Additive manufacturing of hybrid metal/polymer objects via multiple-material laser powder bed fusion

Chueh, Yuan‐Hui; Zhang, Xiaoji; Ke, Jack Chun-Ren; Li, Qian; Wei, Chao; Li, Lin

doi:10.1016/j.addma.2020.101465

Cited by 34 publications

(25 citation statements)

References 37 publications

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“…The other popular multi-material AM technologies include stereolithography, inkjet printing, selective laser sintering, material extrusion, etc. Selective laser sintering and powder bed fusion are AM techniques for metal or metallic materials; however, these techniques have contributed to hybrid polymer/metal materials [ 57 , 58 ]. Excluding inkjet printing, screen printing, and electrospinning, the average publish year of other techniques are mostly in the range from 2018 to 2020, which means most of them are in the research hotspot.…”

Section: Results and Analysismentioning

confidence: 99%

Scientometric Analysis and Systematic Review of Multi-Material Additive Manufacturing of Polymers

et al. 2021

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Multi-material additive manufacturing of polymers has experienced a remarkable increase in interest over the last 20 years. This technology can rapidly design and directly fabricate three-dimensional (3D) parts with multiple materials without complicating manufacturing processes. This research aims to obtain a comprehensive and in-depth understanding of the current state of research and reveal challenges and opportunities for future research in the area. To achieve the goal, this study conducts a scientometric analysis and a systematic review of the global research published from 2000 to 2021 on multi-material additive manufacturing of polymers. In the scientometric analysis, a total of 2512 journal papers from the Scopus database were analyzed by evaluating the number of publications, literature coupling, keyword co-occurrence, authorship, and countries/regions activities. By doing so, the main research frame, articles, and topics of this research field were quantitatively determined. Subsequently, an in-depth systematic review is proposed to provide insight into recent advances in multi-material additive manufacturing of polymers in the aspect of technologies and applications, respectively. From the scientometric analysis, a heavy bias was found towards studying materials in this field but also a lack of focus on developing technologies. The future trend is proposed by the systematic review and is discussed in the directions of interfacial bonding strength, printing efficiency, and microscale/nanoscale multi-material 3D printing. This study contributes by providing knowledge for practitioners and researchers to understand the state of the art of multi-material additive manufacturing of polymers and expose its research needs, which can serve both academia and industry.

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Section: Results and Analysismentioning

confidence: 99%

Scientometric Analysis and Systematic Review of Multi-Material Additive Manufacturing of Polymers

et al. 2021

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“…In another study, Chueh et al (2020) used an exclusive multimaterial LPBF machine to print copper alloy powder (Cu10Sn) and Nylon powder (PA11). Figure 11(a) exemplifies the setup of the LPBF machine, including the parts for metal and polymer materials.…”

Section: Multimaterials Powder Bed Fusion Techniquesmentioning

confidence: 99%

Multimaterial powder bed fusion techniques

Mehrpouya

Tuma

Vaneker

et al. 2022

RPJ

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Purpose This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It reviews the emerging technologies in PBF multimaterial printing and summarizes the latest simulation approaches for modeling them. The topic of “multimaterial PBF techniques” is still very new, undeveloped, and of interest to academia and industry on many levels. Design/methodology/approach This is a review paper. The study approach was to carefully search for and investigate notable works and peer-reviewed publications concerning multimaterial three-dimensional printing using PBF techniques. The current methodologies, as well as their advantages and disadvantages, are cross-compared through a systematic review. Findings The results show that the development of multimaterial PBF techniques is still in its infancy as many fundamental “research” questions have yet to be addressed before production. Experimentation has many limitations and is costly; therefore, modeling and simulation can be very helpful and is, of course, possible; however, it is heavily dependent on the material data and computational power, so it needs further development in future studies. Originality/value This work investigates the multimaterial PBF techniques and discusses the novel printing methods with practical examples. Our literature survey revealed that the number of accounts on the predictive modeling of stresses and optimizing laser scan strategies in multimaterial PBF is low with a (very) limited range of applications. To facilitate future developments in this direction, the key information of the simulation efforts and the state-of-the-art computational models of multimaterial PBF are provided.

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“…A structure with a 2D material transition between steel and copper building on a conventional material and adding an additive one has been demonstrated by Tan et al [31], Santos et al [32], Wallis et al [33], and Yeong and Chen [34]. Investigations of a 2D material transition between two additively build materials have also been performed by Chen et al [35], Chueh et al [36,37], and Liu et al [38]. However, three-dimensional material transitions for steel and copper have also been reported before [4,5,10,11,39].…”

Section: Introductionmentioning

confidence: 98%

Capability of Multi-Material Laser-Based Powder Bed Fusion—Development and Analysis of a Prototype Large Bore Engine Component

Schneck

Horn

Schindler

et al. 2021

Metals

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Additive Manufacturing (AM) allows the manufacturing of functionally graded materials (FGM). This includes compositional grading, which enables the allocation of desired materials corresponding to local product requirements. An upcoming AM process for the creation of metal-based FGMs is laser-based powder bed fusion (PBF-LB/M) utilized for multi-material manufacturing (MM). Three-dimensional multi-material approaches for PBF-LB/M are stated to have a manufacturing readiness level (MRL) of 4 to 5. In this paper, an advancement of multi-material technology is presented by realizing an industry-relevant complex part as a prototype made by PBF-LB/M. Hence, a multi-material injection nozzle consisting of tool steel and a copper alloy was manufactured in a continuous PBF-LB/M process. Single material regions showed qualities similar to the ones resulting from mono-material processes. A geometrically defined transition zone between the two materials was achieved that showed slightly higher porosity than mono-material regions. Nevertheless, defects such as porosity, cracks, and material cross-contamination were detected and must be overcome in further MM technology development.

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Additive manufacturing of hybrid metal/polymer objects via multiple-material laser powder bed fusion

Cited by 34 publications

References 37 publications

Scientometric Analysis and Systematic Review of Multi-Material Additive Manufacturing of Polymers

Scientometric Analysis and Systematic Review of Multi-Material Additive Manufacturing of Polymers

Multimaterial powder bed fusion techniques

Capability of Multi-Material Laser-Based Powder Bed Fusion—Development and Analysis of a Prototype Large Bore Engine Component

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