Manufacturing Process-Related Challenges of Additive Manufactured Parts: A Review

  • Conference paper
  • First Online:
Advances in Engineering Design (FLAME 2022)

Abstract

Additive manufacturing is an integral part of the upcoming digital era and is still develo** to become more effective and affordable. Various challenges are faced during the making of additive manufactured parts. Even after extensively using high-tech designing software to design the parts, we are not able to attain the desired product finish after manufacturing due to some design challenges. Manufacturing using additive technology is new and is slowly evolving. This evolution has been faced with a lot of challenges from various aspects. The challenges are mainly formation of stair steps, void in the packing formation, porosity, limited additive manufacturing material palette, and large-scale building capacity, limiting to personal fabrication and rheological scaling of powder dispersed in thermoplastics. These challenges were identified and reviewed to study its formation and the reason for its occurrence. Review is done in detail about these and manufacturing process-related challenges and their effect on additive manufactured parts.

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

Access this chapter

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
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
Softcover Book
EUR 171.19
Price includes VAT (Germany)
  • Compact, lightweight 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. Gao W, Zhang Y, Ramanujan D, Ramani K, Chen Y, Williams CB, Zavattieri PD (2015) The status, challenges, and future of additive manufacturing in engineering. Comput Aided Des 69:65–89

    Article  Google Scholar 

  2. Kumar MB, Sathiya P (2021) Methods and materials for additive manufacturing: a critical review on advancements and challenges. Thin-Walled Structures 159:107228

    Article  Google Scholar 

  3. Paolini A, Kollmannsberger S, Rank E (2019) Additive manufacturing in construction: a review on processes, applications, and digital planning methods. Addit Manuf 30:100894

    Google Scholar 

  4. Abdulhameed O, Al-Ahmari A, Ameen W, Mian SH (2019) Additive manufacturing: challenges, trends, and applications. Adv Mech Eng 11(2):1687814018822880

    Article  Google Scholar 

  5. Emminghaus N, Hoff C, Hermsdorf J, Kaierle S (2021) Residual oxygen content and powder recycling: effects on surface roughness and porosity of additively manufactured Ti-6Al-4V. Addit Manuf 46:102093

    Google Scholar 

  6. Ngo TD, Kashani A, Imbalzano G, Nguyen KT, Hui D (2018) Additive manufacturing (3D printing): a review of materials, methods, applications and challenges. Compos B Eng 143:172–196

    Article  Google Scholar 

  7. Yasa E, Poyraz O, Solakoglu EU, Akbulut G, Oren S (2016) A study on the stair step** effect in direct metal laser sintering of a nickel-based superalloy. Procedia Cirp 45:175–178

    Article  Google Scholar 

  8. Tronvoll SA, Welo T, Elverum CW (2018) The effects of voids on structural properties of fused deposition modelled parts: a probabilistic approach. Int J Adv Manuf Technol 97(9):3607–3618

    Article  Google Scholar 

  9. Stopyra W, Gruber K, Smolina I, Kurzynowski T, Kuźnicka B (2020) Laser powder bed fusion of AA7075 alloy: influence of process parameters on porosity and hot cracking. Addit Manuf 35:101270

    Google Scholar 

  10. Biswal R, Zhang X, Shamir M, Al Mamun A, Awd M, Walther F, Syed AK (2019) Interrupted fatigue testing with periodic tomography to monitor porosity defects in wire+ arc additive manufactured Ti-6Al-4V. Addit Manuf 28:517–527

    Google Scholar 

  11. Mancisidor AM, Garciandia F, San Sebastian M, Álvarez P, Díaz J, Unanue I (2016) Reduction of the residual porosity in parts manufactured by selective laser melting using skywriting and high focus offset strategies. Phys Procedia 83:864–873

    Article  Google Scholar 

  12. Lu QY, Wong CH (2018) Additive manufacturing process monitoring and control by non-destructive testing techniques: challenges and in-process monitoring. Virtual Phys Prototy** 13(2):39–48

    Article  Google Scholar 

  13. Bourell D, Kruth JP, Leu M, Levy G, Rosen D, Beese AM, Clare A (2017) Materials for additive manufacturing. CIRP Ann 66(2):659–681

    Article  Google Scholar 

  14. Abdulrahman A, Swash M, Seyed G (2018) Scalable additive manufacturing solution for construction

    Google Scholar 

  15. Hasib AG, Niauzorau S, Xu W, Niverty S, Kublik N, Williams J, Azeredo B (2021) Rheology scaling of spherical metal powders dispersed in thermoplastics and its correlation to the extrudability of filaments for 3D printing. Addit Manuf 41:101967

    Google Scholar 

  16. Mackay ME (2018) The importance of rheological behavior in the additive manufacturing technique material extrusion. J Rheol 62(6):1549–1561

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Bhupendra Prakash Sharma .

Editor information

Editors and Affiliations

Rights and permissions

Reprints and permissions

Copyright information

© 2023 The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Samgeetha, S.P.K., Maharaj, N., Sharma, B.P. (2023). Manufacturing Process-Related Challenges of Additive Manufactured Parts: A Review. In: Sharma, R., Kannojiya, R., Garg, N., Gautam, S.S. (eds) Advances in Engineering Design. FLAME 2022. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-99-3033-3_8

Download citation

  • DOI: https://doi.org/10.1007/978-981-99-3033-3_8

  • Published:

  • Publisher Name: Springer, Singapore

  • Print ISBN: 978-981-99-3032-6

  • Online ISBN: 978-981-99-3033-3

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics

Navigation