Challenges in Additive Manufacturing Technology: Post Processing, Design and Material’s Selection

  • Chapter
  • First Online:
Practical Implementations of Additive Manufacturing Technologies

Abstract

It is important to bear in mind that additive manufacturing (AM) did not emerge in isolation but rather built upon earlier technologies. The rapid adoption of 3D printing technology across industries serves as a testament to its effective evolution from a specialized method primarily used for prototy** to a viable industrial production technique. As the trend continues to gain momentum, an increasing number of companies will inevitably embrace AM techniques to manufacture components using diverse materials. This chapter explores significant milestones in the history of additive manufacturing, illustrating the advancements 3D printing has made over the past decade while considering the widespread growth of applications and technology in the mainstream. The transformative journey of 3D printing is examined, shedding light on its profound impact on various industries and its potential for further development and innovation in the future. By examining the historical context and current landscape, this chapter aims to provide a comprehensive understanding of the progressive nature of additive manufacturing and its continued role in sha** the manufacturing industry. In Sect. 1, a brief introduction is given regarding the historical and future trends in additive manufacturing. Sections 26 discuss different additive manufacturing techniques, their working principles, and the suitable materials for each of these techniques. In Sect. 7, the concept of 4D printing is briefly discussed, including its applicability and future trends.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Chapter
EUR 29.95
Price includes VAT (Germany)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
EUR 128.39
Price includes VAT (Germany)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Hardcover Book
EUR 171.19
Price includes VAT (Germany)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free ship** worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Similar content being viewed by others

References

  1. Majeed A, Zhang Y, Ren S, Lv J, Peng T, Waqar S, Yin E (2021) A big data-driven framework for sustainable and smart additive manufacturing. Robot Comput-Integr Manuf 67:102026

    Article  Google Scholar 

  2. Khan HM, Waqar S, Koç E (2022) Evolution of temperature and residual stress behavior in selective laser melting of 316L stainless steel across a cooling channel. Rapid Prototyp J 28(7):1272–1283. https://doi.org/10.1108/RPJ-09-2021-0237

    Article  Google Scholar 

  3. Sunpreet Singh SRRS, Singh S, Ramakrishna S, Singh R (2017) Material issues in additive manufacturing: a review. J Manuf Process 25:185–200. https://doi.org/10.1016/j.jmapro.2016.11.006

    Article  Google Scholar 

  4. Szemkus S, Kempf B, Jahn S, Wiehl G, Heringhaus F, Rettenmayr M (2018) Laser additive manufacturing of contact materials. J Mater Process Technol 252:612–617. https://doi.org/10.1016/j.jmatprotec.2017.09.023

  5. Camargo IL de, Morais MM, Fortulan CA, Branciforti MC (2021) A review on the rheological behavior and formulations of ceramic suspensions for vat photopolymerization. Ceram Int 47(9):11906–11921. https://doi.org/10.1016/j.ceramint.2021.01.031

  6. Layani M, Wang X, Magdassi S (2018) Novel materials for 3D printing by photopolymerization. Adv Mater 30(41):1706344. https://doi.org/10.1002/adma.201706344

  7. Gibson I, Rosen DW, Stucker B (2010) Photopolymerization processes. In: Additive manufacturing technologies. Springer, pp 78–119

    Google Scholar 

  8. Wang M, Li W, Mille LS, Ching T, Luo Z, Tang G, Zhang YS et al (2022) Digital light processing based bioprinting with composable gradients. Adv Mater 34(1):2107038

    Google Scholar 

  9. Guerra Silva R, Torres MJ, Zahr Viñuela J (2021) A comparison of miniature lattice structures produced by material extrusion and vat photopolymerization additive manufacturing. Polymers 13(13):2163

    Google Scholar 

  10. Salmoria GV, Leite JL, Ahrens CH, Lago A, Pires ATN (2007) Rapid manufacturing of PA/HDPE blend specimens by selective laser sintering: microstructural characterization. Polym Test 26(3):361–368. https://doi.org/10.1016/j.polymertesting.2006.12.002

    Article  Google Scholar 

  11. Berretta S, Ghita O, Evans KE (2014) Morphology of polymeric powders in Laser Sintering (LS): from Polyamide to new PEEK powders. Eur Polymer J 59:218–229. https://doi.org/10.1016/j.eurpolymj.2014.08.004

    Article  Google Scholar 

  12. Betancourt N, Chen X (2022) Review of extrusion-based multi-material bioprinting processes. Bioprinting, e00189

    Google Scholar 

  13. Gokuldoss PK, Kolla S, Eckert J (2017) Additive manufacturing processes: selective laser melting, electron beam melting and binder jetting—selection guidelines. Materials 10(6):672

    Google Scholar 

  14. Balogun HA, Sulaiman R, Marzouk SS, Giwa A, Hasan SW (2019) 3D printing and surface imprinting technologies for water treatment: a review. J Water Process Eng 31:100786

    Article  Google Scholar 

  15. Mirzababaei S, Pasebani S (2019) A review on binder jet additive manufacturing of 316L stainless steel. J Manuf Mater Process 3(3):82

    Google Scholar 

  16. Lv X, Ye F, Cheng L, Fan S, Liu Y (2019) Binder jetting of ceramics: powders, binders, printing parameters, equipment, and post-treatment. Ceram Int 45(10):12609–12624

    Article  Google Scholar 

  17. Li M, Du W, Elwany A, Pei Z, Ma C (2020) Metal binder jetting additive manufacturing: a literature review. J Manuf Sci Eng 142(9)

    Google Scholar 

  18. DebRoy T, Wei HL, Zuback JS, Mukherjee T, Elmer JW, Milewski JO, Zhang W et al (2018) Additive manufacturing of metallic components–process, structure and properties. Prog Mater Sci 92:112–224. https://doi.org/10.1016/j.pmatsci.2017.10.001

  19. Melia MA, Carroll JD, Whetten SR, Esmaeely SN, Locke J, White E, Kustas AB (2019) Mechanical and corrosion properties of additively manufactured CoCrFeMnNi high entropy alloy. Addit Manuf 29:100833. https://doi.org/10.1016/j.addma.2019.100833

  20. Saboori A, Gallo D, Biamino S, Fino P, Lombardi M (2017) An overview of additive manufacturing of titanium components by directed energy deposition: microstructure and mechanical properties. Appl Sci 7(9):883

    Article  Google Scholar 

  21. Dass A, Moridi A (2019) State of the art in directed energy deposition: from additive manufacturing to materials design. Coatings 9(7):418

    Article  Google Scholar 

  22. Gibson I, Rosen D, Stucker B (2015) Powder bed fusion processes. In: Additive manufacturing technologies. Springer New York, pp 107–145. https://doi.org/10.1007/978-1-4939-2113-3_5

  23. Tamanna N, Crouch R, Naher S (2019) Progress in numerical simulation of the laser cladding process. Opt Lasers Eng 122:151–163

    Article  Google Scholar 

  24. Luo X, Cao J, Meng G, Chuan Y, Yao Z, **e H (2020) Systematical investigation on the microstructures and tribological properties of Fe–Al laser cladding coatings. Appl Surf Sci 516:146121

    Article  Google Scholar 

  25. Svetlizky D, Das M, Zheng B, Vyatskikh AL, Bose S, Bandyopadhyay A, Eliaz N et al (2021) Directed energy deposition (DED) additive manufacturing: physical characteristics, defects, challenges and applications. Mater Today 49:271–295

    Google Scholar 

  26. Srivastava M, Rathee S, Maheshwari S, Noor Siddiquee A, Kundra TK (2019) A review on recent progress in solid state friction based metal additive manufacturing: friction stir additive techniques. Crit Rev Solid State Mater Sci 44(5):345–377

    Article  Google Scholar 

  27. Khan HM, Karabulut Y, Kitay O, Kaynak Y, Jawahir IS (2021) Influence of the post-processing operations on surface integrity of metal components produced by laser powder bed fusion additive manufacturing: a review. Mach Sci Technol 25(1):118–176. https://doi.org/10.1080/10910344.2020.1855649

    Article  Google Scholar 

  28. Khan HM, Özer G, Yilmaz MS, Koc E (2022) Corrosion of additively manufactured metallic components: a review. Arab J Sci Eng 47(1):5465–5490. https://doi.org/10.1007/s13369-021-06481-y

    Article  Google Scholar 

  29. Diegel O, Nordin A, Motte D (2019) Additive manufacturing technologies, pp 19–39. https://doi.org/10.1007/978-981-13-8281-9_2

  30. Parandoush P, Lin D (2017) A review on additive manufacturing of polymer-fiber composites. Compos Struct 182:36–53

    Article  Google Scholar 

  31. Tascioglu E, Khan HM, Kaynak Y, Coşkun M, Tarakci G, Koç E (2021) Effect of aging and finish machining on the surface integrity of selective laser melted maraging steel. Rapid Prototyp J 27(10):1900–1909. https://doi.org/10.1108/RPJ-11-2020-0269

    Article  Google Scholar 

  32. Plocher J, Panesar A (2019) Review on design and structural optimisation in additive manufacturing: towards next-generation lightweight structures. Mater Des. https://doi.org/10.1016/j.matdes.2019.108164. Elsevier Ltd.

  33. Gibson I, Rosen D, Stucker B (2015) Applications for additive manufacture. In: Additive manufacturing technologies. Springer New York, pp 451–474. https://doi.org/10.1007/978-1-4939-2113-3_19

  34. Kempen K, Thijs L, Yasa E, Badrossamay M, Verheecke W, Kruth JP (2011) Process optimization and micostructural analysis for selective laser melting of AlSi10Mg. In: Solid freeform fabrication, pp 484–495

    Google Scholar 

  35. Sing SL, An J, Yeong WY, Wiria FE (2016) Laser and electron-beam powder-bed additive manufacturing of metallic implants: a review on processes, materials and designs. J Orthop Res 34(3):369–385. https://doi.org/10.1002/jor.23075

    Article  Google Scholar 

  36. Yuan L, Ding S, Wen C (2019) Additive manufacturing technology for porous metal implant applications and triple minimal surface structures: a review. Bioact Mater 4(1):56–70. https://doi.org/10.1016/j.bioactmat.2018.12.003

  37. Sun W, Starly B, Daly AC, Burdick JA, Groll J, Skeldon G, Nishikawa M et al (2020) The bioprinting roadmap. Biofabrication 12(2):22002

    Google Scholar 

  38. Jacobsen M (2016) Clearing the way for pivotal 21st-century innovation. In: Giftedness and talent in the 21st century. Springer, pp 163–179

    Google Scholar 

  39. Ahmed A, Arya S, Gupta V, Furukawa H, Khosla A (2021) 4D printing: fundamentals, materials, applications and challenges. Polymer 228:123926. https://doi.org/10.1016/j.polymer.2021.123926

  40. Bruni A, Serra FG, Deregibus A, Castroflorio T (2019) Shape-memory polymers in dentistry: systematic review and patent landscape report. Materials 12(14):2216

    Article  Google Scholar 

  41. Yu K, Ritchie A, Mao Y, Dunn ML, Qi HJ (2015) Controlled sequential shape changing components by 3D printing of shape memory polymer multimaterials. Procedia IUTAM 12:193–203. https://doi.org/10.1016/j.piutam.2014.12.021

  42. Anas S, Khan MY, Rafey M, Faheem K (2022) Concept of 5D printing technology and its applicability in the healthcare industry. Mater Today Proc 56:1726–1732

    Article  Google Scholar 

  43. Palmero EM, Bollero A (2021) 3D and 4D printing of functional and smart composite materials. In: DBT-E. of Brabazon MC (Ed) Encyclopedia of materials: composites. Elsevier, Oxford, pp 402–419. https://doi.org/10.1016/B978-0-12-819724-0.00008-2

  44. Ashima R, Haleem A, Bahl S, Javaid M, Mahla SK, Singh S (2021) Automation and manufacturing of smart materials in additive manufacturing technologies using internet of things towards the adoption of Industry 4.0. Mater Today Proc 45:5081–5088

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Hamaid Mahmood Khan .

Editor information

Editors and Affiliations

Rights and permissions

Reprints and permissions

Copyright information

© 2024 The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.

About this chapter

Check for updates. Verify currency and authenticity via CrossMark

Cite this chapter

Khan, H.M., Waqar, S. (2024). Challenges in Additive Manufacturing Technology: Post Processing, Design and Material’s Selection. In: Rajendrachari, S. (eds) Practical Implementations of Additive Manufacturing Technologies. Materials Horizons: From Nature to Nanomaterials. Springer, Singapore. https://doi.org/10.1007/978-981-99-5949-5_2

Download citation

  • DOI: https://doi.org/10.1007/978-981-99-5949-5_2

  • Published:

  • Publisher Name: Springer, Singapore

  • Print ISBN: 978-981-99-5948-8

  • Online ISBN: 978-981-99-5949-5

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Navigation