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Multidimensional Additive Manufacturing
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Multidimensional Additive Manufacturing

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Materials Science and Engineering".

Deadline for manuscript submissions: closed (20 March 2024) | Viewed by 18696

Special Issue Editor

Prof. Dr. Soshu Kirihara

E-Mail Website
Guest Editor
Joining and Welding Research Institute, Osaka University, 11–1 Mihogaoka, Ibaraki City, Osaka 567-0047, Japan
Interests: additive manufacturing; laser lithography; electromagnetic devices, bioceramic implant; energy harvesting
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Conventional manufacturing technologies for metal and ceramic components have been developed owing to the increase in structural dimensions. Functional patterns and surfaces were added to solid objects, e.g., machining and coating processes for casted components. Additive manufacturing technologies are globally recognized as novel fabrication processes for advanced materials and components with multidimensional structures. These technologies offer significant potential for design innovation, customization, and distributed digital manufacturing. In this approach, three-dimensional models are designed and created based on theoretical concepts using computer software, and two-dimensional cross-sections are created by slicing operations automatically. Computer-aided design, manufacture, and evaluation are referred to as smart additive processing. In lithography-based approaches, high-resolution laser or electron beams are scanned on a spread metal or ceramic powder bed with or without resin binders to form solid planes of cross-sections. In deposition-based processes, paste materials with ceramic or metal particles dispersed in a binder system are ejected from nozzles moving freely to create composite structures. Recently, periodic patterns with integer dimensions were printed as heating and sensing devices, and fractal or fluctuating features with non-integer dimensions were introduced for mass transfer modulations on metal and ceramic components. Subsequently, inorganic biological implants with compositional gradations and organic resin objects with aging performance were fabricated over three-dimensional objects. Multidimensional additive manufacturing for realizing a sustainable society will be discussed through topics related to the following keywords.

Prof. Dr. Soshu Kirihara
Guest Editor

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Keywords

  • laminated object manufacturing/green tape stacking
  • powder bed fusion/selective laser melting and sintering
  • material extrusion/fused deposition modeling
  • binder jetting processes
  • vat photopolymerization/stereolithography
  • direct writing and ink jet printing technologies
  • multimaterial and hybrid printing techniques
  • design with/for additive manufacturing
  • materials and process characterization tools
  • qualification, certification, standards, and property database
  • applications of additive manufacturing materials and components

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Published Papers (6 papers)

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Research

17 pages, 6714 KiB  
Article
Development of Prediction Method for Dimensional Stability of 3D-Printed Objects
by Kyung-Eun Min, Jae-Won Jang, Jesik Shin, Cheolhee Kim and Sung Yi
Appl. Sci. 2023, 13(19), 11027; https://doi.org/10.3390/app131911027 - 6 Oct 2023
Cited by 3 | Viewed by 1221
Abstract
Fused deposition modeling (FDM), as one of the additive manufacturing processes, is known for strong layer adhesion suitable for prototypes and end-use items. This study used a multiple regression model and statistical analysis to explore the dimensional accuracy of FDM objects. Factors such [...] Read more.
Fused deposition modeling (FDM), as one of the additive manufacturing processes, is known for strong layer adhesion suitable for prototypes and end-use items. This study used a multiple regression model and statistical analysis to explore the dimensional accuracy of FDM objects. Factors such as inclination angle, layer thickness, support space, and raster angle were examined. Machine learning models (Gaussian process regression (GPR), support vector machines (SVM), and artificial neural network (ANN)) predicted dimensions using 81 datapoints. The mean squared dimensional error (MSDE) between the measured and designed surface profiles was selected as an output for the dimensional accuracy. Support spacing, layer thickness, and raster angle were determined to be statistically significant, and all factors were confirmed as significant predictors. The coefficients of determination for multiple linear regression, GPR, SVM, and ANN models were 76%, 98%, 93%, and 99%, respectively. The mean absolute errors (MAEs)—errors between the measured and the predicted MSDEs—were 0.020 mm and 0.034 mm, respectively, for GPR and SVM models. The MAEs for ANN models were 0.0055 mm for supporting cases and 2.1468 × 10−5 mm for non-supporting cases. Full article
(This article belongs to the Special Issue Multidimensional Additive Manufacturing)
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18 pages, 9207 KiB  
Article
Liquid to Fused Deposition Modeling (L-FDM)—A Revolution in Application Chemicals to 3D Printing Technology—Mechanical and Functional Properties
by Robert E. Przekop, Ewa Gabriel, Daria Pakuła and Bogna Sztorch
Appl. Sci. 2023, 13(14), 8462; https://doi.org/10.3390/app13148462 - 21 Jul 2023
Cited by 3 | Viewed by 2004
Abstract
A novel L-FDM technique that builds upon the fundamentals of the FDM additive manufacturing process has been developed. It includes a mechanism that directly incorporates a chemical substance and alters polymer fibers throughout the fine process. This method eliminates the need for additional [...] Read more.
A novel L-FDM technique that builds upon the fundamentals of the FDM additive manufacturing process has been developed. It includes a mechanism that directly incorporates a chemical substance and alters polymer fibers throughout the fine process. This method eliminates the need for additional extrusion operations and compounding equipment to introduce chemical additives and solvents. This advancement opens up new opportunities for printers to be used in chemical labs to test new or known chemical substances. The paper outlines the technological assumptions, potential applications, and practical examples of direct filament modification using the L-FDM technique. The modifications made to the mechanical properties of the printed objects were confirmed through thermal analysis techniques (DSC), water contact angle measurements, electron microscopy (SEM-EDS), and mechanical analysis. Full article
(This article belongs to the Special Issue Multidimensional Additive Manufacturing)
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25 pages, 9272 KiB  
Article
Liquid for Fused Deposition Modeling Technique (L-FDM)—A Revolution in Application Chemicals to 3D Printing Technology: Color and Elements
by Robert E. Przekop, Ewa Gabriel, Daria Pakuła and Bogna Sztorch
Appl. Sci. 2023, 13(13), 7393; https://doi.org/10.3390/app13137393 - 21 Jun 2023
Cited by 9 | Viewed by 9035
Abstract
This article presents a novel 3D printing technique called L-FDM (liquid for fused deposition modeling), which is based on the deposition of molten thermoplastic material. The new method allows for the direct introduction of chemicals and polymer filament modifications during the printing process. [...] Read more.
This article presents a novel 3D printing technique called L-FDM (liquid for fused deposition modeling), which is based on the deposition of molten thermoplastic material. The new method allows for the direct introduction of chemicals and polymer filament modifications during the printing process. In contrast to traditional incremental methods, L-FDM eliminates the need for extra granulating, extrusion, and processing equipment, making it possible to introduce chemical additives to the polymer matrix directly. This opens up exciting possibilities for chemical laboratories to test and experiment with new and known chemicals through 3D printing. The article discusses the technical aspects of L-FDM and its potential applications and provides practical examples of direct filament modifications using the technique. The results of these modifications were verified using a colorimeter, electron microscopy (SEM/EDS), and optical microscopy. Full article
(This article belongs to the Special Issue Multidimensional Additive Manufacturing)
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9 pages, 2112 KiB  
Article
Hybridizing Lithography-Based Ceramic Additive Manufacturing with Two-Photon-Polymerization
by Johanna Christiane Sänger, Martin Schwentenwein, Raúl Bermejo and Jens Günster
Appl. Sci. 2023, 13(6), 3974; https://doi.org/10.3390/app13063974 - 21 Mar 2023
Cited by 4 | Viewed by 2371
Abstract
Stereolithography processes such as lithography-based ceramic manufacturing (LCM) are technologies that can produce centimeter-sized structures in a reasonable time frame. However, for some parts specifications, they lack resolution. Two-photon-polymerization (2PP) ensures the highest geometric accuracy in additive manufacturing so far. Nevertheless, building up [...] Read more.
Stereolithography processes such as lithography-based ceramic manufacturing (LCM) are technologies that can produce centimeter-sized structures in a reasonable time frame. However, for some parts specifications, they lack resolution. Two-photon-polymerization (2PP) ensures the highest geometric accuracy in additive manufacturing so far. Nevertheless, building up parts in sizes as large as a few millimeters or even centimeters is a time-consuming process, which makes the production of 2PP printed parts very costly. Regarding feedstock specification, the requirements for 2PP are different to those for LCM, and generally, feedstocks are designed to meet requirements for only one of these manufacturing technologies. In an attempt to fabricate highly precise ceramic components of a rather large size, it is necessary to develop a feedstock that suits both light-based technologies, taking advantage of LCM’s higher productivity and 2PP’s accuracy. Hybridization should bring the desired precision to the region of interest on reasonably large parts without escalating printing time and costs. In this study, specimens gained from a transparent feedstock with yttria stabilized zirconia (YSZ) particles of 5 nm at 70 wt% were presented. The resin was originally designed to suit 2PP, while being also printable with LCM. This work demonstrates how hybrid parts can be sintered into full YSZ ceramics. Full article
(This article belongs to the Special Issue Multidimensional Additive Manufacturing)
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16 pages, 5759 KiB  
Article
In Situ Microstructure Characterization of Potassium Di-Phosphate (KDP) Densification during Cold Sintering
by Andrew J. Allen, Russell A. Maier, Fan Zhang, Ivan Kuzmenko and Jan Ilavsky
Appl. Sci. 2022, 12(20), 10493; https://doi.org/10.3390/app122010493 - 18 Oct 2022
Cited by 6 | Viewed by 1485
Abstract
In order for ceramic additive manufacturing (AM) to achieve its full potential, it is increasingly important to develop a more rigorous understanding of fundamental phenomena that govern the kinetics and thermodynamics of ceramic AM processes. In the case of additive build processes, such [...] Read more.
In order for ceramic additive manufacturing (AM) to achieve its full potential, it is increasingly important to develop a more rigorous understanding of fundamental phenomena that govern the kinetics and thermodynamics of ceramic AM processes. In the case of additive build processes, such as direct ink write and ceramic extrusion, methods for densifying the resulting green-body product need to be considered to complement the efficiencies of ceramics AM, itself. One densification route, at least for monolithic components, built layer-by-layer, is offered by the recently developed cold sintering process, whereby high-density final product is achieved through addition of a small amount of liquid solvent and application of modest uniaxial compressive stress at relatively low temperature. In situ small-angle X-ray scattering methods and X-ray diffraction have been applied to characterize and quantify the pore morphology evolution during cold sintering for a model system: potassium di-phosphate, KH2PO4 (KDP). It is shown that both temperature and applied stress affect the densification rate, but stress has a stronger effect on the evolving morphology. A regime with an approximate linear densification rate can be identified, yielding an effective densification activation energy of ≈90 kJ/mol. Full article
(This article belongs to the Special Issue Multidimensional Additive Manufacturing)
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Graphical abstract

11 pages, 3147 KiB  
Article
High-Speed Alumina Stereolithography
by Fiona Spirrett, Tatsuya Ito and Soshu Kirihara
Appl. Sci. 2022, 12(19), 9760; https://doi.org/10.3390/app12199760 - 28 Sep 2022
Cited by 1 | Viewed by 1557
Abstract
The additive manufacturing of ceramics offers a reliable and repeatable method for fabricating parts with complex geometries. To compete with conventional ceramic forming methods, the time and cost associated with material and process optimization for ceramic stereolithography should be improved. Computational analysis methods [...] Read more.
The additive manufacturing of ceramics offers a reliable and repeatable method for fabricating parts with complex geometries. To compete with conventional ceramic forming methods, the time and cost associated with material and process optimization for ceramic stereolithography should be improved. Computational analysis methods can be utilized to reduce the number of experimental steps required for material and process optimization. This work used the discrete element method and ray tracing analyses to predict suitable material parameters and processing conditions for ceramic stereolithography. The discrete element method was used to create alumina particle dispersion models to predict suitable paste compositions, and ray tracing was used to predict suitable laser power and scan speed to achieve a sufficient curing depth for stereolithography processing. The predicted conditions of paste composition and processing parameters were comparable to experimental values, reducing the number of experimental iterations required for process optimization. Furthermore, suitable processing parameters for high-speed fabrication by stereolithography was predicted, achieving a processing speed much faster than previously reported ceramic stereolithography. The reduction in process optimization timeline, and the increase in fabrication speed, could increase the appeal of ceramic stereolithography to industry. Full article
(This article belongs to the Special Issue Multidimensional Additive Manufacturing)
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