3D printing of aluminum alloys using laser powder deposition: a review

3D printed electronics with nanomaterials

“…In this technique, resolution limitations are related to the size of the particles to be sintered (or bound) and the spot of the energy beam or the ink drop, but can still achieve a feature size of approximately 50-100 μm. 198,199 Generally, XY and Z resolution is also drive-related as for the FDM or SLA techniques (movement of the build plate, nozzles or optics). Fig.…”

“…This conversion can be achieved by Selective Laser Sintering (SLS), Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS), Electron Beam Melting (EBM), and by ink-jetting a binder on the layer of powder (Binder-Jet) that might be additionally sintered with an IR lamp in Multi-Jet Fusion techniques (MJF) [195][196][197][198][199] or post-processed in furnaces for sintering ink-jet binding metal powders like Metal-Jet. 200,201 As an example of powder techniques, in SLS, instead of a photocurable resin, a bed of polymer, ceramic, or metal powder is sintered (or melted for SLM) with a laser, 198,199 after that the bed retracts, a fresh layer of powder is rolled onto the top of the part, and the process repeats. The powder bed is usually able to support the construct, and hence, no additional supporting structures are needed as required for FDM, SLA or Multi-Jet techniques.…”

“…At the same time, some disadvantages are related to the high porosity of the final parts, and for high-temperature laser or electron beam processes, thermal stresses have to be considered as they can cause distortion to the printed part. 195,199 As for the VAT polymerisation techniques, the drawback for electronics applications is in the "one powder at a time" process, although bulk conductive metal parts are also possible to fabricate. And the same as for SLA, some attempts for multi-material fabrication will be presented in the Perspectives section.…”

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

“…The amount of gas-trapped may instead be minimised by accurately optimising the gas atomisation process [ 85 ]. Notwithstanding these mitigation methods, the dynamics of the PBF-LB/M process make gas porosity unavoidable [ 86 ]. The protective gas (argon or nitrogen) present in the PBF-LB\M chamber becomes inevitably trapped by the powder flow, enters the melt pool through the Marangoni flow and results in trapped gas bubbles.…”

Effect of WC content on microstructure and properties of CrFeMoNiTi(WC)x high‐entropy alloys composite coatings prepared by selective laser melting

“…[ 10 ] To overcome these shortcomings, laser powder deposition (LPD) technique such as LC and selective laser melting (SLM) is widely applied for the preparation of HEAs coating owing to its great directionality, high coherence, and high energy density, which can melt the substrate resulting in excellent interfacial bonding. [ 11 ] It was found that LC is mainly applied to the preparation of HEAs coating due to its high laser power and adjustable scanning speed. However, owing to the large thickness of the presetting powder, the energy uniformity of the LC high‐energy laser beam acting on the powder is poor, resulting in more defects, porosity, and cracks in the formed coating.…”