Progress in Additive Manufacturing

Journal: Progress in Additive Manufacturing

Abbreviation

Prog Addit Manuf

Publisher

Springer

ISSN

2363-9512

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Publications1 - 10 of 15

Functional graded NiTi manufactured with powder bed fusion
Weber, Rico; Tosoratti, Enrico; Spierings, Adriaan B.; et al. (2024)
Progress in Additive Manufacturing
Nickel–titanium (NiTi) is a versatile material with unique inherent properties, such as shape recovery, superelasticity, and biocompatibility, that makes it suitable for various engineering applications. While NiTi can be additively manufactured using powder bed fusion for metals (PBF-LB/M), challenges arise due to the material sensitivity to process parameters and the challenge of achieving desired mechanical and functional properties. Mechanical and functional properties of NiTi are highly infuenced by the alloy composition which in turn is afected by the process parameters. This study aims to investigate the feasibility of tailoring the properties of NiTi to manufacture functionally graded structures. Promising shape recovery strains of 4.16% and superelastic strains of 7% under compression are achieved with cycling stability outperforming the conventional manufactured NiTi. By varying the process parameters, the austenite fnish temperature could be shifted between 29 ± 5 °C and 72 ± 5 °C, while achieving a maximum relative material density of 99.4%. Finally, the study demonstrates the potential of powder bed fusion to manufacture complex and functional graded structures, enabling spatial control. This potential is showcased through the sequential actuation of a demonstrator structure. The fndings of this research highlight the promising capabilities of powder bed fusion in producing functional graded NiTi structures, with potential applications in robotics, aerospace, and biomedical felds.
Laser powder bed fusion of CuCr1Zr on 316 L: a simplified methodology to unravel the effect of intermixing and energy input in the first interfacial layer
Pellin, Raphael L.; Deillon, Léa; Basu, Indranil; et al. (2025)
Progress in Additive Manufacturing
Multi-material laser powder bed fusion (PBF-LB) enables the fabrication of complex components, but presents challenges in material compatibility at interfaces. This study investigates the interface formation between 316 L steel and CuCr1Zr, a promising combination for heat exchanger applications. A simplified approach is adopted by printing single layers of CuCr1Zr within steel cavities using standard PBF-LB equipment. A process window for the first interfacial layer is established, demonstrating that increased layer thickness (2-4 times the standard) limits intermixing. Despite achieving a 14.2 mm-long interface with only 0.7 % cracking in steel, copper contamination cracking (CCC) remains a critical issue, as revealed by microstructural analyses using Energy-Dispersive X-ray Spectroscopy (EDS) and Electron Backscatter Diffraction (EBSD). These findings highlight fundamental limitations in achieving crack-free interfaces over extended lengths, questioning the feasibility of multi-material PBF-LB for certain applications.
A training-free machine learning approach for 3D powder bed reconstruction and defect detection in PBF-LB/M
Tosoratti, Enrico; Potthoff, Ugne; Bennewitz, Christopher; et al. (2025)
Progress in Additive Manufacturing
We introduce a novel in situ quality monitoring approach for the Laser Powder Bed Fusion (PBF-LB/M) process that operates independently of prior experimental data and can be integrated into existing systems. We employ a cost-effective, high-resolution CMOS camera coupled with a bright and darkfield lighting arrangement to acquire data layer-by-layer. Using computer vision techniques, specifically the GrabCut algorithm, we automate the inspection and the virtual reconstruction of fused part geometries. Our results, compared with nominal slice data and computed tomography scan data, indicate a robust accuracy in quantifying geometric deviations (mean deviation of 15.60 μm and 15.20 μm respectively, Jaccard scores of 0.99). The proposed training-free framework, unlike traditional machine learning methods, requires no labeled datasets or prior training, offering a cost-effective and adaptable solution. This eliminates the dependency on material, scan strategy, or part geometry, which typically hinders the scalability of conventional approaches. Additionally, our method facilitates automatic defect detection such as recoater strikes, recoater hopping, and powder shortages, with balanced accuracy scores of up to 0.87. These advantages highlight the framework’s potential as a practical tool for in situ process monitoring and quality assurance in PBF-LB/M systems.
Embedding eddy current sensors into LPBF components for structural health monitoring
Stoll, Philipp; Gasparin, Enrico; Spierings, Adriaan; et al. (2021)
Progress in Additive Manufacturing
Laser powder bed fusion (LPBF) facilitates the integration of external elements like sensors into workpieces during manufacturing. These embedded components enable e.g. part monitoring, thus being a fundamental application of industry 4.0. This study assesses the feasibility of embedding eddy current (EC) sensors for non-destructive testing (NDT) into SLM components aiming at structural health monitoring (SHM). A reliable embedding process for EC sensors is developed, ensuring the survivability of the sensors for the LPBF process and its harsh conditions. The experiments conducted demonstrate the possibility to use the embedded EC sensor to observe and detect a controlled crack growth. The cracks are realized either with direct EDM cutting or on the course of a fatigue test of CT specimens. The data retrieved by the embedded EC sensors are proven to provide a direct information about the severity of a damage and its evolution over time for both approaches. Thus, supporting the validation of such an innovative and promising SHM concept.
Implementation of a design support tool for additive manufacturing using a feature database: an industrial case study
Omidvarkarjan, Daniel; Cipriano, Daniele; Rosenbauer, Ralph; et al. (2020)
Progress in Additive Manufacturing
Powder flowability characterisation methodology for powder-bed-based metal additive manufacturing
Spierings, Adriaan B.; Voegtlin, Mark; Bauer, T.; et al. (2016)
Progress in Additive Manufacturing
Influence of part temperature on in-situ monitoring of powder bed fusion of metals using eddy current testing
Spurek, Marvin A.; Spierings, Adriaan B.; Lany, Marc; et al. (2025)
Progress in Additive Manufacturing
Powder bed fusion of metals (PBF-LB/M) is currently the most widely adopted additive manufacturing technology for the fabrication of metal parts. However, the inconsistent quality of PBF-LB/M-manufactured parts and high costs for part certification are impeding wider industrial adoption. In-situ monitoring technologies are expected to enable process control in order to ensure consistent quality, and to replace some of the post-process inspection steps, therefore, reducing part certification costs. Eddy current testing (ECT) is a standardized nondestructive testing technique, which can be used as an in-situ monitoring technology to measure the part quality during the PBF-LB/M build cycle. However, the process-induced complex temperature fields in PBF-LB/M parts during the build cycle are among the most relevant disturbances due to the temperature dependence of the electrical conductivity. This study investigates the process-induced temperature influence on in-situ monitoring of relative density using ECT. Parts made from AlSi10Mg were manufactured on a PBF-LB/M machine and the build cycle was monitored using ECT and an infrared camera, which was used to extract the part surface temperature right before the ECT measurement. The results demonstrate that the temperature increase of the parts during the build cycle decreases the electrical conductivity independently of the relative part density, which was measured via micro-computed tomography. Therefore, a temperature compensation method was proposed and applied demonstrating that a layer-to-layer difference of 0.15 % relative density can be detected via ECT. Consequently, it has been demonstrated that ECT is an effective in-situ monitoring technology for PBF-LB/M, even in the presence of temperature disparities within parts.
Global sensitivity analysis of 3D printed material with binder jet technology by using surrogate modeling and polynomial chaos expansion
Del Giudice, Lorenzo; Marelli, Stefano; Sudret, Bruno; et al. (2024)
Progress in Additive Manufacturing
The mechanical properties of 3D printed materials produced with additive manufacturing depend on the printing process, which is controlled by several tuning parameters. This paper focuses on Binder Jet technology and studies the influence of printing resolution, activator percentage, droplet mass, and printing speed on the compressive and flexural strength, as well as on the Young's modulus of the bulk printed material. As the number of tests required using a one factor at a time approach is not time efficient, a Design of Experiments approach was applied and optimal points in the 4-dimensional parameter space were selected. Then Sobol' sensitivity indices were calculated for each mechanical property through polynomial chaos expansion. We found that the mechanical properties are primarily controlled by the binder content of the bulk material, namely printing resolution and droplet mass. A smaller dependence on the activator percentage was also found. The printing speed does not affect the mechanical properties studied. In parallel, curing of the specimens at 80-115 degrees C for 30-120 min increases their strength.
Physics-aware feedforward dwell time adjustment for mitigating distortion in additively manufactured cantilevers
Kavas, Barış; Witte, Lars; Balta, Efe; et al. (2025)
Progress in Additive Manufacturing
Heterogeneous temperature distributions in additively manufactured metallic parts, particularly in laser powder bed fusion (PBF-LB/M), pose a major challenge to achieving high-quality components due to thermal distortions, microstructural inconsistencies, and shifts in the process window. This study introduces a physics-aware feedforward approach for regulating dwell time that effectively mitigates distortion in 3D-printed cantilevers by reducing thermal variations along the build direction. A fast, 1D finite volume method thermal simulation is employed to estimate the temperature profile throughout the build. The interlayer dwell time is dynamically adjusted based on a predefined thermal difference threshold between layers to minimize residual stresses and part deformation. Experimental validation on a cantilever beam geometry confirms that the adaptive dwell time strategy significantly reduces distortion compared to a constant dwell time approach. The proposed method enhances thermal stability while maintaining processing times, offering an efficient solution for distortion control in PBF-LB/M. These findings contribute to advancing process optimization strategies by integrating physics-based thermal modeling with feedforward control.
Influence of the particle size distribution of monomodal 316L powder on its flowability and processability in powder bed fusion
Spurek, Marvin A.; Haferkamp, Lukas; Weiss, Christian; et al. (2021)
Progress in Additive Manufacturing
Powder bed fusion (PBF) is the most commonly adopted additive manufacturing process for fabricating complex metal parts via the layer-wise melting of a powder bed using a laser beam. However, the qualifcation of PBF-manufactured parts remains challenging and expensive, thereby limiting the broader industrialization of the technology. Powder characteristics signifcantly infuence part properties, and understanding the infuencing factors contributes to efective quality standards for PBF. In this study, the infuence of the particle size distribution (PSD) median and width on powder fowability and part properties is investigated. Seven gas-atomized SS316L powders with monomodal PSDs, a median particle size ranging from 10 μm to 60 μm, and a distribution width of 15 μm and 30 μm were analyzed and subsequently processed. The PBFmanufactured parts were analyzed in terms of density and melt pool dimensions. Although powder fowability was inversely related to the median particle size, it was unrelated to the distribution width. An inverse relationship between the median particle size and the part density was observed; however, no link was found to the distribution width. Likely, the melt pool depth and width fuctuation signifcantly infuence the part density. The melt pool depth decreases and the width fuctuation increases with an increasing median particle size,

Publications1 - 10 of 15

Journal: Progress in Additive Manufacturing

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