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Inventions
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Revolutionizing Manufacturing: Advances in Additive Manufacturing Technologies
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Revolutionizing Manufacturing: Advances in Additive Manufacturing Technologies

A special issue of Inventions (ISSN 2411-5134). This special issue belongs to the section "Inventions and Innovation in Advanced Manufacturing".

Deadline for manuscript submissions: 31 December 2024 | Viewed by 4001

Special Issue Editors

Prof. Dr. Ismail Fidan

E-Mail Website
Guest Editor
Department of Manufacturing and Engineering Technology, College of Engineering, Tennessee Tech University, Cookeville, TN 38505, USA
Interests: fiber reinforced additive manufacturing; low cost metal additive manufacturing; smart manufacturing; electronics manufacturing; remote laboratories; STEM education focused on manufacturing innovation
Dr. Evren Yasa

E-Mail Website
Guest Editor
Additive Manufacturing, University of Sheffield AMRC, Rotherham S60 5TZ, UK
Interests: additive manufacturing
Dr. Vladimir Popov

E-Mail Website
Guest Editor
Department of Materials Science and Engineering, Tel Aviv University, Ramat Aviv, Tel Aviv 6997801, Israel
Interests: powder bed fusion; binder jetting; materials design; additive manufacturing of metals; ceramics; composites; in situ alloying; alloy development; microstructure characterization; manufacturing processes
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

This Special Issue, "Revolutionizing Manufacturing: Advances in Additive Manufacturing Technologies", explores the dynamic realm of Additive Manufacturing, commonly known as 3D printing, and its transformative impact on modern industry.

Additive Manufacturing has emerged as a catalyst for innovation by reshaping traditional design and manufacturing processes, and enabling the creation of intricate, customized, and sustainable products. This Special Issue is a platform for inventors, researchers, and industry leaders to share their pioneering work, breakthroughs, and novel applications in this field.

Key themes include advancements in materials, novel 3D printing techniques, improvements in post-processing methods, and the integration of Additive Manufacturing into various industries, from aerospace and healthcare to automotive and consumer goods. We invite contributions that highlight inventive solutions, disruptive technologies, and real-world applications that are pushing the boundaries of what is today possible within Additive Manufacturing.

Dr. Ismail Fidan
Dr. Evren Yasa
Dr. Vladimir Popov
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Inventions is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing
  • 3D printing
  • multi-material and multi-process technologies
  • design for additive manufacturing
  • Industry 4.0
  • large-scale additive manufacturing
  • topology optimization
  • digital twin and simulation
  • advanced materials
  • in situ monitoring and quality control
  • AM process qualification and certification
  • functional and graded materials
  • AI
  • optimization
  • sustainability
  • supply chain management
  • bioprinting
  • post-processing

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Published Papers (3 papers)

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Research

24 pages, 3113 KiB  
Article
Pressure Capacity Assessment of L-PBF-Produced Microchannel Heat Exchangers
by Jiabao An, Luyao Guo, Junjia Zou, Keliang Zhang, Yiheng Zhong, Taimingwang Liu, Long Huang and Yi Chen
Inventions 2024, 9(5), 97; https://doi.org/10.3390/inventions9050097 - 6 Sep 2024
Viewed by 526
Abstract
Laser powder bed fusion (L-PBF) manufacturing technology is an emerging field of research that focuses on evaluating constraints in printed products. This study highlights the importance of considering various factors, such as mechanical properties and support structures, during the design phase, particularly in [...] Read more.
Laser powder bed fusion (L-PBF) manufacturing technology is an emerging field of research that focuses on evaluating constraints in printed products. This study highlights the importance of considering various factors, such as mechanical properties and support structures, during the design phase, particularly in the context of microchannel heat exchangers where all limiting factors are critical. This paper presents a methodology for analyzing channel pressure limitations and examines the impact of pipe porosity on the loss of mechanical properties. A combination of simulation experiments and pressure capacity tests is used to elucidate the pressure distribution characteristics of microchannel flat tubes and their true pressure capacity. This study also explores potential methods for improving the performance of L-PBF-printed microchannel flat tubes. The results and the development of the experimental setup are summarized. Full article
(This article belongs to the Special Issue Revolutionizing Manufacturing: Advances in Additive Manufacturing Technologies)
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22 pages, 5758 KiB  
Article
Tailoring Laser Powder Bed Fusion Process Parameters for Standard and Off-Size Ti6Al4V Metal Powders: A Machine Learning Approach Enhanced by Photodiode-Based Melt Pool Monitoring
by Farima Liravi, Sebastian Soo, Sahar Toorandaz, Katayoon Taherkhani, Mahdi Habibnejad-Korayem and Ehsan Toyserkani
Inventions 2024, 9(4), 87; https://doi.org/10.3390/inventions9040087 - 30 Jul 2024
Viewed by 1265
Abstract
An integral part of laser powder bed fusion (LPBF) quality control is identifying optimal process parameters tailored to each application, often achieved through time-consuming and costly experiments. Melt pool dynamics further complicate LPBF quality control due to their influence on product quality. Using [...] Read more.
An integral part of laser powder bed fusion (LPBF) quality control is identifying optimal process parameters tailored to each application, often achieved through time-consuming and costly experiments. Melt pool dynamics further complicate LPBF quality control due to their influence on product quality. Using machine learning and melt pool monitoring data collected with photodiode sensors, the goal of this research was to efficiently customize LPBF process parameters. A novel aspect of this study is the application of standard and off-size powder feedstocks. Ti6Al4V (Ti64) powder was used in three size ranges of 15–53 µm, 15–106 µm, and 45–106 µm to print the samples. This facilitated the development of a process parameters tailoring system capable of handling variations in powder size ranges. Ultimately, per each part, the associated set of light intensity statistical signatures along with the powder size range and the parts’ density, surface roughness, and hardness were used as inputs for three regressors of Feed-Forward Neural Network (FFN), Random Forest (RF), and Extreme Gradient Boosting (XGBoost). The laser power, laser velocity, hatch distance, and energy density of the parts were predicted by the regressors. According to the results obtained on unseen samples, RF demonstrated the best performance in the prediction of process parameters. Full article
(This article belongs to the Special Issue Revolutionizing Manufacturing: Advances in Additive Manufacturing Technologies)
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19 pages, 7211 KiB  
Article
A Novel Hybrid Ultrasound Abrasive-Driven Electrochemical Surface Finishing Technique for Additively Manufactured Ti6Al4V Parts
by Manyou Sun and Ehsan Toyserkani
Inventions 2024, 9(2), 45; https://doi.org/10.3390/inventions9020045 - 19 Apr 2024
Viewed by 1482
Abstract
Poor surface quality is one of the drawbacks of metal parts made by additive manufacturing (AM)—they normally possess relatively high surface roughness and different types of surface irregularities. Post-processing operations are usually needed to reduce the surface roughness to have ready-to-use parts. Among [...] Read more.
Poor surface quality is one of the drawbacks of metal parts made by additive manufacturing (AM)—they normally possess relatively high surface roughness and different types of surface irregularities. Post-processing operations are usually needed to reduce the surface roughness to have ready-to-use parts. Among all the surface treatment techniques, electrochemical polishing has the highest finishing efficiency and flexibility. However, although the average surface roughness can be reduced effectively (more than 80% roughness reduction), large-scale surface waviness still remains an issue when finishing metal AM parts. To maintain the finishing efficiency while reducing the surface waviness, a novel hybrid surface finishing technique is designed, which involves the combination of electropolishing, ultrasonic vibration, and abrasion. Preliminary experiments to prove the feasibility of novel hybrid finishing methods were conducted on Ti6Al4V coupons manufactured via laser powder bed fusion (LPBF). Electropolishing, a combination of ultrasound and abrasion, and hybrid finishing were conducted for process optimization and comparison purposes. The effects of the voltage, inter-electrode gap, temperature, ultrasonic amplitude, abrasive concentration, and processing time were studied and optimized. When similar optimal arithmetic mean height values (Sa ≈ 1 μm) are achieved for both processes, the arithmetic mean waviness values (Wa) obtained from hybrid finishing are much less than those from sole electropolishing after the same processing time, with the amount being 61.7% less after 30 min and 40.0% after 45 min. Full article
(This article belongs to the Special Issue Revolutionizing Manufacturing: Advances in Additive Manufacturing Technologies)
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