Additive Manufacturing: A Comprehensive Review

Additive Manufacturing: A Comprehensive Review

23 April 2024 | Longfei Zhou, Jenna Miller, Jeremiah Vezza, Maksim Mayster, Muhammad Raffay, Quentin Justice, Zainab Al Tamimi, Gavyn Hansotte, Lavanya Devi Sunkara and Jessica Bernat
Additive manufacturing (AM), also known as 3D printing, has evolved from a rapid prototyping tool to a comprehensive manufacturing solution, enabling the production of complex geometries with high customization and reduced waste. This review explores the workflow of AM, including design, modeling, slicing, printing, and post-processing. It discusses various AM technologies such as material extrusion, VAT polymerization, material jetting, binder jetting, selective laser sintering, and others, covering their principles, advantages, disadvantages, material compatibility, applications, and development trends. The future of AM is projected to include advancements in 3D bioprinting, 3D food printing, large-scale 3D printing, 4D printing, and AI-based AM. The review highlights the transformative impact of AM on global manufacturing, emphasizing ongoing challenges and promising innovations. AM distinguishes itself from traditional manufacturing through its ability to produce complex geometries with minimal waste, making it ideal for prototypes and small production runs. However, AM faces limitations in material variety, part size, and requires significant post-processing, potentially leading to anisotropic mechanical properties. Traditional manufacturing excels in mass production efficiency, offering superior mechanical strength, isotropy, and surface finish. While AM can reduce initial costs by eliminating the need for molds or tooling, its cost advantages diminish with scale, unlike traditional methods that benefit from economies of scale. The most popular 3D printing technology is fused deposition modeling (FDM), which extrudes thermoplastic filaments to build objects layer by layer. Recent advancements have focused on enhancing the mechanical properties of FDM-printed parts through reinforced composite filaments and optimizing process parameters for better surface finish and dimensional accuracy. Stereolithography (SLA) uses an ultraviolet laser to cure photosensitive resins, while digital light processing (DLP) uses a digital light projector for faster and more detailed printing. Selective laser sintering (SLS) and direct metal laser sintering (DMLS) use lasers to sinter powdered materials, enabling the production of functional parts with complex geometries. The future of AM is poised for growth in new materials, process innovations, and integration into traditional manufacturing. Research focuses on scalable AM techniques for large structures, bioprinting for medical applications, and AI integration to optimize printing processes. AM continues to push the boundaries of manufacturing, driving towards a future where customized production on-demand becomes a reality. Despite challenges such as printing speed, material limitations, and cost, AM's role in the next manufacturing revolution is increasingly significant. The review also discusses the design and modeling process, conversion to STL, slicing, and post-processing, emphasizing the importance of each step in ensuring the final product meets specifications. It explores the advantages and limitations of various AM technologies, including FDM, VAT polymerization, and material jetting, highlighting their applications and development trends. The review concludes with a discussion on the future of AM,Additive manufacturing (AM), also known as 3D printing, has evolved from a rapid prototyping tool to a comprehensive manufacturing solution, enabling the production of complex geometries with high customization and reduced waste. This review explores the workflow of AM, including design, modeling, slicing, printing, and post-processing. It discusses various AM technologies such as material extrusion, VAT polymerization, material jetting, binder jetting, selective laser sintering, and others, covering their principles, advantages, disadvantages, material compatibility, applications, and development trends. The future of AM is projected to include advancements in 3D bioprinting, 3D food printing, large-scale 3D printing, 4D printing, and AI-based AM. The review highlights the transformative impact of AM on global manufacturing, emphasizing ongoing challenges and promising innovations. AM distinguishes itself from traditional manufacturing through its ability to produce complex geometries with minimal waste, making it ideal for prototypes and small production runs. However, AM faces limitations in material variety, part size, and requires significant post-processing, potentially leading to anisotropic mechanical properties. Traditional manufacturing excels in mass production efficiency, offering superior mechanical strength, isotropy, and surface finish. While AM can reduce initial costs by eliminating the need for molds or tooling, its cost advantages diminish with scale, unlike traditional methods that benefit from economies of scale. The most popular 3D printing technology is fused deposition modeling (FDM), which extrudes thermoplastic filaments to build objects layer by layer. Recent advancements have focused on enhancing the mechanical properties of FDM-printed parts through reinforced composite filaments and optimizing process parameters for better surface finish and dimensional accuracy. Stereolithography (SLA) uses an ultraviolet laser to cure photosensitive resins, while digital light processing (DLP) uses a digital light projector for faster and more detailed printing. Selective laser sintering (SLS) and direct metal laser sintering (DMLS) use lasers to sinter powdered materials, enabling the production of functional parts with complex geometries. The future of AM is poised for growth in new materials, process innovations, and integration into traditional manufacturing. Research focuses on scalable AM techniques for large structures, bioprinting for medical applications, and AI integration to optimize printing processes. AM continues to push the boundaries of manufacturing, driving towards a future where customized production on-demand becomes a reality. Despite challenges such as printing speed, material limitations, and cost, AM's role in the next manufacturing revolution is increasingly significant. The review also discusses the design and modeling process, conversion to STL, slicing, and post-processing, emphasizing the importance of each step in ensuring the final product meets specifications. It explores the advantages and limitations of various AM technologies, including FDM, VAT polymerization, and material jetting, highlighting their applications and development trends. The review concludes with a discussion on the future of AM,
Reach us at info@study.space