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Journal articles on the topic 'Hybrid Metal and Polymer Additive Manufacturing'
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1
Silva, Miguel Reis, Jorge Domingues, João Costa, Artur Mateus, and Cândida Malça. "Study of Metal/Polymer Interface of Parts Produced by a Hybrid Additive Manufacturing Approach." Applied Mechanics and Materials 890 (April 2019): 34–42. http://dx.doi.org/10.4028/www.scientific.net/amm.890.34.
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The additive manufacturing of multimaterial parts, e.g. metal/plastic, with functional gradients represents for current market demands a great potential of applications [1]. Metal Polymer parts combine the good mechanical properties of the metals with the low weight characteristics, good impact strength, good vibration and sound absorption of the polymers. Nevertheless, the coupling between metal and polymers is a great challenge since the processing factors for each one of them are very different. In addition, a system that makes the hybrid processing - metal/polymer - using only one operation is unknown [2, 3]. To overcome this drawback, a hybrid additive manufacturing system based on the additive technologies of SLM and SL was recently developed by the authors. The SLM and SL techniques joined enabling the production of a photopolymerization of the polymer in the voids of a 3D metal mesh previously produced by SLM [4]. The purpose of this work is the study on the metal/polymer interface of hybrid parts manufactured from the hybrid additive manufacturing system [5]. For this, a core of tool steel (H13) and two different types of photo-polymers: one elastomeric (BR3D-DL-Flex) and another one rigid (BR3D-DL-Hard) are considered. A set of six samples for each one of metal core/polymer combination was manufactured and submitted to tensile tests.
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He, Liu, Peiren Wang, Lizhe Wang, Min Chen, Haiyun Liu, and Ji Li. "Multifunctional Polymer-Metal Lattice Composites via Hybrid Additive Manufacturing Technology." Micromachines 14, no. 12 (2023): 2191. http://dx.doi.org/10.3390/mi14122191.
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With increasing interest in the rapid development of lattice structures, hybrid additive manufacturing (HAM) technology has become a competent alternative to traditional solutions such as water jet cutting and investment casting. Herein, a HAM technology that combines vat photopolymerization (VPP) and electroless/electroplating processes is developed for the fabrication of multifunctional polymer-metal lattice composites. A VPP 3D printing process is used to deliver complex lattice frameworks, and afterward, electroless plating is employed to deposit a thin layer of nickel-phosphorus (Ni-P) conductive seed layer. With the subsequent electroplating process, the thickness of the copper layer can reach 40 μm within 1 h and the resistivity is around 1.9×10−8 Ω⋅m, which is quite close to pure copper (1.7 ×10−8 Ω⋅m). The thick metal shell can largely enhance the mechanical performance of lattice structures, including structural strength, ductility, and stiffness, and meanwhile provide current supply capability for electrical applications. With this technology, the frame arms of unmanned aerial vehicles (UAV) are developed to demonstrate the application potential of this HAM technology for fabricating multifunctional polymer-metal lattice composites.
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Setter, Robert, Jan Hafenecker, Richard Rothfelder, et al. "Innovative Process Strategies in Powder-Based Multi-Material Additive Manufacturing." Journal of Manufacturing and Materials Processing 7, no. 4 (2023): 133. http://dx.doi.org/10.3390/jmmp7040133.
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Multi-material additive manufacturing (AM) attempts to utilize the full benefits of complex part production with a comprehensive and complementary material spectrum. In this context, this research article presents new processing strategies in the field of polymer- and metal-based multi-material AM. The investigation highlights the current progress in powder-based multi-material AM based on three successfully utilized technological approaches: additive and formative manufacturing of hybrid metal parts with locally adapted and tailored properties, material-efficient AM of multi-material polymer parts through electrophotography, and the implementation of UV-curable thermosets within the laser-based powder bed fusion of plastics. Owing to the complex requirements for the mechanical testing of multi-material parts with an emphasis on the transition area, this research targets an experimental shear testing set-up as a universal method for both metal- and polymer-based processes. The method was selected based on the common need of all technologies for the sufficient characterization of the bonding behavior between the individual materials.
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He, Liu, Peiren Wang, Junhui Yang, et al. "Smart Lattice Structures with Self-Sensing Functionalities via Hybrid Additive Manufacturing Technology." Micromachines 15, no. 1 (2023): 2. http://dx.doi.org/10.3390/mi15010002.
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Lattice structures are a group of cellular materials composed of regular repeating unit cells. Due to their extraordinary mechanical properties, such as specific mechanical strength, ultra-low density, negative Poisson’s ratio, etc., lattice structures have been widely applied in the fields of aviation and aerospace, medical devices, architecture, and automobiles. Hybrid additive manufacturing (HAM), an integrated manufacturing technology of 3D printing processes and other complementary processes, is becoming a competent candidate for conveniently delivering lattice structures with multifunctionalities, not just mechanical aspects. This work proposes a HAM technology that combines vat photopolymerization (VPP) and electroless plating process to fabricate smart metal-coated lattice structures. VPP 3D printing process is applied to create a highly precise polymer lattice structure, and thereafter electroless plating is conducted to deposit a thin layer of metal, which could be used as a resistive sensor for monitoring the mechanical loading on the structure. Ni-P layer and copper layer were successfully obtained with the resistivity of 8.2×10−7Ω⋅m and 2.0 ×10−8 Ω⋅m, respectively. Smart lattice structures with force-loading self-sensing functionality are fabricated to prove the feasibility of this HAM technology for fabricating multifunctional polymer-metal lattice composites.
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Tosto, Claudio, Jacopo Tirillò, Fabrizio Sarasini, and Gianluca Cicala. "Hybrid Metal/Polymer Filaments for Fused Filament Fabrication (FFF) to Print Metal Parts." Applied Sciences 11, no. 4 (2021): 1444. http://dx.doi.org/10.3390/app11041444.
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The exploitation of mechanical properties and customization possibilities of 3D printed metal parts usually come at the cost of complex and expensive equipment. To address this issue, hybrid metal/polymer composite filaments have been studied allowing the printing of metal parts by using the standard Fused Filament Fabrication (FFF) approach. The resulting hybrid metal/polymer part, the so called “green”, can then be transformed into a dense metal part using debinding and sintering cycles. In this work, we investigated the manufacturing and characterization of green and sintered parts obtained by FFF of two commercial hybrid metal/polymer filaments, i.e., the Ultrafuse 316L by BASF and the 17-4 PH by Markforged. The Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectrometry (EDS) analyses of the mesostructure highlighted incomplete raster bonding and voids like those observed in conventional FFF-printed polymeric structures despite the sintering cycle. A significant role in the tensile properties was played by the building orientation, with samples printed flatwise featuring the highest mechanical properties, though lower than those achievable with standard metal additive manufacturing techniques.
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Falck, R., S. M. Goushegir, J. F. dos Santos, and S. T. Amancio-Filho. "AddJoining: A novel additive manufacturing approach for layered metal-polymer hybrid structures." Materials Letters 217 (April 2018): 211–14. http://dx.doi.org/10.1016/j.matlet.2018.01.021.
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Mahmood, Ayyaz, Fouzia Perveen, Shenggui Chen, Tayyaba Akram, and Ahmad Irfan. "Polymer Composites in 3D/4D Printing: Materials, Advances, and Prospects." Molecules 29, no. 2 (2024): 319. http://dx.doi.org/10.3390/molecules29020319.
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Additive manufacturing (AM), commonly referred to as 3D printing, has revolutionized the manufacturing landscape by enabling the intricate layer-by-layer construction of three-dimensional objects. In contrast to traditional methods relying on molds and tools, AM provides the flexibility to fabricate diverse components directly from digital models without the need for physical alterations to machinery. Four-dimensional printing is a revolutionary extension of 3D printing that introduces the dimension of time, enabling dynamic transformations in printed structures over predetermined periods. This comprehensive review focuses on polymeric materials in 3D printing, exploring their versatile processing capabilities, environmental adaptability, and applications across thermoplastics, thermosetting materials, elastomers, polymer composites, shape memory polymers (SMPs), including liquid crystal elastomer (LCE), and self-healing polymers for 4D printing. This review also examines recent advancements in microvascular and encapsulation self-healing mechanisms, explores the potential of supramolecular polymers, and highlights the latest progress in hybrid printing using polymer–metal and polymer–ceramic composites. Finally, this paper offers insights into potential challenges faced in the additive manufacturing of polymer composites and suggests avenues for future research in this dynamic and rapidly evolving field.
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Silva, Sofia F., Pedro M. S. Rosado, Rui F. V. Sampaio, et al. "A New Methodology to Fabricate Polymer–Metal Parts Through Hybrid Fused Filament Fabrication." Sustainability 17, no. 10 (2025): 4254. https://doi.org/10.3390/su17104254.
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This paper introduces a new methodology that enables the production of polymer–metal parts through hybrid additive manufacturing. The approach combines fused filament fabrication (FFF) of polymers with adhesive bonding of metal inserts, applied during layer-by-layer construction. The work is based on unit cells designed and fabricated using eco-friendly materials—polylactic acid (PLA) and aluminum—which were subsequently analyzed for build quality and for mechanical performance under tensile lap-shear and three-point bending tests. The acquired knowledge in terms of optimal processing parameters for attaining strong polymer–metal bonds was then applied for the fabrication and testing of prototypes representing modular corner connectors for framing applications. Results on build quality demonstrate that issues, such as lumps and warping, can be solved by finetuning the 3D printing stages of the proposed methodology. In terms of destructive testing, significant improvements in the mechanical performance of PLA can be achieved, demonstrating the feasibility of the proposed methodology in integrating the lightweight properties of polymers with the stiffness of metals. This enables the development of innovative, sustainable and eco-friendly solutions that align with the growing demand for eco-friendly materials and processes in manufacturing.
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Ozlati, A., M. Movahedi, M. Tamizi, Z. Tartifzadeh, and S. Alipour. "An alternative additive manufacturing-based joining method to make Metal/Polymer hybrid structures." Journal of Manufacturing Processes 45 (September 2019): 217–26. http://dx.doi.org/10.1016/j.jmapro.2019.07.002.
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Silva, M., A. Mateus, D. Oliveira, and C. Malça. "An alternative method to produce metal/plastic hybrid components for orthopedics applications." Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications 231, no. 1-2 (2016): 179–86. http://dx.doi.org/10.1177/1464420716664545.
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The demand for additive processes that provide components with high technological performance became overriding regardless of the application area. For medical applications, the orthopedics field—multimaterial orthoses and splints—can clearly benefit from direct additive manufacturing using a hybrid process instead of the traditional handmade manufacturing, which is slow, expensive, inaccurate, and difficult to reproduce. The ability to provide faster better orthoses, using innovative services and technologies, resulting in lower recovery times, reduced symptoms, and improved functional capacity, result in a significant impact on quality of life and the well-being of citizens. With these purposes, this work presents an integrate methodology, that includes the tridimensional (3D) scanning, 3D computer-aided design modeling, and the direct digital manufacturing of multimaterial orthoses and splints. Nevertheless, additive manufacturing of components with functional gradients, multimaterial components, e.g. metal/plastic is a great challenge since the processing factors for each one of them are very different. This paper proposes the addition of two advanced additive manufacturing technologies, the selective laser melting and the stereolithography, enabling the production of a photopolymerization of the polymer in the voids of a 3D metal mesh previously produced by selective laser melting. Based on biomimetic structures concept, this mesh is subject to a previous design optimization procedure in order to optimize its geometry, minimizing the mass involved and evidencing increased mechanical strength among other characteristics. A prototype of a hybrid additive manufacturing device was developed and its flexibility of construction, geometrical freedom, and different materials processability is demonstrated through the case study—arm orthosis—presented in this work.
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Chueh, Yuan-Hui, Xiaoji Zhang, Jack Chun-Ren Ke, Qian Li, Chao Wei, and Lin Li. "Additive manufacturing of hybrid metal/polymer objects via multiple-material laser powder bed fusion." Additive Manufacturing 36 (December 2020): 101465. http://dx.doi.org/10.1016/j.addma.2020.101465.
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Silva, M., R. Felismina, A. Mateus, P. Parreira, and C. Malça. "Application of a Hybrid Additive Manufacturing Methodology to Produce a Metal/Polymer Customized Dental Implant." Procedia Manufacturing 12 (2017): 150–55. http://dx.doi.org/10.1016/j.promfg.2017.08.019.
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Barakat, Ali A., Basil M. Darras, Mohammad A. Nazzal, and Aser Alaa Ahmed. "A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures." Polymers 15, no. 1 (2022): 220. http://dx.doi.org/10.3390/polym15010220.
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Metal–polymer hybrid structures are becoming desirable due to their wide range of applications in the automotive, aerospace, biomedical and construction industries. Properties such as a light weight, high specific strength, and design flexibility along with the low manufacturing costs of metal–polymer hybrid structures make them widely attractive in several applications. One of the main challenges that hinders the widespread utilization of metal–polymer hybrid structures is the challenging dissimilar joining of metals to polymers. Friction stir welding (FSW) shows a promising potential in overcoming most of the issues and limitations faced in the conventional joining methods of such structures. Several works in the literature have explored the FSW of different metal-to-polymer combinations. In some of the works, the joints are examined based on processing parameter optimization, microstructural characteristics, and mechanical performances. It is, therefore, important to summarize the findings of these works as a means of providing a reference to researchers to facilitate further research on the utilization of FSW in joining metals to polymers. Thus, this work aims to present a comprehensive technical review on the FSW technique for joining metals to polymers by reviewing the reported literature findings on the impact of materials, tools, process parameters, and defects on the strength and microstructure of the produced joints. In addition, this work reviews and presents the latest practices aiming to enhance the metal–polymer joint quality that have been reported in the literature.
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Fernandez, Ellen, Mariya Edeleva, Rudinei Fiorio, Ludwig Cardon, and Dagmar R. D’hooge. "Increasing the Sustainability of the Hybrid Mold Technique through Combined Insert Polymeric Material and Additive Manufacturing Method Design." Sustainability 14, no. 2 (2022): 877. http://dx.doi.org/10.3390/su14020877.
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To reduce plastic waste generation from failed product batches during industrial injection molding, the sustainable production of representative prototypes is essential. Interesting is the more recent hybrid injection molding (HM) technique, in which a polymeric mold core and cavity are produced via additive manufacturing (AM) and are both placed in an overall metal housing for the final polymeric part production. HM requires less material waste and energy compared to conventional subtractive injection molding, at least if its process parameters are properly tuned. In the present work, several options of AM insert production are compared with full metal/steel mold inserts, selecting isotactic polypropylene as the injected polymer. These options are defined by both the AM method and the material considered and are evaluated with respect to the insert mechanical and conductive properties, also considering Moldex3D simulations. These simulations are conducted with inputted measured temperature-dependent AM material properties to identify in silico indicators for wear and to perform cooling cycle time minimization. It is shown that PolyJetted Digital acrylonitrile-butadiene-styrene (ABS) polymer and Multi jet fusioned (MJF) polyamide 11 (PA11) are the most promising. The former option has the best durability for thinner injection molded parts, and the latter option the best cooling cycle times at any thickness, highlighting the need to further develop AM options.
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Falck, Rielson, Jorge F. dos Santos, and Sergio T. Amancio-Filho. "Microstructure and Mechanical Performance of Additively Manufactured Aluminum 2024-T3/Acrylonitrile Butadiene Styrene Hybrid Joints Using an AddJoining Technique." Materials 12, no. 6 (2019): 864. http://dx.doi.org/10.3390/ma12060864.
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AddJoining is an emerging technique that combines the principles of the joining method and additive manufacturing. This technology is an alternative method to produce metal–polymer (composite) structures. Its viability was demonstrated for the material combination composed of aluminum 2024-T3 and acrylonitrile butadiene styrene to form hybrid joints. The influence of the isolated process parameters was performed using the one-factor-at-a-time approach, and analyses of variance were used for statistical analysis. The mechanical performance of single-lap joints varied from 910 ± 59 N to 1686 ± 39 N. The mechanical performance thus obtained with the optimized joining parameters was 1686 ± 39 N, which failed by the net-tension failure mode with a failure pattern along the 45° bonding line. The microstructure of the joints and the fracture morphology of the specimens were studied using optical microscopy and scanning electron microscopy. From the microstructure point of view, proper mechanical interlocking was achieved between the coated metal substrate and 3D-printed polymer. This investigation can be used as a base for further improvements on the mechanical performance of AddJoining hybrid-layered applications.
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Zhang, Tao, Uzair Sajjad, Akash Sengupta, Mubasher Ali, Muhammad Sultan, and Khalid Hamid. "A Hybrid Data-Driven Metaheuristic Framework to Optimize Strain of Lattice Structures Proceeded by Additive Manufacturing." Micromachines 14, no. 10 (2023): 1924. http://dx.doi.org/10.3390/mi14101924.
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This research is centered on optimizing the mechanical properties of additively manufactured (AM) lattice structures via strain optimization by controlling different design and process parameters such as stress, unit cell size, total height, width, and relative density. In this regard, numerous topologies, including sea urchin (open cell) structure, honeycomb, and Kelvin structures simple, round, and crossbar (2 × 2), were considered that were fabricated using different materials such as plastics (PLA, PA12), metal (316L stainless steel), and polymer (thiol-ene) via numerous AM technologies, including stereolithography (SLA), multijet fusion (MJF), fused deposition modeling (FDM), direct metal laser sintering (DMLS), and selective laser melting (SLM). The developed deep-learning-driven genetic metaheuristic algorithm was able to achieve a particular strain value for a considered topology of the lattice structure by controlling the considered input parameters. For instance, in order to achieve a strain value of 2.8 × 10−6 mm/mm for the sea urchin structure, the developed model suggests the optimal stress (11.9 MPa), unit cell size (11.4 mm), total height (42.5 mm), breadth (8.7 mm), width (17.29 mm), and relative density (6.67%). Similarly, these parameters were controlled to optimize the strain for other investigated lattice structures. This framework can be helpful in designing various AM lattice structures of desired mechanical qualities.
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Hertle, Sebastian, Tobias Kleffel, Andreas Wörz, and Dietmar Drummer. "Production of polymer-metal hybrids using extrusion-based additive manufacturing and electrochemically treated aluminum." Additive Manufacturing 33 (May 2020): 101135. http://dx.doi.org/10.1016/j.addma.2020.101135.
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Syrlybayev, Daniyar, Aidana Seisekulova, Didier Talamona, and Asma Perveen. "The Post-Processing of Additive Manufactured Polymeric and Metallic Parts." Journal of Manufacturing and Materials Processing 6, no. 5 (2022): 116. http://dx.doi.org/10.3390/jmmp6050116.
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The traditional manufacturing industry has been revolutionized with the introduction of additive manufacturing which is based on layer-by-layer manufacturing. Due to these tool-free techniques, complex shape manufacturing becomes much more convenient in comparison to traditional machining. However, additive manufacturing comes with its inherent process characteristics of high surface roughness, which in turn effect fatigue strength as well as residual stresses. Therefore, in this paper, common post-processing techniques for additive manufactured (AM) parts were examined. The main objective was to analyze the finishing processes in terms of their ability to finish complicated surfaces and their performance were expressed as average surface roughness (Sa and Ra). The techniques were divided according to the materials they applied to and the material removal mechanism. It was found that chemical finishing significantly reduces surface roughness and can be used to finish parts with complicated geometry. Laser finishing, on the other hand, cannot be used to finish intricate internal surfaces. Among the mechanical abrasion methods, abrasive flow finishing shows optimum results in terms of its ability to finish complicated freeform cavities with improved accuracy for both polymer and metal parts. However, it was found that, in general, most mechanical abrasion processes lack the ability to finish complex parts. Moreover, although most of post-processing methods are conducted using single finishing processes, AM parts can be finished with hybrid successive processes to reap the benefits of different post-processing techniques and overcome the limitation of individual process.
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Falck, Rielson, and Sergio T. Amancio-Filho. "The Influence of Coating and Adhesive Layers on the Mechanical Performance of Additively Manufactured Aluminum–Polymer Hybrid Joints." Metals 13, no. 1 (2022): 34. http://dx.doi.org/10.3390/met13010034.
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AddJoining technique has been recently introduced to produce metal–polymer composite hybrid layered structures. The methodology combines the principles of joining and polymeric additive manufacturing. This paper presents three AddJoining process-variants investigated and demonstrated for the material combination aluminum 2024-T3 and acrylonitrile butadiene styrene to form hybrid single lap joints. The microstructure and mechanical performance were assessed. The process variant using heating control showed the ultimate lap shear force of 1.2 ± 0.05 kN and displacement at a break of 1.21 ± 0.16 mm as a result of strong bonding formation at the interface of the hybrid joints. For instance, the other two process variants tested (with epoxy adhesive, and with thin-acrylonitrile butadiene styrene (ABS) coating layer applied on the metal) presented reduced mechanical performance in comparison to process variant using heating control, namely approximately 42% and 8.3%, respectively. The former had a mixed adhesive–cohesive failure due to the lower bonding performance between the adhesive and ABS printed layers. The latter displayed a slight decrease in force in comparison to heat-control specimens. This could be explained by the presence of micro-voids formed by solvent evaporation at the ABS coating layer during AddJoining.
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Khan, Zeba, Addythia Saphala, Sabrina Kartmann, et al. "Hybrid Printing of Conductive Traces from Bulk Metal for Digital Signals in Intelligent Devices." Micromachines 15, no. 6 (2024): 750. http://dx.doi.org/10.3390/mi15060750.
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In this article, we explore multi-material additive manufacturing (MMAM) for conductive trace printing using molten metal microdroplets on polymer substrates to enhance digital signal transmission. Investigating microdroplet spread informs design rules for adjacent trace printing. We studied the effects of print distance on trace morphology and resolution, noting that printing distance showed almost no change in the printed trace pitch. Crosstalk interference between adjacent signal traces was analyzed across frequencies and validated both experimentally and through simulation; no crosstalk was visible for printed traces at input frequencies below 600 kHz. Moreover, we demonstrate printed trace reliability against thermal shock, whereby no discontinuation in conductive traces was observed. Our findings establish design guidelines for MMAM electronics, advancing digital signal transmission capabilities.
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Moritz, Juliane, Philipp Götze, Tom Schiefer, et al. "Additive Manufacturing of Titanium with Different Surface Structures for Adhesive Bonding and Thermal Direct Joining with Fiber-Reinforced Polyether-Ether-Ketone (PEEK) for Lightweight Design Applications." Metals 11, no. 2 (2021): 265. http://dx.doi.org/10.3390/met11020265.
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Hybrid joints consisting of metals and fiber-reinforced polymer composites exhibit highly desirable properties for many lightweight design applications. This study investigates the potential of additively manufactured surface structures for enhancing the bond strength of such joints in comparison to face milled and laser structured surfaces. Titanium samples with different surface structures (as-built surface, groove-, and pin-shaped structures) were manufactured via electron beam melting and joined to carbon fiber-reinforced polyether-ether-ketone (PEEK) via adhesive bonding and thermal direct joining, respectively. Bond strength was evaluated by tensile shear testing. Samples were exposed to salt spray testing for 1000 h for studying bond stability under harsh environmental conditions. The initial tensile shear strengths of the additively manufactured samples were competitive to or in some cases even exceeded the values achieved with laser surface structuring for both investigated joining methods. The most promising results were found for pin-shaped surface structures. However, the hybrid joints with additively manufactured structures tended to be more susceptible to degradation during salt spray exposure. It is concluded that additively manufactured structures can be a viable alternative to laser surface structuring for both adhesive bonding and thermal direct joining of metal-polymer hybrid joints, thus opening up new potentials in lightweight design.
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Saptaji, Kushendarsyah, Dindamilenia Choirunnisa Hardiyasanti, Muchammad Fachrizal Ali, Raffy Frandito, and Tiara Kusuma Dewi. "Potential Applications of Hydroxyapatite-Mineralized-Collagen Composites as Bone Structure Regeneration: a Review." JOURNAL OF SCIENCE AND APPLIED ENGINEERING 5, no. 1 (2022): 33. http://dx.doi.org/10.31328/jsae.v5i1.3577.
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The composites materials are known for their flexibility due to the combinations of two or three different materials and manipulation of their compositions. The advantage offered by composite materials make it suitable for biomedical applications especially to be used for implants. There are three types of composites biocompatible materials namely Metal Matrix Composite (MMC), Ceramic Matrix Composite (CMC) and Polymer Matrix Composite (PMC). In order to produce the biocompatible composite materials, various manufacturing processes can be performed. The manufacturing processes of MMCs are stir casting and powder metallurgy; the typical manufacturing process for CMCs is powder metallurgy; and 3-D printing by synthesizing and cross-linking the networks is used for fabricating PMCs. One of the promising biocompatible composites is Hydroxyapatite Mineralized Collagen (HMC). The HMC is used to create bone scaffold in bone regeneration process. The suggested manufacturing process for HMC is hybrid process which collaborate Additive Manufacturing and CNC Machining. In this paper, the HMC is reviewed especially related with its properties, fabrication method, and existed experimentation. In addition, the three types of biocompatible composites are also discussed on the applications and its manufacturing processes.
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Murchio, Simone, Matteo Benedetti, Anastasia Berto, Francesca Agostinacchio, Gianluca Zappini, and Devid Maniglio. "Hybrid Ti6Al4V/Silk Fibroin Composite for Load-Bearing Implants: A Hierarchical Multifunctional Cellular Scaffold." Materials 15, no. 17 (2022): 6156. http://dx.doi.org/10.3390/ma15176156.
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Despite the tremendous technological advances that metal additive manufacturing (AM) has made in the last decades, there are still some major concerns guaranteeing its massive industrial application in the biomedical field. Indeed, some main limitations arise in dealing with their biological properties, specifically in terms of osseointegration. Morphological accuracy of sub-unital elements along with the printing resolution are major constraints in the design workspace of a lattice, hindering the possibility of manufacturing structures optimized for proper osteointegration. To overcome these issues, the authors developed a new hybrid multifunctional composite scaffold consisting of an AM Ti6Al4V lattice structure and a silk fibroin/gelatin foam. The composite was realized by combining laser powder bed fusion (L-PBF) of simple cubic lattice structures with foaming techniques. A combined process of foaming and electrodeposition has been also evaluated. The multifunctional scaffolds were characterized to evaluate their pore size, morphology, and distribution as well as their adhesion and behavior at the metal–polymer interface. Pull-out tests in dry and hydrated conditions were employed for the mechanical characterization. Additionally, a cytotoxicity assessment was performed to preliminarily evaluate their potential application in the biomedical field as load-bearing next-generation medical devices.
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Kehinde Andrew Olu-lawal, Oladiran Kayode Olajiga, Adeniyi Kehinde Adeleke, Emmanuel Chigozie Ani, and Danny Jose Portillo Montero. "INNOVATIVE MATERIAL PROCESSING TECHNIQUES IN PRECISION MANUFACTURING: A REVIEW." International Journal of Applied Research in Social Sciences 6, no. 3 (2024): 279–91. http://dx.doi.org/10.51594/ijarss.v6i3.886.
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Precision manufacturing plays a pivotal role in various industries, demanding high accuracy, efficiency, and quality in the production process. The continual pursuit of innovation in material processing techniques is essential to meet evolving demands and challenges. This review explores the latest advancements and innovations in material processing methods within precision manufacturing. The review encompasses a comprehensive analysis of various innovative material processing techniques, including additive manufacturing, subtractive manufacturing, and hybrid approaches. Additive manufacturing, often referred to as 3D printing, has gained significant attention for its capability to produce complex geometries with high precision. The exploration of novel materials, such as metal alloys, polymers, and composites, expands the applicability of additive manufacturing in diverse industrial sectors. Subtractive manufacturing techniques, such as milling, turning, and grinding, are also undergoing transformative advancements to enhance precision and efficiency. Emerging technologies like abrasive waterjet machining, electrical discharge machining (EDM), and laser machining offer improved accuracy and surface finish while enabling the processing of a wide range of materials, including hard-to-machine alloys and composites. Hybrid manufacturing approaches, combining additive and subtractive techniques, are revolutionizing precision manufacturing by leveraging the strengths of both methods. These hybrid systems enable the production of intricate components with high precision, reduced lead times, and minimized material waste, addressing the challenges of traditional manufacturing processes. Furthermore, the review highlights advancements in process monitoring and control technologies, such as in-process sensing, real-time feedback systems, and adaptive control algorithms, facilitating enhanced quality assurance and productivity in precision manufacturing. The integration of advanced computational tools, simulation techniques, and artificial intelligence further augments the optimization and customization capabilities of material processing techniques, driving efficiency and innovation in precision manufacturing. Overall, this review provides valuable insights into the latest developments and trends in innovative material processing techniques, offering a roadmap for future research directions and applications in precision manufacturing industries.
 Keywords: Material, Processing, Techniques, Precision, Manufacturing, Review.
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Rosenthal, Stephan, Fabian Maaß, Mike Kamaliev, Marlon Hahn, Soeren Gies, and A. Erman Tekkaya. "Lightweight in Automotive Components by Forming Technology." Automotive Innovation 3, no. 3 (2020): 195–209. http://dx.doi.org/10.1007/s42154-020-00103-3.
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AbstractLightweight design is one of the current key drivers to reduce the energy consumption of vehicles. Design methodologies for lightweight components, strategies utilizing materials with favorable specific properties and hybrid materials are used to increase the performance of parts for automotive applications. In this paper, various forming processes to produce light parts are described. Material lightweight design is discussed, covering the manufacturing processes to produce hybrid components like fiber–metal, polymer–metal and metal–metal composites, which can be used in subsequent deep drawing or combined forming processes. Approaches to increasing the specific strength and stiffness with thermomechanical forming processes as well as the in situ control of the microstructure of such components are presented. Structure lightweight design discusses possibilities to plastically form high-strength or high-performance materials like magnesium or titanium in sheet, profile and tube forming operations. To join those materials and/or dissimilar materials, new joining by forming technologies are shown. To economically produce lightweight parts with gears or functional elements, incremental sheet-bulk metal forming is presented. As an important part property, the damage evolution during the forming operations will be discussed to enable even lighter parts through a more reliable design. New methods for predicting and tailoring the mechanical properties like strength and residual stresses will be shown. The possibilities of system lightweight design with forming technologies are presented. A combination of additive manufacturing and forming to produce highly complex parts with integrated functions will be shown. The integration of functions by a hot extrusion process for the manufacturing of shape memory alloys is presented. An in-depth understanding of the newly developed processes, methodologies and effects allows for a more accurate dimensioning of components. This facilitates a reduction in the total mass and an increasing performance of vehicle components.
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Oliveira, Filipa M., Teresa G. Nunes, Nadya V. Dencheva, and Zlatan Z. Denchev. "Structure and Molecular Dynamics in Metal-Containing Polyamide 6 Microparticles." Crystals 12, no. 11 (2022): 1579. http://dx.doi.org/10.3390/cryst12111579.
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Polymer microparticles are used in additive manufacturing, separation and purification devices, biocatalysis, or for the recognition of biomolecules. This study reports on the effect of metal fillers on the structure and molecular dynamics of polyamide 6 (PA6) microparticles (MPs) containing up to 19 wt.% of Al, Cu, or Mg. These hybrid MPs are synthesized via reactive microencapsulation by anionic ring-opening polymerization in solution, in the presence of the metal filler. 13C high-resolution solid-state NMR (ssNMR) spectroscopy is employed as the primary characterization method using magic angle spinning (MAS) and cross-polarization (CP)/MAS. Depending on the metal filler, the ssNMR crystallinity index of the MP varies between 39–50%, as determined by deconvolution of the 13C MAS and CP/MAS spectra. These values correlate very well with the crystallinity derived from thermal or X-ray diffraction data. The molecular dynamics study on PA6 and Cu-containing MP shows similar mobility of carbon nuclei in the kHz, but not in the MHz frequency ranges. The paramagnetic Al and Mg have an observable effect on the relaxation; however, conclusions regarding the PA6 carbon motions cannot be unequivocally made. These results are useful in the preparation of hybrid microparticles with customized structures and magneto-electrical properties.
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Tsui, Lok-kun, Yongkun Sui, Thomas Michael Hartmann, Joshua Dye, and Judith Maria Lavin. "Additive Manufacturing of Inductors and Transformers by Hybrid Aerosol Jet Printing and Electrochemical Deposition." ECS Meeting Abstracts MA2023-01, no. 22 (2023): 1558. http://dx.doi.org/10.1149/ma2023-01221558mtgabs.
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Aerosol jet printing (AJP) is an attractive additive manufacturing process for printed electronic applications due to its high resolution (< 10 µm), flexible stand-off distance, and support of both metal and dielectric materials. A slow deposition rate (< 1 µm per layer) and the relatively low conductivity achievable with commercially available nanoparticle inks (~40% bulk) present some of the current limitations associated with AJP. Electrochemical deposition methods including both electrodeposition and electroless deposition are widely used in the microelectronics industry. Dense, high conductivity layers several 10s of µm can be deposited with well-established plating processes. Metals including Cu and Ni which are challenging to deposit by AJP, can be easily/readily deposited using commercially available plating baths. A hybrid approach of seed layer deposition using AJP and electrochemical deposition of highly conductive copper is used to improve the overall conductance of the printed structures. [1] Here, we apply this combined approach to the manufacturing of transformer and inductor devices. We have successfully prepared a two-layer secondary inductor on top of a two-layer primary inductor to form a coreless flyback transformer (Figure 1(a)). These inductors were fabricated by AJP of an Ag seed layer, followed by electroless deposition and electrodeposition of Cu and Ni. UV-curable dielectric polymer layers were deposited by AJP to separate each inductor layer. The flyback transformer produced a gain of 75.3x with an input voltage of 17 V at 400 kHz resulting in an output voltage of 1250 V (Figure 1(b)). We also demonstrated the repeated stacking of 8 coil layers by AJP of Ag seed layers and electrodeposition of Cu and Ni (Figure 1(c)). These inductors had an average equivalent series resistance of 0.6 Ω and a 1.7 µH inductance at 100 kHz (Figure 1(d)). Finally, we will study the deposition of these inductor and transformer devices on magnetic substrates, characterizing changes in inductance and gain. SNL is managed and operated by NTESS under DOE NNSA contract DE-NA0003525. SAND2022-17001 A References: [1] L. Tsui, S.C. Kayser, S.A. Strong, J.M. Lavin. ECS J. Solid State Sci. Technol. 10 (2021) 047001. Figure 1. (a) Additively manufactured coreless flyback transformer fabricated by combined aerosol jet printing, electroless deposition, and electrodeposition. (b) Output voltage vs. input voltage at 400 kHz resulting in a gain of 73.5x. (c) 8-layer inductor fabricated by combined aerosol jet printing and electrodeposition. (d) Inductance at 100 kHz as a function of number of layers for the multi-layer inductor up to 8 layers. Figure 1
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De, Pasquale Giorgio, and Fikret Enes Altunok. "Multiphase modeling of matrix/fiber-related damaging mechanism in multimaterial additively manufactured joints with 3D interlocking." Engineering Failure Analysis 170 (January 5, 2025): 109272. https://doi.org/10.1016/j.engfailanal.2025.109272.
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The efficient joining of dissimilar materials, such as metals and carbon fiber-reinforced polymers (CFRP), remains a critical challenge in advanced engineering applications. This study introduce the MIMOSA joint, a novel technique for joining metals and CFRP through additive manufacturing by modification of the metal adherend surface with inclusion of anchors. These anchors mechanically interlock with the CFRP, eliminating the need for adhesives or mechanical fasteners, thereby simplifying the joining process while improving structural integrity. The joint is fabricated using an autoclave curing process, where CFRP layers are applied directly over the anchor-modified metal surface. To investigate the failure mechanisms of this joint, numerical simulations were conducted under two main configurations: (1) a fully bonded system, and (2) a partially bonded system that allows for debonding between the metal and CFRP. A Representative Volume Element (RVE) approach was used to simulate fiber translation, resin pockets, and interfacial debonding with Cohesive Zone Modeling (CZM) to predict failure modes. The key findings reveal that fiber translation around the metal anchors leads to stress concentrations in resin-rich regions and at the metal-matrix interface, causing early failure in these areas. While the anchors improve load transfer between the materials, stress concentrations at the anchor base remain a critical factor for premature failure. The importance of optimizing anchor geometry is highlighted to mitigate these issues and improve overall joint strength. Additionally, optical microscopy was used to verify fiber distribution and the formation of resin pockets around the anchors. This research provides insights into the design and optimization of multimaterial joints. The combined contribution of innovative MIMOSA joint and detailed failure analysis provides valuable guidance for improving joint performance, particularly for applications requiring lightweight, high-strength structures.
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Martins, Guilherme, Carlos M. S. Vicente, and Marco Leite. "Polymer-Metal Adhesion of Single-Lap Joints Using Fused Filament Fabrication Process: Aluminium with Carbon Fiber Reinforced Polyamide." Applied Sciences 13, no. 7 (2023): 4429. http://dx.doi.org/10.3390/app13074429.
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Additive manufacturing (AM) is often used for prototyping; however, in recent years, there have been several final product applications, namely the development of polymer-metal hybrid (PMH) components that have emerged. In this paper, the objective is to characterize the adhesion of single-lap joints between two different materials: aluminium and a polymer-based material manufactured by fused filament fabrication (FFF). Single-lap joints were fabricated using an aluminium substrate with different surface treatments: sandpaper polishing (SP) and grit blasting (GB). Three filaments for FFF were tested: acrylonitrile butadiene styrene (ABS), polyamide (PA), and polyamide reinforced with short carbon fibers (PA + CF). To characterize the behaviour of these single-lap joints, mechanical tension loading tests were performed. The analysis of the fractured surface of the joints aimed to correlate the adhesion performance of each joint with the occurred failure mode. The obtained results show the impact of surface roughness (0.16 < Ra < 1.65 µm) on the mechanical properties of the PMH joint. The ultimate lap shear strength (ULSS) of PMH single-lap joints produced by FFF (1 < ULSS < 6.6 MPa) agree with the reported values in the literature and increases for substrates with a higher surface roughness, remelting of the primer (PA and PA + CF), and higher stiffness of the polymer-based adherent.
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Chakravarthy, Chitra, Daisy Aranha, Santosh Kumar Malyala, and Ravi S. Patil. "Cast Metal Surgical Guides: An Affordable Adjunct to Oral and Maxillofacial Surgery." Craniomaxillofacial Trauma & Reconstruction Open 5 (January 1, 2020): 247275122096026. http://dx.doi.org/10.1177/2472751220960268.
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Additive manufacturing or 3-dimensional (3D) printing technology has an incredulous ability to create complex constructs with high exactitude. Surgical guides printed using this technology allows the transfer of the virtual surgical plan to the operating table, optimizing aesthetic outcomes, and functional rehabilitation. A vast variety of materials are currently being used in medical 3D printing, including metals, ceramics, polymers, and composites. The guides fabricated with titanium have high strength, excellent biocompatibility, and are sterilizable but take time to print and are expensive. We have thus followed a hybrid approach to fabricate an inexpensive surgical guide using metal where the advantage of 3D printing technology has been combined with the routinely followed investment casting procedure to fabricate guides using nickel–chromium, which has all the advantages of a metal and is cost-effective.
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Verma, Ayush, Angshuman Kapil, Damjan Klobčar, and Abhay Sharma. "A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure." Materials 16, no. 15 (2023): 5246. http://dx.doi.org/10.3390/ma16155246.
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Additive manufacturing (AM) has experienced exponential growth over the past two decades and now stands on the cusp of a transformative paradigm shift into the realm of multi-functional component manufacturing, known as multi-material AM (MMAM). While progress in MMAM has been more gradual compared to single-material AM, significant strides have been made in exploring the scientific and technological possibilities of this emerging field. Researchers have conducted feasibility studies and investigated various processes for multi-material deposition, encompassing polymeric, metallic, and bio-materials. To facilitate further advancements, this review paper addresses the pressing need for a consolidated document on MMAM that can serve as a comprehensive guide to the state of the art. Previous reviews have tended to focus on specific processes or materials, overlooking the overall picture of MMAM. Thus, this pioneering review endeavors to synthesize the collective knowledge and provide a holistic understanding of the multiplicity of materials and multiscale processes employed in MMAM. The review commences with an analysis of the implications of multiplicity, delving into its advantages, applications, challenges, and issues. Subsequently, it offers a detailed examination of MMAM with respect to processes, materials, capabilities, scales, and structural aspects. Seven standard AM processes and hybrid AM processes are thoroughly scrutinized in the context of their adaptation for MMAM, accompanied by specific examples, merits, and demerits. The scope of the review encompasses material combinations in polymers, composites, metals-ceramics, metal alloys, and biomaterials. Furthermore, it explores MMAM’s capabilities in fabricating bi-metallic structures and functionally/compositionally graded materials, providing insights into various scale and structural aspects. The review culminates by outlining future research directions in MMAM and offering an overall outlook on the vast potential of multiplicity in this field. By presenting a comprehensive and integrated perspective, this paper aims to catalyze further breakthroughs in MMAM, thus propelling the next generation of multi-functional component manufacturing to new heights by capitalizing on the unprecedented possibilities of MMAM.
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Falco, Marisa, Gabriele Lingua, Silvia Porporato, et al. "An Overview on Polymer-Based Electrolytes with High Ionic Mobility for Safe Operation of Solid-State Batteries." ECS Meeting Abstracts MA2023-02, no. 4 (2023): 604. http://dx.doi.org/10.1149/ma2023-024604mtgabs.
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Liquid electrolytes used in commercial Li-ion batteries are generally based on toxic volatile and flammable organic carbonate solvents, thus raising safety concerns in case of thermal runaway. The most striking solution at present is to switch on all solid-state designs exploiting polymer materials, films, ceramics, low-volatile, green additives, etc. The replacement of liquids component with low-flammable solids is expected to improve the safety level of the device intrinsically. Moreover, a solid-state configuration is expected to guarantee improved energy density systems. However, low ionic conductivity, low cation transport properties and issues in cell manufacturing processes must be overcome [1]. Electrochemical performance in lab-scale devices can be readily improved using different RTILs or specific low-volatile additives. Here, an overview is offered of the recent developments in our labs on innovative polymer-based electrolytes allowing high ionic mobility, particularly attractive for safe, high-performing, solid-state Li-metal batteries, and obtained by different techniques, including solvent-free UV-induced photopolymerization. Cyclic voltammetry and galvanostatic charge/discharge cycling coupled with electrochemical impedance spectroscopy exploiting different electrode materials (e.g., LFP, Li-rich NMC, LNMO, Si/C) demonstrate specific capacities approaching theoretical values even at high C-rates and stable operation for hundreds of cycles at ambient temperature [2,3]. Direct polymerization procedures on top of the electrode films are also used to obtain an intimate electrode/electrolyte interface and full active material utilization in both half and full-cell architectures. In addition, results of composite hybrid polymer electrolytes [4] and new single-ion conducting polymers [5] are shown, specifically developed to attain improved ion transport and high oxidation stability for safe operation with high voltage electrodes even at ambient conditions. References [1] Ferrari, S.; Falco, M.; Muñoz-García, A.B.; Bonomo, M.; Brutti, S.; Pavone, M.; Gerbaldi, C. Solid-State Post Li Metal Ion Batteries: A Sustainable Forthcoming Reality? Adv. Energy Mater. 2021, 11, 2100785. [2] Falco, M.; Simari, C.; Ferrara, C.; Nair, J.R.; Meligrana, G.; Nicotera, I.; Mustarelli, P.; Winter, M.; Gerbaldi, C. Understanding the Effect of UV-Induced Cross-Linking on the Physicochemical Properties of Highly Performing PEO/LiTFSI-Based Polymer Electrolytes. Langmuir 2019, 35, 8210-8219. [3] Lingua, G.; Falco, M.; Stettner, T.; Gerbaldi, C.; Balducci, A. Enabling safe and stable Li metal batteries with protic ionic liquid electrolytes and high voltage cathodes. J. Power Sources 2021, 481, 228979. [4] Falco, M.; Castro, L.; Nair, J.R.; Bella, F.; Bardé, F.; Meligrana, G.; Gerbaldi, C. UV-Cross-Linked Composite Polymer Electrolyte for High-Rate, Ambient Temperature Lithium Batteries. ACS Appl. Energy Mater. 2019, 2 1600-1607. [5] Lingua, G.; Grysan, P.; Vlasov, P.S.; Verge, P.; Shaplov, A.S.; Gerbaldi, C. Unique Carbonate-Based Single Ion Conducting Block Copolymers Enabling High-Voltage, All-Solid-State Lithium Metal Batteries. Macromolecules, 2021, 54, 6911-6924. Acknowledgements The Si-DRIVE project has received funding from the EU's Horizon 2020 research and innovation program under GA 814464. The PSIONIC project has received funding from the European Union's Horizon Europe Research and Innovation Programme under Grant Agreement N. 101069703.
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Pragana, João P. M., Stephan Rosenthal, Ivo M. F. Bragança, Carlos M. A. Silva, A. Erman Tekkaya, and Paulo A. F. Martins. "Hybrid Additive Manufacturing of Collector Coins." Journal of Manufacturing and Materials Processing 4, no. 4 (2020): 115. http://dx.doi.org/10.3390/jmmp4040115.
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The objective of this paper is to present a new hybrid additive manufacturing route for fabricating collector coins with complex, intricate contoured holes. The new manufacturing route combines metal deposition by additive manufacturing with metal cutting and forming, and its application is illustrated with an example consisting of a prototype coin made from stainless steel AISI 316L. Experimentation and finite element analysis of the coin minting operation with the in-house computer program i-form show that the blanks produced by additive manufacturing and metal cutting can withstand the high compressive pressures that are attained during the embossing and impressing of lettering and other reliefs on the coin surfaces. The presentation allows concluding that hybrid additive manufacturing opens the way to the production of innovative collector coins with geometric features that are radically different from those that are currently available in the market.
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Mak, Sze Yi, Kwong Leong Tam, Ching Hang Bob Yung, and Wing Fung Edmond Yau. "Hybrid Metal 3D Printing for Selective Polished Surface." Materials Science Forum 1027 (April 2021): 136–40. http://dx.doi.org/10.4028/www.scientific.net/msf.1027.136.
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Metal additive manufacturing has found broad applications in diverse disciplines. Post processing to homogenize and improve surface finishing remains a critical challenge to additive manufacturing. We propose a novel one-stop solution of adopting hybrid metal 3D printing to streamlining the additive manufacturing workflow as well as to improve surface roughness quality of selective interior surface of the printed parts. This work has great potential in medical and aerospace industries where complicated and high-precision additive manufacturing is anticipated.
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Balyakin, A. V., M. A. Oleynik, E. P. Zlobin, and D. L. Skuratov. "A review of hybrid additive manufacturing of metal parts." VESTNIK of Samara University. Aerospace and Mechanical Engineering 21, no. 2 (2022): 48–64. http://dx.doi.org/10.18287/2541-7533-2022-21-2-48-64.
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This article provides an overview of the latest developments in the field of hybrid additive manufacturing of metal parts. The concept and various kinds of additive manufacturing are discussed. Special attention is paid to hybridization of additive technologies and various processes of forming: die forging, deep drawing, and others. The background and significance of the technologies, as well as their applicability in production are presented. The combination of additive manufacturing with forming processes is carried out with a dual purpose: to expand the area of application of additive manufacturing and overcome its limitations associated with low productivity, metallurgical defects, surface roughness and lack of dimensional accuracy; new application of traditional forming processes.
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Ley, Jazmin, Cristian Pantea, John Greenhall, and Joseph A. Turner. "Resonant ultrasound spectroscopy of hybrid metal additive manufacturing." Journal of the Acoustical Society of America 154, no. 4_supplement (2023): A150. http://dx.doi.org/10.1121/10.0023085.
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Additive manufacturing has been targeted as the next high-impact fabrication technique for parts and components. Hybrid metal additive manufacturing (AM) refers to the 3-D printed fabrication process involving secondary manufacturing processes or energy sources and multifunctional printing. Specific layers are altered within the build using additional processes (i.e., milling or peening) that are synergistic with the additive process. This combination alters the sample microstructure and can refine grains, increase dislocation density, or induce residual stresses. The effect of these hybrid layers is typically not confined within the layer alone but has a compounding effect on preceding layers. The goal is to control the changes in print parameters throughout the build to enhance component performance, but unique challenges remain for nondestructive validation of such samples. Traditional ultrasonic methods on hybrid-AM components have successfully mapped material variations with sufficient spatial resolution. However, the use of resonance ultrasound spectroscopy (RUS) for hybrid-AM is less developed. In this presentation, the use of RUS is described relative to the characterization of hybrid AM 316L stainless steel samples. The spatial organization of the hybrid samples affects the resonances relative to their mode shape. Computational models are used to quantify the impact of the hybrid processes.
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Yue, Wenwen, Yichuan Zhang, Zhengxin Zheng, and Youbin Lai. "Hybrid Laser Additive Manufacturing of Metals: A Review." Coatings 14, no. 3 (2024): 315. http://dx.doi.org/10.3390/coatings14030315.
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Due to the unparalleled benefits of traditional processing techniques, additive manufacturing technology has experienced rapid development and continues to expand its applications. However, as industrial standards advance, the pressing needs for high precision, high performance, and high efficiency in the manufacturing sector have emerged as critical bottlenecks hindering the technology’s progress. Single-laser additive manufacturing methods are insufficient to meet these demands. This review presents a comprehensive exploration of metal hybrid laser additive manufacturing technology, encompassing various aspects, such as multi-process hybrid laser additive manufacturing, additive–subtractive hybrid manufacturing, multi-energy hybrid additive manufacturing, and multi-material hybrid additive manufacturing. Through a thorough examination of the principles of laser additive manufacturing technology and the concept of hybrid manufacturing, this paper investigates in depth the notable advantages of hybrid laser additive manufacturing technology. It provides valuable insights and recommendations to guide the development and research of innovative machining technologies.
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Pawlowski, Alexander E., Derek A. Splitter, Thomas R. Muth, et al. "Producing Hybrid Composites By Combining Additive Manufacturing and Casting." AM&P Technical Articles 175, no. 7 (2017): 16–21. http://dx.doi.org/10.31399/asm.amp.2017-07.p016.
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Abstract Additive manufacturing by itself provides many benefits, but by combining different materials processing techniques like traditional casting with additive manufacturing to create hybrid processes, custom materials can be tailor-made and mass produced for applications with specific performance needs. This article reports on research to create metal-metal interpenetrating phase composite materials using additive manufacturing and casting methods in combination.
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Chen, Zhenwen, Yanning Liang, Cong Li, et al. "Hybrid Fabrication of Cold Metal Transfer Additive Manufacturing and Laser Metal Deposition for Ti6Al4V: The Microstructure and Dynamic/Static Mechanical Properties." Materials 17, no. 8 (2024): 1862. http://dx.doi.org/10.3390/ma17081862.
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The titanium alloy components utilized in the aviation field are typically large in size and possess complex structures. By utilizing multiple additive manufacturing processes, the precision and efficiency requirements of production can be met. We investigated the hybrid additive manufacturing of Ti-6Al-4V using a combination of cold metal transfer additive manufacturing (CMTAM) and laser metal deposition (LMD), as well as the feasibility of using the CMT-LMD hybrid additive manufacturing process for fabricating Ti-6Al-4V components. Microstructural examinations, tensile testing coupled with digital image correlation and dynamic compressive experiments (by the split Hopkinson pressure bar (SHPB) system) were employed to assess the parts. The results indicate that the interface of the LMD and CMTAM zone formed a compact metallurgical bonding. In the CMTAM and LMD zone, the prior-β grains exhibit epitaxial growth, forming columnar prior-β grains. Due to laser remelting, the CMT-LMD hybrid additive zone experiences grain refinement, resulting in equiaxed prior-β grains at the interface with an average grain size smaller than that of the CMTAM and LMD regions. The microstructures reveal significant differences in grain orientation and morphology among the zones, with distinct textures forming in each zone. In the CMT-LMD hybrid zone, due to interfacial strengthening, strain concentration occurs in the arc additive zone during tensile testing, leading to fracture on the CMTAM zone. Under high-strain-rate dynamic impact conditions, the LMD region exhibits ductile fracture, while the CMTAM zone demonstrates brittle fracture. The hybrid zone combines ductile and brittle fracture modes, and the CMT-LMD hybrid material exhibits superior dynamic impact performance compared to the single deposition zone.
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Di Caprio, Francesco, Valerio Acanfora, Stefania Franchitti, Andrea Sellitto, and Aniello Riccio. "Hybrid Metal/Composite Lattice Structures: Design for Additive Manufacturing." Aerospace 6, no. 6 (2019): 71. http://dx.doi.org/10.3390/aerospace6060071.
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This paper introduces a numerical tool developed for the design and optimization of axial-symmetrical hybrid composite/metal structures. It is assumed that the defined structures are produced by means of two different processes: Additive Layer Manufacturing (ALM) for the metallic parts and Filament Winding (FW) for the composite parts. The defined optimization procedure involves two specific software: ANSYS and ModeFrontier. The former is dedicated to the production of the geometrical and FE models, to the structural analysis, and to the post-process, focusing on the definition of the Unit Cells for the modelling of the metal part. The latter is dedicated to the definition of the best design set and thus to the optimization flow management. The core of the developed numerical procedure is the routine based on the Ansys Parametric Design Language (APDL), which allows an automatic generation of any geometrical model defined by a generic design set. The developed procedure is able to choose the best design, in terms of structural performance, changing the lattice metallic parameters (number of unit cells and their topology) and the composite parameters (number of plies and their orientation). The introduced numerical tool has been used to design several hybrid structures configurations. These configurations have been analysed in terms of mechanical behaviour under specific boundary conditions and compared to similar conventional metal structure.
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Królikowski, Marcin A., and Marta B. Krawczyk. "Metal cutting and additive manufacturing as an integral stages of metals hybrid manufacturing in Industry 4.0." Mechanik 91, no. 8-9 (2018): 769–71. http://dx.doi.org/10.17814/mechanik.2018.8-9.129.
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This paper describes the role of metal cutting process as integral part of manufacturing with application of MAM (metal additive manufacturing) techniques. Additive manufacturing is written explicit as main feature included in Industry 4.0 cycle. AM techniques lead to hybrid manufacturing techniques as well. This paper points that AM almost always is accompanied by supplementary conventional machining.
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Lutter-Günther, Max, Stephan Wagner, Christian Seidel, and Gunther Reinhart. "Economic and Ecological Evaluation of Hybrid Additive Manufacturing Technologies Based on the Combination of Laser Metal Deposition and CNC Machining." Applied Mechanics and Materials 805 (November 2015): 213–22. http://dx.doi.org/10.4028/www.scientific.net/amm.805.213.
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Hybrid additive manufacturing technologies combine selective material deposition with a conventional milling process in one machine, enabling the production of complex metal parts and reducing the need for part specific tools. The hybrid technology offers technological advantages compared to more established additive fabrication processes, such as powder bed fusion. Compared to powder bed based additive processes, which are currently in a prevailing positon regarding AM adaption, hybrid additive technologies enable increased build rates, enhanced build volumes and a reduction of machine changes. In the Laser Metal Deposition (LMD) process, metal powder is deposited through a nozzle and melted by a laser on the surface of the part. By integrating the LMD process into a machining center, good surface roughness and low tolerances can be realized by means of e. g. milling without reclamping. In comparison to powder bed based processes, cost and resource input have not been investigated in detail. In this study, hybrid additive manufacturing technologies are analyzed regarding cost and resource input. A cost model for hybrid additive processes is introduced that enables the analysis of the manufacturing cost structure for a given part. Furthermore, the resource inputs for the operation of a hybrid production machine are estimated.
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Holzer, K., L. Maier, V. Böhm, and W. Volk. "Dimensional precision and wear of a new approach for prototype tooling in deep drawing." IOP Conference Series: Materials Science and Engineering 1284, no. 1 (2023): 012078. http://dx.doi.org/10.1088/1757-899x/1284/1/012078.
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Abstract In this work, we present and evaluate a new approach for prototype tooling in deep drawing based on direct polymer additive tooling. With fused filament fabrication (FFF) a PLA shell is printed additively. Afterwards, this is filled with ultra-high performance concrete (UHPC). UHPC is characterized by its higher strength properties compared to conventional concrete materials, which makes the material feasible for forming applications. Two configurations of these hybrid UHPC polymer additive are possible: either the PLA shell is in contact with the sheet metal during forming or UHPC. The hybrid UHPC polymer additive tooling approach has the potential to be more cost-efficient for small series. The dimensional precision and wear of such hybrid tools is evaluated using a standard cup geometry. A test series of 30 cups with sheet metal DX56+Z with 1 mm thickness was drawn with the hybrid tools as well as with a polymeric tool and a conventional steel tool. The dimensional precision and wear of the prototype tools was evaluated optically.
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Escher, C., and C. Mutke. "Additive Manufacturing of Tool Steels*." HTM Journal of Heat Treatment and Materials 77, no. 2 (2022): 143–55. http://dx.doi.org/10.1515/htm-2022-1002.
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Abstract Additive manufacturing of tool steels represents a great challenge, yet it offers new possibilities for the tool manufacture of, for example, complex forming tools with conformal cooling. First, this contribution gives an overview of the most relevant additive manufacturing processes, the materials and processing concepts. By means of a hybrid manufactured press hardening tool for high-strength sheet metal parts, an example of practical implementation is presented subsequently.
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Stavropoulos, Panagiotis, Harry Bikas, Oliver Avram, Anna Valente, and George Chryssolouris. "Hybrid subtractive–additive manufacturing processes for high value-added metal components." International Journal of Advanced Manufacturing Technology 111, no. 3-4 (2020): 645–55. http://dx.doi.org/10.1007/s00170-020-06099-8.
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Abstract Hybrid process chains lack structured decision-making tools to support advanced manufacturing strategies, consisting of a simulation-enhanced sequencing and planning of additive and subtractive processes. The paper sets out a method aiming at identifying an optimal process window for additive manufacturing, while considering its integration with conventional technologies, starting from part inspection as a built-in functionality, quantifying geometrical and dimensional part deviations, and triggering an effective hybrid process recipe. The method is demonstrated on a hybrid manufacturing scenario, by dynamically sequencing laser deposition (DLM) and subtraction (milling), triggered by intermediate inspection steps to ensure consistent growth of a part.
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Strong, Danielle, Issariya Sirichakwal, Guha P. Manogharan, and Thomas Wakefield. "Current state and potential of additive – hybrid manufacturing for metal parts." Rapid Prototyping Journal 23, no. 3 (2017): 577–88. http://dx.doi.org/10.1108/rpj-04-2016-0065.
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Purpose This paper aims to investigate the extent to which traditional manufacturers are equipped and interested in participating in a hybrid manufacturing system which integrates traditional processes such as machining and grinding with additive manufacturing (AM) processes. Design/methodology/approach A survey was conducted among traditional metal manufacturers to collect data and evaluate the ability of these manufacturers to provide hybrid – AM post-processing services in addition to their standard product offering (e.g. mass production). Findings The original equipment manufacturers (OEMs) surveyed have machine availability and an interest in adopting hybrid manufacturing to additionally offer post-processing services. Low volume parts which would be suitable for hybrid manufacturing are generally more profitable. Access to metal AM, process engineering time, tooling requirements and the need for quality control tools were equally identified as the major challenges for OEM participation in this evolving supply chain. Practical implications OEMs can use this research to determine if hybrid manufacturing is a possible fit for their industry using existing machine tools. Originality/value Survey data offer an unique insight into the readiness of metal manufacturers who play an integral role in the evolving hybrid supply chain ecosystem required for post-processing of AM metal parts. This study also suggests that establishing metal AM centers around OEMs as a shared resource to produce near-net AM parts would be beneficial.
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Hinton, Jack, Dejan Basu, Maria Mirgkizoudi, David Flynn, Russell Harris, and Robert Kay. "Hybrid additive manufacturing of precision engineered ceramic components." Rapid Prototyping Journal 25, no. 6 (2019): 1061–68. http://dx.doi.org/10.1108/rpj-01-2019-0025.
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Purpose The purpose of this paper is to develop a hybrid additive/subtractive manufacturing platform for the production of high density ceramic components. Design/methodology/approach Fabrication of near-net shape components is achieved using 96 per cent Al3O2 ceramic paste extrusion and a planarizing machining operations. Sacrificial polymer support can be used to aid the creation of overhanging or internal features. Post-processing using a variety of machining operations improves tolerances and fidelity between the component and CAD model while reducing defects. Findings This resultant three-dimensional monolithic ceramic components demonstrated post sintering tolerances of ±100 µm, surface roughness’s of ∼1 µm Ra, densities in excess of 99.7 per cent and three-point bending strength of 221 MPa. Originality/value This method represents a novel approach for the digital fabrication of ceramic components, which provides improved manufacturing tolerances, part quality and capability over existing additive manufacturing approaches.
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Sporysheva, Daria, and Aleksandr Khairulin. "Additive manufacturing and numerical modeling polymer stents." Russian journal of biomechanics. 28, no. 4 (2024): 83–95. https://doi.org/10.15593/rjbiomech/2024.4.08.
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Biodegradable stents are one of the promising trends in cardiology with a number of advantages over metal stents. Studies show that these stents can effectively restore the vessel lumen and at the same time dissolve organically in the body tissues, minimizing the risk of complications. The production of biodegradable stents by FDM-printing allows to diversify the types of fabricated structures and is also an economically advantageous solution. Numerical modeling of the expansion process of 6 stent geometries was performed. A biodegradable polymer, polylactide (PLA), was used as the stent material. The maximum expansion at the ends was achieved by stent no. 2 with five-element struts. However, in the central region, the best expansion is obtained by stent no. 4 consisting of nine-element struts. The minimum and maximum stresses of the structures are 77.1 and 83.1 MPa, respectively. In all stents after unloading, the transition to the zone of plastic deformations in the crown and link regions was revealed (max = 0.65, min = 0.1). Based on the modeling results, the coefficients of radial elasticity, shortening and unevenness of stent opening were calculated. A comparative analysis of the influence of the stent wall thickness on its ability to expand and maintain its stress-strain state was also performed, which showed that stents with 0.4 mm thickness, in contrast to 0.2 mm thickness, expand better and retain a significant opening after the load is removed from the stent.
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Pragana, J. P. M., R. F. V. Sampaio, I. M. F. Bragança, C. M. A. Silva, and P. A. F. Martins. "Hybrid metal additive manufacturing: A state–of–the-art review." Advances in Industrial and Manufacturing Engineering 2 (May 2021): 100032. http://dx.doi.org/10.1016/j.aime.2021.100032.
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Baqershahi, Mohammad Hassan, Can Ayas, and Elyas Ghafoori. "Design optimisation for hybrid metal additive manufacturing for sustainable construction." Engineering Structures 301 (February 2024): 117355. http://dx.doi.org/10.1016/j.engstruct.2023.117355.
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