j.addlet.2025.100326
Jesus Rivas , Jorge Mireles , R.B. Wicker
This study investigates position accuracy, repeatability, and reproducibility of the scanning system in a metal laser powder bed fusion (PBF-LB/M) process using a novel data collection method. Deviations between Commanded and Actual scanning positions were quantified using Euclidean distance metrics across a series of builds and geometries. Results showed a build mean accuracy of 0.014 mm, increasing to 0.029 mm at the 95th percentile, with deviations reaching >0.100 mm at complex geometric paths and corners. Layers containing high scanning path deviations, showed up to 10 times more porosity than other areas, underscoring a strong correlation between scan accuracy and anomaly formation. Reproducibility testing across multiple build plate locations showed a 95th percentile deviation of 0.042 mm, with maximum deviations up to 0.080 mm. Scanning accuracy anomalies that can alter local energy density such as missing or additional hatch sections were found as a function of the build plate location, suggesting a root cause of part variability in addition to other process conditions such as gas flow. Despite high repeatability (0.004 mm mean deviation) of the scanning path, only ∼30 % of pores appeared in consistent locations, suggesting that scanner qualification alone is insufficient to explain pore final location. The study also highlighted the influence of geometry, speed, and scanning parameters in the scanning system accuracy. These findings provide new insights into how scanning system performance affects part quality and repeatability and provide a framework for incorporating scanning data metrics into future qualification protocols.
{"title":"Scanner position accuracy, repeatability, and process anomalies correlation in PBF-LB/M","authors":"Jesus Rivas , Jorge Mireles , R.B. Wicker","doi":"10.1016/j.addlet.2025.100326","DOIUrl":"10.1016/j.addlet.2025.100326","url":null,"abstract":"<div><div>This study investigates position accuracy, repeatability, and reproducibility of the scanning system in a metal laser powder bed fusion (PBF-LB/M) process using a novel data collection method. Deviations between Commanded and Actual scanning positions were quantified using Euclidean distance metrics across a series of builds and geometries. Results showed a build mean accuracy of 0.014 mm, increasing to 0.029 mm at the 95th percentile, with deviations reaching >0.100 mm at complex geometric paths and corners. Layers containing high scanning path deviations, showed up to 10 times more porosity than other areas, underscoring a strong correlation between scan accuracy and anomaly formation. Reproducibility testing across multiple build plate locations showed a 95th percentile deviation of 0.042 mm, with maximum deviations up to 0.080 mm. Scanning accuracy anomalies that can alter local energy density such as missing or additional hatch sections were found as a function of the build plate location, suggesting a root cause of part variability in addition to other process conditions such as gas flow. Despite high repeatability (0.004 mm mean deviation) of the scanning path, only ∼30 % of pores appeared in consistent locations, suggesting that scanner qualification alone is insufficient to explain pore final location. The study also highlighted the influence of geometry, speed, and scanning parameters in the scanning system accuracy. These findings provide new insights into how scanning system performance affects part quality and repeatability and provide a framework for incorporating scanning data metrics into future qualification protocols.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100326"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145267140","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-10-30DOI: 10.1016/j.addlet.2025.100337
Sean Eckstein , Sophia Benkirane , George Youssef
The intersection between additive manufacturing and metamaterials reinvigorated the pursuit of optimal protective structures in civilian and military applications by challenging the process-structure-performance nexus. This letter introduces a novel subclass of mechanical metamaterials, termed meta-skins, which are printed with continuous carbon fiber composites in pseudo-woven patterns to achieve higher impact efficacy-to-weight ratios. High-performance elastomeric foam cores were adhered to the carbon fiber meta-skins in two configurations: monocoque and sandwich. The impact efficacy was evaluated using direct impact loading scenarios at 4.43 m/s and 15 m/s, respectively, using a fully instrumented drop tower and a small-scale shock tube. Digital image correlation (DIC) revealed the full-field kinematics of deformation as a function of strain rate. Postmortem failure analysis cross-referenced the dynamic mechanical behavior with the failure modes, epitomizing the interrelation between sample configuration and impact efficacy. Generally, monocoque structures outperformed their sandwich counterparts under low-velocity impacts, whereas the opposite was observed under moderate-velocity loading conditions, such that the performance of the sandwich structures surpassed that of the monocoque structures in nearly all dynamic evaluation metrics. Moreover, the meta-skin-capped specimens outperformed their cross-ply benchmarks by 15 % under similar impact events, demonstrating the novelty of the newly introduced subclass of metamaterials. The research outcomes unlock the scientific and technological potential of the next generation of protective armors by leveraging advanced weaving and fiber materials.
{"title":"3D-printed carbon fiber meta-skins for impact mitigating sandwich structures","authors":"Sean Eckstein , Sophia Benkirane , George Youssef","doi":"10.1016/j.addlet.2025.100337","DOIUrl":"10.1016/j.addlet.2025.100337","url":null,"abstract":"<div><div>The intersection between additive manufacturing and metamaterials reinvigorated the pursuit of optimal protective structures in civilian and military applications by challenging the process-structure-performance nexus. This letter introduces a novel subclass of mechanical metamaterials, termed meta-skins, which are printed with continuous carbon fiber composites in pseudo-woven patterns to achieve higher impact efficacy-to-weight ratios. High-performance elastomeric foam cores were adhered to the carbon fiber meta-skins in two configurations: monocoque and sandwich. The impact efficacy was evaluated using direct impact loading scenarios at 4.43 m/s and 15 m/s, respectively, using a fully instrumented drop tower and a small-scale shock tube. Digital image correlation (DIC) revealed the full-field kinematics of deformation as a function of strain rate. Postmortem failure analysis cross-referenced the dynamic mechanical behavior with the failure modes, epitomizing the interrelation between sample configuration and impact efficacy. Generally, monocoque structures outperformed their sandwich counterparts under low-velocity impacts, whereas the opposite was observed under moderate-velocity loading conditions, such that the performance of the sandwich structures surpassed that of the monocoque structures in nearly all dynamic evaluation metrics. Moreover, the meta-skin-capped specimens outperformed their cross-ply benchmarks by 15 % under similar impact events, demonstrating the novelty of the newly introduced subclass of metamaterials. The research outcomes unlock the scientific and technological potential of the next generation of protective armors by leveraging advanced weaving and fiber materials.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100337"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145465392","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-12-04DOI: 10.1016/j.addlet.2025.100347
Berk Baris Celik , Amir Hossein Mirzaei , Nima Razavi , Brecht Van Hooreweder
Metallic lattice structures are increasingly employed in advanced engineering applications where a high strength-to-weight ratio and enhanced dynamic response are required. Recent studies on functionally graded lattice structures show that these structures stand out for their tuneable properties. This study presents novel insights into the mechanical and dynamic properties of modal simulation-driven, density-gradient strut-based lattices fabricated from aluminum A205 powder using laser powder bed fusion (LPBF). Cubic bounding volume diamond unit cell lattice specimens with identical mass and four distinct gradient profiles were designed. One specimen without a density gradient and three with mode shape-informed density gradients were included in the study. A new printing parameter set was developed to enable density gradient samples to be printed at high material densities and in a robust manner. Modal and static finite element simulations were conducted to validate the dynamic property optimization of density gradient structures. Impulse excitation technique (IET) tests showed that the field-optimized design (FO) has an increase of 23.7% and 16.1% in natural frequency in two different modes, and an increase of 130% and 45% in damping capacity in the same modes, compared to the uniform density sample (NG). Compression tests showed that FO was slightly less stiff but had better maximum compressive stress values than NG. FO also outperformed the other three designs in terms of energy absorption. Despite being optimized for natural frequency and damping capacity, FO demonstrated acceptable fatigue performance with hysteresis analyses indicating greater energy dissipation per cycle than the uniform lattice design. The insights and results from this work therefore opens new opportunities for creating lightweight yet high-performance and multifunctional metal lattice structures.
{"title":"Mode shape-informed design of lightweight metal lattice structures produced by laser powder bed fusion for enhanced dynamic properties","authors":"Berk Baris Celik , Amir Hossein Mirzaei , Nima Razavi , Brecht Van Hooreweder","doi":"10.1016/j.addlet.2025.100347","DOIUrl":"10.1016/j.addlet.2025.100347","url":null,"abstract":"<div><div>Metallic lattice structures are increasingly employed in advanced engineering applications where a high strength-to-weight ratio and enhanced dynamic response are required. Recent studies on functionally graded lattice structures show that these structures stand out for their tuneable properties. This study presents novel insights into the mechanical and dynamic properties of modal simulation-driven, density-gradient strut-based lattices fabricated from aluminum A205 powder using laser powder bed fusion (LPBF). Cubic bounding volume diamond unit cell lattice specimens with identical mass and four distinct gradient profiles were designed. One specimen without a density gradient and three with mode shape-informed density gradients were included in the study. A new printing parameter set was developed to enable density gradient samples to be printed at high material densities and in a robust manner. Modal and static finite element simulations were conducted to validate the dynamic property optimization of density gradient structures. Impulse excitation technique (IET) tests showed that the field-optimized design (FO) has an increase of 23.7% and 16.1% in natural frequency in two different modes, and an increase of 130% and 45% in damping capacity in the same modes, compared to the uniform density sample (NG). Compression tests showed that FO was slightly less stiff but had better maximum compressive stress values than NG. FO also outperformed the other three designs in terms of energy absorption. Despite being optimized for natural frequency and damping capacity, FO demonstrated acceptable fatigue performance with hysteresis analyses indicating greater energy dissipation per cycle than the uniform lattice design. The insights and results from this work therefore opens new opportunities for creating lightweight yet high-performance and multifunctional metal lattice structures.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100347"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693142","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-08-16DOI: 10.1016/j.addlet.2025.100318
Camille Pauzon , Rémi Daudin , Pierre Lhuissier , Xavier Bataillon , Pierre Lapouge , Pierre Hébrard , Patrice Peyre , Frédéric Coste , Lucas Varoto , Elodie Boller , Jean-Jacques Blandin
When laser powder bed fusion (LPBF) is applied to bulk metallic glasses rather than traditional crystalline alloys, one has to avoid conditions that could cause crystals to form. To achieve a balance between the porosity content and devitrification in the heat affected zone, it is common practice to process such material with a thin layer thickness, and thereby reduce the laser power necessary for melting. In this manufacturing regime, lack-of-fusion defects typically subsist. This work investigates how laser rescanning can densify metallic glasses while still ensuring their amorphous nature. Synchrotron X-ray Computed Tomography during LPBF allows imaging in situ the pores upon the glass construction. This non-destructive cutting-edge technique helps understanding the consolidation mechanism associated with rescanning and in particular its effect on layer surface roughness and the homogeneity of the powder recoating. Applied to the well-established Zr-Cu-Al-Nb grade, this work paves the way towards the adoption of less thermally stable glasses for LPBF, and the control of defect distribution. In particular, it is revealed that the hatch spacing effect is of primary importance in the production of viscous materials such as glasses, and that laser rescanning allows the surface of the deposited layer to be smoothed, improving consolidation without associated crystallisation.
{"title":"In situ porosity imaging with synchrotron X-ray tomography during laser rescanning of Zr-based metallic glass by laser powder bed fusion","authors":"Camille Pauzon , Rémi Daudin , Pierre Lhuissier , Xavier Bataillon , Pierre Lapouge , Pierre Hébrard , Patrice Peyre , Frédéric Coste , Lucas Varoto , Elodie Boller , Jean-Jacques Blandin","doi":"10.1016/j.addlet.2025.100318","DOIUrl":"10.1016/j.addlet.2025.100318","url":null,"abstract":"<div><div>When laser powder bed fusion (LPBF) is applied to bulk metallic glasses rather than traditional crystalline alloys, one has to avoid conditions that could cause crystals to form. To achieve a balance between the porosity content and devitrification in the heat affected zone, it is common practice to process such material with a thin layer thickness, and thereby reduce the laser power necessary for melting. In this manufacturing regime, lack-of-fusion defects typically subsist. This work investigates how laser rescanning can densify metallic glasses while still ensuring their amorphous nature. Synchrotron X-ray Computed Tomography during LPBF allows imaging in situ the pores upon the glass construction. This non-destructive cutting-edge technique helps understanding the consolidation mechanism associated with rescanning and in particular its effect on layer surface roughness and the homogeneity of the powder recoating. Applied to the well-established Zr-Cu-Al-Nb grade, this work paves the way towards the adoption of less thermally stable glasses for LPBF, and the control of defect distribution. In particular, it is revealed that the hatch spacing effect is of primary importance in the production of viscous materials such as glasses, and that laser rescanning allows the surface of the deposited layer to be smoothed, improving consolidation without associated crystallisation.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100318"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144866102","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-09-08DOI: 10.1016/j.addlet.2025.100322
Morgan Mosco, Christopher B. Williams, Bart Raeymaekers
Ultra-high molecular weight polyethylene (UHMWPE) is widely used in applications that need abrasion resistance, impact toughness, and chemical inertness, including bushings, prosthetic joints, naval dock bumpers, and mooring buoys. However, its high molecular weight restricts conventional processing to ram extrusion or compression molding, which require a die or mold that limits the complexity and customizability of part geometries. Additive manufacturing (AM) offers an alternative to producing complex UHMWPE parts without the need for specialized tooling. Recent advances have demonstrated AM of UHMWPE via a process chain that combines laser powder bed fusion (L-PBF) with a pressure-assisted thermal post-processing step. However, despite the critical importance in most of its applications, no information exists about wear of L-PBF printed UHMWPE compared to that of conventionally processed parts. Here, UHMWPE specimens of controlled density are produced using the L-PBF process chain and their process-structure-wear relationship is characterized. The results reveal that the steady-state wear rate decreases exponentially with increasing density and approaches that of conventionally processed benchmark specimens. This improvement is attributed to reduced porosity and corresponding increased hardness. This study provides the first process-structure-wear relationship for additively manufactured UHMWPE, and demonstrates that L-PBF can deliver wear resistance comparable to conventional processing while enabling complex, customized geometries. These findings establish a scientific and technological foundation for extending L-PBF of UHMWPE into advanced applications such as precision bushings, orthopedic components, and other high-performance parts that require both geometric freedom and excellent tribological performance.
{"title":"Wear of ultra-high molecular weight polyethylene manufactured with laser powder bed fusion","authors":"Morgan Mosco, Christopher B. Williams, Bart Raeymaekers","doi":"10.1016/j.addlet.2025.100322","DOIUrl":"10.1016/j.addlet.2025.100322","url":null,"abstract":"<div><div>Ultra-high molecular weight polyethylene (UHMWPE) is widely used in applications that need abrasion resistance, impact toughness, and chemical inertness, including bushings, prosthetic joints, naval dock bumpers, and mooring buoys. However, its high molecular weight restricts conventional processing to ram extrusion or compression molding, which require a die or mold that limits the complexity and customizability of part geometries. Additive manufacturing (AM) offers an alternative to producing complex UHMWPE parts without the need for specialized tooling. Recent advances have demonstrated AM of UHMWPE via a process chain that combines laser powder bed fusion (L-PBF) with a pressure-assisted thermal post-processing step. However, despite the critical importance in most of its applications, no information exists about wear of L-PBF printed UHMWPE compared to that of conventionally processed parts. Here, UHMWPE specimens of controlled density are produced using the L-PBF process chain and their process-structure-wear relationship is characterized. The results reveal that the steady-state wear rate decreases exponentially with increasing density and approaches that of conventionally processed benchmark specimens. This improvement is attributed to reduced porosity and corresponding increased hardness. This study provides the first process-structure-wear relationship for additively manufactured UHMWPE, and demonstrates that L-PBF can deliver wear resistance comparable to conventional processing while enabling complex, customized geometries. These findings establish a scientific and technological foundation for extending L-PBF of UHMWPE into advanced applications such as precision bushings, orthopedic components, and other high-performance parts that require both geometric freedom and excellent tribological performance.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100322"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145049659","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-11-19DOI: 10.1016/j.addlet.2025.100342
John P. Reidy , Catherine Ott , Alexandra J. Barbosa , Fernando Reyes Tirado , Gianna M. Valentino , Ian McCue
Nb-base alloys offer excellent high-temperature properties, but many legacy compositions were sidelined due to poor machinability. Additive manufacturing (AM) provides a pathway to bypass these limitations while simultaneously producing heterogeneous microstructures that can enhance performance. In this work, the legacy alloy Cb752 was gas-atomized to produce spherical powder feedstock for laser powder bed fusion, and a modified powder variant was prepared by tumbling HfC nanoparticles with the base powder. Tensile specimens were fabricated from both powders under optimized laser parameters, alongside arc-melted Cb752 for comparison. Compared to arc-melted Cb752, AM specimens exhibited consistently higher strength across 800–1600°C due to stable subgrain dislocation networks that delay recrystallization and enhance strain hardening. The HfC additions further stabilized these networks, improving post-yield performance at intermediate temperatures, though their contribution diminished after particle coarsening at 1600°C. These findings demonstrate that custom atomization and feedstock modification can unlock new performance in Nb-base alloys and provide a generalizable strategy for advancing refractory alloy systems through tailored AM processing.
{"title":"High-temperature deformation behavior of additively manufactured niobium alloys from in-house gas-atomized feedstock","authors":"John P. Reidy , Catherine Ott , Alexandra J. Barbosa , Fernando Reyes Tirado , Gianna M. Valentino , Ian McCue","doi":"10.1016/j.addlet.2025.100342","DOIUrl":"10.1016/j.addlet.2025.100342","url":null,"abstract":"<div><div>Nb-base alloys offer excellent high-temperature properties, but many legacy compositions were sidelined due to poor machinability. Additive manufacturing (AM) provides a pathway to bypass these limitations while simultaneously producing heterogeneous microstructures that can enhance performance. In this work, the legacy alloy Cb752 was gas-atomized to produce spherical powder feedstock for laser powder bed fusion, and a modified powder variant was prepared by tumbling HfC nanoparticles with the base powder. Tensile specimens were fabricated from both powders under optimized laser parameters, alongside arc-melted Cb752 for comparison. Compared to arc-melted Cb752, AM specimens exhibited consistently higher strength across 800–1600°C due to stable subgrain dislocation networks that delay recrystallization and enhance strain hardening. The HfC additions further stabilized these networks, improving post-yield performance at intermediate temperatures, though their contribution diminished after particle coarsening at 1600°C. These findings demonstrate that custom atomization and feedstock modification can unlock new performance in Nb-base alloys and provide a generalizable strategy for advancing refractory alloy systems through tailored AM processing.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100342"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145623561","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-01Epub Date: 2025-08-11DOI: 10.1016/j.addlet.2025.100316
Alexander Koch , Sebastian Stammkoetter , Arvid Abel , Abootorab Chehreh , Joerg Hermsdorf , Stefan Kaierle , Frank Walther
Magnesium alloys are renowned for their high strength-to-weight ratio and low density, making them highly sought-after in the lightweight engineering sector. Among these, the high-strength magnesium alloy WE43, characterized by its Mg-4Y-3RE composition, stands out for its superior mechanical strength and thermal stability. These properties, coupled with its creep resistance, render WE43 a suitable alloy in elevated temperature applications, particularly in aerospace and automotive engineering. Despite its potential, the characterization of the load direction- and temperature-dependent deformation behavior remains incomplete for WE43, especially in additive manufacturing contexts. This study explores the quasi-static and cyclic creep properties of WE43 produced via laser-based powder bed fusion.
The research involved tensile and compression testing to evaluate quasi-static deformation and tensile-compression asymmetry. Cyclic creep behavior was studied under diverse mechanical (tension, compression) and thermal (RT, 200 °C, 300 °C) conditions by load-increase fatigue tests. Microstructural analyses based on cross-sections, XRD and computed tomography were conducted to assess manufacturing quality and identify potential inhomogeneities. The results reveal the interplay between mechanical load, temperature, and structural integrity in WE43. It could be shown that especially at 300 °C increased creep rates occure.
{"title":"Load direction and temperature impacts on cyclic creep behavior of laser-based powder bed fusion-produced WE43 magnesium alloy","authors":"Alexander Koch , Sebastian Stammkoetter , Arvid Abel , Abootorab Chehreh , Joerg Hermsdorf , Stefan Kaierle , Frank Walther","doi":"10.1016/j.addlet.2025.100316","DOIUrl":"10.1016/j.addlet.2025.100316","url":null,"abstract":"<div><div>Magnesium alloys are renowned for their high strength-to-weight ratio and low density, making them highly sought-after in the lightweight engineering sector. Among these, the high-strength magnesium alloy WE43, characterized by its Mg-4Y-3RE composition, stands out for its superior mechanical strength and thermal stability. These properties, coupled with its creep resistance, render WE43 a suitable alloy in elevated temperature applications, particularly in aerospace and automotive engineering. Despite its potential, the characterization of the load direction- and temperature-dependent deformation behavior remains incomplete for WE43, especially in additive manufacturing contexts. This study explores the quasi-static and cyclic creep properties of WE43 produced via laser-based powder bed fusion.</div><div>The research involved tensile and compression testing to evaluate quasi-static deformation and tensile-compression asymmetry. Cyclic creep behavior was studied under diverse mechanical (tension, compression) and thermal (RT, 200 °C, 300 °C) conditions by load-increase fatigue tests. Microstructural analyses based on cross-sections, XRD and computed tomography were conducted to assess manufacturing quality and identify potential inhomogeneities. The results reveal the interplay between mechanical load, temperature, and structural integrity in WE43. It could be shown that especially at 300 °C increased creep rates occure.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"15 ","pages":"Article 100316"},"PeriodicalIF":4.7,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144907320","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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