RAPID PROTOTYPING JOURNAL

Angela Jadwiga Andrzejewska-Sroka

Purpose Understanding the effects of environmental aging is crucial for the implementation of additively manufactured components in diverse applications, including biomedical devices and structural systems. This study aims to investigate the impact of hydrolytic degradation on the fatigue life of fused filament fabricated polylactide. Design/methodology/approach An experimental…

Yih-Lin Cheng, Po-Yuan Chen, Yen-Ting Li

Purpose This study addresses the resin refilling challenge in digital light processing (DLP)-type high-speed three-dimensional (3D) printing when the cured cross-section exhibits a high area-to-layer-thickness ratio. In bottom-up systems with an inhibiting film that creates a “dead zone” at the vat bottom, raising the platform by only one layer thickness can leave the gap betwe…

Deepak Mudakavi, Somashekara M. Adinarayanappa

Purpose Functionally graded materials (FGMs) possess gradual compositional and microstructural transitions. This study aims to predict the mechanical properties of FGMs, especially the microhardness, by integrating experimentation and machine learning (ML). The work investigates the microstructures and mechanical behaviour. Design/methodology/approach The study utilized a twin-…

Burak Özel, Altug Bakirci, Mehmet Kivanc Turan

Purpose This study aims to investigate the tensile and flexural strength of composite parts produced by joining different materials in a butt joint using additive manufacturing. Design/methodology/approach International Organization for Standardization standards were used for the specimen designs, and Fused Deposition Modeling was used for sample production. Pure polylactic aci…

Sanjeeviprakash Karunanithi, Rajesh Kannan Arasappan, Siva Shanmugam Nallathambi

Purpose This study aims to investigate the influence of heat treatment on the microstructure and mechanical properties of wire arc additively manufactured (WAAM) duplex stainless steel (DSS). Design/methodology/approach Gas metal arc welding based WAAM process was used for the fabrication of DSS wall structure using ER2209 filler wire. The as-fabricated WAAM part is predominant…

Prasanna Nagasai Bellamkonda, Maheshwar Dwivedy

Purpose This study investigates the fabrication of a functionally graded material (FGM) combining Inconel 825 (IN825) and austenitic stainless steel (SS) 309LSi using the pulsed cold metal transfer (pulsed CMT) wire arc additive manufacturing (WAAM) process. The aim of this study is to evaluate the mechanical and microstructural properties of the produced FGMs. Design/methodolo…

Murat Celik

Purpose This study aims to systematically investigate the cyclic shape memory behaviour of 4D-printed polylactic acid (PLA)-thermoplastic polyurethane (TPU) core-shell structures subjected to repeated programming-recovery cycles, with emphasis on understanding the influence of filament-level architecture and printing parameters. Design/methodology/approach Core-shell PLA-TPU fi…

Rezgar Hasanzadeh

Purpose The purpose ofthis study is to quantify how infill geometry affects the crashworthiness of fused filament fabrication (FFF) 3D-printed polylactic acid (PLA) tubular structures subjected to axial compression, with the aim of identifying an infill pattern that maximizes energy management and deformation stability. Design/methodology/approach PLA tubes were designed and ma…

Ehsan Farabi, Mahyar Khorasani, Ahmad Mirzaei, Amir Hossein Ghasemi et al.

Purpose This study aims to introduce an algorithm that can successfully define optimum laser-based powder bed fusion (LB-PBF) processing and post-heat treatment parameters for manufacturing 316L stainless steels with limited energy usage and enhanced properties. Design/methodology/approach Taguchi’s design of the experiment (DoE) was elaborated to define the ideal LB-PBF proces…

Andi Ard Maidhah, Libor Beránek, Wojciech Macek, Maziar Ramezani et al.

Purpose Oxide dispersion strengthening (ODS) is an effective strategy for improving the high-temperature performance of Ni-based superalloys. Recent advances in additive manufacturing, particularly laser powder bed fusion (LPBF), have enabled the fabrication of ODS Ni-based superalloys with complex geometries and enhanced mechanical performance. This study aims to critically ex…

Maryam Shokrollahi, Adam W. Smith, Martine Dubé, Ilyass Tabiai

Purpose Interlayer weakness limits the mechanical performance of material extrusion additive manufacturing (MEAM) parts. Interlayer behaviour is governed by two mechanisms: the quality of bonding at welded regions and naturally occurring interface notches formed by the extrudate’s geometry. This study aims to investigate the interplay between these mechanisms in polyethylene te…

Yuewei Ai, Chuanbin Du, Yang Zhang, Yiyuan Wang et al.

Purpose The purpose of this study is to analyze the influence of substrate posture (SP) on the process and characteristics of cladding layer formation in wire laser directed energy deposition (WLDED). The study aims to improve the stability of WLDED process. Design/methodology/approach A dynamic simulation model for WLDED process is proposed and verified by comparing the claddi…

Hadi Moutablaleh, Mehrshad Mehrpouya, Tom Vaneker, Ian Gibson

Purpose This study aims to provide an end-user materials perspective for multimaterial Laser Powder Bed Fusion (MM-LPBF) based on functionality and application. The main reason for using MM-LPBF over single material LPBF is multifunctionality. This review summarizes the current literature covering metallic multimaterial parts produced by MM-LPBF techniques based on their additi…

Ashish Sharma, Sunil Kumar Yadav, Deo Kiran, Dinesh Kalyanasundaram

Purpose Materials with three-dimensional architectures yield a wide range of mechanical properties, and the architecture can be tailored to exhibit anisotropic mechanical properties conducive for specific applications. The purpose of this study is to design mathematically modelled novel 3D open cell lattice structures with tunable biomechanical properties. Design/methodology/ap…

Felipe Mateus Franco, Aleksander Czekanski

Purpose This paper systematically reviews the impact of non-planar slicing strategies on the mechanical performance of fused filament fabrication (FFF) components. While prior studies have explored geometric and surface quality improvements, a consolidated understanding of mechanical performance enhancement remains limited. This review aims to quantify these improvements and id…

Zhaogui Wang, Shuo Zhang, Wei Wang, Bohao Yi

Purpose This study aims to investigate the application of composite sandwich structures fabricated via additive manufacturing (AM) in green maritime industries, aiming to provide scaled process references for large-scale marine component manufacturing, enabling weight reduction and improved fuel efficiency in green maritime applications. Design/methodology/approach Spiral and h…

Zidong Wu, Yongquan Zhang, Hong Lu, He Huang et al.

Purpose Robotic autonomous welding possesses the advantages of high efficiency and low cost. It is used for rapid prototyping and remanufacturing of large-scale components in advanced equipment. Many welding tasks involve automatic multi-layer and multi-pass motions. However, owing to errors in the multi-bead model and metal shaping uncertainties, current automatic multi-layer …

Francesco Dalle Mura, Rocco Furferi, Lapo Governi

Purpose This study aims to improve the mechanical behaviour and aesthetic realism of costal cartilages (CCs) in clinical simulators. Current mannequin components use thermoplastic polyurethane (TPU) with reduced infill, which inadequately replicates the anisotropic mechanical properties and anatomical appearance of actual CCs. An alternative approach was therefore developed to …

Mehtap Türkdayı, Ömer Necati Cora

Purpose This paper intended to systematically review and examine the development and enhancement of polymer-based filaments used in fused deposition modeling (FDM). It also highlights the effects of incorporating nano and micro particles, organic and inorganic additives and fiber reinforcements, as well as the role of bio-based and recycled materials in promoting environmental …

Akhil Kumar D, Veera Siva Reddy B, Aditya Ranjan Gupta, Chandrasekhara Sastry C et al.

Purpose Additively manufactured metallic lattice structures are promising candidates for impact-resistant and energy-absorbing applications; however, the role of lattice topology in governing deformation stability and energy absorption (EA) under extreme strain-rate loading remains insufficiently understood, particularly for high-strength nickel-based superalloys. The purpose o…