latest research paper on additive manufacturing

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Additive Manufacturing (AM) – Top research papers

Additive manufacturing (AM) or 3D printing introduces a novel production method in design, manufacturing, and distribution to end-users. This technology provides great freedom in design for creating complex components, highly customizable products, and efficient waste minimization.

Thanks to its numerous benefits, such as time and material saving, rapid prototyping, high efficiency, and decentralized production methods, AM plays a principal role in industry 4.0 that employs the integration of smart manufacturing systems and developed information technologies.

The additive manufacturing technique was first employed by Charles Hull for the stereolithography (SLA) process in 1986. However, over three decades, many other printing methods were discovered and several improvements, transforming the manufacturing and logistics processes. This encouraged the market for more investments in various industries, such as biomedical, aerospace, and automotive.

Notably, there is a significant growth in the investment in AM technology from $4 billion in 2014 to over $21 billion by 2020. AM benefits attract much attention in manufacturing, such as mass-customized production, prototyping, sustainable production, and minimized lead time and cost.

Top research papers on Additive Manufacturing

1. Additive Manufacturing (AM) at Industry 4.0: A Review by Diogo José Horst (2018) – This paper presents the fundamental principles of 3D printing, its roles in industry 4.0 in saving time and cost, and the benefits, e.g., higher flexibility and individualization.

2. Additive manufacturing (3D printing): A review of materials, methods, applications, and challenges by Tuan D. Ngo (2018) – This paper covers the main advantage of additive manufacturing in fast prototyping and its capabilities for producing complex structures, mass customization, freedom of design, and waste minimization. It also explains the industrial revolution of additive manufacturing in aerospace, biomedical, building, and protective structures and the fast transition from conventional machining and traditional methods.

3. Methods and Materials for Smart Manufacturing: Additive Manufacturing, Internet of Things, Flexible Sensors and Soft Robotics by Arkadeep Kumar (2018) – The paper presents various additive manufacturing applications for factories in the future. It also talks about industry 4.0 and smart manufacturing systems using 3D printing and developing and innovation in manufacturing methods and material using additive manufacturing.

4. Advanced Material Strategies for Next-Generation Additive Manufacturing by Jinke Chang (2018) – This paper talks about the application of AM in various fields and industrial productions, e.g., microelectronic and biomedical devices. It also introduces the novel additive manufacturing process for multiple materials, including smart materials, biomaterials, and conductive materials.

5. Additive Manufacturing, Cloud-Based 3D Printing, and Associated Services—Overview by Felix W. Baumann (2017) – This covers the application of Cloud Manufacturing (CM) in the concept of a service-oriented approach over the internet and the historical development in the field of CM and AM in the smart manufacturing process between 2002 to 2006.

6. The role of additive manufacturing in the era of Industry 4.0 by Ugur M Dilberoglu (2017) – This paper covers the recent development of the additive manufacturing process, the benefits of additive manufacturing in design improvement, and industry 4.0. and the current technological methods and highlights in the additive manufacturing process.

7. Smart manufacturing: Characteristics, technologies, and enabling factors by Sameer Mittal (2017) – This paper reviews all published works on various applied technologies and processes related to the smart manufacturing topic and a comprehensive list of the influential factors associated with smart manufacturing and industry 4.0.

8. The rise of 3-D printing: The advantages of additive manufacturing over traditional manufacturing by Mohsen Attaran (2017) – This presents the future of additive manufacturing and identifying the challenges, technologies, and trends, the benefits of additive manufacturing compared with conventional machining and discuss its influence on the supply chain process and the potential of additive manufacturing and impact on the various industry.

9. Industrial Additive Manufacturing: A manufacturing systems perspective by Daniel R. Eyers (2017) – This paper covers the current applications of the additive manufacturing process in the industry, various methods including mechanisms, controls, and activities, and the development in industrial applications and the potentials and opportunities to improve the future of manufacturing.

10. Industrie 4.0 and Smart Manufacturing A Review of Research Issues and Application Examples by Klaus-Dieter Thoben (2017) – This paper presents an overview of smart manufacturing in industry 4.0. It also identifies the current and the future states of technology, besides offering an analysis of cyber-physical systems (CPS) and investigating the potential and applications of this system in production, design, and maintenance processes.

11. Material issues in additive manufacturing: A review by Sunpreet Singh (2017) – This paper presents a review of the biomedical applications of the additive manufacturing process, an introduction to Additive Bio-Manufacturing (ABM) technique for having a safer production, and review the helpful papers on this topic.

12. The evolution and future of manufacturing: A review by Behzad Esmaeilian (2016) – This explores a study of the manufacturing systems and all published works on this topic and the future of manufacturing processes focusing on design development sustainability issues as people, profit, planet.

13. Smart Manufacturing: Past Research, Present Findings, and Future Directions by Hyoung Seok Kang (2016) – This paper analyzes smart manufacturing in the past, current applications, and future by investigating various research papers. It also examines a new paradigm of Information and communications technology (ICT) and manufacturing technologies in industrial revolution 4.0 or smart manufacturing.

14. Additive manufacturing management: a review and future research agenda by Mojtaba khorram (2016) – This covers the multidimensional, systematic, and quantitative analysis to discover the structure of the additive manufacturing process in various scopes, including management, economic, and business. It also investigates the eight principle spectra of the research, including the additive manufacturing process, supply chain management, production design and cost model, strategies challenges, manufacturing systems, sustainability, innovation, and business model.

15. Current Standards Landscape for Smart Manufacturing Systems by Yan Lu (2016) – This report reviews the body of relevant standards upon which future smart manufacturing systems will rely. This report allows manufacturing practitioners to better understand those standards applicable to integrating smart manufacturing technologies. The report concludes that existing manufacturing standards are insufficient to fully enable smart manufacturing, especially in cybersecurity, cloud-based manufacturing services, supply chain integration, and data analytics.

16. Opportunities for Sustainable Manufacturing in Industry 4.0 by Tim Stock (2016) – This presents various sustainability issues in smart manufacturing industry 4.0 and development in sustainable manufacturing and provides solutions in the manufacturing processes.

17. Additive manufacturing and sustainability: an exploratory study of the advantages and challenges by Simon Ford (2016) – This paper covers an overview of advanced manufacturing processes and technologies such as additive manufacturing process, and benefits and challenges of the additive manufacturing process on sustainability issues in terms of business model, value chains, and innovation.

18. The status, challenges, and future of additive manufacturing in engineering by Wei Gao (2015) – This paper shares comprehensive knowledge of the additive manufacturing process, current challenges, achievements and the trend of the future, and the potential of the additive manufacturing process to achieve “print-it-all” image as the primary goal of the AM process shortly.

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Catching additive manufacturing defects with nanoseconds to spare

T he United States is on the cusp of a manufacturing renaissance. Federal legislation has ushered in billions of dollars of investment in manufacturing capabilities that will streamline the supply chain and strengthen national security.

One capability poised to have a profound impact on the nation's industrial base is additive manufacturing, which encompasses a variety of fabrication techniques that build structures layer by layer.

"Additive manufacturing allows you to create so many different structures that are optimized for specific applications," said Vince Pagán, an experimental optics scientist and project manager at the Johns Hopkins Applied Physics Laboratory (APL) in Laurel, Maryland.

"But its Achilles' heel is that the process generates defects that can cause parts to weaken and fail, and you can't have that when they're used in critical applications like national defense, biotechnology and aerospace."

This problem remains one of the most significant obstacles to widespread adoption of additive manufacturing technology, but APL experts are addressing it by developing sensors that are fast enough to identify defects before they materialize.

"If we can identify defect formation while still in the melt state, then we have the opportunity to repair these imperfections before they result in performance-limiting flaws," said Morgan Trexler, who leads APL's Science of Extreme and Multifunctional Materials program. "We are working to make manufacturing processes more intelligent, which will inherently lead to more rapid manufacturing and trusted components."

Bubble trouble

Some of the most common defects created during additive manufacturing—and among the hardest to prevent—are keyhole formations. These appear during the process of powder bed fusion, a method of additive manufacturing that uses lasers to melt metal powders and solidify them into complex geometries.

When the lasers deposit too much energy too quickly into the melted metal or melt pool, tiny bubbles of vapor form and become trapped as the metal cools, weakening a part's structural integrity. Because they form beneath actively printed layers, keyhole defects are hard to spot in real-time—but not impossible.

"We can identify rocks below the surface of rivers from space, not because we can actually see them directly, but because we can see rapids where the water flow is disrupted," explained Steve Storck, project manager and chief scientist for manufacturing technologies in APL's Research and Exploratory Development Department.

"Similarly, if a pore is about to form in a part, then the thermal flow around it will be disrupted, which indicates a defect in the formation process. If we can measure that temperature and spectral anomalies accurately and rapidly, we should be able to tell if something is forming in, underneath or adjacent to the active melting location."

The researchers hypothesized that these keyhole defects were occurring during transitional states. If they could pause the depositing laser just before the anomaly began to form, then the molten metal could cool long enough to settle and close the vapor depression, preventing bubble formation.

"To eliminate keyhole defects, we need to be able to detect and prevent them in real time, but this all happens exceptionally fast," said Storck. "In the additive manufacturing process, solidification happens about 1 to 3,000 times faster than during traditional processes, which means conventional sensing and control methods would not work. This drove us to develop custom methods."

To find out just how long they needed to pause the laser, Li Ma, a senior engineer and additive manufacturing process modeling expert, ran a simulation using computational fluid dynamics. The simulation determined that response times faster than 10 to 20 microseconds were required to identify a thermal disruption, augment the process, and let the molten pool cool slightly without a defect forming.

"This is where the magic happens," said Pagán. "We're essentially slowing down time."

From concept to process

The team first tested conventional sensors to see if they could identify the defect signatures fast enough, but ran into optical resolution and speed limitations. This prompted a collaboration with Mark Foster, an associate professor of electrical and computer engineering with the Johns Hopkins University's Whiting School of Engineering, and several Whiting School postdoctoral students to enhance an APL-developed and patented sensor.

Melding expertise in materials science, additive manufacturing, optical engineering and data science, they added photodiodes at multiple wavelengths and increased the sample frequency to measure high spatial- and temporal-resolution data on the melt pool and its dynamics, enabling them to gather the information needed to identify the early stages of a keyhole defect on a timescale that could enable real-time repair.

With the high-speed sensor up and running, the researchers developed a control framework that could communicate between the sensor and the laser and tell the laser to shut off when the melt pool got too hot and was likely to create a defect—all within 10 to 20 millionths of a second.

Continuing to draw on expertise from across APL, Storck and Pagán reached out to developer Mike Brown, who adapted a high-speed field-programmable gate array—essentially an integrated circuit that can be programmed to meet specific needs—that was originally designed for defense purposes, to seek missiles in the sky.

"One of the unique aspects of working at APL is the ability to leverage technology from areas that seemingly do not relate; for example, we can take the knowledge and expertise we apply to missile defense—responding to measurement inputs very quickly and making adjustments even faster—and apply it to additive manufacturing," said Storck.

After integrating all the systems, the team successfully demonstrated the system's ability to respond in a mere 952 nanoseconds—less than one microsecond, or faster than the blink of an eye.

"Those were great results, because at a minimum we need to measure at least twice as fast as what's actually happening physically, so we can capture the peaks and valleys of the spectral response as it correlates to temperature," Storck explained. "Our system can measure the spectral and temperature readings and respond 10 times faster than required based on simulations of keyhole formation."

The team plans to incorporate artificial intelligence into the process to speed up the feedback loop and more accurately indicate where and how the defects are forming. Storck said this will enable real-time control and repair as APL works toward producing parts that can be trusted straight from the build.

Provided by Johns Hopkins University

New Technique Improves Finishing Time for 3D-Printed Machine Parts

Original article: New Technique Improves Finishing Time for 3D Printed Machine Parts

Original author: Matt Shipman

North Carolina State University researchers have demonstrated a technique that allows people who manufacture metal machine parts with 3D printing technologies to conduct automated quality control of manufactured parts during the finishing process. The technique allows users to identify potential flaws without having to remove the parts from the manufacturing equipment, making production time more efficient.

“One of the reasons people are attracted to 3D printing and other additive manufacturing technologies is that these technologies allow users to quickly replace critical machine components that are otherwise difficult to make outside of a factory,” says Brandon McConnell, co-corresponding author of a paper on the work. “And additive manufacturing tools can do this as needed, rather than dealing with supply chains that can have long wait times. That usually means using 3D printing to create small batches of machine parts on demand.” McConnell is an assistant research professor in NC State’s Edward P. Fitts Department of Industrial and Systems Engineering.

After a metal machine part is printed, it requires additional finishing and has to be measured to ensure the part meets critical tolerances. In other words, every aspect of the part must be the right size. Currently, that involves taking a part out of the relevant manufacturing equipment, measuring it, and then putting it back into the manufacturing equipment to make modest adjustments.

“This may need to be done repeatedly, and can take a significant amount of time,” McConnell says. “Our work here expedites that process.”

Specifically, the researchers have integrated 3D printing, automated machining, laser scanning and touch-sensitive measurement technologies with related software to create a largely automated system that produces metal machine components that meet critical tolerances.

Here’s how it works.

When end users need a specific part, they pull up a software file that includes the measurements of the desired part. A 3D printer uses this file to print the part, which includes metal support structures. Users then take the printed piece and mount it in a finishing device using the support structure. At this point, lasers scan the mounted part to establish its dimensions. A software program then uses these dimensions and the desired critical tolerances to guide the finishing device, which effectively polishes out any irregularities in the part. As this process moves forward, the finishing device manipulates the orientation of the printed part so that it can be measured by a touch-sensitive robotic probe that ensures the part’s dimensions are within the necessary parameters.

To test the performance of the new approach, researchers manufactured a machine part using conventional 3D printing and finishing techniques, and then manufactured the same part using their new process.

“We were able to finish the part in 200 minutes using conventional techniques; we were able to finish the same part in 133 minutes using our new technique,” McConnell says. “Depending on the situation, saving 67 minutes could be incredibly important. Time is money in most professional settings. And in emergency response contexts, for example, it could be the difference between life and death.”

The researchers note that this work focuses on printing and finishing machine parts that include circles or cylinders, such as pistons. However, the approach could be adapted for machine parts with other features.

“All of the hardware we used in this technique is commercially available, and we outline the necessary software clearly in the paper – so we feel that this new approach could be adopted and put into use almost immediately,” McConnell says. “And we are certainly open to working with partners who are interested in making use of this technique in their operations.”

The paper, “ Automatic Feature Based Inspection and Qualification for Additively Manufactured Parts with Critical Tolerances ,” is published in the  International Journal of Manufacturing Technology and Management . First author of the paper is Christopher Kelly, a former graduate student at NC State who now works for Celonis, Inc. The paper was co-authored by Richard Wysk, professor emeritus in the Fitts Department of Industrial and Systems Engineering; Ola Harrysson, Edward P. Fitts Distinguished Professor in the Fitts Department of Industrial and Systems Engineering; and Russell King, the Henry L. Foscue Distinguished Professor of Industrial and Systems Engineering at NC State.

The work was done with support from the U.S. Army Research Office, under grant number W911NF1910055.

“Automatic Feature Based Inspection and Qualification for Additively Manufactured Parts with Critical Tolerances”

Authors : Christopher J. Kelly, Deloitte; Richard A. Wysk, Ola A. Harrysson, Russell E. King and Brandon M. McConnell, North Carolina State University

Published : May 1,  International Journal of Manufacturing Technology and Management

DOI : 10.1504/IJMTM.2024.138337

Abstract:  This work expands the capabilities of the Digital Additive and Subtractive Hybrid (DASH) system by including “geometric qualification” of mechanical products. Specifically, this research incorporates the extended Additive Manufacturing Format files (AMF-TOL) which include American Society of Mechanical Engineers (ASME) Y14.5 specifications for planes, cylinders and other features so that “in-process” inspection can be completed automatically. An example for the production of holes is provided to illustrate On-Machine-Measurement collects sample radii to estimate the size and position of finished cylindrical features. Statistical analysis was used to measure bounds for comparison to specified tolerance callouts to determine whether a part is within specification, within a user-defined level of confidence. Seven different sampling strategies were evaluated on a DASH part including the bird cage sampling strategy defined in ISO-12180. Part data was utilized to show that for large data samples no statistically significant difference in accuracy was identified for four methods. Finally, analysis shows that using the DASH process with automatic inspection is economically advantageous for low volume production runs.

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New Technique Improves Finishing Time for 3D Printed Machine Parts

North Carolina State University researchers have demonstrated a technique that allows people who manufacture metal machine parts with 3D printing technologies to conduct automated quality control of manufactured parts during the finishing process. The technique allows users to identify potential flaws without having to remove the parts from the manufacturing equipment, making production time more efficient.

“One of the reasons people are attracted to 3D printing and other additive manufacturing technologies is that these technologies allow users to quickly replace critical machine components that are otherwise difficult to make outside of a factory,” says Brandon McConnell, co-corresponding author of a paper on the work. “And additive manufacturing tools can do this as needed, rather than dealing with supply chains that can have long wait times. That usually means using 3D printing to create small batches of machine parts on demand.” McConnell is an assistant research professor in NC State’s Edward P. Fitts Department of Industrial and Systems Engineering.

After a metal machine part is printed, it requires additional finishing and has to be measured to ensure the part meets critical tolerances. In other words, every aspect of the part must be the right size. Currently, that involves taking a part out of the relevant manufacturing equipment, measuring it, and then putting it back into the manufacturing equipment to make modest adjustments.

“This may need to be done repeatedly, and can take a significant amount of time,” McConnell says. “Our work here expedites that process.”

Specifically, the researchers have integrated 3D printing, automated machining, laser scanning and touch-sensitive measurement technologies with related software to create a largely automated system that produces metal machine components that meet critical tolerances.

Here’s how it works.

When end users need a specific part, they pull up a software file that includes the measurements of the desired part. A 3D printer uses this file to print the part, which includes metal support structures. Users then take the printed piece and mount it in a finishing device using the support structure. At this point, lasers scan the mounted part to establish its dimensions. A software program then uses these dimensions and the desired critical tolerances to guide the finishing device, which effectively polishes out any irregularities in the part. As this process moves forward, the finishing device manipulates the orientation of the printed part so that it can be measured by a touch-sensitive robotic probe that ensures the part’s dimensions are within the necessary parameters.

To test the performance of the new approach, researchers manufactured a machine part using conventional 3D printing and finishing techniques, and then manufactured the same part using their new process.

“We were able to finish the part in 200 minutes using conventional techniques; we were able to finish the same part in 133 minutes using our new technique,” McConnell says. “Depending on the situation, saving 67 minutes could be incredibly important. Time is money in most professional settings. And in emergency response contexts, for example, it could be the difference between life and death.”

The researchers note that this work focuses on printing and finishing machine parts that include circles or cylinders, such as pistons. However, the approach could be adapted for machine parts with other features.

“All of the hardware we used in this technique is commercially available, and we outline the necessary software clearly in the paper – so we feel that this new approach could be adopted and put into use almost immediately,” McConnell says. “And we are certainly open to working with partners who are interested in making use of this technique in their operations.”

The paper, “ Automatic Feature Based Inspection and Qualification for Additively Manufactured Parts with Critical Tolerances ,” is published in the International Journal of Manufacturing Technology and Management . First author of the paper is Christopher Kelly, a former graduate student at NC State who now works for Celonis, Inc. The paper was co-authored by Richard Wysk, professor emeritus in the Fitts Department of Industrial and Systems Engineering; Ola Harrysson, Edward P. Fitts Distinguished Professor in the Fitts Department of Industrial and Systems Engineering; and Russell King, the Henry L. Foscue Distinguished Professor of Industrial and Systems Engineering at NC State.

The work was done with support from the U.S. Army Research Office, under grant number W911NF1910055.

Note to Editors: The study abstract follows.

“Automatic Feature Based Inspection and Qualification for Additively Manufactured Parts with Critical Tolerances”

Authors : Christopher J. Kelly, Deloitte; Richard A. Wysk, Ola A. Harrysson, Russell E. King and Brandon M. McConnell, North Carolina State University

Published : May 1, International Journal of Manufacturing Technology and Management

DOI : 10.1504/IJMTM.2024.138337

Abstract: This work expands the capabilities of the Digital Additive and Subtractive Hybrid (DASH) system by including “geometric qualification” of mechanical products. Specifically, this research incorporates the extended Additive Manufacturing Format files (AMF-TOL) which include American Society of Mechanical Engineers (ASME) Y14.5 specifications for planes, cylinders and other features so that “in-process” inspection can be completed automatically. An example for the production of holes is provided to illustrate On-Machine-Measurement collects sample radii to estimate the size and position of finished cylindrical features. Statistical analysis was used to measure bounds for comparison to specified tolerance callouts to determine whether a part is within specification, within a user-defined level of confidence. Seven different sampling strategies were evaluated on a DASH part including the bird cage sampling strategy defined in ISO-12180. Part data was utilized to show that for large data samples no statistically significant difference in accuracy was identified for four methods. Finally, analysis shows that using the DASH process with automatic inspection is economically advantageous for low volume production runs.

This post was originally published in NC State News.

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Research Progress in metal additive manufacturing: Challenges and Opportunities

• Published: 12 December 2023

Cite this article

• Ashish Kumar Srivastava 1 ,
• Ajay Kumar   ORCID: orcid.org/0000-0001-7306-1902 2 ,
• Parveen Kumar 3 ,
• Preeti Gautam 4 &
• Namrata Dogra 5  

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The revolutionary changes in aircraft and automobile industries persuaded the rapid productional technology which introduced additive manufacturing of three-dimensional products. The layer-by-layer development techniques with the uniqueness of producing intricate shapes with negligible wastage of material make it famous for many sectors like defence, automobile, aircraft, medical etc. The present work focuses on different aspects of additive manufacturing especially metal additive manufacturing in terms of their microstructural and morphological aspects. It highlights the different technologies involve in additive manufacturing and discuss the advantages, opportunities and challenges associated with different types of metal additive manufacturing. At last, the present work also highlights the utilization of additive manufacturing techniques in different sectors of use.

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Ashish Kumar Srivastava

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Srivastava, A.K., Kumar, A., Kumar, P. et al. Research Progress in metal additive manufacturing: Challenges and Opportunities. Int J Interact Des Manuf (2023). https://doi.org/10.1007/s12008-023-01661-6

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DOI : https://doi.org/10.1007/s12008-023-01661-6

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