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1. Additive manufacturing as a tool for high-throughput experimentation

   https://doi.org/10.20517/jmi.2022.19  

   Xiong, Wei ( January 2022 , Journal of Materials Informatics)

   Additive manufacturing (AM) is a disruptive technology with a unique capability in fabricating parts with complex geometry and fixing broken supply chains. However, many AM techniques are complicated with their processing features due to complex heating and cooling cycles with the melting of feedstock materials. Therefore, it is quite challenging to directly apply the materials design and processing optimization method used for conventional manufacturing to AM techniques. In this viewpoint paper, we discuss some of the ongoing efforts of high-throughput (HT) experimentation, which can be used for materials development and processing design. Particularly, we focus on the beam- and powder-based AM techniques since these methods have demonstrated success in HT experimentation. In addition, we propose new opportunities to apply AM techniques as the materials informatic tools contributing to materials genome. 

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2. Part decomposition and assembly-based (Re) design for additive manufacturing: A review

   https://doi.org/https://doi.org/10.1016/j.addma.2018.04.018  

   Oh, Yosep ; Zhou, Chi ; Behdad, Sara ( August 2018 , Additive manufacturing)

   Additive Manufacturing (AM), also known as 3D printing, has been highlighted as a complementary method to the traditional (subtractive and formative) manufacturing. This mainly results from its distinctive characteristics to directly produce complex shapes and assemblies without an assembly process. With these aspects, AM has affected the way products are designed and formed, which leads to an exclusive research area, known as Design for AM (DfAM). As a step towards addressing DfAM, this paper reviews the literature on re-designing an original model into assemblies produced in AM, named as Part Decomposition (PD). Although PD has received less attention in DfAM compared with Part Consolidation (PC) that is re-designing assemblies into a consolidated single part, PD has been studied with various motives and challenges for AM. To investigate the research trend in PD, 37 main publications are categorized under five motives including printability, productivity, functionality, artistry and flexibility. Additionally, from technical and methodological aspects, relevant studies are organized into decomposition issues (automatic, semi-automatic and manual decompositions), buildup issues (orientation decision for single- and multi-part and packing problem), and assembly issues (connection design and assembly process planning). As witnessed in this comprehensive review, the concept of PD leaves further research challenges spanning several disciplines. Along this line, we further elaborate future research directions of PD under three main categories: (1) enhancing the AM productivity for mass customization; (2) developing novel decomposition methods and guidelines; and (3) applying conventional design methodologies to PD. 

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3. Advances and Challenges in Predictive Modeling for Additive Manufacturing of Dissimilar Metals and Complex Alloys

   https://doi.org/10.3390/ma16165680  

   Adak, Debajyoti ; Sreeramagiri, Praveen ; Roy, Somnath ; Balasubramanian, Ganesh ( August 2023 , Materials)

   We present a scrutiny on the state of the art and applicability of predictive methods for additive manufacturing (AM) of metals, alloys, and compositionally complex metallic materials, to provide insights from the computational models for AM process optimization. Our work emphasizes the importance of manufacturing parameters on the thermal profiles evinced during processing, and the fundamental insights offered by the models used to simulate metal AM mechanisms. We discuss the methods and assumptions necessary for an educated tradeoff between the efficacy and accuracy of the computational approaches that incorporate multi-physics required to mimic the associated fluid flow phenomena as well as the resulting microstructures. Finally, the current challenges in the existing approaches are summarized and future scopes identified.

    

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4. Multi-Institutional Collaboration in Additive Manufacturing

   Fidan, Ismail ; Chitiyo, George ; Wooldridge, Eric N ; Singer, Thomas ( January 2019 , ASEE Annual Conference proceedings)

   During the Fall 2018 semester, two community colleges and one university shared their design and additive manufacturing (AM) facilities and capabilities. While student teams learn the depth of technical drafting in one community college’s design course, the other two institutions have opened the doors of their AM labs so that students can solidify the knowledge they acquire which is largely limited to the computer screen in their design course. As the design files are received by the AM labs of the other two institutions, the files are evaluated for AM related issues and modifications are suggested. Following any revisions, the AM labs begin production of the files, both in single version and batch production for potential, larger volume applications while demonstrating to the students and stakeholders the versatility and cloud manufacturing capabilities that AM has to offer on a variety of levels, as well as helping to improve the student’s design competencies that are necessary for AM. This current paper will report the nature of the current AM coalition and share a sample student project designed and produced during the Fall 2018 semester. The feedback received from the students will also be shared. 

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5. Nature-inspired materials and structures using 3D Printing

   https://doi.org/doi.org/10.1016/j.mser.2021.100609  

   Bandyopadhyay, Amit ; Traxel, Kellen ; Bose, Susmita ( July 2021 , Materials science engineering)

   null (Ed.)

   Emulating the unique combination of structural, compositional, and functional gradation in natural materials is exceptionally challenging. Many natural structures have proved too complex or expensive to imitate using traditional processing techniques despite recent advances. Recent innovations within the field of additive manufacturing (AM) or 3D Printing (3DP) have shown the ability to create structures that have variations in material composition, structure, and performance, providing a new design-for-manufacturing platform for the imitation of natural materials. AM or 3DP techniques are capable of manufacturing structures that have significantly improved properties and functionality over what could be traditionally-produced, giving manufacturers an edge in their ability to realize components for highly-specialized applications in different industries. To this end, the present work reviews fundamental advances in the use of naturally-inspired design enabled through 3DP / AM, how these techniques can be further exploited to reach new application areas and the challenges that lie ahead for widespread implementation. An example of how these techniques can be applied towards a total hip arthroplasty application is provided to spur further innovation in this area. 

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