Although distributed additive manufacturing can provide high returns on investment the current markup on commercial filament over base polymers limits deployment. These cost barriers can be surmounted by eliminating the entire process of fusing filament by 3-D printing products directly from polymer granules. Fused granular fabrication (FGF) (or fused particle fabrication (FPF)) is being held back in part by the accessibility of low-cost pelletizers and choppers. An open-source 3-D printable invention disclosed here provides for precise controlled pelletizing of both single thermopolymers as well as composites for 3-D printing. The system is designed, built and tested for its ability to provide high tolerance thermopolymer pellets from a number of sizes capable of being used in a FGF printer. In addition, the chopping pelletizer is tested for its ability to chop multi-materials simultaneously for color mixing and composite fabrication as well as precise fractional measuring back to filament. The US$185 open-source 3-D printable pelletizer chopper system was successfully fabricated and has a 0.5 kg/hr throughput with one motor, and 1.0 kg/hr throughput with two motors using only 0.24 kWh/kg during the chopping process. Pellets were successfully printed directly via FGF and indirectly after being converted into high-tolerance filament in a recyclebot.

This paper discusses a possible approach to validate the Goldbach conjucture which states that all even numbers can be expressed as a summation of two prime numbers. For this purpose the paper begins with the concept of successive-addition-of-digits-of-an-integer-number (SADN) and its properties in terms of basic algebraic functions like addition, multiplication and subtraction. This concept of SADN forms the basis for classifying all odd numbers into 3 series- the S1, S3 and S5 series- which comprise of odd numbers of SADN(7,4,1), SADN(3,9,6) and SADN(5,2,8) respectively and follow a cyclical order. The S1 and S5 series are of interest in the analysis since they include both prime and composite numbers while the S3 series exclusively consists of composite numbers. Furthermore, the multiplicative property of SADN shows why composites on the S1 series are derived as products of intra-series elements of the S1 and S5 series while composites on the S5 series are derived as products of inter-series elements of the S1 and S5 series. The role of SADN is also important in determining the relevant series for identifying the combination of primes for a given even number since it shows why such combinations for even numbers of SADN(1,4,7) will be found on the S5 series while those for even numbers of SADN(2,5,8) will lie on the S1 series and both the series have a role to play in identifying the prime number combinations for even numbers with SADN(3,6,9). Thereafter, the analysis moves to calculating the total number of acceptable combinations for a given even number that would include combinations in the nature of two composites (c1+c2), one prime and one composite (p+c) and two primes (p1+p2). A cyclical pattern followed by even numbers is also discussed in this context. Identifying the c1+c2 and p+c combinations and thereafter subtracting them from the total number of combinations will yield the number of p1+p2 combinations. For this purpose the paper discusses a general method to calculate the number of composites on the S1 and S5 series for a given number and provides a detailed method for deriving the number of c1+c2 combinations. The paper presents this analysis as a proof to validate the Goldbach conjecture. Since even numbers can be of SADN 1 to 9 and the relation between nTc (i.e. total number of acceptable combinations) and nc(i.e. number of composites) for all even numbers can either be of nTc > nc or nTc ≤ nc, the paper shows that the Goldbach conjecture is true for both these categories of even numbers. In this manner this analysis is totally inclusive of all even numbers in general terms and since the analysis of every even number is common in methodology but unique in compilation, apart from being totally inclusive, it is also mutually exclusive in nature. This proves that the Goldbach conjecture which states that all even numbers can be expressed as atleast one combination of two prime numbers holds true for all even numbers, across all categories possible. Additionally this approach proves that the identification of p1+p2 combinations which would validate the Goldbach conjecture lies in the identification of c1+c2 combinations.

The heat values of waste mineral oils are equal to the heat value of the fuel oil. However, heat value alone is not sufficient for the use of waste mineral oils. as fuel. However, the critical physical properties of fuels such as density and viscosity need to be adapted to the system in order to be used. In this study, the engine oils used in the first 10,000 km of the vehicles were used as waste mineral oil. An organic-based Mn additive was synthesized to improve the properties of the waste mineral oil. It was observed that mixing the Mn additive with the waste mineral oil at different doses (4, 8, 12 and 16 ppm) improves the viscosity of the waste oil and the flash point. The resulting fuel was evaluated for emission using different loads in a 5 kW capacity generator to compare the fuel with standard diesel fuel and to determine the effect of Mn addition. In the experimental study, it was observed that the emission characteristics of the fuel obtained from waste mineral oil were worse than diesel fuel, but some improvement with Mn addition. As a result, we found that the use of waste mineral oils in engines in fuel standards was not appropriate, but may be improved with additives.

The synergic features and enhancing strategies for various photopolymerization systems are reviewed by kinetic schemes and the associated measurements. The important topics include: (i) photo crosslinking of corneas for the treatmnet of corneal deseases using UVA-light (365 nm) light and riboflavin as the photosensitizer; (ii) synergic effects by a dual-function enhancer in a 3-initiator system; (iii) synergic effects by a 3-initiator C/B/A system, having an electron-transfer and oxygen-mediated energy-transfer pathways; (iv) copper-complex (G1) photoredox catalyst in G1/Iod/NVK systems for free radiical (FRP) and cationic photopolymeriation (CP); (v) radical-mediated thiol-ene (TE) photopolymerizations; (vi) superbase photogenerator based-catalyzed thiol−acrylate Michael (TM) addition reaction; and the combined system of TE and TM usinghual wavelength; (vii) dual-wavelength (UV and blue) controlled photopolymerization confinement (PC); (viii) dual-wavelength (UV and red) selectively controlled 3D printing; and (ix) 3-wavelength selectively controlled in 3D printing and additive manufacturing (AM). With minimum mathematics, we present ( for the first time), the synergic features and enhancing strategies for various systems of multi-commponents, initiators, monomers, and under one- two- and there-wavelength light. Therefore, this Review provides not only the bridging between modeling and measurements, but also guidances for further experimantal stuides and new applications in 3D printings and additive manufacturing (AM), based on the innovative concepts (kinetics/schemes).

This work opens a new pathway to fabricate high dimensional stability Invar36 aerospace devices with Binder Jetting technology, for applications where temperature fluctuations directly interfere in the correct performance of high sensibility systems. Since full density part fabrication is one of the main ongoing challenges for Binder Jetting, the leading objective of this work is to study and optimise the main process parameters to increase the final density of Invar36 printed parts. Microstructural analysis and obtained density and CTE values, confirmed the feasibility to fabricate Invar36 parts.

Additive manufacturing (AM) is a promising new technology that is having a very fast growth from home workshops to high-tech cutting-edge factories. As any manufacturing technique, adequate metrology services are needed to assure the quality of items manufactured by AM. One of the most widely used instruments to measure the characteristics of surfaces manufactured with AM is the confocal microscope. In this paper, authors present a whole calibration procedure for confocal microscopes designed to be implemented preferably in workshops or industrial environments rather than in research and development departments. Because of that, it is as simple as possible. The procedure is designed without forgetting any of the key aspects that need to be taken into account and based on classical reference material standards. These standards can be easily found in industrial dimensional laboratories and easily calibrated in accredited calibration laboratories.

While L-PBF offers advantages in terms of geometrical freedom or lightweight construction, its use is often limited by economic constraints or currently achievable part costs. With an anticipated increase of L-PBF machine productivity during the next years, an increase of the share of material costs and the share of non-productive time for powder layer application process is to be expected. This results in a demand for less expensive powder materials and advanced processing strategies for the short-and medium-term advancement of L-PBF. As one possible approach, the processing of gas- and water atomized stainless steel (316L) powders with different morphology and particle size distribution as well as their impact on L-PBF productivity is investigated. The actual powder applicability in L-PBF systems and the L-PBF processability determines the minimum necessary powder quality. The main focus of the presented work is put on the interaction between powder quality, powder layer properties, part quality and cost-effectiveness of the L-PBF process. To this end, the influence of the gas and water-atomized powder properties (particle size and morphology) during the powder layer application process at highest possible powder recoater speeds and the resulting powder bed properties (powder layer density, powder bed density, powder demixing) and part properties (part density and tensile strength) is investigated.

The kinetics and modeling of dual-wavelength controlled photopolymerization confinement (PC) are presented and measured data are analyzed by analytic formulas and numerical data. The UV-light initiated inhibition effect is strongly monomer-dependent and different monomers have different C=C bond rate constants and conversion efficacy. Without the UV-light, for a given blue-light intensity, higher initiator concentration (C₁₀) and rate constant (k’) lead to higher conversion, as also predicted by analytic formulas, in which the total conversion rate (R_T) is an increasing function of k’R, which is proportional to k[gB₁C₁]^0.5. However, the coupling factor b₁ plays a different role that higher b₁ leads to higher conversion only in the transient regime; whereas higher b₁ leads lower steady-state conversion. For a fixed initiator concentration C₁₀, higher inhibitor concentration (C₂₀) leads to lower conversion due to stronger inhibition effect. However, same conversion reduction was found for the same H-factor of H₀ = [b₁C₁₀ - b₂C₂₀]. Conversion of blue-only are much higher than that of UV-only and UV-blue combined, in which high C₂₀ results a strong reduction of blue-only-conversion, such that the UV-light serves as the turn-off (trigger) mechanism for the purpose of spatial confirmation within the overlap area of UV and blue light. For example, UV-light controlled methacrylate conversion of a glycidyl dimethacrylate resin formulated with a tertiary amine co-initiator, and butyl nitrite, subject to a continuous exposure of a blue light, but an on-off exposure of a UV-light. Finally, we developed a theoretical new finding for the criterion of a good material/candidate governed by a double ratio of light-intensity and concentration, [I₂₀C₂₀.]/[I₁₀C₁₀].

We present progress in fast, high-resolution imaging, material classification, and fault detection using hyperspectral X-ray measurements. Classical X-ray CT approaches rely on data from many projection angles, resulting in long acquisition and reconstruction times. Additionally, conventional CT cannot distinguish between materials with similar densities. However, in additive manufacturing, the majority of materials used are known a priori. This knowledge allows to vastly reduce the data collected and increase the accuracy of fault detection. In this context, we propose an imaging method for non-destructive testing of materials based on the combination of spectral X-ray CT and discrete tomography. We explore the use of spectral X-ray attenuation models and measurements to recover the characteristic functions of materials in heterogeneous media with piece-wise uniform composition. We show by means of numerical simulation that using spectral measurements from a small number of angles, our approach can alleviate the typical deterioration of spatial resolution and the appearance of streaking artifacts.

We propose a non-invasive approach to control the quality of spheroids and their fusion into a complex bioconstruct. The proposed method is based on the union of the nutrient concentration change calculated using Fick's law and the "reaction-diffusion" equations, taking into account absorption coefficient with specifying the exact fusion geometry using implicit Function Repre-sentation (FRep) functions. The proposed approach allows us to analyze the viability of cells within the spheroid, predict the fusion of spheroids, and accurately model complex heteroge-neous biostructures as a future task for our research. These results will significantly accelerate the development of such a promising field of additive biotechnologies as 3D bioprinting.

Food analysis demands fast methods for routine control and high throughput of samples. Chromatographic separation enables simultaneous determination of numerous compounds in complex matrices, several approaches increasing separation efficiency and speed of analysis were involved. In this work, modern types of column with monolithic rod or superficially porous particles were employed and compared for determination of eight synthetic food dyes, their chromatographic performance was evaluated. During method optimization, cyano stationary phase Chromolith Performance CN 100 × 4.6 mm and Ascentis Express ES-CN 100 × 4.6 mm, 5 µm were selected for the separation of polar colorants. The separation was performed by gradient elution of acetonitrile/methanol and 2% water solution of ammonium acetate at flow rate 2.0 ml min-1. Mobile phase composition and the gradients were optimized in order to enable efficient separation on both columns. The method using fused-core particle column provided higher separation efficiency, narrow peaks of analytes resulted in increased peak capacity and shortening of analysis time. After the validation, the method was applied for analysis of colored beers, soft drinks and candies.

Nine variants of regular lattice structures with different relative densities have been designed and successfully manufactured. The produced structures have been subjected to geometrical quality control, and the manufacturability of the implemented selective laser melting SLM technique has been assessed. It was found that the dimensions of the produced lattice struts differ from those of the designed struts. These deviations depend on the direction of geometrical evaluation. Additionally, the microstructures and phase compositions of the obtained structures were characterized and compared with those of conventionally produced 316L stainless steel. The microstructure analysis and X-Ray Diffraction XRD patterns revealed a single austenite phase in the SLM samples. Both a certain broadening and a displacement of the austenite peaks were observed due to residual stresses and a crystallographic texture induced by the SLM process. Furthermore, the mechanical behavior of the lattice structure material has been defined. It was demonstrated that under both quasi-static and dynamic testing, lattice structures with high relative densities are stretch-dominated, whereas those with low relative densities are bending-dominated. Moreover, the linear relationship between the energy absorption and relative density under dynamic loading conditions has been defined

Powder Bed Fusion (PBF) is a type of Additive Manufacturing (AM) technology that builds parts in a layer-by-layer fashion out of a bed of metal powder via the selective melting action of a laser or electron beam heat source. The technology has become widespread, however the demand is growing for closed loop process monitoring and control in PBF systems to replace the open loop architectures that exist today. This paper demonstrates the simulated efficacy of applying closed-loop state estimation to the problem of monitoring temperature fields within parts during the PBF build process. A simplified LTI model of PBF thermal physics with the properties of stability, controllability and observability is presented. An Ensemble Kalman Filter is applied to the model. The accuracy of this filters’ predictions are assessed in simulation studies of the temperature evolution of various test parts when subjected to simulated laser heat input. The significant result of this study is that the filter supplied predictions that were about 2.5x more accurate than the open loop model in these simulation studies.

A pilot study on laser 3D printing of inorganic free-form micro-optics is experimentally validated. Ultrafast laser nanolithography is employed for structuring hybrid organic-inorganic material SZ2080TM followed by high-temperature calcination post-processing. The combination allows production of 3D architectures and the heat-treatment results in converting the material to inorganic substance. The produced miniature optical elements are characterized and their optical performance demonstrated. Finally, the concept is validated for manufacturing compound optical components such as stacked lenses. This is opening for new directions and applications of laser made microoptics under harsh conditions such as high intensity radiation, temperature, acidic environment, pressure variations, which include open space, astrophotonics, and remote sensing.

In the production of green parts from powder, there is unavoidable slight deviation in the die filling, even when high-quality powders are used. The quantity of powder in the die varies and thus affects the weight of the compact. This filling variation results in variation of the pressing force, and thus influences the part geometry. The development of the DORST Netshape® System was conceived as an autonomous manufacturing system in order to compensate for these effects. Based on the Dorst Industry 4.0 innovations for part weight measuring immediately after pressing in combination with a laser dimension measuring system, this technology package attempts to reach enhanced precision and consistency in production. The paper presents results from various trials that show the capability of this new system, designed to improve the quality of pressed parts.

The paper describes problems with the current additive manufacturing chain before considering additive manufacturing as part of a modern manufacturing chain. Additive manufacturing can be used for near net-shape for finishing, for repair or for adding special features which cannot be made with traditional manufacturing. This paper describes how STEP-NC deals with these different scenarios in terms of accuracy, multi-material and variation of slice direction. The possibilities of multi-material objects also raises questions about the design of such objects and how these need to be handled by an advanced controller. The paper also describes non-planar slicing. Curved direction and cylindrical direction are shown to improve the accuracy of curved structure additive manufacturing. STEP-NC using boundary representation has better capability of depicting complex internal structures for additive processes. By using exact model of the final product represented by STEP-NC, the paper demonstrates improvements in data size reduction, slicing accuracy, and precise manipulation of internal structure.

It is a common practice to detect outliers in a financial time series in order to avoid the adverse effect of additive outliers. This paper investigated the performance of GARCH family models (sGARCH; gjrGARCH; iGARCH; TGARCH and NGARCH) in the presence of different sizes of outliers (small, medium and large) for different time series lengths (250, 500, 750, 1000, 1250 and 1500) using root mean square error (RMSE) and mean absolute error (MAE) to adjudge the models. In a simulation iteration of 1000 times in R environment using rugarch package, results revealed that for small size of outliers, irrespective of the length of time series, iGARCH dominated, for medium size of outliers, it was sGARCH and gjrGARCH that dominated irrespective of time series length, while for large size of outliers, irrespective of time series length, gjrGARCH dominated. The study further leveled that in the presence of additive outliers on time series analysis, both RMSE and MAE increased as the time series length increased.

In this study, a novel task of printing speed optimization for continuous fiber composites is investigated. Using continuous fibers is an innovative approach to reinforce products made by fused filament fabrication (FFF) additive manufacturing (AM) technology. In the printing process of composites with continuous fibers, the printing speed is critical because of its significant effect on the geometric shape of the samples, especially their corners. During optimization in this research, continuous glass fiber (CGF) and polylactic acid (PLA) filaments were utilized as reinforcing phase and matrix, respectively, and were simultaneously fed into the extrusion-based polymer 3D printer to form PLA/CGF composites. The optimization was carried out by calculating the temperature changes of the deposited rasters in the presence and absence of fibers as a first step and then determining the special relationship between the printing speeds and rasters temperature changes. Finally, the optimal and the maximum printing speed was computed based on a hypothesis, which is proved by the results of high-quality printed composites with different geometric shapes.

Three kinds of Ni based alloy cladding coatings were prepared on 316L stainless steel at different power. The microstructure of the cladding layer was observed and analyzed by XRD, metallographic microscope and SEM. The hardness of the cladding layer was measured, and the wear resistance of the cladding layer was tested by friction instrument. The results show that the effect of laser cladding is good and the cladding layer has a good metallurgical bonding with the substrate. Different microstructures such as dendritic and equiaxed grains can be observed in the cladding layer. With the increase of laser power, more equiaxed and columnar dendrites can be observed. The phase composition of the cladding layer is mainly composed of γ - Ni solid solution and some intermetallic compounds such as Ni3B, Cr5B3 and Ni17Si3. The results of EDS show that there are some differences in the distribution of C and Si between dendrites. The hardness of the cladding layer is about 600 HV0.2, which is about three times of the substrate (~ 200 HV0.2). Through the analysis of the wear morphology, the substrate wear is serious, there are serious shedding, mainly adhesive wear and abrasive wear. However, the wear of cladding layer is slight, which is abrasive wear, and there are some grooves on the surface.

This paper aims to analyse the mechanical properties response of polylactic acid (PLA) parts manufactured through fused filament fabrication. The influence of six manufacturing factors (layer height, filament width, fill density, layer orientation, printing velocity, and infill pattern) on the flexural resistance of PLA specimens is studied through an L27 Taguchi experimental array. Different geometries have been tested on a four-point bending machine and on a rotating bending machine. From the first experimental phase, an optimal set of parameters deriving in the highest flexural resistance have been determined. Results show that layer orientation is the most influential parameter, followed by layer height, filament width, and printing velocity, whereas the fill density and infill pattern show no significant influence. Finally, the fatigue fracture behaviour is evaluated and compared with previous studies results, to present a comprehensive study of the mechanical properties of the material under different kind of solicitations.

In this paper, the fatigue response of Fused Filament Fabrication (FFF) Acrylonitrile butadiene styrene (ABS) parts is studied. Different building parameters (layer height, nozzle diameter, infill density, and printing speed) were chosen to study their influence on the lifespan of cylindrical specimens according to a design of experiments (DOE) using the Taguchi methodology. The same DOE was applied on two different specimen sets using two different infill patterns: rectilinear and honeycomb. The results show that infill density is the most important parameter for both studied patterns. The specimens manufactured with the honeycomb pattern show longer lifespans. The best parameter set associated to that infill was chosen for a second experimental phase, in which the specimens were tested under different maximum bending stresses to construct the Wöhler curve associated to this 3D printing configuration. The results of this study are useful to design and manufacture ABS end-use parts that are expected to work under oscillating periodic loads.

In this work, a xylan-based antimicrobial additive agent was prepared and aimed for uses in paper products against Escherichia coli bacteria. The derived Cationic-Xylan-grafted-PHGH (CX-g-PHGH) was successfully synthesized by graft copolymerization of cationic-xylan with guanidine polymer (PHGH) using ceric ammonium nitrate as initiator. The obtained CX-g-PHGH had maximum PHGH grafting ratio of 18.45% and efficiency of 58.45%, and showed good viscosity and thermal stability. Furthermore, the paper samples prepared in this work were reinforced obviously with the addition of CX-g-PHGH by improved mechanical properties. Compared to the reference paper without any of the xylan-derivatives, the index of tensile, tear, burst and folding endurance of the paper had increases up to 20.07%, 25.31%, 30.20% and 77.78%, respectively. Moreover, the prepared CX-g-PHGH paper exhibited an efficient antimicrobial activity against E. coli bacterial, by which a lot of applications based on the new xylan-derived additive agent obtained in this work could be found, especially in field of antimicrobial paper products against E. Coli bacteria from contaminated food.

Additive manufacturing (AM) is today’s buzzword—and not only in commercial production. One of the AM techniques produces 3D objects with complex geometry using a laser beam. The relationship between the morphology of individual powder particles and the printing process has not been adequately documented yet. This article presents a detailed microscopic analysis of virgin and reused powder particles of maraging steel. Metallographic observation was performed using a scanning electron microscope (SEM). Detailed analyses of individual particles were carried out using SEM with a focused ion beam (FIB) milling capability. Analyses of elemental distribution and phase distribution were performed using EDS and EBSD, respectively. The findings have led to a better understanding and prediction of defects in additive-manufactured products.

The current paper aims to study the impact properties of additively manufactured Maraging steel (1.2709) using laser powder bed fusion (PBF-L) processing. The specimens were manufactured using 3Dsystems ProX 300 equipment under constant specific power input, or Andrew Number. The interactions between the build strategy and parameters, such as Hatch spacing and Scan speed was, and the impact strength and fracture were investigated. The Impact energy anisotropy was also investigated parallel and perpendicular to the build direction. Instrumented impact testing was performed, and the fractography supported that the fusion zone geometry dictated the fracture behaviour. The influence from gaseous elements such as Nitrogen, Oxygen and Hydrogen was found insignificant at the levels found in the printed material.

Powder bed fusion (PBF) process is a metal additive manufacturing process which can build parts with any complexity from a wide range of metallic materials. PBF process research has predominantly focused on the impact of only a few parameters on product properties due to the lack of a systematic approach for optimizing a large set of process parameters simultaneously. The pivotal challenges regarding this process require a quantitative approach for mapping the material properties and process parameters onto the ultimate quality; this will then enable the optimization of those parameters. In this study, we propose a two-phase framework for optimizing the process parameters and developing a predictive model for 316L stainless steel material. We also discuss the correlation between process parameters -- i.e., laser specifications -- and mechanical properties and how to achieve parts with high density (> 98%) as well as better ultimate mechanical properties. In this paper, we introduce and test an innovative approach for developing AM predictive models, with a relatively low error percentage of 10.236% that are used to optimize process parameters in accordance with user or manufacturer requirements. These models use support vector regression, random forest regression, and neural network techniques. It is shown that the intelligent selection of process parameters using these models can achieve an optimized density of up to 99.31% with uniform microstructure, which improves hardness, impact strength, and other mechanical properties.

Advanced ceramics are recognized as key enabling materials possessing combinations of properties not achievable in other material classes. They are characterized by very high thermal, chemical and mechanical resistance and also usually have a lower density than metals. These properties predestine ceramics for many different applications, especially space applications.In the aerospace sector aerospike nozzles promise performance and application advantages compared to classic bell nozzles but are also inherently more complex to manufacture due to their shape. AM methods drastically simplify or even enable the fabrication of those complex structures while minimising the number of individual parts. The applicability of ceramic AM (“CerAMfacturing”) on rocket engines and especially nozzles is consequently investigated in the frame of the “MACARONIS” project, a cooperation of the Institute of Aerospace Engineering at Technische Universität Dresden and the Fraunhofer Institute for Ceramic Technologies and Systems (IKTS) in Dresden. The goal is to develop novel large size aerospike thrust nozzles including areas of highest resolution and fineness. Finding a suitable AM process that enables the realisation of both aspects is extremely challenging. One possibility could be the hybridization of shaping methods, in that case CerAM VPP (ceramic additive manufacturing via vat photopolymerization) and CerAM FFF (ceramic additive manufacturing via fused filament fabrication) in combination with sinter joining. This contribution focuses on the high resolution CerAM VPP process, in particular the development, characterization and testing of a new photoreactive Al₂O₃ suspension validated by AM of novel aerospike nozzles.

Welding processes offer a unique capability with a wide range of applications in industries. In recent times, welding has established itself as a tool for large scale additive manufacturing. In general, the quality and repeatability assurance for welding and specifically for additive manufacturing necessitates integrating process monitoring techniques with existing welding and additive manufacturing processes. The process-specific signals such as welding current fluctuations, temperature, and acoustic, generated during the welding operations, make them a suitable candidate for digitization. This chapter comprehensively describes the process monitoring techniques relevant to welding and additive manufacturing. Firstly, various sensors used during welding are described for their construction and working. Subsequently, specific applications of the sensors in digitizing the welding processes are presented.

The paper contains the results of the 100-hour test campaign of the Additive Manufactured (AM) spare part (retainer – slipper) dedicated for an exact axial piston pump. The material of the retainer-slipper has been identified by using energy dispersive spectroscopy and replaced by other – with similar material properties as the original one. The obtained spare part had been subjected to only one postprocessing type (sandblasting) to analyze the influence of the rough part after the AM process. The whole test campaign has been divided into stages, where after each stage microscopic measurements have been made. During microscopical investigation roughness and geometrical measurements were conducted. The results revealed that it is possible to replace parts in hydraulic pumps with the use of AM. 100-hour test campaign caused about 500% increase in the surface roughness of the pump’s original part which was cooperated with the AM spare retainer-slipper, without any damages to the test system.

We prove general stability theorems for $n$-dimensional quartic-cubic-quadratic-additive type functional equations of the form \begin{eqnarray*} \sum_{i=1}^\ell c_i f \big( a_{i1}x_1 + a_{i2}x_2 + \cdots + a_{in}x_n \big) = 0 \end{eqnarray*} by applying the direct method. These stability theorems can save us much trouble of proving the stability of relevant solutions repeatedly appearing in the stability problems for various functional equations.

Metal powder bed fusion (PBF) additive manufacturing (AM) builds metal parts layer by layer upon a substrate material. The strength of this interface between substrate and printed material is important to characterize, especially in applications where the substrate is retained and included in the finished part. This paper studied the tensile and torsional strengths of wrought and additively manufactured (through PBF) SS316L and compared them to specimens composed of half wrought material and half PBF material. The PBF specimens consistently exhibited higher strength and lower ductility than the wrought specimens. The hybrid PBF/wrought specimens performed similarly to the wrought material. In no specimens did any failure appear to occur at or near the interface between wrought substrate and PBF material. In addition, most of the deformation in the PBF/wrought specimens appeared to be limited to the wrought portion of the specimens. These results are consistent with microscopy showing smaller grain size in the PBF material, which often leads to increased strength in SS316L due to the Hall-Petch relationship.

Selective Laser Melting (SLM) is an additive manufacturing technique. It allows to produce elements with very complex geometry using metallic powders. A geometry of manufacturing elements bases only on 3D CAD data. The metal powder is melt selectively layer by layer using ytterbium laser. The paper contains results of porosity and microhardness analysis made on specimens which were manufactured during specially prepared process. Final analysis helped to discover connections between changing hatching distance, exposure speed and porosity. There was no significant differences in microhardness and porosity measurement results in the planes: perpendicular and parallel to the machine building platform surface.

The paper is focused on the examination of the internal quality of joints created in a multi-material - additive manufacturing process. The main part of the work focuses on experimental production and non-destructive testing of restrained joints of modified PLA (polylactic acid) and ABS (Acrylonitrile butadiene styrene) 3Dprinted on RepRap 3D device that works on the "open source" principle. The article presents the outcomes of non-destructive materials test in the form of the data from the Laser Amplified Ultrasonography, microscopic observations of the joints area and tensile tests of the specially designed samples. The samples with designed joints were additively manufactured of two materials: specially blended PLA (Market name – PLA Tough) and conventionally made ABS. The tests are mainly focused on the determination of the quality of material connection in the joints area. Based on the results obtained, the samples made of two materials were compared in the end to establish which produced material joint is stronger and have a lower amount of defects.

If a lubricant contains structures capable of conducting energy, reactions involving zinc dialkyldithiophosphate (ZDDP) may take place both very close to and away from the solid surfaces, with this indicating that ZDDP can be a highly effective anti-wear (AW) additive. The central thesis of this article is that the tribocatalytic effect is observed only when the energy emitted by the solids is transmitted by ordered molecular structures present in the lubricant, e.g., graphene. The friction tests were carried out for 100Cr6 steel balls in a sliding contact with uncoated or a:C-H-coated HS6-5-2C steel discs in the presence of polyalphaolefin 8 (PAO 8) as the lubricant, which was enhanced with graphene and/or ZDDP. There is sufficient evidence of the interactions occurring between ZDDP and graphene and their effects on the tribological performance of the system. It was also found that the higher the concentration of zinc in the wear area, the lower the wear. This was probably due to the energy transfer resulting from the catalytic decomposition of ZDDP molecules. Graphene, playing the role of the catalyst, contributed to that energy transfer.

Cladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these residual stresses could be effectively utilized by modifying processes and geometrical parameters. This paper introduces a novel methodology for using the weld-cladding process as a cost-effective alternative to various existing reinforcement techniques. The numerical analyses are performed to maximize the reinforcement of a cylindrical tool. The investigation of how the weld cladding develops compressive stresses on the specimen in response to a change in the weld beads and the welding sequence is presented. For the benchmark shape, experimental verification of the numerical model is performed. The impact of the distance between the weld beads and the effect of the tool diameter is numerically investigated. Furthermore, the variation in compressive stresses due to temperature fluctuations during the extrusion process has been evaluated. The results showed that adequate compressive stresses are generated on the welded parts through the cladding process after cooling. Hence, the targeted reinforcement of the substrate can be achieved by optimizing the welding sequence and process parameters.

The use of commodity polymers such as polypropylene (PP) is key to open new market segments and applications for the additive manufacturing industry. Technologies such as powder-bed fusion (PBF) can process PP powder; however, much is still to learn concerning process parameters for reliable manufacturing. This study focusses in the process-property relationships of PP using laser-based PBF. The research presents an overview of the intrinsic and the extrinsic characteristic of a commercial PP powder as well as fabrication of tensile specimens with varying process parameters to characterize tensile, elongation at break, and porosity properties. The impact of key process parameters, such as power and scanning speed are systematically modified in a controlled design of experiment. The results were compared to the existing body of knowledge; the outcome is to present a process window and optimal process parameters for industrial use of PP. The computer tomography data revealed a highly porous structure inside specimens ranging between 8.46% and 10.08%, with porosity concentrated in the interlayer planes in the build direction. The results of the design of experiment for this commercial material show a narrow window of 0.122 ≥ Ev ≥ 0.138 J/mm³ led to increased mechanical properties while maintaining geometrical stability.

This paper presents a physical and mathematical model that has been developed in the framework of the approach used in the computational mechanics of materials. The model is designed to enable the study of the patterns of deformation and fracture of ceramic composites with a transformation-hardened matrix that are obtained by additive technologies at the mesoscopic and macroscopic levels under intense dynamic loading. The influence of the loading rate on the formation of the fracture and energy dissipation fronts for composite materials, based on the Al2O3 20%ZrO2 system, is shown. Nonlinear effects under intense dynamic loading in the considered composites are associated with the processes of self-organization of structural fragments at the mesoscopic level, as well as the occurrence of martensitic phase transformations in matrix volumes adjacent to the strengthening particles.

The Wolfram (W), Silicium (Si) and Molybdenum (Mo) doped Co-Cr biomedical alloy were fabricated by additive manufacturing method, which is part of powder metadology. The mixture of Wolfram (W), Silicium (Si), Chrome (Cr) and Cobalt (Co) alloy is known good wear and corrosion resistance among of biomedical applications. By addition of Molybdenum (Mo) into the structure of alloy, the structure become more stbale also increase the corrosion and wear resistance. In addition, the effects of secondary annealing process on the alloy were investigated. The microstructure of the produced alloy was analyzed by X-ray diffraction method XRD, Energy Dispersive X-Ray Analysis EDX and scanning electron microscope SEM. Moreover, Electrochemical corrosion test, micro hardness and density measurements were performed to investigate the mechanical properties of the alloy. As a result of the analyzes, the effects of Molydenum (Mo) doped and secondary annealing on the microstructure and mechanical properties of bioalloying were determined.

Design for Manufacture and Assembly (DfMA) in architectural, engineering, and construction (AEC) industry is attracting the attention of designers, practitioners, and construction project stakeholders. Digital fabrication (Dfab) and design for additive manufacturing (DfAM) practices are found in current needs for further research and development. The DfMA's conceptual function is to maximize the process efficiency of Dfab and AM building projects. This work reviewed 171 relevant research articles over the past few decades. The concept of DfMA and the fundamentals of DfMA in building and construction were explored. In addition, DfMA procedures associated with Dfab and DfAM, as well as its AM assembly process, were discussed. Lastly, the current machine learning research on DfMA in construction was also highlighted. Large research gaps in the DfMA for Dfab and DfAM can be filled to increase operational efficiency and sustainable practices.

The power conversion efficiency (PCE) of polymer solar cells (PSCs) are strongly depended on the bulk-heterojunction active layer. Here, the 1,8-diiodooctane (DIO) additives have been added into the PCDTBT: PC70BM blend PSCs. Based on the higher boiling point than host solvent ODB and better solubility of PC71BM, the device photovoltaic properties with DIO additive were changed obviously. The investigations of EQE indicate that the DIO can influence the charge recombination and transportation process, and absorption studies demonstrate that the charge carriers generation process can also be affected by DIO. The overall impact reflected on the decreased equivalent resistant. With 3% v/v DIO, the Jsc, Voc and FF are both increased. Correspondingly, a highest PCE is achieved of 6.15%, while the reference device without DIO only has a PCE of 5.23%. Hence, adding DIO solvent additive is a effective method for the photovoltaic properties improving of PCDTBT: PC70BM blend PSCs.

The effects of build orientation and heat treatment on the crack growth behavior of 316L stainless steel (SS) fabricated via a selective laser melting (SLM) additive manufacturing process were investigated. Significant growth of available research results of additively manufactured metallic parts still needs to be improved. The most important issue connected with properties after additive manufacturing is properties high anisotropy, especially from the fatigue point of view. The research included crack growth behavior of additively manufactured 316L in comparison to conventionally made reference material. Both groups of samples were obtained using precipitation heat treatment. Different build orientation in additively manufactured samples and rolling direction in reference samples were taken into account as well. Precipitation heat treatment of additively manufactured parts allowed to reach similar microstructure and tensile properties to elements conventionally made. The heat treatment positively affected fatigue properties. Additionally, precipitation heat treatment of additively manufactured elements significantly affected the reduction of fatigue cracking velocity and changed the fatigue cracking mechanism.

The development of high complexity geometry parts is one of the main goals of the additive manufacturing technology. However, the failure of printed structures and the joining of different parts to create complex assemblies represents a real challenge in the research of efficient and sustainability techniques for the permanent assembly of polymers. Laser welding processes have been used as a single step method to join metals until years ago. Nowadays, the growing trend in the use of thermoplastics for additive manufacturing has led to the need to adapt this technique to materials with a very specific nature and more sensitive to thermal effects. Also, the possibility of transmitting the laser beam through transparent polymer layers allows to focus the energy supply on internal sections of the assembled components. In this research, an infrared laser marking system was used to join two different samples of polylactic acid manufactured by fused deposited modeling technology. In order to increase the effectiveness of the bonding process, a transparent and a dark sample have been used as assembly material, focusing the laser beam on the interface area of the two parts. By means of tensile tests, dimensional measurement and the use of optical microscopy techniques, a basis was established that links the supplied energy by laser to the joining performance.

Rapid solidification during metal additive manufacturing (AM) leads to non-equilibrium microsegregation, which can result in the formation of detrimental phases and cracking. Most of the microsegregation models, assume a Scheil-type solidification, where the solidification interface is planar and there exists local equilibrium at the interface along with either zero or infinite solute diffusion in the respective participating phases - solid and liquid. This assumption leads to errors in prediction. One has to account for finite solute diffusion and the curvature at the dendritic tip for more accurate predictions. In this work, we compare different microsegregation models that do and do not consider finite diffusion and dendrite tip kinetics against the experiments. We also propose a method to couple dendrite tip kinetics with the diffusion module (DICTRA®) implemented in Thermo-Calc®. The models which accounted for both finite diffusion and dendrite tip kinetics matched well with the experimental data.

Laser metal deposition with wire (LMD-w) is a developing additive manufacturing (AM) technology that has a high deposition material rate and efficiency, and is suitable for fabrication of large aerospace components. However, control of material properties, geometry, and residual stresses is needed before LMD-w technology can be widely adopted for the construction of critical structural components. In this study, we investigated the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses in large-scale laser additive manufactured Ti-6Al-4V components using finite element method (FEM). The simulations were validated with the temperature and the distortion measurements obtained from a real LMD-w process. We found that a shorter interlayer cooling time, full clamping constraints on the build plates, and a bidirectional tool path with 180⁰ rotation minimized part distortion and residual stresses and resulted in symmetric stress distribution.

Powder and SLM additively manufactured parts of X5CrNiCuNb17-4 maraging steel were systematically investigated by electron microscopy to understand the relationship between the properties of the powder grains and the microstructure of the printed parts. We prove that satellites, irregularities and superficial oxidation of powder particles can be transformed into an advantage through the formation of nanoscale (AlMnSiTiCr)-oxides in the matrix during the printing process. The nano-oxides showed extensive stability in terms of size, spherical morphology, chemical composition and crystallographic disorder upon in situ heating up to 950°C in the scanning transmission electron microscope. Their presence thus indicates a potential for oxide-dispersive strengthening of this steel, which may be beneficial for creep resistance at elevated temperatures. The nucleation of copper clusters and their evolution into nanoparticles as well as the precipitation of Ni and Cr particles upon in situ heating have as well been systematically documented.

The space shuttle, a revolutionary spacecraft that has played a significant role in human space exploration, was composed of various advanced materials that were carefully selected to meet the extreme demands of spaceflight. This review paper provides a comprehensive examination of the materials historically employed in the construction of space shuttles and explores the latest trends shaping the field. The evolution of space shuttle materials is traced from the inception of the space program to contemporary missions, highlighting key milestones, challenges, and breakthroughs. Emphasis is placed on the critical role that materials play in the overall performance, safety, and sustainability of space shuttles. The paper begins by elucidating the diverse requirements that materials must fulfill in the harsh and complex environment of space, encompassing extreme temperatures, radiation exposure, and mechanical stresses. A detailed analysis of the materials utilized in the fabrication of various shuttle components, such as thermal protection systems, structural elements, and propulsion systems, is presented. Special attention is given to the challenges posed by re-entry and the strategies employed to mitigate heat-related issues. Furthermore, the review explores recent innovations and emerging materials that are reshaping the landscape of space shuttle design. Advancements in nanotechnology, composite materials, and additive manufacturing are discussed in the context of their potential applications for enhancing shuttle performance and reducing mission costs. The paper also addresses the importance of sustainability in space exploration, exploring materials with lower environmental impact and improved recyclability. The review concludes with a forward-looking perspective on the future of materials, considering ongoing research, development, and the potential incorporation of cutting-edge technologies. Insights are provided into how the evolving landscape of materials science may influence the design and manufacturing processes of the next generation of space vehicles. This paper provides an overview of the materials used in the construction of the space shuttle, including their properties, applications, and challenges. The materials used in the space shuttle are critical in ensuring the safety, performance, and longevity of the spacecraft, and understanding their characteristics and performance in space is crucial for the advancement of aerospace engineering.

The Coronavirus disease 2019 (COVID-19) rapidly spread to over 180 countries and abruptly disrupted the production rates and supply chains worldwide. Since then, 3D printing also recognized as additive manufacturing (AM) and known to be a novel technique that uses layer-by-layer deposition of material to produce the intricate 3D geometry, has been engaged in reducing the distress caused by the outbreak. During the early stages of this pandemic, shortages of Personal Protection Equipment (PPE), including facemasks, shields, respirators, and other medical gears, were significantly answered by remotely 3D printing them. Amidst the growing testing requirements, the 3D printing emerged as a potential and fast solution manufacturing process to meet the production needs due to its flexibility, reliability, and rapid response capabilities. In the recent past, some of the other medical applications that have gained prominence in the scientific community include 3D printed ventilator splitters, device components, and patient-specific products. Regarding the non-medical applications, researchers have successfully developed contact-free devices to address the sanitary crisis in public places. This work aims to systematically review the applications of 3D printing or AM techniques that have been involved in producing various critical products essential to limit this deadly pandemic's progression.

Background: Residents of a large area of North-Eastern Italy were exposed for decades to high concentrations of perfluoroalkyl and polyfluoroalkyl substances (PFAS) via drinking water. Despite the large amount of evidence in adults of a positive association between serum PFAS and metabolic outcomes, studies focusing on children and adolescents are limited. We evaluated the associations between serum PFAS concentrations and lipid profile, blood pressure and body mass index (BMI) in highly exposed adolescents and children. Methods: A cross-sectional analysis was conducted in 6669 adolescents (14-19 years) and 2693 children (8-11 years) enrolled in the health surveillance program of the Veneto Region. Non-fasting blood samples were obtained and analyzed for perfluorooctanoic acid (PFOA) perfluorooctane sulfonate (PFOS), perfluorohexanesulfonic acid (PFHxS), perfluorononanoic acid (PFNA), total cholesterol (TC) high-density lipoprotein cholesterol (HDL-C) and triglycerides. Low-density lipoprotein cholesterol (LDL-C) was calculated. Systolic and diastolic blood pressure (BP) were measured and BMI z-score accounting for age and sex was estimated. The associations between ln-transformed PFAS (and categorized into quartiles) and continuous outcomes were assessed using generalized additive models. Analyses were stratified by gender and adjusted for potential confounders. Results: Among adolescents, significant associations were detected between all investigated PFAS and TC, LDL-C, and to a fewer extent HDL-C. Among children, PFOS and PFNA had significant associations with TC, LDL-C and HDL-C, while PFOA and PFHxS had significant associations with HDL-C only. Increased serum concentrations of PFAS, particularly PFOS, were associated with decreased BMI z-score. No statistically significant associations were observed between PFAS concentrations and BP. Conclusions: Our study supports a consistent association between PFAS concentration and serum lipids, stronger for PFOS and PFNA and with a greater magnitude among children compared to adolescents, and a negative association of PFAS with BMI.

In this article, metallic additive manufacturing (AM) processes were classified and demonstrated. AM technology can be applied to a wide range of industrial areas because of its great feasibility in the design and manufacturing of various complex parts. The main factor that distinguishes various metallic AM processes from each other is the deposition method. Deposited metal can be imported in the form of melt or semi-solid. AM technology also covers a wide range of materials like aluminum, titanium, and many other alloys. Some of the common applications of metallic AM processes are the quick manufacturing of the parts which utilized in various industries like medical, automotive, aerospace, and jewelry industries. AM can help to fabricate parts that are impossible to be manufactured by other processes.

A Chinese superalloy GH4099 (~20 vol.% γ' phase), which can operate for long periods of time at temperatures of 1173-1273 K, was fabricated by electron beam melting (EBM). Argon gas atomized (AA) and plasma rotation electrode process (PREP) powders with the similar composition and size distribution were used as raw materials for comparison. Microstructure and mechanical properties of both the as-EBMed and post-treated alloy samples were investigated. The results show that the different powder characteristics resulted in the different build temperatures for AA and PREP samples, which were 1253 K and 1373 K, respectively. With increasing the building temperature, the EBM processing window shifted towards the higher scanning speed direction. Furthermore, intergranular cracking was observed for the as-fabricated PREP sample as a result of local enrichment of Si at grain boundaries. The cracks were completely eliminated by hot isostatic pressing (HIPing) and did not re-open during subsequent solution treatment and aging (STA). Fine spherical γ' phase precipitated uniformly after STA. The tensile strength of the HIP+STA samples was ~920 MPa in the building direction and ~850 MPa in the horizontal direction, comparable with that of the wrought alloy.

How to effectively suppress thermal cracks in the metal laser additive manufacturing process is still one of the key issues to be solved in the field of laser additive manufacturing. Metal tin, with wide liquid phase working temperature range, high boiling point, low viscosity, high thermal conductivity and excellent electrical conductivity. The use of tin as an auxiliary thermal management material in the metal additive manufacturing process is expected to achieve effective regulation of the temperature field and stress field of the formed part, thereby inhibiting the initiation of cracks and obtaining formed parts with the target grain structure and high reliability. This paper presented a novel liquid metal-assisted laser additive manufacturing method (LMAAM). A numerical model for the laser additive manufacturing of tin-assisted titanium alloys was established. The differences of the flow field, temperature field and stress field of the formed parts with tin and without tin were compared and analyzed. The influence of the interaction position between the tin liquid level and the forming part on the temperature field and stress field of the forming part was deeply studied. The laser additive manufacturing experiment of tin-assisted titanium alloy was carried out, and the experimental results were basically consistent with the simulation results, which verified the validity of the model. LMAAM technology has proven to be an effective method for additive manufacturing of highly reliable formed parts.

Laser Powder Directed Energy Deposition (LP-DED) is an Additive Manufacturing process in which a laser beam is used to generate a melt pool onto a substrate. The additional material, in form of powder material, is fed into the generated melt pool and a raised track is obtained. The LP-DED process is very powerful for different applications such as the repair operations and the production of functionally graded material, however the application is still limited and one of the main reasons is related to the lack of knowledge in the physics of the process mechanisms. The process is influenced by a huge number of parameters and three main mechanisms can be identi-fied. These mechanisms are the powder flow, the generation of the molten pool and the solidifica-tion process and for each of these mechanisms the process parameters have a different relevance. In this paper, a review of the main mechanisms and the relationship between the process parame-ters and the outcome of each step of the process is presented.

The osseointegration process in and around additively manufactured (AM) lattice structures of a new titanium alloy, Ti–19Nb–14Zr, was evaluated. Three different implants, including lattices with increasing high sidewalls gradually closing them, were designed, manufactured and implanted in the tibia and metatarsal bone of two sheep for twelve weeks. After removal, they were characterized with X-ray computed tomography (XCT). The 3D XCT images were segmented using machine learning. The bone-interface implant (BII) and bone-implant contact (BIC) were studied. The results show that, since AM naturally leads to high roughness surface finish, the wettability of the implant is increased. The new alloy possesses an increased affinity to the bone enhancing the quality of osseointegration. The lattice provides crevices, in which the biological tissue can jump in and cling. The combination of these factors is pushing ossification beyond its natural limits. Therefore, the quality and speed of the ossification and osseointegration in and around these Ti–19Nb–14Zr AM laterally closed lattice implants open the possibility of bone spline key of prostheses. This enables the stabilization of the implant into the bone while keeping the possibility of punctual hooks allowing the implant to be removed more easily if required.

: TiAl6V4 alloy is widely used in selective laser melting and direct laser melting. In turn, works devoted to the issue of how the track stacking scheme affects the value of mechanical properties is not enough. The influence of the Ti6Al4V alloy track trajectories on the microstructure and mechanical properties during direct laser deposition is studied in this article for the first time. The results were obtained on the influence of «parallel» and «perpendicular» technique of laying tracks in direct laser synthesis. All studied samples have a microstructure typical of the hardened two-phase condition titanium. It is shown that the method of laying tracks and the direction of load application during compression testing relative to the location of the tracks leads to a change in the ultimate strength of the Ti-6Al-4V alloy from 1794 to 1910 MPa. The plasticity of the Ti-6Al-4V alloy obtained by direct laser alloying can vary from 21.3 to 33.0% depending on the direction of laying the tracks and the direction of the compression test. The hardness of alloys varies in the range from 409 to 511 HV and depends on the method of laying the tracks and the direction of hardness measurements.

Selective Paste Intrusion (SPI) is an additive manufacturing (AM) process in which thin layers of aggregates are selectively bonded by cement paste only where the structure is to be produced. In this way, concrete elements with complex geometries and structures can be created. Reinforcement is required to increase the flexural strength of the concrete elements and, thus, enable their applicability in practice. Integrating the reinforcement is a difficult task, particularly in the case of SPI due to the layer-wise printing method. Especially with respect to possible complex structures, the production of the reinforcement needs to be adapted to SPI, thereby offering a high degree of freedom. One concept for a reinforcement integration is combining the two additive manufacturing processes SPI and Wire and Arc Additive Manufacturing (WAAM). However, since the two processes serve different fields of application, their compatibility is not necessarily given. Ongoing investigations show that the temperatures caused by WAAM adversely affect both, the cement paste rheology required for sufficient paste penetration into the particle bed and the overall concrete strength. This paper provides an overview of ongoing research focusing on different cooling strategies and their effects on the compressive strength of SPI-printed concrete parts.

As the additive manufacturing industry grows, it is compounding the global plastic waste problem. Distributed recycling and additive manufacturing (DRAM) offers an economic solution to this challenge, but it has been relegated to either small-volume 3D printers (limiting waste recycling throughput) or expensive industrial machines (limiting accessibility and lateral scaling). To overcome these challenges, this paper provides proof-of-concept for a novel open-source hybrid 3D printer that combines a low-cost hanging printer design with a compression screw-based end-effector that allows direct extrusion of recycled plastic waste in large expandable printing volumes. Mechanical testing of the resultant prints from 100% waste plastic, however, showed that combining challenges of non-uniform feedstocks and a heavy printhead for a hangprinter reduced the strength of the parts compared to fused filament fabrication. The preliminary results are technologically promising, however, and provide opportunities to improve on the open source design to help process the volumes of waste plastic needed for DRAM to address the negative environmental impacts of global plastic use.

In the current paper, we present our work towards developing a solution combining computer vision and AI to support footrest design customization in the wheelchair industry. Wheelchairs and postural systems are complex and often user centric in the design process. Those products require a wide range of adjustments to adapt to the various anthropometries and disabilities of patients. Most commercial products, dedicated to severe disability, also include a series of additional elements, designed to keep the patient in a comfortable but “fixed” position. Such systems do not allow to “fix and maintain” the position of patient foot, especially for patients who have no control over their lower limbs. For that reason, it becomes essential to supply wheelchairs with specific elements to hold patient's shoe in place. Commercial foot supports are typically developed on standard sizes and do not always cover the entire population. In addition, those designs are based on standard shoes, thus they do not lend themselves well to adapting to special shoes or orthopedic shoes. Feet final position therefore becomes a key element in correct postural management. In this paper, we investigate the use of computer vision and AI to correctly define customization parameters of the footrest. The proposed design has been developed based on the specifications received from the Pro Medicare S.r.l orthopedic technicians. We present suitable algorithms, design principles and well defined components towards the implementation of our proof of concept. We also present the testing activities we have undertaken and the obtained performance results.

Functionally graded materials (FGM) have attracted considerable attention in the field of composite materials and rekindled interest in research on composite materials, due to their unique mechanical response achieved through material design and optimization. Compared to conventional composites, FGMs offer several advantages and exceptional properties, including improved deformation resistance, improved toughness, lightness properties, and excellent recoverability. This study focused on the production of functionally graded (FG) polymer materials by additive manufacturing (AM) method. FG structures were produced by the Fused Deposition Modeling (FDM) method using Acrylonitrile benzidine styrene (ABS) and Polylactic acid (PLA) materials and tensile tests were performed according to ASTM D638. The effects of different layer thicknesses, volume ratios, and total thicknesses on mechanical behavior were investigated. In addition, tensile tests were carried out by producing single-layer samples at certain volume ratios to create a numerical model with the Finite element method to verify the experimental data. As a result of this study, it is presented that the FG structure produced with FDM improves mechanical behavior.

The paper delves into an extensive exploration of the integration of the circular economy paradigm within the realm of additive manufacturing (AM). The objective is to comprehensively investigate existing methodologies for structuring the symbiotic relationship between circular economy and additive manufacturing, while meticulously analyzing the current research gap concerning the implementation of circular economy principles in additive manufacturing practices. A thorough review focusing on the sustainability of additive manufacturing within the circular economy framework was conducted. This review aims to recognize and delineate pertinent aspects related to post-use material valuation in AM, recyclability of materials, and the environmental footprint associated with these processes. Emphasis was placed on the significance of examining circular economy facets concerning additive manufacturing processes to establish a holistic understanding. The overarching goal of this review is to augment knowledge regarding the potential advantages and benefits derived from the seamless integration of circular economy principles within AM. By elucidating the activities essential to attain compliance with the Sustainable Development Goals, this study endeavors to illuminate the pathway toward promoting sustainable development through the harmonious marriage of additive manufacturing and the circular economy.

Notwithstanding the advances achieved in the last decades in the field of synthetic bone substitutes, the development of biodegradable 3D scaffolds with ideal mechanical and biological properties remains an unattained challenge. In this work, a novel approach is explored to produce synthetic bone grafts mimicking the complex bone structure using additive manufacturing. For the first time, scaffolds were produced, using an extrusion technique, composed of a thermoplastic polymer, polycaprolactone (PCL), hydroxyapatite nanoparticles (HANp), and polyethylene glycol diacrylate (PEGDA). These scaffolds were further compared with two groups of scaffolds: one composed of PCL and another of PCL and HANp. After production, optimisation and characterisation of these scaffolds, an in vitro evaluation was performed using human dental pulp stem/stromal cells (hDPSCs). Through the findings it was possible to conclude that PEGDA scaffolds were successfully produced presenting networks of interconnected channels, presenting hydrophilic properties (15.15 4.06°), adequate mechanical performance (10.41MPa 0.934), and allowing a cell viability significantly superior to the other groups analysed. To conclude, findings in this study demonstrated that PCL, HANp and PEGDA scaffolds may have promising effects on bone regeneration and might open new insights for 3D tissue substitutes.

Sulphites are the most widely used food additives for their versatile applications in processing; perhaps we are negligence of its shortcomings. On account of various research studies, sulphites induce serious allergic reactions and other health alignments, but still regulatory agents permit its usage. Is it a wiser choice? The purpose of this paper is to clear up ambiguity and provide a clear view on why sulphites are employed in the food industry, why its usage is restricted, and why sulphite is a toxicant

Nitrate and nitrite are the most extensively used food additives in the food industry for their multifunctional properties, and they have been in the spotlight for decades for its controversial back effects. The conversion of nitrate and nitrite to various nitroso compounds, specifically N-nitrosamine raises the question of the integrity of these additives. Nitrosamine is a well-known carcinogen and mutagen. A large number of studies demonstrate the carcinogenic effects of these salts. Are these findings credible? Nonetheless, the regulatory agencies approve its usage; is it biased? Are we feeding on the carcinogens in processed foods? The current work provides an insight into the basic and toxicological findings of the food additives -nitrate and nitrite.

Structural integrity is a crucial aspect of engineering components, particularly in the field of additive manufacturing (AM). Surface roughness is a vital parameter that significantly influences the structural integrity of additively manufactured parts. In this study, we present a comprehensive investigation into the relationship between surface roughness and structural integrity of Polyactic Acid (PLA) specimens produced through additive manufacturing. This research work focuses on the prediction of surface roughness of Additive Manufactured Polyactic Acid (PLA) specimens using eight different supervised machine learning regression-based algorithms. For the first time, Explainable AI techniques are employed to enhance the interpretability of the machine learning models. The eight algorithms used in this study are Support Vector Regression, Random Forest, XG Boost, Ada Boost, Catboost, Decision Tree, Extra Tree regressor, and Gradient Boosting regressor. The study analyzes the performance of these algorithms to predict the surface roughness of PLA specimens, while also investigating the impact of individual input parameters through Explainable AI methods. The experimental results indicate that the XG Boost algorithm outperforms the other algorithms with the highest coefficient of determination value of 0.9634. This value demonstrates that the XG Boost algorithm provides the most accurate predictions for surface roughness compared to other algorithms. The study also provides a comparative analysis of the performance of all the algorithms used in this study, along with insights derived from Explainable AI techniques.

Artificial intelligence (AI) and 3D printing (3DP) play critical roles in what is known as the 4th Industrial Revolution by developing data- and machine-intelligence-based integrated production technologies. This shift has led to increasingly complex design requirements and fabrication methods, posing several challenges for implementing design, fabrication process, and architectural quality standardization. This paper systematically reviews AI techniques applied in diverse stages of 3DP production in architecture. The research goals are to (1) offer a comprehensive critical analysis of the body of literature; (2) identify and categorize approaches to integrating AI in the production of 3D-printed structures; (3) identify and discuss challenges and opportunities of AI integration in architectural production of 3DP structures; and (4) identify gap and provide recommendations for future research. The findings indicate that topics related to AI applications are current and trending, receiving increasing attention from researchers in general and particularly those working in machine and deep learning, artificial neural networks, and pattern recognition. However, the potential of the application of AI in architectural production using additive manufacturing still needs to be explored. Considering this, the paper emphasizes the necessity of redefining traditional field boundaries and opening new opportunities in the sector.

We overview recent findings achieved in the field of model-driven development of additively manufactured porous materials for development of a new generation of bioactive implants for orthopedic applications. Porous structures produced of biocompatible titanium alloys by selective laser melting can present a promising material to design scaffolds with regulated mechanical properties and with capacity to be loaded with pharmaceutical products. Adjusting pore geometry, one could control elastic modulus and strength/fatigue properties of the engineered structures to be compatible with bone tissues, thus preventing the stress shield effect when replacing a diseased bone fragment. Adsorption of medicals by internal spaces would make it possible to emit the antibiotic and anti-tumor agents into surrounding tissues. We critically analyze the recent advances in the field featuring model design approaches, virtual testing of the designed structures, capabilities of additive printing of porous structures, biomedical issues of the engineered scaffolds and so on. A special attention is paid to highlight the current troubles in the field and the ways of their solutions.

Investment management is a common process and practice used for achieving a desirable investment goal or outcome. Investment assessment should be carried out at various stages of project realization in accordance with capital investment volume. Investment risk management implies the effective control of all procedures and monitoring of risks in all phases of the investment project. Because of the reason that a single indicator in probability calculation of achieving optimal return from the investment does not exist, performing sufficiently reliable estimates of the quality of investments becomes a tedious task. There are many indicators, factors, and criteria required for consideration to reach the effective solution of the investment problem. Unfortunately, the systematic variation of economic situations in the marketplace stipulates the continuous and frequent changes of investment conditions and environment in which the investor should act and operate. Hence, the rules required for providing a reasonable quality of investment projects can be based only on investor’s management strategy and rely on investor’s intuition and practice. The importance of classification in investment management and decision making process is undeniable. The objects to be classified are described using assessments in accordance with various criteria which can be both quantitative and qualitative. With a competent formulation of the investment process, both methods are used in parallel. There exist various decision making approaches for the investment management, and simple additive weighting (SAW) is one of the well-known multi-criteria decision making (MCDM) methods aiming to provide an optimal decision for decision maker when solving various real-life problems, and particularly, investment problem. In this paper, fuzzy simple additive weighting (FSAW) method in group decision making is applied to undertake the capital investment expenditure for purchasing cars with the purpose of renting them to the public. The development of existing FSAW method is accomplished and this process involves the sensibility of outcomes to changes in the rate of fuzziness represented with decisions taken. Eventually, the degree of fuzziness involved in an analysis that directly attempts to model the immanent vagueness and imperfectness in particular precedency judgments made, is determined. A numerical example illustrates the importance and effectiveness of the suggested approach with the aim of ranking alternatives and hence, determining the most preferred alternative in MCDM problem.

Additive manufacturing (AM) technologies show potential for the development of functionally integrated lightweight designs, biomimetic structures and material savings. Typically, as-built surfaces show powder particle agglomerations and re-entrant features, leading to rough surfaces, which are associated with poor fatigue performance. To benefit from the full range of advantages with special focus on aerospace applications, critical features for crack initiation when subjected to fatigue loading need to be identified and mitigated. A first step toward achieving this goal is the surface texture characterisation based on the quantification of surface features. In this paper, selected areal height, functional and feature parameters from ISO 25178-2:2022 are generated and process-specific features are examined for as-built AlSi7Mg0.6 from laser powder bed fusion (PBF-LB). A connection with the particle size distribution of the used powder is demonstrated. It is shown that surface feature analysis opens up opportunities to use physically meaningful surface characteristics in future quality assurance and part qualification processes.

Metal additive manufacturing technologies have large potential for future use in load bearing aerospace applications, requiring a deeper understanding of mechanical performance and influencing factors. The objective of this study is to manufacture fatigue specimens by laser powder bed fusion with comparable bulk and different as-built surface quality (without post-processing). This goal was pursued by using identical bulk/hatch scan parameters while varying contour scan parameters. The bulk quality was evaluated by density measurements according to Archimedes’ principle and tensile testing. The surfaces were investigated using the optical fringe projection method and surface quality was assessed by the areal surface texture parameters Sa (arithmetic mean height) and Sk (core height, derived from material ratio curve). The resulting mean values of max (ultimate tensile strength) were between 375 and 405 MPa, which is a variation of roughly 8%, for seven different surface conditions. It could be confirmed that the influence of contour scan variation on bulk quality is insignificant for the assessed samples.

The Selective Paste Intrusion (SPI) method is a layer-by-layer additive manufacturing technique that allows for the production of complex geometries in concrete elements by selectively bonding aggregates with cement paste in a particle bed. To create reinforced concrete, the Wire and Arc Additive Manufacturing (WAAM) process shall be integrated into SPI. This technique allows the production of almost free-formed reinforcement and thus complements the advantage of SPI to produce free-formed structures of almost any geometry. However, integration of WAAM into SPI poses a considerable challenge, as high temperatures are generated during the welding process. These temperatures can negatively affect the rheological properties of the cement paste, in turn the penetration behavior of the paste in the particle bed and, subsequently, the mechanical properties of the hardened concrete. A possible passive cooling strategy is to increase the protruding length of the reinforcement bars out of the particle-bed. This requires that the distance of the print nozzle to the particle bed is as well increased, since it must be possible to move it across the reinforcement. The objective was thus to investigate the effect of that distance on print quality and to quantify a maximum allowable distance for an adequate print quality (for the printer setting used) in terms of shape accuracy and concrete strength. Compressive and flexural strength tests as well as geometrical measurements using a 3D scanning method were performed on specimen, printed with varying print nozzle to particle bed distances. It can be stated that for the used SPI print-heads, nozzle-types and parameter settings, the distance between the nozzle and the particle bed should not exceed 50 mm to ensure sufficient print quality in both shape accuracy and mechanical strength.

Three-dimensional (3D) and four-dimensional (4D) printing emerged as the next generation of manufacturing techniques, spanning several research areas such as engineering, chemistry, biology, computing, and materials science. Three-dimensional printing allows the manufacture of complex shapes with high precision, by adding layer by layer of different materials. The use of smart materials that change shape or color, produce an electrical current, become bioactive, or perform an intended function in response to an external stimulus. Shape memory materials (SMMs) in 3D printing technology have attracted a lot of attention due to their ability to respond to external stimuli, leading this technology towards an emerging area of research, "4D printing technology." The core part of this review summarizes the effect of the main external stimuli on 4D textile materials followed by the main applications 4D printed textiles can change their shape over time due to external stimuli such as temperature.

Surfaces of additively manufactured metal parts from powder-based processes typically show powder particle agglomerations and other features, resulting in high surface roughness. Proper characterization of those surfaces is necessary in order to assess part quality with respect to coatability, mechanical performance or corrosion resistance for use in aerospace, automotive, medical and more industrial applications. Optical surface texture measurement allows for collection of areal surface data, while the established contact stylus method only captures line profile data. When applying optical methods for surface topography measurements, proper data acquisition and post-processing in order to assess surface texture may be complex. A number of variables can be adjusted, such as different measurement settings, approaches to outlier removal, evaluated area size or form removal. This work shows the influence of selected z-range prior to measurement and the influence of choosing pre-defined outlier removal settings in MountainsMap 9.2 on selected ISO 25178-2:2022 parameters calculated from data obtained from confocal microscopy for as-built Ti6Al4V from laser powder bed fusion. The aim is to show the influence of variation in measurement and post-processing on calculated surface texture parameters and stress the importance of proper documentation in order to achieve reproducibility of data for quality management.

Additive Manufacturing (AM) has been proving suitable to support or even replace traditional manufacturing in several industries, offering many advantages such as delivery time and reduction in terms of material waste, energy consumption and greenhouse gas (GHG) emissions. This study aimed to carry out a comparative assessment of the life cycle, from gate to gate, in the production of a low alloy carbon steel flange part using ER-90 wire. The methods utilized were Wire and Arc Additive Manufacturing (WAAM) and conventional manufacturing (CM) by forging, and comparative factors were energy demands, GHG emissions and generated solid waste. The total energy consumption in WAAM was 10,239.40 MJ, total carbon footprint in CO2 equivalent (CO2e) was 714.1 kgCO2e kg-1, and generated solid waste was 68.6 kg, respectively, 90%, 95% and 76% lower than consumption calculated in conventional manufacturing.

There is evidence that Additive Manufacturing plays a crucial role in the fourth industrial revolution. The design freedom provided by this technology is disrupting limits and rules from the past enabling engineers to have new products otherwise unfeasible. Recent developments in the field of SLM have led to a renewed interest in lattice structures that can be produced non-stochastically in previously unfeasible dimensional scales. One of the primary applications is aerospace engineering where the need of lightweight and performance is urgent to reduce the carbon footprint of civil transport around the globe. Of particular concern is fatigue strength. Being able to predict fatigue life in both LCF (Low Cycle Fatigue) and HCF (High Cycle Fatigue) is crucial for a safe and reliable design in aerospace systems and structures. In the present work, an experimental evaluation of compressive-compressive fatigue behavior has been performed to evaluate the fatigue curves of different cells, varying sizes and relative density. A Design of Experiment approach has been adopted in order to maximize the information extractable in a reliable form.

In this study, an optimized multi-material system was designed and developed to print samples in various applications, including biomedical fields (e.g., mandibular bone loss). To improve the mechanical and biological properties of scaffolds utilized for dental bone loss applications, a multi-material setup was devised, which employs digital light processing technology. This setup consists of a linear system comprising two resin vats and one ultrasonic cleaning tank, enabling the integration of diverse materials and structures to optimize the composition of the scaffold. This approach was used to print multi-material PLLA scaffolds containing 20 wt.%. HA on the interior side, and PLLA containing 1 wt.% GO on the exterior surface of the scaffold, which were evaluated mechanically and biologically after printing. The scaffold was designed using a triply periodic minimal surface (TPMS) lattice structure, which is known to possess favorable mechanical and biological properties. Various multi-material samples were successfully printed and evaluated to illustrate the multiple-material setup's potential for ensuring proper function, cleaning, and adequate interface bonding. By numerically evaluating several TMPS structures, a novel Gyroid TPMS scaffold with a nominal porosity of 50% was developed and validated experimentally. The biological properties of the scaffolds were also evaluated, including surface morphology, (3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide) MTT assay, and cell adhesion. Based on the results, multi-material components with the least contaminations with suitable mechanical and biological properties were successfully printed. By combining PLLA-HA and PLLA-GO, this innovative technique holds tremendous potential for enhancing the effectiveness of regenerative procedures in the field of dentistry.

In this study composite with alternate layers of 5056 and 1580 alloys was manufactured by wire arc additive manufacturing technology. It is shown that increased strength characteristics of composite material can be obtained due to deformation treatment by high-pressure torsion (HPT) technique. The microstructure and mechanical properties of the HPT-processed material in different structural states were investigated. The HPT-processed material exhibits high value of ultimate tensile strength (~ 770 MPa) but low ductility. Short-term annealing at 250 oС and additional deformation by HPT to 0.25 of revolution at room temperature resulted in a slight decrease in material’s strength to ~ 700 MPa but provided ductility ∼ 9%. Physical mechanisms to improve plasticity in correlation with microstructure evolution is discussed.

Open-source 3-D printing has played a pivotal role in revolutionizing the additive manufacturing (AM) landscape, by making distributed manufacturing economic, democratizing access, and fostering far more rapid innovation than antiquated proprietary systems. Unfortunately, some 3-D printing manufacturing companies began deviating from open-source principles and violating licenses for the detriment of the community. To determine if a pattern has emerged of companies patenting clearly open-source innovations, this study presents three case studies from the three primary regions of open-source 3-D printing development (EU, U.S. and China) as well as three aspects of 3-D printing technology (AM materials, an open-source 3-D printer, and core open-source 3-D printing concepts used in most 3-D printers). The results of this review have shown that non-inventing entities called patent parasites are patenting open-source inventions already well-established in the open source community and in the most egregious cases commercialized by one (or several) firms at the time of the patent filing. Patent parasites are able to patent open-source innovations by using a different language, vague patent titles and broad claims that encompass enormous swaths of widely diffused open-source innovation space. This practice poses a severe threat to innovation and several approaches to irradicate the threat are discussed.

The Laser Thermal-Joule Heating Composite Process was studied by orthogonal tests based on an analysis of fabrication parameters such as the laser power, wire feeding speed, and electric current. Temperature profiles and the geometric morphology of deposited layers under different process parameters were analyzed, and the overlaps between the layers and the substrate were observed. Results show that when the temperature at the bottom layer of the additive manufacturing is higher than the melting point of the substrate, and the highest temperature at the top layer does not exceed the over-firing temperature, good morphology and close bonding with the substrate can be obtained. Finally, appropriate process parameters were identified and verified to print multiple layers continuously.

3D printing with cement-based materials is a promising manufacturing technique for civil engineering applications that already allows for the design and the construction of complex and highly customized structures using a layer-by-layer deposition approach. Usually, in this type of additive manufacturing, a mixture of cement, water, aggregate and additives is extruded through a specific print head and deposited in successive layers to form the desired shape. The extrusion mechanism is one of the most expensive parts of the 3D printer. Also, for low scale 3D printers, based on the shape of the extruder and the geometry limitation of the mixing blade, the 3D mixture is often limited to a narrow range of materials due to the risk of layer splitting or blockage. Therefore, there is a need to develop affordable and feasible alternatives to the current design-fabrication-application approach of 3D printers. In this paper, various new designed mixtures of fiber reinforced mortars that can be 3D printed using only a commercially available screw pump are analyzed based on their fresh properties and mechanical characteristics. The reduced facility requirements in this approach allow 3D-printing to be more available for civil engineering applications. With further innovation in the future, this method and mixtures can be extended for sustainable and economically feasible printing of single-family housing units.

In this study, a new structure is proposed based on the body-centered cubic (BCC) lattice structure: adding a cubic truss in the center of the BCC structure, which is denoted by TLC (Truss-lattice-cube). The different dimensions of the central cube can affect the mechanical properties of the lattice structure notably. With a fixed length (15mm) of a unit cell, the optimal size for the central cube is determined to be 5 mm. Quasi-static compressive tests are performed on specimens made of Polylactic Acid (PLA) using additive manufacturing technology. The deformation characteristics of the new structure is analyzed in detail by experiments and numerical simulations. Compared to the BCC structure, the mechanical properties of the TLC structure are significantly improved. The initial flow stress of the TLC has been increased by 122% at a strain of 0.1; the specific strength has been enhanced by 293% at a strain of 0.5; and the specific energy absorption has been improved by 312% at the strain of 0.6. Printing defects in the lattice structure could deteriorate the mechanical property remarkably. In this work, incorporation of microcracks into the finite element model makes the simulation capture the influence of printing defects and improve the predictive accuracy of simulation significantly.

Classification predictive modeling involves the accurate assignment of observations in a dataset to target classes or categories. There is an increasing growth of real-world classification problems with severely imbalanced class distributions. In this case, minority classes have much fewer observations to learn from than those from majority classes. Despite this sparsity, a minority class is often considered the more interesting class yet developing a scientific learning algorithm suitable for the observations presents countless challenges. In this article, we suggest a novel multi-class classification algorithm specialized to handle severely imbalanced classes based on the method we refer to as SAMME.C2. It blends the flexible mechanics of the boosting techniques from SAMME algorithm, a multi-class classifier, and Ada.C2 algorithm, a cost-sensitive binary classifier designed to address highly class imbalances. Not only do we provide the resulting algorithm but we also establish scientific and statistical formulation of our proposed SAMME.C2 algorithm. Through numerical experiments examining various degrees of classifier difficulty, we demonstrate consistent superior performance of our proposed model.

In this study, 3D printing of poly-l-lactic acid (PLLA) scaffolds reinforced with graphene oxide (GO) nanoparticles via Digital Light Processing (DLP) was investigated to mimic bone tissue. Stereolithography is one of the most accurate additive manufacturing method, but the dominant available materials used in this method are toxic. In this research, a biocompatible resin (PLLA) was synthetized and functionalized to serve the purpose. Due to the low mechanical properties of the printed product with the neat resin, graphene oxide nanoparticles in three levels (0.5, 1, and 1.5 Wt.%) were added with the aim of enhancing the mechanical properties. At first, the optimum post cure time of the neat resin was investigated. Consequently, all the parts were post-cured for three hours after printing. Due to the temperature-dependent structure of GO, all samples were placed in an oven at 85 ° C for different time periods of 0, 6, 12, and 18 hours to increase mechanical properties. The compression test of heat treated samples reveals that the compressive strength of the printed parts containing 0.5,1, and 1.5 % of GO increased by 151,162 ad 235%, respectively. Scaffolds with the designed pore sizes of 750 microns and a porosity of 40% were printed. Surface hydrophilicity test was performed for all samples showing that the hydrophilicity of the samples increased with increasing GO percentage. The degradation behavior of the samples was evaluated in a PBS environment, and it revealed that by increasing GO, the rate of component degradation increased, but the heat treatment had the opposite effect and decreased the degradation rate. Finally, besides improving biological properties, a significant increase in mechanical properties under compression can introduce the printed scaffolds as a suitable option for bone implants.

This comprehensive review explores the advancements in Orthognathic and Oral Maxillofacial Surgery, focusing on the integration of 3D Printing and Virtual Surgical Planning (VSP). Traditional surgical methods, while effective, come with inherent risks and complications, and can lead to variability in outcomes due to the reliance on the surgeon's skill and experience. The shift towards patient-centric care necessitates personalized surgical methods, which can be achieved through advanced technology. The amalgamation of 3D printing and VSP revolutionizes surgical planning and implementation by providing tactile 3D models for visualization and planning, and accurately designed surgical guides for execution. This convergence of digital planning and physical modeling facilitates a more predictable, personalized, and precise surgical process. However, the adoption of these technologies presents challenges, including the need for extensive software training and the steep learning curve associated with computer-aided design programs. Despite these challenges, the integration of 3D printing and VSP paves the way for advanced patient care in orthognathic and oral maxillofacial surgery.

The most modern technique utilized to create intricate and complexly manufactured parts for a variety of applications is called additive manufacturing (AM). Fused deposition modeling (FDM) has received the greatest attention in the development and manufacturing sectors. The main objective of this study was to investigate how printing factors affected the mechanical characteristics of printed samples. Samples were produced using an FDM 3D printer in compliance with ASTM D638 using a variety of input settings, including orientation, layer thickness, speed, and infill pattern. On the printed samples, tensile tests and morphological analysis using a scanning electron microscope (SEM) were done. The findings of this study demonstrate that factors including layer thickness, printing speed, and orientation significantly affect the tensile strength of ABS printed samples. Discovering the process settings that could lead to superior mechanical and physical characteristics would undoubtedly assist designers and manufacturers worldwide as the FDM 3D printer becomes more and more crucial in manufacturing engineering parts.

Metal Additive Manufacturing (MAM) has emerged as a promising technology in the aerospace industry, enabling the production of complex components with enhanced design flexibility and reduced lead times. Concurrently, Industry 4.0 has gained significant attention for its potential to revolutionize aerospace manufacturing processes. The paper aims to cluster and review the literature on MAM in the aerospace industry, specifically focusing on its relevance to Industry 4.0 and its applicability throughout the various stages of the product life cycle for the chief purpose of matching supply with demand. Identified gaps and challenges are analyzed, highlighting the need for further research and outlining research agenda aimed at advancing the integration of MAM for Industry 4.0 in the aerospace sector. By addressing these research areas, the aerospace industry can unlock the value of MAM within an Industry 4.0 framework, leading to improved efficiency, productivity, and competitiveness.

With increasing constraints on energy and resource markets and the non-decreasing trend in energy demand, the need for relevant clean energy generation and storage solutions is growing and is gradually reaching the individual home. But small-scale energy storage is still an expensive investment in 2022 and the risk/reward ratio is not yet attractive enough for individual homeowners. One solution is for homeowners not to store excess clean energy individually but to produce hydrogen for mutual use. In this paper a collective production of hydrogen for a daily filling of a bus is considered. Following our previous work on the subject, the investigation consists of finding an optimal buy/sell rule to the grid, and the use of the energy with an additional objective: mobility. The dominant technique in the energy community is reinforcement learning, which is however difficult to use when the learning data is limited as in our study. We chose a less data-intensive and yet technically well-documented approach. Our results show that rulebooks, different but more interesting than the usual robust rule, exist and can be cost-effective. But they require fine-tuning as to not deteriorate system performance. In some cases, it is worth missing the H2 production requirement in exchange for higher economic performance.

In this study, additive manufacturing of reinforced parts using metallic wire as both a reinforcement component and a shape memory stimulus through Fused Deposition Modeling (FDM) was investigated. A Shape Memory Polymer (SMP) restores its original shape and recovers it upon specific stimuli. This research employed chromium-nickel metal wire as a reinforcing component to enhance mechanical properties and introduce the capability for thermal stimulation of polylactic acid (PLA) via electrical current using the "in-situ impregnation" method within FDM process. Reinforced specimens were fabricated with wire with two diameters of 0.1 and 0.15 mm, along with two volume percentages of 5 and 10. Comprehensive evaluations encompassing mechanical (tensile and flexural) and thermal properties of the printed specimens were conducted. The outcomes revealed a significant enhancement in both tensile and flexural properties of the polymer matrix due to the embedding metallic wire, even under elevated temperatures during bending test. Furthermore, the thermal properties of the reinforced specimens were examined by subjecting them to various voltages, resulting in temperature ranging from 36.4 to 150.1°C. These findings highlight the ability to tailor a wide range of mechanical properties and shape recovery in the reinforced specimens by carefully selecting the wire volume fraction, voltage, and wire diameter, thus regulating the materials properties with specific application requirements.

Literature review indicates that the basic microstructure of Ti-6Al-4V is bimodal which consist of two phases: α + β, and it occurs after the fabrication in conventional methods such as casting, plastic forming or machining processes. After the additive manufacturing methods, there could be significant changes in the microstructure. Due to the rapid heat exchange during heat-treatment process, bimodal microstructure transforms into lamellar microstructure which consists of two phases α′ + β. Despite applying optimum printing parameters, 3D-printed products exhibit typical surface defects and discontinuities. Recently, two of the primary technologies for the improvement of surface layer properties of titanium alloys are shot peening and electropolishing. Literature review signalizes that shot peening and electropolishing processes have positive impact on the corrosion behaviour, mechanical properties and the condition of the surface layer of titanium alloy. Furthermore, there is a lack of studies about combining shot peening and electropolishing in one hybrid process on titanium alloys, which could synthesize the benefits of both processes. The scope of future investigation is also included in this review.

A chairside polishing kit is an alternative to a laboratory polishing technique. This study aimed to evaluate the effects of different polishing techniques on the surface roughness of three-dimensional (3D)-printed acrylic denture bases (ADB). One hundred twenty disc-shaped specimens were fabricated from one conventional heat-polymerized (HP) ADB resin and two 3D-printed (Asiga (AS) and NextDent (ND)) ADB resins (n=40 per ADB resin). Each group was furtherly divided based on the polishing protocol (n=10) as follows: convectional polishing protocol (C), Microdont chairside polishing kit (M), Shofu chairside polishing kit (S), and unpolished group (U). The surface roughness (surface roughness average (Ra) and average maximum profile height (Rz)) of the printed specimens were measured using an optical profilometer, and the scanning electron microscope (SEM) was used to capture the surface at ×1000. Two-way ANOVA and post hoc tests were used for data analysis (α = 0.05) at significant levels. In unpolished groups, there was a statically significant difference between HP vs 3D-printed ADBs (p < 0.0001). For Ra values, the lowest values were presented in HP-C, AS-S, and ND-C. While the highest values were shown in all unpolished groups. Within the material, there were statistically significant differences between the three polishing protocols (C, M, and S) vs unpolished (p < 0.0001), while there was no significant between C, M, and S groups (p = 0.05). The Rz values had the same pattern as the Ra values. The two chairside polishing kits were comparable to conventional polishing technique, and it could be recommended for the clinical application.

Nature provides plenty of good examples for simple and very efficient joint assemblies. One example is the enormously flexible cervical spine of American barn owls, which consists of 14 cervical vertebrae. Each pair of vertebrae produces a comparatively small individual movement in order to provide a large overall movement of the entire cervical spine. The biomimetic replication of such joints is difficult due to the delicate and geometric unrestricted joint shapes as well as the muscles that have to be mimicked. Using X-ray as well as micro computed tomography images and with the utilisation of additive manufacturing, it is possible to produce the owl neck vertebrae in scaled-up form, to analyse them and then to transfer them into technically usable joint assemblies. The muscle substitution of these joints is realised by smart materials actuators in the form of shape memory alloy wire actuators. This actuator technology is outstanding for its muscle-like movement and for its enormous energy density [1,2]. The disadvantage of this wire actuator technology is the low rate of contraction, which means that a large length of wire has to be installed to generate adequate movement. For this reason, the actuator wires are integrated into additively manufactured carrier components to mimic the biological joints. This results in joint designs that compensate for the disadvantages of the small contraction of the actuators by intelligently installing large wire lengths on comparatively small installation spaces, while also providing a sufficient force output. With the help of a test rig, the developed technical joint variants are examined and evaluated. This demonstrates the technical applicability of this bionic joints.

Extrusion-based additive manufacturing (AM) technologies (i.e., fused filament fabrication, FFF) mostly produce thermoplastic parts. However, producing metallic or ceramic parts by FFF is also a sintered-based AM process. FFF for metallic parts can be divided into five steps: (1) raw materials selection and feedstock mixture (including palletization), (2) filament production (extrusion), (3) production of AM components using the filament extrusion process, (4) debinding, and (5) sintering. These steps are interrelated, where the parameters interact with the other ones and have a key role in the integrity and quality of the final metallic parts. FFF can produce high-accuracy and complex metallic parts, potentially revolutionizing the manufacturing industry and taking AM components to a new level. In the FFF technology for metallic materials, material compatibility, production quality, and cost-effectiveness are the challenges to overcome to make it more competitive compared to other AM technologies, like the laser processes. This review provides a comprehensive overview of the recent developments in FFF for metallic materials, including the metals and binders used, the challenges faced, potential applications, and the impact of FFF on the manufacturing (prototyping and end parts), design freedom, customization, sustainability, supply chain, among others.

Additive Friction Extrusion Deposition (AFED) is a recently developed additive manufacturing technique that promises high deposition rates at low forces. Due to the novelty of the process, the underlying phenomena and their interactions are not fully understood, and in particular the processing strategy and tool design are still in their infancy. This work contributes to the state of the art of AFED through a comprehensive analysis of its working principles and an experimental program including a representative sample component. The working principle and process mechanics of AFED are broken down into their individual components. Forces, their origins and effects on the process are described, and measures of process efficiency and theoretical minimum energy consumption are derived. Three geometrical features of the extrusion die are identified as most relevant to the active material flow, process forces and deposition quality: the topography of the inner and outer circular surfaces and the geometry of its extrusion channels. Based on this, the experimental program investigates seven different tool designs in terms of efficiency, force reduction and throughput. The experiments using AA 6061-T6 as feedstock show that AFED is capable of both high material throughput (close to 550 mm³/s) and reduced substrate forces: For example, the forces for a run at 100 mm³/s remained continuously below 500 N, and for a run at 400 mm³/s below 3500 N. Material flow and microstructure of the AFED are assessed from the macrosections. Significant differences are found between the advancing and retracting sides for both process effects and material flow. Banded structures show strong similarities to other solid state processes. The fabrication of the sample components demonstrates that AFED is already capable of producing industrial grade components. In mechanical testing, interlayer bonding defects result in a more brittle failure behavior in the direction of the structure, in the microstructure show strong similarities to other solid-state processes. The manufacturing of the sample components demonstrates that AFED is already capable of producing industrial grade components. In mechanical tests, interlayer bonding defects result in a more brittle failure behavior in the direction of the structure, while in the horizontal direction of the structure mechanical properties corresponding to a T4 temper have been achieved.

The radiation stability of polymer test objects fabricated by direct laser writing is studied. The two groups of 6 cubes (50×50×50 μm3) were printed on a common silicon substrate. 6 cubes were irradiated with X-rays in the synchrotron radiation beam (12 keV, 1010 photons/mm2/s), the other 6 kept non-irradiated for the reference. In each group, the fabrication parameters (laser power and slicing step) were uniformly varied from cube to cube. Each irradiated cube was exposed with the dose of 1013 X-ray photons. The calibration of this dose in the radiological units (Gy) was carried out using the tissue-equivalent thermoluminescent detectors (TLD-800). The corresponding exposition dose was estimated as 30 kGy for each cube. The radiation effects were evaluated by Raman spectroscopy and by morphological changes observed with the raster electron microscope. The primary radiation effect appears in the essential increase of the polymerization degree with consuming carbon-carbon double bonds in favor of the polymer cross-linking. Only one cube of 6 has changed the size and shape due to this effect, while the others retained the initial shape. Morphological changes are connected with the improper fabrication parameters (laser power and slicing step). Properly fabricated objects withstand the X-rays of the synchrotron radiation beam.

In recent years, Additive Manufacturing (AM), commonly referred to as 3D printing, has garnered the attention of the scientific community due to its capacity to transform ordinary and traditional items into customized materials at an affordable cost, through various AM processes. Antimicrobial/antibiofilm 3D printed materials are one of the most trending research topics, owing to the growing concerns over the emergence of complex microbial structures called "biofilms" on various surfaces. The review provides an overview of the evolution of additive manufacturing (AM) technologies and their various derivatives, along with a brief description of their materials and applications. It also introduces how biofilms can represent an advantageous lifestyle for microbial populations. The primary objective of this research was to conduct a systematic review on the development of planctonic or biofilm forms of microorganisms on 3D printed materials. The article summarizes commonly studied microorganisms on these materials and presents their 3D printing process, materials, as well as the fields covered by each of the analyzed papers. To the best of our knowledge, this is the first all-inclusive systematic review that amalgamated research conducted in diverse fields to assess the development of biofilms on surfaces produced through three-dimensional printing. Most notably, this review presents a comprehensive account of sustainable approaches for producing antimicrobial materials through 3D printing. Additionally, we assess their advancements in various fields such as medicine, environment, agri-food, and other relevant sectors. The findings of our literature review can be used to recommend appropriate microorganisms, 3D printing materials, and technologies for academic and industrial research purposes focusing on the development of microbial biofilms on 3D printed surfaces. Furthermore, it highlights the potential of environmentally-friendly modified AM technologies to combat biofilms in clinical and non-clinical areas. Our goal with this review is to help readers gain a better understanding of fundamental concepts, inspire new researchers, and provide valuable insights for future empirical studies focused on eradicating biofilms from 3D printed materials.

To stabilize the Earth’s climate a large-scale transition is needed to non-carbon emitting renewable energy technologies like wind and solar energy. Although these renewable energy sources are now lower-cost than fossil fuels, their inherent intermittency make them unable to supply a constant load without storage. To address these challenges rechargeable electric batteries are currently the most promising option; however, their high capital costs limit current deployment velocities. To both reduce the cost as well as improve performance 3D printing technology has emerged as a promising solution. This literature review provides the state-of-the-art enhancements of battery properties with 3D printing including efficiency, mechanical stability, energy and power density, customizability and sizing, production process efficiency, material conservation and environmental sustainability as well as the progress in solid-state batteries. The principles, advantages, limitations, and recent advancements associated with the most common types of 3D printing are reviewed focusing on their contributions to the battery field. 3D printing batteries offer design flexibility, material flexibility, reduces pack weight, minimizes material waste, increases the range of applications and has the potential to reduce costs. As 3D printing technologies become more accessible, the prospect of cost-effective production for customized batteries is extremely promising.

We explore 3D printing modules for self-assembling spacecraft and robots – structure, actuators, electrics. Self-assembly has long been viewed as a highly desirable capability for autonomous construction of large space structures. We review self-assembly in space which focusses on the self-assembly of modules that demonstrate the range of applications. However, self-assembly may be synergised with 3D printing to offer an automated capability from raw material to modules for assembling new spacecraft or habitats. One application of 3D printing is using space debris on-orbit as an in-situ resource - defunct spacecraft may be salvaged as raw material for in-situ construction on demand. The common features of all self-assembling modules are that the modules constitute a structure housing a computer-controlled actuator internally and a reversible latching mechanism externally. We have demonstrated a 3D printed DC electric motor in which the only components that were not 3D printed are the wire coils. We have married our 3D printed motor prototype as an actuated joint between two 3D printed trigon-type panels developed as part of a trigon self-assembling system concept. The trigon concept underlies a modular approach to self-assembling and self-deploying structures. The 3D printed motorised panel system demonstrates that the motor aspect and structural aspects of robotic self-assembling machines are amenable to 3D printing. This has implications for self-assembling systems into modular satellites as a solution to space debris.

In this research, a screw-barrel system was designed and implemented, coupled with material extrusion, to print high-melt-temperature thermoplastic materials. The aim was to integrate two methods: the direct extrusion of thermoplastic polymer pellets with material extrusion,utilize various polymers in the form of pellets, especially high melt temperature ones, instead of traditional filaments. This addresses one of the significant challenges in filament preparation for various materials that are not readily available in the market or nearly impossible to fabricate (such as highly filled plastics). First, the screw-barrel assembly performance and factors influencing feed rate were evaluated. Subsequently, specimens were printed with polyether ether ketone (PEEK), an advanced plastic material known for its outstanding mechanical properties, high-temperature tolerance, and broad applications in various sectors, such as medical. Additionally, the material was reinforced with 2.5% continuous glass fibers while printing, which presented a novel product. Upon comparing theoretical values with experimental data from the tensile testing, a notable observation emerged: the inclusion of 2.5% glass fibers led to an approximate 43% increase in the tensile strength of the material. Furthermore, SEM images provided visual evidence of satisfactory adhesion between layers and fibers.

Background: Drought, N deficiency and herbivory are considered the most important stressors caused by climate change in the agro- and eco-systems and varied in space and time shaping a highly dynamic and heterogeneous stressful environments. This study aims to evaluate the to-mato morpho-physiological and metabolic responses to combined abiotic and herbivory at dif-ferent within-plant spatial levels and temporal scales. Methods: Leaf-level morphological, gas exchange traits and VOC profiles were measured in to-mato plants exposed to N deficiency and drought, T. absoluta larvae and their combination. Ad-ditive, synergistic or antagonistic effects of the single stress when combined were also evaluat-ed. Morpho-physiological traits and VOC profile were also measured on leaves located at three different positions along the shoot axes. Results: The combination of the abiotic and biotic stress has been more harmful than single stress with antagonistic and synergistic but non-additive effects for the morpho-physiological and VOC tomato responses, respectively. Combined stress also determined a high within-plant phenotypic plasticity of the morpho-physiological responses. Conclusions: These results suggest that the combined stress in tomato determined a “new stress state” and a higher within-plant phenotypic plasticity which could permit an efficient use of the growth and defence resources in the heterogeneous and multiple stressful environmental condi-tions.

The performance of a small reconfigurable unmanned aerial vehicle (UAV) is evaluated, 1 combining a multidisciplinary approach in computational analysis of additive manufactured struc- 2 tures, fluid dynamics, and experiments. Reconfigurable UAVs promise cost savings and efficiency 3 without sacrificing performance, while demonstrating versatility to fulfill different military mission 4 profiles. The use of computational fluid dynamics (CFD) in UAV design produces higher accuracy 5 aerodynamic data, which is particularly important for complex aircraft concepts such as blended 6 wing bodies. To address challenges relating to anisotropic materials, the Tsai-Wu failure criterion is 7 applied to structural analysis, using CFD solutions as load inputs. Aerodynamic performance results 8 show the low-speed variant attains an endurance of 1 hour, 48 minutes, whereas for its high-speed 9 counterpart, it is 29 minutes at 66.7% higher cruise speed. Each variant serves different aspects of 10 small UAS deployment in combat, with low-speed envisioned for close surveillance, and high-speed 11 for incursions. Experimental and simulation results suggest room for design iteration, in wing area 12 and geometry adjustments. Structural simulations demonstrated the need for airframe improvements 13 in the low-speed configuration. This paper highlights the potential of reconfigurable UAVs to disrupt 14 the industry, advocating for further research and design improvements.

Methacrylated silk (Sil-MA) is a chemically modified silk fibroin specifically designed to be crosslinkable under UV light. This allows the structuring of this material throught additive manufacturing techniques and then to easily prototype patient specific construct. In this study we used Sil-MA to produce single layer crosslinked structures that can be withdrawal and ejected recovering their shape after rehydration. A complete chemical and physical characterization of the material has been conducted. Additionally, we tested the material biocompatibility according to the International Standard Organization protocols (ISO 10993) ensuring the possibility to use it in future trials. The material was also tested to verify its ability to support the osteogenesis. Two different additive manufacturing techniques have been tested (a Digital Light Processing (DLP) UV projector and a pneumatic extrusion technique) to develop Sil-MA grid. Finally, we provide a proof-of-concept that the printed Sil-MA structures are injectable.

The recent decade has witnessed the evolution of a novel paradigm of alloying which is based on utilising multiple elements to design compositionally complex alloys also known as high entropy alloys (HEAs). Conventional manufacturing of HEAs has a number of drawbacks, especially in terms of mechanical properties and design complexities. This has been addressed by additive manufacturing (AM), which has not only led to the fabrication of complex-shaped HEA components but has also enabled both ex-situ and in-situ tailoring of alloy microstructures. Considering the increasing interest in AM-based fabrication of HEAs in the last ten years, the present chapter is aimed at highlighting the present status and challenges in the avenue of AM of HEAs. This has been followed by a discussion on the recent trends in the avenue of AM-based fabrication of HEAs from the viewpoints of (i) microstructure evolution and mechanical properties, and (ii) alloy fabrication techniques. The chapter ends with a discussion on the future prospects in the aforementioned avenue.

Three-dimensional (3D) printing technology, also known as additive manufacturing (AM), has emerged as an attractive state-of-the-art tool for precisely fabricating functional materials with complex geometries, championing several advancements in tissue engineering, regenerative medicine, and therapeutics. However, this technology has an untapped potential for biotechnological applications, such as sensor and biosensor development. By exploring these avenues, the scope of 3D printing technology can be expanded and pave the way for groundbreaking innovations in the biotechnology field. Indeed, new printing materials and printers would offer new possibilities for seamlessly incorporating biological functionalities within the growing 3D scaffolds. Herein, we review the extrusion-based 3D printing modalities emphasizing biosensor applications. We highlighted the application of natural, synthetic, and composite biomaterials as 3D-printed soft hydrogels. Emphasis was placed on the approach by which the sensing molecules were introduced during the fabrication process. Finally, the future perspective was provided.