Machines. Technologies. Materials.
Vol. 18 (2024), Issue 9, pg(s) 290-293

TECHNOLOGIES

Technologies for additive manufacturing of metal structures

  • 1 Space Research and Technology Institute, Bulgarian Academy of Sciences, Sofia, Republic of Bulgaria
  • 2 Institute of Physical Chemistry, Bulgarian Academy of Sciences, Sofia, Republic of Bulgaria

Abstract

Additive manufacturing (AM) of metal structures is transforming industries by enabling the creation of complex, efficient, and customizable components. This article explores key AM technologies for metals, including Powder Bed Fusion (PBF), Directed Energy Deposition (DED), Binder Jetting, Metal Extrusion, and Sheet Lamination. Each is analyzed in terms of principles, strengths, limitations, and applications. A comparative evaluation highlights factors like precision, scalability, cost, and environmental impact to identify optimal technologies for various industries. Despite its advantages, challenges remain in material quality, process reliability, cost, and certification. Emerging trends such as hybrid manufacturing, AI-driven process optimization, advanced materials, and sustainable practices hold promise for overcoming these barriers. By examining current technologies and future opportunities, this article provides valuable insights for advancing metal AM in diverse applications.

Keywords

References

  1. I. Gibson, D. W. Rosen, B. Stucker, et al., Additive manufacturing technologies (17, 160-186, Cham, Switzerland: Springer. 2021)
  2. I. Gibson, D. Rosen, B. Stucker, Additive manufacturing technologies: 3D printing, rapid prototyping, and direct digital manufacturing. (2015)
  3. I, Jin, X. Zhai, K. Wang, et al., Big data, machine learning, and digital twin assisted additive manufacturing: A review, Materials & Design, p.113086. (2024)
  4. D. Herzog, V. Seyda, E. Wycisk, et al., Additive manufacturing of metals, Acta Materialia, 117, 371-392, (2016), https://doi.org/10.1016/j.actamat.2016.07.019
  5. Z. Liu, D. Zhao, P. Wang, et al., Additive manufacturing of metals: Microstructure evolution and multistage control, Journal of Materials Science & Technology, 100, 224-236, (2022), https://doi.org/10.1016/j.jmst.2021.06.011
  6. L. Yang, K. Hsu, B. Baughman, et al., Additive Manufacturing of Metals: The Technology, Materials, Design and Production, (Springer, 2017)
  7. G. R. Kumar, M. Sathishkumar, M. Vignesh, et al., Metal additive manufacturing of commercial aerospace components–A comprehensive review, Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 237(2), 441-454 (2023).
  8. F. Careri, R. H. Khan, C. Todd, et al., Additive manufacturing of heat exchangers in aerospace applications: a review, Applied Thermal Engineering, 121387 (2023).
  9. G. R.Kumar, M. Sathishkumar, M. Vignesh, et al., Metal additive manufacturing of commercial aerospace components–A comprehensive review. Proceedings of the Institution of Mechanical
  10. Engineers, Part E: Journal of Process Mechanical Engineering, 237(2), 441-454 (2023).
  11. C. Radhika, R. Shanmugam, M. Ramoni, et al., A Review on Additive Manufacturing for Aerospace Application. Materials Research Express (2024).
  12. V. Mohanavel, K. A. Ali, K. Ranganathan, et al., The roles and applications of additive manufacturing in the aerospace and automobile sector. Materials Today: Proceedings, 47, 405-409 (2021).
  13. H. A. Colorado, C. A. Cardenas, E. I. Gutierrez-Velazquez, et al., Additive manufacturing in armor and military applications: research, materials, processing technologies, perspectives, and challenges Journal of Materials Research and Technology.--- JMRT, (2023), https://doi.org/10.1016/j.jmrt.2023.11.030
  14. S. Rouf, A. Malik, N. Singh, et al., Additive manufacturing technologies: Industrial and medical applications. Sustainable Operations and Computers, 3, 258-274 (2022).
  15. A. Haleem, M. Javaid, 3D printed medical parts with different materials using additive manufacturing, Clinical Epidemiology and Global Health, 8(1), 215-223 (2020).
  16. S. Boopathi, P. Kumar, Advanced bioprinting processes using additive manufacturing technologies: Revolutionizing tissue engineering. 3D Printing Technologies: Digital Manufacturing. Artificial Intelligence, Industry, 4,.95 (2024).
  17. Z. Wawryniuk, E. Brancewicz-Steinmetz, J. Sawicki, Revolutionizing transportation: An overview of 3D printing in aviation, automotive, and space industries, The International Journal of Advanced Manufacturing Technology, 1-23 (2024).
  18. S. G. Sarvankar, S. N. Yewale, Additive manufacturing in automobile industry, Int. J. Res. Aeronaut. Mech. Eng, 7(4), 1-10 (2019).
  19. A. Bhatia, A. K. Sehgal, Additive manufacturing materials, methods and applications: A review, Materials Today: Proceedings, 81, 1060-1067 (2023), https://doi.org/10.1016/j.matpr.2021.04.379

Article full text

Download PDF