The Next Generation of Metal Additive Manufacturing

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Additive Manufacturing".

Deadline for manuscript submissions: closed (30 September 2024) | Viewed by 947

Special Issue Editor


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Guest Editor
Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM, Winterbergstraße 28, 01277 Dresden, Germany
Interests: additive manufacturing; next generation additive manufacturing; material science; powder metallurgy; sinter-based AM; process transformation

Special Issue Information

Dear Colleagues,

Metal additive processes have predominantly revolved around laser powder bed fusion (PBF-LB or LPBF), a trend evident in both academic publications and general interest. Given the specific limitations of PBF-LB in material selection, geometry generation, and productivity, a growing interest in alternative processes has been observed in recent years. In this context, we are witnessing the emergence of innovative technologies, representing the next generation of additive manufacturing approaches.

These groundbreaking technologies encompass a diverse range of sinter-based processes, including 3D screen printing, gel casting, MoldJet, lithography-based metal manufacturing (LMM), cold metal fusion (CMF), liquid metal printing (LMP), and increasingly popular methods such as fused filament fabrication (FFF) and metal binder jetting. Additionally, alternative beam processes like electron beam melting (PBF-EB) are gaining traction. In comparison to LPBF, these technologies push the boundaries and limitations of additive manufacturing, offering a new horizon for AM. However, the published results, in some cases, exhibit significant variations, making it challenging for potential users to accurately assess the opportunities and risks associated with these potentially promising methods.

This Special Issue aims to shed light on the technical status of these emerging technologies—next-generation additive manufacturing. We invite researchers to submit articles that provide insightful examinations of these procedures. Potential topics include the consideration of materials that facilitate a comparison of properties with PBF-LB or materials that pose challenges or are impossible with PBF-LB, such as those that are difficult to weld or susceptible to hot cracking. Other, but not exclusive, topics include investigations into surface quality and geometric features differing from PBF-LB. In general, we welcome all cutting-edge research and activities related to the development of these new technologies, as well as supporting technologies related to these processes, such as feedstock development, heat treatment, and oven technologies.

Dr. Chongliang Zhong
Guest Editor

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Keywords

  • additive manufacturing
  • 3D printing
  • powder metallurgy
  • 3D screen printing
  • gel casting
  • MoldJet
  • lithography-based metal manufacturing (LMM)
  • fused filament fabrication (FFF)
  • metal binder jetting
  • electron beam melting
  • cold metal fusion (CMF)
  • liquid metal printing (LMP)

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Published Papers (1 paper)

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Research

18 pages, 5457 KiB  
Article
Lithography-Based Metal Manufacturing of Copper: Influence of Exposure Parameters on Green Part Strength
by Jakob Scheibler, Alina Sabine Kosmehl, Thomas Studnitzky, Chongliang Zhong and Thomas Weißgärber
Metals 2024, 14(11), 1268; https://doi.org/10.3390/met14111268 - 8 Nov 2024
Viewed by 590
Abstract
Copper’s high thermal and electrical conductivity enables its application in heat exchangers and high-frequency components. For those applications, additive manufacturing has advantages with respect to functional integration, miniaturization, and reduced waste. However, the processing of copper is a challenge for established laser-based processes [...] Read more.
Copper’s high thermal and electrical conductivity enables its application in heat exchangers and high-frequency components. For those applications, additive manufacturing has advantages with respect to functional integration, miniaturization, and reduced waste. However, the processing of copper is a challenge for established laser-based processes since copper’s high reflectivity impedes energy input. Sinter-based additive manufacturing processes do not exhibit this limitation since the energy for the fusion of material is applied by thermal energy during sintering. This makes them an ideal candidate for copper manufacturing. In the following work, Lithography-based Metal Manufacturing (LMM) of copper is demonstrated. Curing behavior is investigated by single-layer exposure (SLE) tests measuring curing thickness for different loading factors, particle sizes, and exposure times. Bending strength is investigated as a function of exposure time, loading factor, and orientation in the building space. A higher exposure time and lower loading factors increase bending strength. Furthermore, samples with different loading factors are produced to measure the impact of the loading factor on sintered density. For these parameters, no clear trend is demonstrated. Full article
(This article belongs to the Special Issue The Next Generation of Metal Additive Manufacturing)
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