Article
Polymer Science
Abdulsalam Abdulaziz Al-Tamimi, Mehdi Tlija, Mustufa Haider Abidi, Arfat Anis, Abd Elaty E. Abd Elgawad
Summary: Material extrusion (ME) is an additive manufacturing technique that requires further exploration in multi-material fabrication. This study investigates different conditions and designs to optimize PLA-ABS composite parts without pre- or post-processing procedures. The results show that it is possible to create composite structures with good mechanical properties and surface roughness values without costly post-processing procedures.
Article
Engineering, Multidisciplinary
Shangqin Yuan, Shaoying Li, Jihong Zhu, Yulong Tang
Summary: This review discusses the advantages of polymeric composites with multi-functionality over metals and the intensive attention that additive manufactured composites have received over the past decade. The focus is on the design and manufacturing methods for polymeric composites using additive manufacturing, including different types of reinforcements and designs for multi-functional applications.
COMPOSITES PART B-ENGINEERING
(2021)
Article
Engineering, Manufacturing
Benjamin C. Stump, Brian T. Gibson, Jay T. Reynolds, Charles C. Wade, Michael C. Borish, Peter L. Wang
Summary: As powder bed fusion (PBF) additive manufacturing (AM) progresses, system configurations are shifting towards unconventional configurations to increase throughput. The inclusion of multiple heat sources increases the complexity of control schemes and load balancing becomes crucial. This paper introduces high-performing load balancing methods for multi-beam systems of any complexity, enabling on-the-fly load balancing in case of beam failures and improving system robustness.
ADDITIVE MANUFACTURING
(2023)
Article
Engineering, Civil
Marco Montemurro, Thibaut Roine, Jerome Pailhes
Summary: This study presents a multi-scale topology optimization method based on NURBS hyper-surfaces and an improved multiphase material interpolation scheme, which is successfully applied to 2D and 3D problems without the need for artificial filtering techniques. It is sensitive to the optimized configuration of the RVE, and investigates the influence of the starting point and macroscopic loads on the optimal solution.
ENGINEERING STRUCTURES
(2022)
Article
Chemistry, Multidisciplinary
Francesco Leoni, Pierandrea Dal Fabbro, Stefano Rosso, Luca Grigolato, Roberto Meneghello, Gianmaria Concheri, Gianpaolo Savio
Summary: This paper proposes a methodology for producing multi-material parts using 3D printing through editing a G-code. By integrating local variations between materials into a single part, new functionality and flexibility can be achieved. The proposed approach modifies the G-code based on a volumetric model that describes the combination of materials. Test results demonstrate the effectiveness of this method within the limits of the material co-extrusion additive manufacturing process.
APPLIED SCIENCES-BASEL
(2023)
Article
Engineering, Manufacturing
Brandon Hayes, Travis Hainsworth, Robert MacCurdy
Summary: This study extensively characterizes a liquid-solid co-printing process in multi-material material jetting additive manufacturing. The mechanism of this process is explained through experimental high speed imaging and computational fluid dynamic studies. Design rules for liquid-solid co-printing of micro/mesofluidic devices are presented, and case studies of various structures are shown. The liquid-solid co-printing process is considered a key new capability in additive manufacturing for the simple and rapid fabrication of integrated multi-material fluidic circuits and hydraulic structures.
ADDITIVE MANUFACTURING
(2022)
Article
Polymer Science
Pablo Zapico, Pablo Rodriguez-Gonzalez, Pablo Robles-Valero, Ana Isabel Fernandez-Abia, Joaquin Barreiro
Summary: The complexity and material compatibility of 3D printing create a new paradigm in design and manufacturing. However, standardization is lacking, necessitating characterization studies to fully utilize the advantages in functional parts. Post-processing is crucial for part finishing, and different methods can affect part quality similar to other process parameters.
Article
Green & Sustainable Science & Technology
Li Yi, Xiangqian Wu, Aarish Nawaz, Moritz Glatt, Jan C. Aurich
Summary: To evaluate and confirm the environmental benefits of AM, it is important to consider environmental issues during the design stage. Improving energy performance in AM has been mostly focused on process planning or the process chain/network design, with product design for AM (DfAM) rarely being considered. To address this issue, a framework called the multi-player competition algorithm (MPCA) is proposed, where the energy performance improvement in DfAM is modeled as a game of multiple players picking design variants to find the highest energy performance. MPCA has shown energy demand reduction rates of up to 3.9% and 5.8% in two use cases during the DfAM stage.
JOURNAL OF CLEANER PRODUCTION
(2023)
Article
Mechanics
Zunyi Duan, Yuqi Liu, Junling Fan, Kai Long, Bin Xu, Jihong Zhu, Jun Yan
Summary: This study proposes an effective methodology for the design optimization of fiber-reinforced composite structures using the Multi-scale and Multi-material Composite Anisotropic Penalization (MMCAP) model. The model considers both macroscopic multi-material structural topology and microscopic discrete fiber laying angle selection as independent design variables. The proposed MMCAP scheme demonstrates the capability of achieving multi-material and multi-scale design optimization for fiber-reinforced composite structures.
COMPOSITE STRUCTURES
(2023)
Article
Chemistry, Multidisciplinary
Tiffany Cheng, Marc Thielen, Simon Poppinga, Yasaman Tahouni, Dylan Wood, Thorsten Steinberg, Achim Menges, Thomas Speck
Summary: This study introduces a material programming approach based on biological role models for designing 4D-printed self-shaping material systems. Computational design methods and extrusion-based 3D printing are used to customize bio-inspired behaviors, transferring the principle of force generation by climbing plants to self-tightening splints. This approach allows for novel biomimetic design strategies to be applied to 4D-printed motion mechanisms, expanding the design possibilities for wearable assistive technologies.
Review
Engineering, Civil
Sian I. Evans, Jie Wang, Jian Qin, Yongpeng He, Paul Shepherd, Jialuo Ding
Summary: This paper provides a review of the capabilities of WAAM in manufacturing steel components for the construction industry, specifically focusing on the structural stability and design. It discusses manufacturing techniques for WAAM construction, reviews material and geometric properties, and evaluates the structural stability performance of WAAM steel structures. It also explores structural optimization techniques suitable for WAAM construction and concludes with future research directions.
Review
Materials Science, Multidisciplinary
Aamer Nazir, Ozkan Gokcekaya, Kazi Md Masum Billah, Onur Ertugrul, Jingchao Jiang, Jiayu Sun, Sajjad Hussain
Summary: This article provides a comprehensive summary of multi-material additive manufacturing (MMAM) systems and their working principles. It reviews the strategies for multi-material combination, modeling, and analysis, and discusses the limitations and challenges at multi-material interfaces. Possible strategies to overcome these challenges are discussed, and future directions are stated.
MATERIALS & DESIGN
(2023)
Article
Materials Science, Multidisciplinary
Wenjun Wu, Pai Liu, Yiqiang Wang, Zhan Kang
Summary: This paper introduces a new design of bistable structures that achieve torsional bistability under uniaxial compression. The proposed structure is composed of two co-axis polygonal prisms connected by struts, and torsional bistability is achieved by opposite rotations of the prisms. An analytical model and numerical simulations demonstrate the need for a dual-material design for the inclined and connecting struts to induce bistability.
MATERIALS & DESIGN
(2023)
Review
Polymer Science
Yufan Zheng, Wenkang Zhang, David Moises Baca Lopez, Rafiq Ahmad
Summary: This study provides a comprehensive overview of the current research status and future challenges in multi-material additive manufacturing of polymers through scientometric analysis and systematic review. The research identifies key research trends and highlights the importance of developing technologies in this field, offering valuable insights for practitioners and researchers to guide future research directions.
Article
Materials Science, Multidisciplinary
Shitong Zhou, Qiaosong Cai, Iuliia S. Tirichenko, Victoria Vilchez, Oriol Gavalda-Diaz, Florian Bouville, Eduardo Saiz
Summary: In this study, ceramics with continuous weak interlayers were successfully printed using a combination of direct ink writing and coextrusion of multi-material pastes. The introduction of weak interlayers can increase fracture resistance and direct crack propagation. This method demonstrates the potential of enhancing mechanical properties using multi-material inks.
Article
Materials Science, Composites
W. Douglas Hartley, John McCann, Scott Davis, Tom Hocker, Somasekhar Bobba, Nikhil Verghese, Devendra Bajaj, Hang Z. Yu, David A. Dillard
Summary: A general testing approach is presented for studying interfacial delamination behavior in overmolded composite materials. The approach uses a fracture mechanics study and a variant of the double cantilever beam geometry to analyze the fracture modes and the effects of residual stress on fracture mode mixity. The study reveals unexpected fiber bridging behavior at the failure interface and suggests that the polymer/glass interface is more susceptible to crack propagation than the desired overmold interface.
JOURNAL OF THERMOPLASTIC COMPOSITE MATERIALS
(2022)
Article
Materials Science, Multidisciplinary
Yi Han, R. Joey Griffiths, Hang Z. Yu, Yunhui Zhu
JOURNAL OF MATERIALS RESEARCH
(2020)
Article
Materials Science, Multidisciplinary
Hang Z. Yu, Rajiv S. Mishra
Summary: Additive friction stir deposition, as a counterpart to fusion-based additive processes, offers a solid-state deformation processing route for metal additive manufacturing. Its key advantages include producing fully-dense material in the printed state with fine, equiaxed microstructures, making it suitable for industries requiring high load-bearing capacity with minimal post-processing.
MATERIALS RESEARCH LETTERS
(2021)
Article
Materials Science, Multidisciplinary
Jake K. Yoder, R. Joey Griffiths, Hang Z. Yu
Summary: This study successfully prints high-strength 7075 aluminum alloy using a deformation-based additive process, achieving excellent mechanical properties. The method consistently achieves wrought-like mechanical properties without the need for adding new elements or nanoparticles.
MATERIALS & DESIGN
(2021)
Article
Engineering, Industrial
W. Douglas Hartley, David Garcia, Jake K. Yoder, Eric Poczatek, Joy H. Forsmark, S. George Luckey, David A. Dillard, Hang Z. Yu
Summary: Additive friction stir deposition can produce high-quality cladding without porosity even in thin substrates as thin as 1.4 mm, preserving the original strength and formability of the substrate. Despite mild global substrate distortion during cooling, the system reconfigures itself to minimize potential energy and reduce residual stress.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Mackenzie E. J. Perry, Hunter A. Rauch, R. Joey Griffiths, David Garcia, Jennifer M. Sietins, Yunhui Zhu, Yuntian Zhu, Hang Z. Yu
Summary: This study investigates the deformation fundamentals of additive friction stir deposition using tracer-based feed material to uncover the plastic deformation path and concurrent grain structure evolution. The results demonstrate significant grain refinement during initial material feeding via geometric dynamic recrystallization, but no further grain refinement during steady-state deposition. The findings provide insights into developing future deformation processing-based additive technologies.
Article
Chemistry, Physical
Yi Je Cho, David Garcia, Hang Z. Yu, Zhifei Deng, Ling Li, Kathy Lu
Summary: Matrix-grade graphite ARB-B1 oxidation behavior was studied under simulated water ingress accidental conditions, revealing an activation energy of 121.5 kJ/mol and primarily pore diffusion assisted by cracks as the oxidation mechanism. The cracks, originating from the fabrication process, played a crucial role in the oxidation behavior.
Article
Engineering, Manufacturing
Hunter A. Rauch, Huachen Cui, Kendall P. Knight, R. Joey Griffiths, Jake K. Yoder, Xiaoyu Zheng, Hang Z. Yu
Summary: This work presents a stereolithography-based additive manufacturing approach for yttrium-stabilized tetragonal zirconia polycrystals (Y-TZP), which shows promising mechanical and functional properties. The printed Y-TZP parts achieved a relative density of 98% after post-processing. The bulk-scale Y-TZP micro-honeycombs exhibited stretch-dominated behavior and had a high energy dissipation density, mainly attributed to the progressive wall collapse and stress-induced martensitic transformation.
ADDITIVE MANUFACTURING
(2022)
Article
Engineering, Industrial
Jee Yun Kim, David Garcia, Yunhui Zhu, David M. Higdon, Hang Z. Yu
Summary: This paper presents an interdisciplinary framework that combines experimentation, mechanical modeling, and statistical learning to address the challenges of multi-material design in additive manufacturing. By using advanced Bayesian learning and inference, this framework enables parameter calibration, fast and accurate prediction of physical response, and uncertainty quantification.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Multidisciplinary Sciences
Rongxuan Wang, David Garcia, Rakesh R. Kamath, Chaoran Dou, Xiaohan Ma, Bo Shen, Hahn Choo, Kamel Fezzaa, Hang Z. Yu, Zhenyu (James) Kong
Summary: This study applies and integrates three advanced sensing technologies, namely synchrotron X-ray imaging, high-speed IR camera, and high-spatial-resolution IR camera, to investigate the behavior of the melt pool in laser powder bed fusion. It presents a novel algorithm for accurately identifying melt pool geometries based on high-speed X-ray imaging data and implements preprocessing methods for IR data to estimate emissivity values. Quantifications on various parameters are conducted, revealing the strong correlation between thermal and X-ray data. The findings demonstrate the feasibility of using relatively inexpensive IR cameras for predicting features that currently require costly synchrotron X-ray imaging.
SCIENTIFIC REPORTS
(2022)
Article
Materials Science, Multidisciplinary
R. Joey Griffiths, Nikhil Gotawala, Greg D. Hahn, David Garcia, Hang Z. Yu
Summary: This paper explores the underwater operation potential of an emerging solid-state additive technology: additive friction stir deposition. It is demonstrated that additive friction stir deposition of 304 stainless steel can be successfully performed with the print head and substrate immersed in water, resulting in fully-dense as-deposited material with microstructure changes.
MATERIALS & DESIGN
(2022)
Article
Materials Science, Multidisciplinary
Hang Z. Yu, Greg D. Hahn
Summary: This letter examines the potential and challenges of using additive friction stir deposition for large-scale near-net-shaping of 7xxx Al alloys. Additive friction stir deposition is capable of producing fully-dense AA7075 and AA7050 without feedstock modification. The process is well-suited for large-scale printing but still faces challenges.
MATERIALS LETTERS-X
(2023)
Article
Engineering, Manufacturing
Jake K. Yodera, Greg D. Hahna, Nanzhu Zhaob, Raymond E. Brennan, Kyu Choc, Hang Z. Yu
Summary: Additive Friction Stir Deposition (AFSD) technology is used to consolidate Al chips from automotive castings into fully-dense components, addressing the challenges of energy, environment, and efficiency in chip recycling. AFSD of cold-pressed porous feed-rods results in porosity-free material with improved tensile elongation and strain hardening due to microstructure evolution. Si and Fe-based particles in the chips are refined and uniformly distributed in the Al matrix after deposition, leading to an equiaxed grain structure. The energy consumption of AFSD-enabled upcycling is compared to melt-based recycling, and potential pathways for energy consumption reduction are evaluated.
ADDITIVE MANUFACTURING LETTERS
(2023)
Article
Chemistry, Multidisciplinary
Ryan B. Gottwald, R. Joey Griffiths, Dylan T. Petersen, Mackenzie E. J. Perry, Hang Z. Yu
Summary: Structural metal components are essential in various industries but often face damage. Structural repair technologies are cost-effective methods to restore components, reducing the need for replacement.
ACCOUNTS OF MATERIALS RESEARCH
(2021)
Article
Materials Science, Multidisciplinary
R. Joey Griffiths, David Garcia, Jie Song, Vijay K. Vasudevan, Matthew A. Steiner, Wenjun Cai, Hang Z. Yu
Summary: The study investigates the process-microstructure linkages in additive friction stir deposition using aluminum-magnesium-silicon alloy and copper, showing that the microstructure in aluminum-magnesium-silicon evolves primarily through continuous dynamic recrystallization, while copper exhibits heterogeneous microstructure due to discontinuous recrystallization. The differences in microstructure evolution are attributed to intrinsic thermomechanical properties and interactions with the tool head.