Compared to the common selective laser sintering (SLS) manufacturing method, fused deposition modeling (FDM) seems to be an economical and efficient three-dimensional (3D) printing method for high temperature polymer materials in medical applications. In this work, a customized FDM system was developed for polyether-ether-ketone (PEEK) materials printing. The effects of printing speed, layer thickness, printing temperature and filling ratio on tensile properties were analyzed by the orthogonal test of four factors and three levels. Optimal tensile properties of the PEEK specimens were observed at a printing speed of 60 mm/s, layer thickness of 0.2 mm, temperature of 370 °C and filling ratio of 40%. Furthermore, the impact and bending tests were conducted under optimized conditions and the results demonstrated that the printed PEEK specimens have appropriate mechanical properties.

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Wire and Arc Additive Manufacturing (WAAM) was used for fabrication of NiTi parts using a commercialy available Ni-rich NiTi wire as the feedstock material. The as-built parts are near fully austenitic at room temperature as confirmed by differential scanning calorimetry, X-ray diffraction and superelastic cycling. The as-built microstructure changed from collumnar, in the first deposited layers, to equiaxed in the last deposited ones as a result of the different thermal cycle conditions. This is the 2 first work where WAAM NiTi parts exhibit superelastic behavior under tensile conditions, highlighting the potential use of the technique for the creation of parts shaped in a complex manner based on this material and process. The potential to use WAAM for deposition of advanced functional materials is demonstrated.

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In this work, laser welding of a rolled CoCrFeMnNi high entropy alloy to 316 stainless steel was performed. Defect-free joints were obtained. The microstructure evolution across the welded joints was assessed and rationalized by coupling electron microscopy, high energy synchrotron X-ray diffraction, mechanical property evaluation, and thermodynamic calculations. The fusion zone microstructure was composed of a single FCC phase, and a hardness increase at this location was observed. Such results can be attributed to the formation of a new solid solution (arising from the mixing of the two base materials). Moreover, the incorporation of carbon in the fusion zone upon melting of the stainless steel also aids in the strengthening effect observed. The welded joints presented good mechanical properties, with fracture occurring at the fusion zone. This can be ascribed to the non-favourable, i.e., large grain size, microstructure that developed at this location.