A Review on Binder Jet Additive Manufacturing of 316L Stainless Steel

Progress in Additive Manufacturing of Magnesium Alloys: A Review

Magnesium alloys, renowned for their lightweight yet high-strength characteristics, with exceptional mechanical properties, are highly coveted for numerous applications. The emergence of magnesium alloy additive manufacturing (Mg AM) has further propelled their popularity, offering advantages such as unparalleled precision, swift production rates, enhanced design freedom, and optimized material utilization. This technology holds immense potential in fabricating intricate geometries, complex internal structures, and performance-tailored microstructures, enabling groundbreaking applications. In this paper, we delve into the core processes and pivotal influencing factors of the current techniques employed in Mg AM, including selective laser melting (SLM), electron beam melting (EBM), wire arc additive manufacturing (WAAM), binder jetting (BJ), friction stir additive manufacturing (FSAM), and indirect additive manufacturing (I-AM). Laser powder bed fusion (LPBF) excels in precision but is limited by a low deposition rate and chamber size; WAAM offers cost-effectiveness, high efficiency, and scalability for large components; BJ enables precise material deposition for customized parts with environmental benefits; FSAM achieves fine grain sizes, low defect rates, and potential for precision products; and I-AM boasts a high build rate and industrial adaptability but is less studied recently. This paper attempts to explore the possibilities and challenges for future research in AM. Among them, two issues are how to mix different AM applications and how to use the integration of Internet technologies, machine learning, and process modeling with AM, which are innovative breakthroughs in AM.

Enhancing Quality Control: Image-Based Quantification of Carbides and Defect Remediation in Binder Jetting Additive Manufacturing

While binder jetting (BJ) additive manufacturing (AM) holds considerable promise for industrial applications, defects often compromise part quality. This study addresses these challenges by investigating binding mechanisms and analyzing common defects, proposing tailored solutions to mitigate them. Emphasizing defect identification for effective quality control in BJ-AM, this research offers strategies for in-process rectification and post-process evaluation to elevate part quality. It shows how to successfully process metallic parts with complex geometries while maintaining consistent material properties. Furthermore, the paper explores the microstructure of AISI M2 tool steel, utilizing advanced image processing techniques like digital image analysis and SEM images to evaluate carbide distribution. The results show that M2 tool steel has a high proportion of M6C carbides, with furnace-cooled samples ranging from ~2.4% to 7.1% and MC carbides from ~0.4% to 9.4%. M6C carbides ranged from ~2.6% to 3.8% in air-cooled samples, while water-cooled samples peaked at ~8.52%. Sintering conditions also affected shrinkage, with furnace-cooled samples showing the lowest rates (1.7 ± 0.4% to 5 ± 0.4%) and water-cooled samples showing the highest (2 ± 0.4% to 14.1 ± 0.4%). The study recommends real-time defect detection systems with autonomous corrective capabilities to improve the quality and performance of BJ-AM components.

Graphene Oxide-Based Nanocomposites for Stereolithography (SLA) 3D Printing: Comprehensive Mechanical Characterization under Combined Loading Modes

Additive manufacturing, particularly Stereolithography (SLA), has gained widespread attention thanks to its ability to produce intricate parts with high precision and customization capacity. Nevertheless, the inherent low mechanical properties of SLA-printed parts limit their use in high-value applications. One approach to enhance these properties involves the incorporation of nanomaterials, with graphene oxide (GO) being a widely studied option. However, the characterization of SLA-printed GO nanocomposites under various stress loadings remains underexplored in the literature, despite being essential for evaluating their mechanical performance in applications. This study aimed to address this gap by synthesizing GO and incorporating it into a commercial SLA resin at different concentrations (0.2, 0.5, and 1 wt.%). Printed specimens were subjected to pure tension, combined stresses, and pure shear stress modes for comprehensive mechanical characterization. Additionally, failure criteria were provided using the Drucker--Prager model.

Additive Manufacturing: A Comprehensive Review

Additive manufacturing has revolutionized manufacturing across a spectrum of industries by enabling the production of complex geometries with unparalleled customization and reduced waste. Beginning as a rapid prototyping tool, additive manufacturing has matured into a comprehensive manufacturing solution, embracing a wide range of materials, such as polymers, metals, ceramics, and composites. This paper delves into the workflow of additive manufacturing, encompassing design, modeling, slicing, printing, and post-processing. Various additive manufacturing technologies are explored, including material extrusion, VAT polymerization, material jetting, binder jetting, selective laser sintering, selective laser melting, direct metal laser sintering, electron beam melting, multi-jet fusion, direct energy deposition, carbon fiber reinforced, laminated object manufacturing, and more, discussing their principles, advantages, disadvantages, material compatibilities, applications, and developing trends. Additionally, the future of additive manufacturing is projected, highlighting potential advancements in 3D bioprinting, 3D food printing, large-scale 3D printing, 4D printing, and AI-based additive manufacturing. This comprehensive survey aims to underscore the transformative impact of additive manufacturing on global manufacturing, emphasizing ongoing challenges and the promising horizon of innovations that could further elevate its role in the manufacturing revolution.

Influence of Different Powder Conditioning Strategies on Metal Binder Jetting with Ti-6Al-4V

Metal binder jetting shows great potential for medical technology. This potential can be exploited by integrating binder jetting into existing process routes known from metal injection molding. The biggest challenge here is the flowability and packing behavior of the powders used, due to their low size distributions. This paper investigates different powder-drying strategies to improve flowability using a statistical experimental design. Because of its relevance for medical applications, spherical Ti-6Al-4V powder with a size distribution under 25 µm is dried under various parameters using vacuum and gas purging. The investigated parameters, time and temperature, are selected in a central-composite-circumscribed test plan with eleven tests and three center points. The target parameters-water content, flowability and impurity levels (oxygen, nitrogen)-of the powder are analyzed. For validation, practical test trials are carried out on an industrial binder jetting system with unconditioned powder and conditioning with optimized parameters, comparing the manufactured parts and the powder bed. An optimized drying cycle with a duration of 6 h at 200 °C was determined for the investigated powder. Significant improvements in the dimensional accuracy (from ±1.5 to 0.3%) of the components and the visual impression of the powder bed are demonstrated.

A Comprehensive Overview of Additive Manufacturing Processes Through a Time-Based Classification Model

The ongoing crisis caused by the COVID-19 pandemic produced major reshuffles on the world map, bringing imbalance, uncertainty, and accumulated stress. Due to supply chain disruptions, the need for innovation has emerged both as a priority and a necessity and three-dimensional printing (3DP) proved to be a primary, smart, effective, and innovative additive manufacturing (AM) method. AM refers to the direct fabrication of complex geometries, using a computer-aided design (CAD) model or a three-dimensional scanner output. This article presents a literature review of AM technologies, chronologically sorted, and proposes a multilevel classification model. The suggested research approach appears a triangular methodology that encompasses the current ISO/ASTM 52900:2021 report. The first objective of this article is to form two double-level classification models of AM processes, depending on the technology and material factors. The second objective is to clarify in which of the proposed categories each AM process is included; and the third one is to investigate if the proposed taxonomy is related to the time spot, in which AM processes were invented. The contribution of this article lies in determining the factors that are crucial for the growth of AM ecosystem. The novelty of the proposed classification lies in the definition of an optimal option for each industrial application based on the different AM processes, the variety of materials, and the evolution of technology over the years. In this way, investing in AM is more systematic and less risky.

Magnesium-Based Temporary Implants: Potential, Current Status, Applications, and Challenges

Biomedical implants are important devices used for the repair or replacement of damaged or diseased tissues or organs. The success of implantation depends on various factors, such as mechanical properties, biocompatibility, and biodegradability of the materials used. Recently, magnesium (Mg)-based materials have emerged as a promising class of temporary implants due to their remarkable properties, such as strength, biocompatibility, biodegradability, and bioactivity. This review article aims to provide a comprehensive overview of current research works summarizing the above-mentioned properties of Mg-based materials for use as temporary implants. The key findings from in-vitro, in-vivo, and clinical trials are also discussed. Further, the potential applications of Mg-based implants and the applicable fabrication methods are also reviewed.

Fatigue Behavior of Additively Manufactured Stainless Steel 316L

316L stainless steel is the material of choice for several critical applications in which a combination of mechanical strength and resistance to corrosion is required, as in the biomedical field. Additive Manufacturing (AM) technologies can pave the way to new design solutions, but microstructure, defect types, and surface characteristics are substantially different in comparison to traditional processing routes, making the assessment of the long-term durability of AM materials and components a crucial aspect. In this paper a thorough review is presented of the relatively large body of recent literature devoted to investigations on fatigue of AM 316L, focusing on the comparison between different AM technologies and conventional processes and on the influence of processing and post-processing aspects in terms of fatigue strength and lifetime. Overall fatigue data are quite scattered, but the dependency of fatigue performances on surface finish, building orientation, and type of heat treatment can be clearly appreciated, as well as the influence of different printing processes. A critical discussion on the different testing approaches presented in the literature is also provided, highlighting the need for shared experimental test protocols and data presentation in order to better understand the complex correlations between fatigue behavior and processing parameters.

Construction and Validation of Simulation Models of Samples Made from 316L Steel by Applying Additive Technique

The main aim of the study includes research concerning the strength of samples printed out of 316L steel in the form of laminates and the creation of reflective simulation models with regard to the results obtained during the research. In addition, the tests addressed the effect of the arrangement of the printed layers on the final strength of the object. Static tensile tests allowed the material constants of 316L steel in the form of dimensionally printed laminate to be determined. Tests were conducted on samples with different printed angles. The tests also covered the impact of the printing envelope on samples with the printing angles. Based on the determined material constants, simulation models for calculations using the finite element method were created. Furthermore, the study includes analytical and simulation calculations of plain laminate in order to verify the accuracy of the Composite Layup module in Abaqus CAE software. The study was summarized by compiling and commenting on the results obtained from the conducted research. Tests showed that there is a possibility of simulating the strength of the printouts from 316L steel using the FEM calculations. It was shown that the FEM model results are similar to those obtained in the tests. The calculated errors were from 3.6 to 14.4%. The linear model describes well the first part of the stress-strain curve, but in further research, it is strongly recommended that a proper and checked nonlinear anisotropic one is presented.

Bonding and Strengthening the PLA Biopolymer in Multi-Material Additive Manufacturing

3D printing is a revolutionary additive manufacturing method that enables rapid prototyping and design flexibility. A variety of thermoplastic polymers can be used in printing. As it is necessary to reduce the consumption of petrochemical resources, alternative solutions are being researched, and the interest in using bioplastics and biocomposites is constantly growing. Often, however, the properties of biopolymers are insufficient and need to be improved to compete with petroleum-based plastics. The paper aims to analyze the available information on elements produced from more than one material, with additive manufacturing resulting from 3D printing using biopolymer Polylactic Acid (PLA). The study notes the possibility of modifying and improving the properties of PLA using layered printing or by modifying PLA filaments. Several modifications improving and changing the properties of PLA were also noted, including printing parameters when combined with other materials: process temperatures, filling, and surface development for various sample geometries.

Fused Deposition Modeling Parameter Optimization for Cost-Effective Metal Part Printing

Metal 3D-printed parts are critical in industries such as biomedical, surgery, and prosthetics to create tailored components for patients, but the costs associated with traditional metal additive manufacturing (AM) techniques are typically prohibitive. To overcome this disadvantage, more cost-effective manufacturing processes are needed, and a good approach is to combine fused deposition modeling (FDM) with debinding-sintering processes. Furthermore, optimizing the printing parameters is required to improve material density and mechanical performance. The design of experiment (DoE) technique was used to evaluate the impact of three printing factors, namely nozzle temperature, layer thickness, and flow rate, on the tensile and bending properties of sintered 316L stainless steel in this study. Green and sintered samples were morphologically and physically characterized after printing, and the optimal printing settings were determined by statistical analysis, which included the surface response technique. The mechanical properties of the specimens increased as the flow rate and layer thickness increased and the nozzle temperature decreased. The optimized printing parameters for the ranges used in this study include 110% flow rate, 140 μm layer thickness, and 240 °C nozzle temperature, which resulted in sintered parts with a tensile strength of 513 MPa and an elongation at break of about 60%.

Additive Manufacturing: An Opportunity for the Fabrication of Near-Net-Shape NiTi Implants

Nickel–titanium (NiTi) is a shape-memory alloy, a type of material whose name is derived from its ability to recover its original shape upon heating to a certain temperature. NiTi falls under the umbrella of metallic materials, offering high superelasticity, acceptable corrosion resistance, a relatively low elastic modulus, and desirable biocompatibility. There are several challenges regarding the processing and machinability of NiTi, originating from its high ductility and reactivity. Additive manufacturing (AM), commonly known as 3D printing, is a promising candidate for solving problems in the fabrication of near-net-shape NiTi biomaterials with controlled porosity. Powder-bed fusion and directed energy deposition are AM approaches employed to produce synthetic NiTi implants. A short summary of the principles and the pros and cons of these approaches is provided. The influence of the operating parameters, which can change the microstructural features, including the porosity content and orientation of the crystals, on the mechanical properties is addressed. Surface-modification techniques are recommended for suppressing the Ni ion leaching from the surface of AM-fabricated NiTi, which is a technical challenge faced by the long-term in vivo application of NiTi.

Benchmarking of 316L Stainless Steel Manufactured by a Hybrid Additive/Subtractive Technology

This research study investigated the hybrid processing of 316L stainless steel using laser powder bed (LPB) processing with high-speed machining in the same build envelope. Benchmarking at four laser powers (160 W, 240 W, 320 W, and 380 W) was undertaken by building additively with machining passes integrated sequentially after every ten deposited layers, followed by the final finishing of select surfaces. The final geometry was inspected against the computer-aided design (CAD) model and showed deviations smaller than 280 µm for the as-built and machined surfaces, which demonstrate the good efficacy of hybrid processing for the net-shape manufacturing of stainless steel products. The arithmetic average roughness values for the printed surfaces, Ra (linear) and Sa (surface), were 11.4 um and 14.9 um, respectively. On the other hand, the vertical and horizontal machined surfaces had considerably lower roughness, with Ra and Sa values ranging between 0.33 µm and 0.70 µm. The 160 W coupon contained layered, interconnected lack of fusion defects which affected the density (7.84 g·cm−3), yield strength (494 MPa), ultimate tensile strength (604 MPa), Young’s modulus (175 GPa), and elongation at break (17.3%). By contrast, at higher laser powers, near-full density was obtained for the 240 W (7.96 g·cm−3), 320 W (7.94 g·cm−3), and 380 W (7.92 g·cm−3) conditions. This, combined with the isolated nature of the small pores, led to the tensile properties surpassing the requirements stipulated in ASTM F3184—16 for 316L stainless steel.

Recent Advances in the Development of Highly Conductive Structured Supports for the Intensification of Non-adiabatic Gas-Solid Catalytic Processes: The Methane Steam Reforming Case Study

Structured catalysts are strong candidates for the intensification of non-adiabatic gas-solid catalytic processes thanks to their superior heat and mass transfer properties combined with low pressure drops. In the past two decades, different types of substrates have been proposed, including honeycomb monoliths, open-cell foams and, more recently, periodic open cellular structures produced by additive manufacturing methods. Among others, thermally conductive metallic cellular substrates have been extensively tested in heat-transfer limited exo- or endo-thermic processes in tubular reactors, demonstrating significant potential for process intensification. The catalytic activation of these geometries is critical: on one hand, these structures can be washcoated with a thin layer of catalytic active phase, but the resulting catalyst inventory is limited. More recently, an alternative approach has been proposed, which relies on packing the cavities of the metallic matrix with catalyst pellets. In this paper, an up-to-date overview of the aforementioned topics will be provided. After a brief introduction concerning the concept of structured catalysts based on highly conductive supports, specific attention will be devoted to the most recent advances in their manufacturing and in their catalytic activation. Finally, the application to the methane steam reforming process will be presented as a relevant case study of process intensification. The results from a comparison of three different reactor layouts (i.e. conventional packed bed, washcoated copper foams and packed copper foams) will highlight the benefits for the overall reformer performance resulting from the adoption of highly conductive structured internals.

Additive Manufacturing of Micro-Electro-Mechanical Systems (MEMS)

Recently, additive manufacturing (AM) processes applied to the micrometer range are subjected to intense development motivated by the influence of the consolidated methods for the macroscale and by the attraction for digital design and freeform fabrication. The integration of AM with the other steps of conventional micro-electro-mechanical systems (MEMS) fabrication processes is still in progress and, furthermore, the development of dedicated design methods for this field is under development. The large variety of AM processes and materials is leading to an abundance of documentation about process attempts, setup details, and case studies. However, the fast and multi-technological development of AM methods for microstructures will require organized analysis of the specific and comparative advantages, constraints, and limitations of the processes. The goal of this paper is to provide an up-to-date overall view on the AM processes at the microscale and also to organize and disambiguate the related performances, capabilities, and resolutions.

Printability and Setting Time of CSA Cement with Na2SiO3 and Gypsum for Binder Jetting 3D Printing

The purpose of this study is to optimize the composition of CSA (calcium sulfoaluminate) cement with sodium silicate (Na₂SiO₃) and gypsum for binder jetting 3D printing. The preliminary test was carried out with an applicator to decide the proper thickness of one layer before using the 3D printer. A liquid binder was then selected to maintain the shape of the particles. Based on the results, the optimal mixture of dry materials and a liquid activator was derived through various parametric studies. For dry materials, the optimum composition of CSA cement, gypsum, and sand was suggested, and the liquid activator made with sodium silicate solution and VMA (viscosity modified agent) were selected. The setting time with gypsum and sodium silicate was controlled within 30 s. In case of the delayed setting time and the rapid setting mixture, the jetting line was printed thicker or thinner and the accuracy of the printout was degraded. In order to adjust the viscosity of the liquid activator, 10% of the VMA was used in 35% of sodium silicate solution and the viscosity of 200-400 cP was suitable to be sprayed from the nozzle. With this optimal mixture, a prototype of atypical decorative wall was printed, and the compressive strength was measured at about 7 MPa.

Geometrical Degrees of Freedom for Cellular Structures Generation: A New Classification Paradigm

Cellular structures (CSs) have been used extensively in recent years, as they offer a unique range of design freedoms. They can be deployed to create parts that can be lightweight by introducing controlled porous features, while still retaining or improving their mechanical, thermal, or even vibrational properties. Recent advancements in additive manufacturing (AM) technologies have helped to increase the feasibility and adoption of cellular structures. The layer-by-layer manufacturing approach offered by AM is ideal for fabricating CSs, with the cost of such parts being largely independent of complexity. There is a growing body of literature concerning CSs made via AM; this presents an opportunity to review the state-of-the-art in this domain and to showcase opportunities in design and manufacturing. This review will propose a novel way of classifying cellular structures by isolating their Geometrical Degrees of Freedom (GDoFs) and will explore the recent innovations in additively manufactured CSs. Based on the present work, the design inputs that are common in CSs generation will be highlighted. Furthermore, the work explores examples of how design inputs have been used to drive the design domain through various case studies. Finally, the review will highlight the manufacturability limitations of CSs in AM.

Additive Manufacturing of Polymer Materials: Progress, Promise and Challenges

The use of additive manufacturing (AM) has moved well beyond prototyping and has been established as a highly versatile manufacturing method with demonstrated potential to completely transform traditional manufacturing in the future. In this paper, a comprehensive review and critical analyses of the recent advances and achievements in the field of different AM processes for polymers, their composites and nanocomposites, elastomers and multi materials, shape memory polymers and thermo-responsive materials are presented. Moreover, their applications in different fields such as bio-medical, electronics, textiles, and aerospace industries are also discussed. We conclude the article with an account of further research needs and future perspectives of AM process with polymeric materials.

A modular testbed for mechanized spreading of powder layers for additive manufacturing

Powder bed additive manufacturing (AM) processes, including binder jetting (BJAM) and powder bed fusion (PBF), can manufacture complex three-dimensional components from a variety of materials. A fundamental understanding of the spreading of thin powder layers is essential to develop robust process parameters for powder bed AM and to assess the influence of powder feedstock characteristics on the subsequent process outcomes. Toward meeting these needs, this work presents the design, fabrication, and qualification of a testbed for modular, mechanized, multi-layer powder spreading. The testbed is designed to replicate the operating conditions of commercial AM equipment, yet features full control over motion parameters including the translation and rotation of a roller spreading tool and precision motion of a feed piston and the build platform. The powder spreading mechanism is interchangeable and therefore can be customized, including the capability for dispensing of fine, cohesive powders using a vibrating hopper. Validation of the resolution and accuracy of the machine and its subsystems, as well as the spreading of exemplary layers from a range of powder sizes typical of BJAM and PBF processes, are described. The precision engineered testbed can therefore enable the optimization of powder spreading parameters for AM and correlation to build process parameters in future work, as well as exploration of spreading of specialized powders for AM and other techniques.

Powder-Based 3D Printing for the Fabrication of Device with Micro and Mesoscale Features

Customized manufacturing of a miniaturized device with micro and mesoscale features is a key requirement of mechanical, electrical, electronic and medical devices. Powder-based 3D-printing processes offer a strong candidate for micromanufacturing due to the wide range of materials, fast production and high accuracy. This study presents a comprehensive review of the powder-based three-dimensional (3D)-printing processes and how these processes impact the creation of devices with micro and mesoscale features. This review also focuses on applications of devices with micro and mesoscale size features that are created by powder-based 3D-printing technology.

Development of AM Technologies for Metals in the Sector of Medical Implants

Additive manufacturing (AM) processes have undergone significant progress in recent years, having been implemented in sectors as diverse as automotive, aerospace, electrical component manufacturing, etc. In the medical sector, different devices are printed, such as implants, surgical guides, scaffolds, tissue engineering, etc. Although nowadays some implants are made of plastics or ceramics, metals have been traditionally employed in their manufacture. However, metallic implants obtained by traditional methods such as machining have the drawbacks that they are manufactured in standard sizes, and that it is difficult to obtain porous structures that favor fixation of the prostheses by means of osseointegration. The present paper presents an overview of the use of AM technologies to manufacture metallic implants. First, the different technologies used for metals are presented, focusing on the main advantages and drawbacks of each one of them. Considered technologies are binder jetting (BJ), selective laser melting (SLM), electron beam melting (EBM), direct energy deposition (DED), and material extrusion by fused filament fabrication (FFF) with metal filled polymers. Then, different metals used in the medical sector are listed, and their properties are summarized, with the focus on Ti and CoCr alloys. They are divided into two groups, namely ferrous and non-ferrous alloys. Finally, the state-of-art about the manufacture of metallic implants with AM technologies is summarized. The present paper will help to explain the latest progress in the application of AM processes to the manufacture of implants.