Latest Technologies, Design Considerations, and Quality Concerns of Additive Polymers Manufacturing



Abstract Views
157

Downloads
155

Citations

Share

##plugins.themes.bootstrap3.article.sidebar##

Submitted Dec 21, 2022
Published Jul 30, 2023
10.24018/ejeng.2023.8.4.2956

Abstract viewed = 157 times

Table of Contents

##plugins.themes.bootstrap3.article.main##

Additive manufacturing (AM or 3D printing) is known for large capacities like design freedom, reduced tooling, and production hours. AM evolving exciting advancements for new business models in different industries. Few research papers and studies are limited to material specifications, processes, or quality issues. So, this literature review combined with considerations of AM for polymers materials to quality process to get basic ideas or to lay the groundwork for future researchers. To outline the critical points for investigative queries and identify research gaps in this literature with primarily detailed info on innovation technologies. This review states polymers materials optimization and its manufacturing, all-purpose design considerations, and limitations define CAD source printing and step-by-step quality processes for the fortitude of the analysis to create previous research intended to advantage researchers for future business practices in Industrial revolution 4.0.
Keywords: Additive Manufacturing (AM) Digital Manufacturing Polymers Quality Control Technical Trends

Downloads

Download data is not yet available.

References

  1. Abdullah AM, Tuan Rahim TNA, Mohamad D, Akil HM, Rajion ZA. Mechanical and physical properties of highly ZrO2 /β-TCP filled polyamide 12 prepared via fused deposition modelling (FDM) 3D printer for potential craniofacial reconstruction application. Materials Letters, 2017 Feb; 189: 307–9.
    DOI  |   Google Scholar
  2. Abdullah Kafi, Wu H, Langston JH, Ozen Atak, Kim HW, Kim SB, et al. Evaluation of additively manufactured ultraperformance polymers to use as thermal protection systems for spacecraft. 2020 Feb 19;137(37):49117–7.
    DOI  |   Google Scholar
  3. Agarwala MK, Jamalabad VR, Langrana NA, et al. Structural quality of parts processed by fused deposition. Rapid Prototyping Journal, 1996; 2: 4-19.
    DOI  |   Google Scholar
  4. Angjellari M, Tamburri E, Montaina L, Natali M, Passeri D, Rossi M, et al. Beyond the concepts of nanocomposite and 3D printing: PVA and nanodiamonds for layer-by-layer additive manufacturing. Materials & Design, 2017 Apr; 119: 12–21.
    DOI  |   Google Scholar
  5. Azarniya A, Colera XG, Mirzaali MJ, Sovizi S, Bartolomeu F, St Weglowski M, et al. Additive manufacturing of Ti–6Al–4V parts through laser metal deposition (LMD): Process, microstructure, and mechanical properties. Journal of Alloys and Compounds, 2019;804:163–91.
    DOI  |   Google Scholar
  6. BSBEDGE. Best Standard Service Providers in India [Internet]. Available from: https://www.bsbedge.com/
     Google Scholar
  7. Wałpuski B, Słoma M. Additive Manufacturing of Electronics from Silver Nanopowders Sintered on 3D Printed Low‐Temperature Substrates. 2021 Jan 25; 23(4): 2001085–5.
    DOI  |   Google Scholar
  8. Supplementary Line - BASF FORWARD AM. BASF 3D Printing Materials and Services. [Internet]. Available from: https://forward-am.com/material-portfolio/ultracur3d-photopolymers/supplementary-line/
     Google Scholar
  9. Engineering PRV. Bridging The Gap with Additive Manufacturing [Internet]. PRV Engineering Blog. 2021 [cited 2023 Jul 20]. Available from:https://blog.prv-engineering.co.uk/bridging-the-gap-with-additive-manufacturing/
     Google Scholar
  10. Bryant ST, Straker K, Wrigley C. The rapid product design and development of a viable nanotechnology energy storage product. Journal of Cleaner Production. 2020 Jan;244:118725.
    DOI  |   Google Scholar
  11. Burov V, Ogneva T, Dul’beeva O. The issue of quality assurance of materials in additive manufacturing of metal products. IOP Conference Series: Materials Science and Engineering. 2019 Nov 21;681:012006.
    DOI  |   Google Scholar
  12. Wohlersadmin. New Wohlers Report 2020 Documents More than [Internet]. Wohlers Associates. 2020. Available from: https://wohlersassociates.com/press-releases/new-wohlers-report-2020-documents-more-than/
     Google Scholar
  13. Cong W, Ning F. A fundamental investigation on ultrasonic vibration-assisted laser engineered net shaping of stainless steel. International Journal of Machine Tools and Manufacture. 2017 Oct;121:61–9.
    DOI  |   Google Scholar
  14. DebRoy T, Wei HL, Zuback JS, Mukherjee T, Elmer JW, Milewski JO, et al. Additive manufacturing of metallic components – Process, structure and properties. Prog Mater Sci, 2018;92:112–224.
    DOI  |   Google Scholar
  15. Ding G, He R, Zhang K, Xie C, Wang M, Yang Y, et al. Stereolithography‐based additive manufacturing of gray‐colored SiC ceramic green body. Journal of the American Ceramic Society, 2019 Jul;102(12):7198–209.
    DOI  |   Google Scholar
  16. Dutra TA, Ferreira RTL, Resende HB, Blinzler BJ, Asp LE. Mechanism based failure of 3D-printed continuous carbon fiber reinforced thermoplastic composites. Compos Sci Technol, 2021;213(108962):108962.
    DOI  |   Google Scholar
  17. Edwards P, O’Conner A, Ramulu M. Electron Beam Additive Manufacturing of Titanium Components: Properties and Performance. Journal of Manufacturing Science and Engineering, 2013; 135(6).
    DOI  |   Google Scholar
  18. EOS. Industrial 3D Printing for Dental Technology. [Internet]. www.eos.info. [cited 2023 Jul 20]. Available from: https://www.eos.info/en/innovations/all-3d-printing-applications/medical/dental.
     Google Scholar
  19. Farzadi A, Solati-Hashjin M, Asadi-Eydivand M, Abu Osman NA. Effect of Layer Thickness and Printing Orientation on Mechanical Properties and Dimensional Accuracy of 3D Printed Porous Samples for Bone Tissue Engineering. PLoS ONE [Internet]. 2014 Sep 18;9(9):e108252. Available from: https://www.ncbi.nlm.nih.gov/pmc/articles/PMC4169505/
    DOI  |   Google Scholar
  20. Fitter HN, Pandey AB, Patel DD, Mistry JM. A Review on Approaches for Handling Bezier Curves in CAD for Manufacturing. Procedia Engineering. 2014;97:1155–66.
    DOI  |   Google Scholar
  21. Flir. Rolling down the cost of 3D confocal microscopy. [Internet]. 2015 Available from: https://www.flir.com/discover/iis/machine-vision/rolling-down-the-cost-of-3d-confocal-microscopy.
     Google Scholar
  22. Gao C, Wolff S, Wang S. Eco-friendly additive manufacturing of metals: Energy efficiency and life cycle analysis. Journal of Manufacturing Systems. 2021 Jul;60:459–72.
    DOI  |   Google Scholar
  23. Gillani F, Chatha KA, Sadiq Jajja MS, Farooq S. Implementation of digital manufacturing technologies: Antecedents and consequences. International Journal of Production Economics. 2020 Nov;229:107748.
    DOI  |   Google Scholar
  24. Ghoshal S. Polymer/Carbon Nanotubes (CNT) Nanocomposites Processing Using Additive Manufacturing (Three-Dimensional Printing) Technique: An Overview. Fibers. 2017 Oct 23;5(4):40.
    DOI  |   Google Scholar
  25. Balachandramurthi AR, Moverare J, Mahade S, Pederson R. Additive Manufacturing of Alloy 718 via Electron Beam Melting: Effect of Post-Treatment on the Microstructure and the Mechanical Properties. Materials, 2018; 12(1):68.
    DOI  |   Google Scholar
  26. DyeMansion | Additive manufacturing finishing systems [Internet]. DyeMansion. Available from: https://dyemansion.com/en/
     Google Scholar
  27. Gokuldoss PK, Kolla S, Eckert J. Additive Manufacturing Processes: Selective Laser Melting, Electron Beam Melting and Binder Jetting—Selection Guidelines. Materials, 2017 Jun 19;10(6):672.
    DOI  |   Google Scholar
  28. Haleem A, Javaid M. 3D printed medical parts with different materials using additive manufacturing. Clinical Epidemiology and Global Health, 2020 Mar;8(1):215–23.
    DOI  |   Google Scholar
  29. Hansen HJ, Jesper Henri Hattel, David Bue Pedersen, Mohanty SD, Andersen SB, Venkata Karthik Nadimpalli, et al. Additive manufacturing of metal components – process-material interaction in different process chains. 2019;580(1):012006–6.
    DOI  |   Google Scholar
  30. Hollister SJ, Flanagan CL, Morrison RJ, Patel JJ, Wheeler MB, Edwards SP, et al. Integrating Image-Based Design and 3D Biomaterial Printing to create Patient Specific Devices within a Design Control Framework for Clinical Translation. ACS biomaterials science & engineering, 2016;2(10):1827–36. Available from: https://europepmc.org/article/med/31231678.
    DOI  |   Google Scholar
  31. SME. AM in the Medical Field [Internet]. Available from: https://www.sme.org/technologies/articles/2020/may/am-in-the-medical-field/.
     Google Scholar
  32. Jabbari A, Abrinia K. A metal additive manufacturing method: semi-solid metal extrusion and deposition. The International Journal of Advanced Manufacturing Technology, 2017 Sep 25;94(9-12):3819–28.
    DOI  |   Google Scholar
  33. Jackson B. BMW Group kicks off project for serial automotive additive manufacturing [Internet]. 3D Printing Industry. 2019. Available from: https://3dprintingindustry.com/news/bmw-group-kicks-off-project-for-serial-automotive-additive-manufacturing-153665/
     Google Scholar
  34. Jasveer S, Jianbin X. Comparison of Different Types of 3D Printing Technologies. International Journal of Scientific and Research Publications, 2018; 8(4): 2250-3153.
    DOI  |   Google Scholar
  35. Kaveh M, Badrossamay M, Foroozmehr E, Hemasian Etefagh A. Optimization of the printing parameters affecting dimensional accuracy and internal cavity for HIPS material used in fused deposition modeling processes. Journal of Materials Processing Technology, 2015 Dec;226:280–6.
    DOI  |   Google Scholar
  36. Additive manufacturing of advanced ceramic materials. Progress in Materials Science, 2021; 116:100736. Available from: https://www.sciencedirect.com/science/article/pii/S0079642520301006.
    DOI  |   Google Scholar
  37. Li JY, Yao XX, Wang YF, et al. (2021). The Simulation of Post-Heat Treatment in Selective Laser Melting Additive Manufacturing. Integr Mater Manuf Innov. https://doi.org/10.1007/s40192-021-00222-7.
    DOI  |   Google Scholar
  38. Ligon SC, Liska R, Stampfl J, Gurr M, Mülhaupt R. Polymers for 3D Printing and Customized Additive Manufacturing. Chemical Reviews, 2017 Jul 30;117(15):10212–90.
    DOI  |   Google Scholar
  39. Liu J, Yan J, Yu H. Stress-constrained topology optimization for material extrusion polymer additive manufacturing. Journal of Computational Design and Engineering, 2021; 8(3).
    DOI  |   Google Scholar
  40. Liu W, Zhu Z, Ye S. A decision-making methodology integrated in product design for additive manufacturing process selection. Rapid Prototyping Journal, 2020; 26(5): 895-909.
    DOI  |   Google Scholar
  41. Duy Xuan Luong, Subramanian A, Gladys Lizama Silva, Yoon J, Cofer S, Yang K, et al. Laminated Object Manufacturing of 3D‐Printed Laser‐Induced Graphene Foams. 2018 May 29;30(28):1707416–6.
    DOI  |   Google Scholar
  42. Qualifying Additive Manufacturing Parts – DSIAC [Internet]. Dsiac.org. 2017 [cited 2023 Jul 21]. Available from: https://dsiac.org/state-of-the-art-reports/qualifying-additive-manufacturing-parts/.
     Google Scholar
  43. Muthusamy M, Safaee S, Chen R. Additive Manufacturing of Overhang Structures Using Moisture-Cured Silicone with Support Material. Journal of Manufacturing and Materials Processing. 2018 Apr 17;2(2):24.
    DOI  |   Google Scholar
  44. Prosser M. This Boat Was 3D Printed—and Bigger, Wilder Projects Will Soon Follow [Internet]. Singularity Hub. 2019 [cited 2023 Jul 21]. Available from: https://singularityhub.com/2019/11/14/this-boat-was-3d-printed-and-bigger-wilder-projects-will-soon-follow/
     Google Scholar
  45. 3D printing trends 2020 [Internet]. Hubs. [cited 2023 Mar 19]. Available from: https://www.hubs.com/blog/3d-printing-trends-2020/
     Google Scholar
  46. Schmid M, Amado A, Wegener K. Materials perspective of polymers for additive manufacturing with selective laser sintering. Journal of Materials Research, 2014 Jul 8;29(17):1824–32.
    DOI  |   Google Scholar
  47. Shi J, Li F, Chen S, Zhao Y, Tian H. Effect of in-process active cooling on forming quality and efficiency of tandem GMAW–based additive manufacturing. 2018 Nov 19;101(5-8):1349–56.
    DOI  |   Google Scholar
  48. Quality Control & Assurance For Additive Manufacturing [Internet]. Sigma Additive Solutions. Available from: https://sigmalabsinc.com/quality-control-assurance-additive-manufacturing/
     Google Scholar
  49. Sing SL, An J, Yeong WY, Wiria FE. Laser and electron-beam powder-bed additive manufacturing of metallic implants: A review on processes, materials and designs. Journal of Orthopaedic Research. 2015 Oct 29;34(3):369–85.
    DOI  |   Google Scholar
  50. Sing S, Yeong W. Process–Structure–Properties in Polymer Additive Manufacturing. Polymers, 2021 Mar 30;13(7):1098.
    DOI  |   Google Scholar
  51. MultiFab: A Machine Vision Assisted Platform for Multi-material 3D Printing [Internet]. cdfg.mit.edu. Available from: https://cdfg.mit.edu/publications/multifab-machine-vision-assisted-platform-multi-material-3d-printing.
     Google Scholar
  52. Sohrabian M, Vaseghi M, Khaleghi H, Dehrooyeh S, Kohan MSA. Structural Investigation of Delicate-Geometry Fused Deposition Modeling Additive Manufacturing Scaffolds: Experiment and Analytics. Journal of Materials Engineering and Performance, 2021 May 26;30(9):6529–41.
    DOI  |   Google Scholar
  53. Soler M, Scholtz A, Zeto R, Armani AM. Engineering photonics solutions for COVID-19. APL Photonics. 2020 Sep 1;5(9):090901.
    DOI  |   Google Scholar
  54. Fused Deposition Modeling [FDM] Technology [Internet]. www.stratasys.com. Available from: https://www.stratasys.com/en/guide-to-3d-printing/technologies-and-materials/FDM-technology/
     Google Scholar
  55. Insights S. 5 Top Additive Manufacturing Startups Impacting the Construction Industry [Internet]. StartUs Insights. 2019. Available from: https://www.startus-insights.com/innovators-guide/5-top-additive-manufacturing-startups-impacting-the-construction-industry/
     Google Scholar
  56. Touri M, Kabirian F, Saadati M, Ramakrishna S, Mozafari M. Additive Manufacturing of Biomaterials − The Evolution of Rapid Prototyping. Advanced Engineering Materials, 2019 Jan 3;21(2):1800511.
    DOI  |   Google Scholar
  57. Trumpf. Laser plastic welding [Internet]. Available from: https://www.trumpf.com/en_US/solutions/applications/laser-welding/laser-plastic-welding/
     Google Scholar
  58. Center for Devices and Radiological Health. Technical Considerations for Additive Manufactured Medical Devices [Internet]. U.S. Food and Drug Administration. 2020. Available from: https://www.fda.gov/regulatory-information/search-fda-guidance-documents/technical-considerations-additive-manufactured-medical-devices
     Google Scholar
  59. Verbeeten WMH, Arnold-Bik RJ, Lorenzo-Bañuelos M. Print Velocity Effects on Strain-Rate Sensitivity of Acrylonitrile-Butadiene-Styrene Using Material Extrusion Additive Manufacturing. Polymers. 2021;13(1):149.
    DOI  |   Google Scholar
  60. Vialva T. 3D Printing Industry. 2023 [Internet]. Available from: https://3dprintingindustry.com/news/author/tia-vialva/
     Google Scholar
  61. Manoharan V, Chou SM, Forrester S, Chai GB, Kong PW. Application of additive manufacturing techniques in sports footwear. Virtual and Physical Prototyping, 2013 Dec;8(4):249–52.
    DOI  |   Google Scholar
  62. Vyavahare S, Teraiya S, Panghal D, Kumar S. Fused deposition modelling: a review. Rapid Prototyping Journal, 2020 Jan 6;26(1):176–201.
    DOI  |   Google Scholar
  63. Wang M, Xie C, He R, Ding G, Zhang K, Wang G, et al. Corrections to: Polymer‐derived silicon nitride ceramics by digital light processing based additive manufacturing. 2019 Jul 22;102(12):7769–70.
    DOI  |   Google Scholar
  64. Wiese M, Leiden A, Rogall C, Thiede S, Herrmann C. Modeling energy and resource use in additive manufacturing of automotive series parts with multi-jet fusion and selective laser sintering. Procedia CIRP [Internet]. 2021 Jan 1 [cited 2023 Jul 21];98:358–63. Available from: https://www.sciencedirect.com/science/article/pii/S2212827121001475
    DOI  |   Google Scholar
  65. Wong H, Neary D, Jones E, Fox PT, Sutcliffe C. Pilot capability evaluation of a feedback electronic imaging system prototype for in-process monitoring in electron beam additive manufacturing. The International Journal of Advanced Manufacturing Technology. 2019 Jan 1;100(1-4):707–20.
    DOI  |   Google Scholar
  66. Wu D, Rosen DW, Wang L, Schaefer D. Cloud-based design and manufacturing: A new paradigm in digital manufacturing and design innovation. Computer-Aided Design. 2015 Feb;59:1–14.
    DOI  |   Google Scholar
  67. Yang Y, Li L, Pan Y, Sun Z. Energy Consumption Modeling of Stereolithography-Based Additive Manufacturing Toward Environmental Sustainability. Journal of Industrial Ecology, 2017;21(S1): S168–78.
    DOI  |   Google Scholar
  68. Yoo B, Ko H, Chun S. Prosumption perspectives on additive manufacturing: a reconfiguration of consumer products with 3D printing. Rapid Prototyping Journal, 2016; 22: 691-705.
    DOI  |   Google Scholar
  69. Yuasa K, Tagami M, Yonehara M, Ikeshoji TT, Takeshita K, Aoki H, et al. Influences of powder characteristics and recoating conditions on surface morphology of powder bed in metal additive manufacturing. The International Journal of Advanced Manufacturing Technology. 2021 Jun 12;115(11-12):3919–32.
    DOI  |   Google Scholar
  70. Zhao J, Yang Y, Li L. A comprehensive evaluation for different post-curing methods used in stereolithography additive manufacturing. Journal of Manufacturing Processes, 2020 Aug;56:867–77.
    DOI  |   Google Scholar
  71. Zhou X, Li X. Trajectory Tracking Control for Electro-Optical Tracking System Using ESO Based Fractional- Order Sliding Mode Control. IEEE Access. 2021;9:45891–902.
    DOI  |   Google Scholar