The status, challenges, and future of additive manufacturing in engineering

Published on Dec 1, 2015in Computer-aided Design3.156
· DOI :10.1016/J.CAD.2015.04.001
Wei Gao6
Estimated H-index: 6
(Purdue University),
Yunbo Zhang8
Estimated H-index: 8
(Purdue University)
+ 7 AuthorsPablo D. Zavattieri37
Estimated H-index: 37
(Purdue University)
Sources
Abstract
Additive manufacturing (AM) is poised to bring about a revolution in the way products are designed, manufactured, and distributed to end users. This technology has gained significant academic as well as industry interest due to its ability to create complex geometries with customizable material properties. AM has also inspired the development of the maker movement by democratizing design and manufacturing. Due to the rapid proliferation of a wide variety of technologies associated with AM, there is a lack of a comprehensive set of design principles, manufacturing guidelines, and standardization of best practices. These challenges are compounded by the fact that advancements in multiple technologies (for example materials processing, topology optimization) generate a "positive feedback loop" effect in advancing AM. In order to advance research interest and investment in AM technologies, some fundamental questions and trends about the dependencies existing in these avenues need highlighting. The goal of our review paper is to organize this body of knowledge surrounding AM, and present current barriers, findings, and future trends significantly to the researchers. We also discuss fundamental attributes of AM processes, evolution of the AM industry, and the affordances enabled by the emergence of AM in a variety of areas such as geometry processing, material design, and education. We conclude our paper by pointing out future directions such as the "print-it-all" paradigm, that have the potential to re-imagine current research and spawn completely new avenues for exploration. The fundamental attributes and challenges/barriers of Additive Manufacturing (AM).The evolution of research on AM with a focus on engineering capabilities.The affordances enabled by AM such as geometry, material and tools design.The developments in industry, intellectual property, and education-related aspects.The important future trends of AM technologies.
📖 Papers frequently viewed together
2009
3 Authors (Ian Gibson, ..., Brent Stucker)
2,564 Citations
901 Citations
926 Citations
References291
Newest
#1Jacob Preston Moore (Penn State Mont Alto)H-Index: 4
#2Christopher B. Williams (VT: Virginia Tech)H-Index: 37
Purpose – This paper aims to seek to fill a gap in the literature by characterizing the fatigue life and microstructure of a printed elastomer material, the TangoBlackPlus material. Design/methodology/approach – Because the TangoBlackPlus material is marketed as “rubber-like”, the printed elastomer specimens were tested according to the ASTM D4482-11 “Test Method for Rubber Property Extension Cycling Fatigue”. The microstructure of the printed material and multi-material interface was examined b...
45 CitationsSource
#1Nicholas A. Meisel (VT: Virginia Tech)H-Index: 11
#2Amy M. Elliott (VT: Virginia Tech)H-Index: 16
Last. Christopher B. Williams (VT: Virginia Tech)H-Index: 37
view all 3 authors...
Additive manufacturing’s layer-by-layer fabrication approach allows the user to access the entire volume of the part throughout the build process. This allows for the embedding of functional components and actuators to enable the fabrication of complex systems in a single process. A process for the embedding of shape memory alloy actuating wire within direct PolyJet 3D printed parts is presented in this article. A series of “Design for Embedding” considerations are presented for achieving succes...
44 CitationsSource
#1Yi Zheng (CAS: Chinese Academy of Sciences)H-Index: 82
#2Zhi-Zhu He (CAS: Chinese Academy of Sciences)H-Index: 17
Last. Jing Liu (CAS: Chinese Academy of Sciences)H-Index: 76
view all 4 authors...
Printed electronics is becoming increasingly important in a variety of newly emerging areas. However, restricted to the rather limited conductive inks and available printing strategies, the current electronics manufacture is usually confined to industry level. Here, we show a highly cost-effective and entirely automatic printing way towards personal electronics making, through introducing a tapping-mode composite fluid delivery system. Fundamental mechanisms regarding the reliable printing, tran...
130 CitationsSource
#1Hongyi Xu (SC: University of Southern California)H-Index: 9
#2Yijing Li (SC: University of Southern California)H-Index: 5
Last. Jernej Barbič (SC: University of Southern California)H-Index: 21
view all 4 authors...
We demonstrate an interactive method to create heterogeneous continuous deformable materials on complex three-dimensional meshes. The user specifies displacements and internal elastic forces at a chosen set of mesh vertices. Our system then rapidly solves an optimization problem to compute a corresponding heterogeneous spatial distribution of material properties using the Finite Element Method (FEM) analysis. We apply our method to linear and nonlinear isotropic deformable materials. We demonstr...
67 CitationsSource
#1Neri Oxman (MIT: Massachusetts Institute of Technology)H-Index: 20
#2Christine Ortiz (MIT: Massachusetts Institute of Technology)H-Index: 52
Last. Matthias Kohler (ETH Zurich)H-Index: 21
view all 4 authors...
17 CitationsSource
#1Eugeni L. Doubrovski (TU Delft: Delft University of Technology)H-Index: 8
#2E.Y. Tsai (MIT: Massachusetts Institute of Technology)H-Index: 1
Last. Neri Oxman (MIT: Massachusetts Institute of Technology)H-Index: 20
view all 6 authors...
We present a bitmap printing method and digital workflow using multi-material high resolution Additive Manufacturing (AM). Material composition is defined based on voxel resolution and used to fabricate?a design object?with locally varying material stiffness, aiming to?satisfy the design objective. In this workflow voxel resolution is set by the printer's native resolution, eliminating the need for slicing and path planning. Controlling geometry and material property variation at the resolution ...
109 CitationsSource
#1Jorge Duro-Royo (MIT: Massachusetts Institute of Technology)H-Index: 5
#2Katia Zolotovsky (MIT: Massachusetts Institute of Technology)H-Index: 1
Last. Christine Ortiz (MIT: Massachusetts Institute of Technology)H-Index: 52
view all 7 authors...
Many exoskeletons exhibit multifunctional performance by combining protection from rigid ceramic components with flexibility through articulated interfaces. Structure-to-function relationships of these natural bioarmors have been studied extensively, and initial development of structural (load-bearing) bioinspired armor materials, most often nacre-mimetic laminated composites, has been conducted. However, the translation of segmented and articulated armor to bioinspired surfaces and applications...
33 CitationsSource
#1Deepankar Pal (University of Louisville)H-Index: 15
#2Nachiket PatilH-Index: 9
Last. Brent Stucker (University of Louisville)H-Index: 37
view all 4 authors...
67 CitationsSource
#1J. Michael Wilson (Purdue University)H-Index: 4
#2Cecil Piya (Purdue University)H-Index: 8
Last. Karthik Ramani (Purdue University)H-Index: 46
view all 5 authors...
Laser direct deposition provides an attractive and cost effective means for repairing or remanufacturing high value engineering components. This study demonstrates the successful repair of defective voids in turbine airfoils based on a new semi-automated geometric reconstruction algorithm and a laser direct deposition process. A Boolean difference between the original defective model and the final reconstructed model yields a parameterized geometric representation of the repair volume. The exper...
199 CitationsSource
Aug 24, 2014 in ICPR (International Conference on Pattern Recognition)
#1Shuntaro YamazakiH-Index: 13
#2Satoshi KagamiH-Index: 48
Last. Masaaki MochimaruH-Index: 23
view all 3 authors...
We propose a method of extracting watermark from 3D prints created from 3D mesh data. The watermark is embedded to the 3D mesh in the spectral domain using a robust, imperceptible, and informed algorithm based on the spread spectrum technique, and then extracted from 3D prints by reconstructing the 3D mesh homologous to the original. A suspect 3D mesh is reconstructed accurately and robustly from noisy and incomplete 3D scans of the 3D prints, by optimizing a sparse subset of the spectrum using ...
10 CitationsSource
Cited By1062
Newest
view all 5 authors...
Source
#2P. Sudhakar RaoH-Index: 4
view all 3 authors...
Source
#1Wanbin Pan (Hangzhou Dianzi University)
#2Wen Feng Lu (NUS: National University of Singapore)H-Index: 28
Abstract null null Part integration is to integrate parts to be a fabrication and assembly unit. It can effectively reduce the fabrication and assembly unit quantity of a product and has been deemed as an effective way to promote the productivity of manufacturing. Although additive manufacturing (AM) has great potential to further promote the part integration for any product (assembly) model, part integration works using AM at present are often ad hoc, human-dependent and time-consuming. One mai...
Source
Source
#1Shengjun Liu (CSU: Central South University)H-Index: 12
#1Shengjun Liu (CSU: Central South University)H-Index: 1
Last. Charlie C. L. Wang (University of Manchester)H-Index: 41
view all 6 authors...
Lattice structures have been widely used in various applications of additive manufacturing due to its superior physical properties. If modeled by triangular meshes, a lattice structure with huge number of struts would consume massive memory. This hinders the use of lattice structures in large-scale applications (e.g., to design the interior structure of a solid with spatially graded material properties). To solve this issue, we propose a memory-efficient method for the modeling and slicing of ad...
1 CitationsSource
#1George Besseris (UWest: University of the West)
Abstract Additive manufacturing (AM) has revolutionized the local production realization of highly customizable items. However, the high process complexity - inherent to AM operations - renders uncertain the quality performance of the final products. Consequently, there is often a need to assess the unique fabrication capabilities of AM against the reoccurring issues of process instability and end-product inconsistency. Improvement opportunities may be identified by empirically exploring the com...
Source
#1Ali Yeilaghi Tamijani (Embry-Riddle Aeronautical University, Daytona Beach)H-Index: 11
Abstract null null Gradient additive manufacturing techniques are capable of implementing multiple materials with graded compositions into the fabrication of a single component. This provides a unique opportunity to control the properties of materials, such as thermal expansion, Young’s modulus, and yield stress, and create a structure that otherwise would be infeasible. To utilize this capability, a density-based topology optimization framework is developed to optimize the spatial distribution ...
Source
#1Sabarish S (K. L. N. College of Engineering)
#2P. Udhayakumar (K. L. N. College of Engineering)
Last. R. Pandiyarajan (K. L. N. College of Engineering)H-Index: 5
view all 3 authors...
Source
#7Bo Chen (University of Leicester)H-Index: 1
Abstract null null High cost of metal powders has increased the demand for recycling of unmelted powder in electron beam powder bed fusion additive manufacturing process. However, powder characteristics are likely to change during manufacturing, recovery and reuse. It is important to track the evolution of powder characteristics at different stages of recycling to produce components with consistent properties. The present work evaluates the changes in Ti6Al4V powder properties during manufacturi...
Source
#1Mattia Mele (UNIBO: University of Bologna)H-Index: 5
#2Giampaolo Campana (UNIBO: University of Bologna)H-Index: 14
Last. Giovanni Fumelli (UNIBO: University of Bologna)
view all 3 authors...
Abstract null null Arburg Plastic Freeforming (APF) is an advanced and original Additive Manufacturing (AM) technology that melts granulate thermoplastics through a heated reciprocating screw and deposits droplets layer-by-layer to build three-dimensional objects. The process requires technological decisions, the environmental repercussions of which are still unexplored. null This study provides a parametric cradle-to-gate life-cycle assessment of the APF process based on the Ecoinvent dataset a...
Source