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Applied Sciences
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Smart Additive Manufacturing, Design and Evaluation
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Smart Additive Manufacturing, Design and Evaluation

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Materials Science and Engineering".

Deadline for manuscript submissions: closed (30 June 2021) | Viewed by 17428

Special Issue Editor

Prof. Dr. Soshu Kirihara

E-Mail Website
Guest Editor
Joining and Welding Research Institute, Osaka University, 11–1 Mihogaoka, Ibaraki City, Osaka 567-0047, Japan
Interests: additive manufacturing; laser lithography; electromagnetic devices, bioceramic implant; energy harvesting
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing and 3D printing technologies are globally recognized as novel fabrication processes for advanced materials and components with multifunctional structures. These technologies offer tremendous potential for design innovations and customization, complex part fabrication, rapid prototyping, and distributed digital manufacturing. In this approach, three-dimensional models are designed and created according to theoretical concepts using computer software, and two-dimensional cross-sections are created by slicing operations automatically. Computer-aided design, manufacture, and evaluation are referred to as smart additive processing. In lithography-based approaches, high-resolution laser or electron beams are scanned on a spread metal or ceramic powder bed with or without resin binders to form solid planes of two-dimensional cross-sections. In deposition processes, paste materials with ceramic/metal particles dispersed in a binder system are fused from nozzles moving freely in three dimensions to create composite structures. Outstanding coating and patterning processes are used to modify surface functions of the fabricated 3D components. Various functional metal or ceramic components of dielectric or magnetic lattices to control electromagnetic fields, electrodes or catalysts with large surface areas, and bio-materials components for medical applications could also be developed. Large scale structural components for aerospace and other high-temperature applications can be fabricated with internal cooling path networks formed without casting molds. By using Smart Additive Manufacturing, Design, and Evaluation, practical metal and ceramic components with functionally geometric structures are developed to modulate effectively energy dispersions and mass transfers through computer-aided theoretical design, automatic manufacture and visualized evaluation. Smart processes that will help to realize a sustainable society will be discussed through topics related to the following keywords.

Prof. Dr. Soshu Kirihara
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Green tape stacking
  • Selective laser melting/sintering
  • Fused deposition
  • Binder jetting
  • Powder bed fusion
  • Stereolithography
  • Direct writing
  • Inkjet printing
  • Multi-material
  • Nano/micro surface improvement

Published Papers (6 papers)

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Research

14 pages, 3607 KiB  
Article
Structured Alumina Substrates for Environmental Catalysis Produced by Stereolithography
by Oscar Santoliquido, Francesco Camerota, Marco Pelanconi, Davide Ferri, Martin Elsener, Panayotis Dimopoulos Eggenschwiler and Alberto Ortona
Appl. Sci. 2021, 11(17), 8239; https://0-doi-org.brum.beds.ac.uk/10.3390/app11178239 - 06 Sep 2021
Cited by 7 | Viewed by 2281
Abstract
Modern catalysts for internal combustion engine applications are traditionally constituted by honeycomb substrates on which a coating of the catalytically active phase is applied. Due to the laminar flow of the gases passing through their straight channels, these structures present low heat and [...] Read more.
Modern catalysts for internal combustion engine applications are traditionally constituted by honeycomb substrates on which a coating of the catalytically active phase is applied. Due to the laminar flow of the gases passing through their straight channels, these structures present low heat and mass transfer, thus leading to relatively large catalyst sizes to compensate for the low catalytic activity per unit of volume. Better conversion efficiency can be achieved if three-dimensional periodic structures are employed, because of the resulting gases’ tortuous paths. Furthermore, the increased catalytic activity implies a reduction in the overall catalyst volume, which can translate to a decreased usage of precious metals as active phase. By exploiting the ceramic Stereolithography technique (i.e., SLA) it is nowadays possible to accurately 3D print complex alumina-based lattices to be used as ceramic substrates for catalysis. In this work, closed-walls lattices consisting of a rotated cubic cell of 2 mm dimensions were designed, 3D printed via SLA and finally washcoated with V2O5-WO3-TiO2. The samples were tested for the selective catalytic reduction of NO by NH3 in a heated quartz glass reactor and the performance of the innovative 3D-printed substrate was compared with the catalytic efficiency of the conventional cordierite honeycombs. Full article
(This article belongs to the Special Issue Smart Additive Manufacturing, Design and Evaluation)
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10 pages, 3985 KiB  
Article
Stereolithographic Additive Manufacturing of Zirconia Electrodes with Dendritic Patterns for Aluminum Smelting
by Masaya Takahashi and Soshu Kirihara
Appl. Sci. 2021, 11(17), 8168; https://0-doi-org.brum.beds.ac.uk/10.3390/app11178168 - 03 Sep 2021
Cited by 5 | Viewed by 1515
Abstract
Zirconia electrodes with dendritic patterns were fabricated by stereolithographic additive manufacturing (STL-AM). A solid electrolyte of yttria-stabilized zirconia (YSZ) was selected for oxygen separation in the molten salt electrolysis of aluminum smelting without carbon dioxide excretion. Thereafter, 4, 6, 8 and 12-coordinated dendritic [...] Read more.
Zirconia electrodes with dendritic patterns were fabricated by stereolithographic additive manufacturing (STL-AM). A solid electrolyte of yttria-stabilized zirconia (YSZ) was selected for oxygen separation in the molten salt electrolysis of aluminum smelting without carbon dioxide excretion. Thereafter, 4, 6, 8 and 12-coordinated dendritic structures composed of cylindrical lattices were designed as computer graphics. The specific surface area of each structure was maximized by changing the aspect ratio. The spatial profile and surface pressure of the hot liquid propagation in the dendrite patterns were systematically visualized by computational fluid dynamics (CFD). During the fabrication process, a photosensitive resin containing zirconia particles was spread on a substrate, and an ultraviolet (UV) laser beam was scanned to create a two-dimensional (2D) cross-section. Through layer laminations, three-dimensional (3D) objects with dendritic structures were successfully fabricated. The ceramics were obtained through dewaxing and sintering. Full article
(This article belongs to the Special Issue Smart Additive Manufacturing, Design and Evaluation)
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16 pages, 4880 KiB  
Article
Directed Energy Deposition-Arc (DED-Arc) and Numerical Welding Simulation as a Hybrid Data Source for Future Machine Learning Applications
by Jan Reimann, Stefan Hammer, Philipp Henckell, Maximilian Rohe, Yarop Ali, Alexander Rauch, Jörg Hildebrand and Jean Pierre Bergmann
Appl. Sci. 2021, 11(15), 7075; https://0-doi-org.brum.beds.ac.uk/10.3390/app11157075 - 30 Jul 2021
Cited by 6 | Viewed by 3218
Abstract
This research presents a hybrid approach to generate sample data for future machine learning applications for the prediction of mechanical properties in directed energy deposition-arc (DED-Arc) using the GMAW process. DED-Arc is an additive manufacturing process which offers a cost-effective way to generate [...] Read more.
This research presents a hybrid approach to generate sample data for future machine learning applications for the prediction of mechanical properties in directed energy deposition-arc (DED-Arc) using the GMAW process. DED-Arc is an additive manufacturing process which offers a cost-effective way to generate 3D metal parts, due to its high deposition rate of up to 8 kg/h. The mechanical properties additively manufactured wall structures made of the filler material G4Si1 (ER70 S-6) are shown in dependency of the t8/5 cooling time. The numerical simulation is used to link the process parameters and geometrical features to a specific t8/5 cooling time. With an input of average welding power, welding speed and geometrical features such as wall thickness, layer height and heat source size a specific temperature field can be calculated for each iteration in the simulated welding process. This novel approach allows to generate large, artificial data sets as training data for machine learning methods by combining experimental results to generate a regression equation based on the experimentally measured t8/5 cooling time. Therefore, using the regression equations in combination with numerically calculated t8/5 cooling times an accurate prediction of the mechanical properties was possible in this research with an error of only 2.6%. Thus, a small set of experimentally generated data set allows to achieve regression equations which enable a precise prediction of mechanical properties. Moreover, the validated numerical welding simulation model was suitable to achieve an accurate calculation of the t8/5 cooling time, with an error of only 0.3%. Full article
(This article belongs to the Special Issue Smart Additive Manufacturing, Design and Evaluation)
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19 pages, 7670 KiB  
Article
Additive Manufacture of 3D Auxetic Structures by Laser Powder Bed Fusion—Design Influence on Manufacturing Accuracy and Mechanical Properties
by Sibi Maran, Iain G. Masters and Gregory J. Gibbons
Appl. Sci. 2020, 10(21), 7738; https://0-doi-org.brum.beds.ac.uk/10.3390/app10217738 - 01 Nov 2020
Cited by 13 | Viewed by 3169
Abstract
The mechanical response of steel auxetic structures manufactured using laser-powder bed fusion was explored. The level of control exerted by the key design parameters of vertical strut length (H), re-entrant strut length (L), strut thickness (t) and re-entrant angle (ϴ) on the mechanical [...] Read more.
The mechanical response of steel auxetic structures manufactured using laser-powder bed fusion was explored. The level of control exerted by the key design parameters of vertical strut length (H), re-entrant strut length (L), strut thickness (t) and re-entrant angle (ϴ) on the mechanical response was examined through a design of experiment approach with ANOVA statistical analysis methods applied. The elastic modulus in directions normal to (Ex) and parallel to (Ey) the vertical strut was found to be primarily dependent upon t and L, respectively, whereas yield strength in both test directions (σx and σy) was strongly dependent on t and L. A large variation in modulus was found between the two test directions (Ex / Ey – 1.02 ± 0.07 GPa/ 4.4 ± 0.1 GPa), whereas, yield strength showed little anisotropy (σx / σy–45 ± 6 MPa/ 45 ± 9 MPa). Poisson’s ratio parallel to the vertical strut varied considerably with geometry but not in a direction normal to the vertical strut. Deformation mechanisms were found to be different of compression in the x and y directions, being a combination of stretching of the vertical strut; compression, bending and hinging of the re-entrant strut (x); and vertical strut compression and re-entrant strut stretching and bending (y). Full article
(This article belongs to the Special Issue Smart Additive Manufacturing, Design and Evaluation)
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13 pages, 2791 KiB  
Article
Classifying Thermal Degradation of Polylactic Acid by Using Machine Learning Algorithms Trained on Fourier Transform Infrared Spectroscopy Data
by Sung-Uk Zhang
Appl. Sci. 2020, 10(21), 7470; https://0-doi-org.brum.beds.ac.uk/10.3390/app10217470 - 23 Oct 2020
Cited by 2 | Viewed by 2096
Abstract
Polylactic acid (PLA) is the most common polymeric material in the 3D printing industry but degrades under harsh environmental conditions such as under exposure to sunlight, high-temperatures, water, soil, and bacteria. An understanding of degradation phenomena of PLA materials is critical to manufacturing [...] Read more.
Polylactic acid (PLA) is the most common polymeric material in the 3D printing industry but degrades under harsh environmental conditions such as under exposure to sunlight, high-temperatures, water, soil, and bacteria. An understanding of degradation phenomena of PLA materials is critical to manufacturing robust products by using 3D printing technologies. The objective of this study is to evaluate four machine learning algorithms to classify the degree of thermal degradation of heat-treated PLA materials based on Fourier transform infrared spectroscopy (FTIR) data. In this study, 3D printed PLA specimens were subjected to high-temperatures for extended periods of time to simulate thermal degradation and subsequently examined by using two types of FTIR spectrometers: desktop and portable spectrometers. Classifiers created by multi-class logistic regression and multi-class neural networks were appropriate prediction models for these datasets. Full article
(This article belongs to the Special Issue Smart Additive Manufacturing, Design and Evaluation)
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12 pages, 4950 KiB  
Article
Adaptability Evaluation of Metal-Ceramic Crowns Obtained by Additive and Subtractive Technologies
by Cristina Elena Savencu, Costela Șerban and Liliana Porojan
Appl. Sci. 2020, 10(16), 5563; https://0-doi-org.brum.beds.ac.uk/10.3390/app10165563 - 11 Aug 2020
Cited by 8 | Viewed by 4154
Abstract
(1) Background: Traditional metal-ceramic restorations are considered as a standard in the evaluation of new technologies. A critical factor in their longevity is represented by their adaptability; The purpose of this study was to evaluate the marginal and internal gap of ceramic-fused to [...] Read more.
(1) Background: Traditional metal-ceramic restorations are considered as a standard in the evaluation of new technologies. A critical factor in their longevity is represented by their adaptability; The purpose of this study was to evaluate the marginal and internal gap of ceramic-fused to metal crowns with frameworks obtained by additive manufacturing (AM) technologies and the influence of veneering process on their fit; (2) Methods: Metal-ceramic crowns have been produced by conventional lost-wax technology (T), digital milling (F), selective laser sintering (SLS) and selective laser melting (SLM). The adaptability was assessed using silicone replicas before and after ceramic veneering; (3) Results: The best values were obtained for the milled group followed closely by SLM and SLS, and a significantly higher gap for casted copings. The veneering process did not significantly influence the adaptability of the crowns, regardless of the manufacturing process used for frameworks. The present study promotes additive technologies (AT) as a fast, efficient, and cost-effective alternative to traditional technology. There are fewer steps in which errors can occur when digital technologies are used and the risk of distortion is diminished. (4) Conclusions: CAD/CAM technologies, both additive and subtractive, represent an excellent option to produce time-effective, precise metal-ceramic crowns with excellent adaptation. Full article
(This article belongs to the Special Issue Smart Additive Manufacturing, Design and Evaluation)
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