Recent progress and scientific challenges in multi-material additive manufacturing via laser-based powder bed fusion

Wei, Chao; Li, Lin

doi:10.1080/17452759.2021.1928520

Cited by 157 publications

(42 citation statements)

References 154 publications

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“…Witnessing the advantages of multi-material approaches for part manufacture confirms that there is a need to generate different combinations of materials [38,39]. These multi-material parts or structures need to be carefully designed and evaluated to take full advantage of their use.…”

Section: Conventional Methods Of Fabricating Multi-materials Partsmentioning

confidence: 99%

“…Electric motors and turbine engines with integrated sub-elements of different materials and structures are examples of components that are built with the aid of MMAM to attain unique and superior properties (e.g., microstructure, mechanical, electrical, thermal and magnetic) [52]. Laser-based powder bed fusion is one of the AM processes that can be used or combined with another AM process to build metallic and non-metallic materials (e.g., metal-metal, metal-ceramic, and metal-polymer components) with high geometrical resolution [38].…”

Section: Applications Of Mmammentioning

confidence: 99%

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Review on Additive Manufacturing of Multi-Material Parts: Progress and Challenges

Hasanov

Alkunte

Rajeshirke

et al. 2021

JMMP

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Additive manufacturing has already been established as a highly versatile manufacturing technique with demonstrated potential to completely transform conventional manufacturing in the future. The objective of this paper is to review the latest progress and challenges associated with the fabrication of multi-material parts using additive manufacturing technologies. Various manufacturing processes and materials used to produce functional components were investigated and summarized. The latest applications of multi-material additive manufacturing (MMAM) in the automotive, aerospace, biomedical and dentistry fields were demonstrated. An investigation on the current challenges was also carried out to predict the future direction of MMAM processes. It was concluded that further research and development is needed in the design of multi-material interfaces, manufacturing processes and the material compatibility of MMAM parts.

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Section: Conventional Methods Of Fabricating Multi-materials Partsmentioning

confidence: 99%

Section: Applications Of Mmammentioning

confidence: 99%

Review on Additive Manufacturing of Multi-Material Parts: Progress and Challenges

Hasanov

Alkunte

Rajeshirke

et al. 2021

JMMP

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“…The liquid-based methods mostly include material jetting (MJ) and vat-based printing such as stereolithography (SLA) and digital light processing (DLP). We refer to these excellent review articles to get a comprehensive insight into the above-mentioned AM techniques, LOM [44][45][46], FDM [47][48][49][50][51][52], WAAM [53,54], EBF3 [55], SLS [56,57], EBM [58,59], SLM [39,59,60], LMD [61,62], SLA [63][64][65], DLP [66][67][68], and MJ [69][70][71]. A polymer is a substance or material consisting of very large molecules, or macromolecules, composed of many repeating subunits [73].…”

Section: Introductionmentioning

confidence: 99%

3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA)

et al. 2021

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Additive manufacturing (AM) or 3D printing is a digital manufacturing process and offers virtually limitless opportunities to develop structures/objects by tailoring material composition, processing conditions, and geometry technically at every point in an object. In this review, we present three different early adopted, however, widely used, polymer-based 3D printing processes; fused deposition modelling (FDM), selective laser sintering (SLS), and stereolithography (SLA) to create polymeric parts. The main aim of this review is to offer a comparative overview by correlating polymer material-process-properties for three different 3D printing techniques. Moreover, the advanced material-process requirements towards 4D printing via these print methods taking an example of magneto-active polymers is covered. Overall, this review highlights different aspects of these printing methods and serves as a guide to select a suitable print material and 3D print technique for the targeted polymeric material-based applications and also discusses the implementation practices towards 4D printing of polymer-based systems with a current state-of-the-art approach.

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“…To manufacture the prototype component by PBF-LB/M, prior multi-material approaches that have demonstrated applicability on simpler geometries and demonstrator parts [42][43][44] were utilized. At first, a CAD model of the MM injection nozzle was created in Siemens NX.…”

Section: Method Materials and Component Manufacturingmentioning

confidence: 99%

Capability of Multi-Material Laser-Based Powder Bed Fusion—Development and Analysis of a Prototype Large Bore Engine Component

Schneck

Horn

Schindler

et al. 2021

Metals

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Additive Manufacturing (AM) allows the manufacturing of functionally graded materials (FGM). This includes compositional grading, which enables the allocation of desired materials corresponding to local product requirements. An upcoming AM process for the creation of metal-based FGMs is laser-based powder bed fusion (PBF-LB/M) utilized for multi-material manufacturing (MM). Three-dimensional multi-material approaches for PBF-LB/M are stated to have a manufacturing readiness level (MRL) of 4 to 5. In this paper, an advancement of multi-material technology is presented by realizing an industry-relevant complex part as a prototype made by PBF-LB/M. Hence, a multi-material injection nozzle consisting of tool steel and a copper alloy was manufactured in a continuous PBF-LB/M process. Single material regions showed qualities similar to the ones resulting from mono-material processes. A geometrically defined transition zone between the two materials was achieved that showed slightly higher porosity than mono-material regions. Nevertheless, defects such as porosity, cracks, and material cross-contamination were detected and must be overcome in further MM technology development.

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Recent progress and scientific challenges in multi-material additive manufacturing via laser-based powder bed fusion

Cited by 157 publications

References 154 publications

Review on Additive Manufacturing of Multi-Material Parts: Progress and Challenges

Review on Additive Manufacturing of Multi-Material Parts: Progress and Challenges

3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA)

Capability of Multi-Material Laser-Based Powder Bed Fusion—Development and Analysis of a Prototype Large Bore Engine Component

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