Additive manufacturing (AM), or 3D printing, has emerged as a promising alternative to traditional sensor manufacturing methods. This review provides a comprehensive analysis of AM processes, materials, and applications for sensors that are either fully or partially produced by AM. The review highlights key challenges in material development and processes that limit the production of fully 3D-printed sensors. It also explores the role of AM sensors in green technology. The review aims to provide researchers with a comprehensive understanding of the processes and materials used to produce sensors for various applications.
Sensors are widely used to detect environmental changes and for condition monitoring, with broad applications in modern devices and systems requiring data acquisition and processing. Advances in technology have led to various methods for manufacturing sensors. AM, also known as 3D printing, is an advanced manufacturing process that enables fabrication capabilities previously unachievable by conventional methods. The ISO/ASTM 52,900 standard defines AM as the process of joining materials to make parts from 3D model data, usually layer by layer. This standard provides a consistent language and framework for the AM industry.
AM technologies used for this purpose can generally be classified into several processes, such as material extrusion (MEX), vat photopolymerization (VPP), powder bed fusion (PBF), sheet lamination (SHL), binder jetting (BJT), material jetting (MJT), and directed energy deposition (DED). A variety of materials can be 3D-printed, including polymers, ceramics, metals, and their composites in different states such as liquid or solid.
AM technologies have been widely used for fabricating sensing components, molds, and sensor housing. Because various parts of a sensor are often made from different materials, it is necessary to develop AM systems capable of fabrication with multiple materials. As not many AM systems are currently capable of fulfilling this requirement, it has been challenging to produce an entire sensor by AM. The hybrid manufacturing process combines AM with other manufacturing methods as a secondary process to improve the accuracy of the fabricated parts, their physical properties, and their architecture.
This review aims to provide a detailed analysis of fully 3D-printed sensors and hybrid 3D-printed sensors by comparing their performance, functionality, and potential applications. This article is expected to be helpful for researchers, engineers, and manufacturers aiming to develop fully 3D-printed sensors. Additionally, this review has also attempted to clarify and understand the various contributions related to the use of AM technologies in the development and fabrication of sensors specifically designed for applications in the realm of sustainable and green technologies.Additive manufacturing (AM), or 3D printing, has emerged as a promising alternative to traditional sensor manufacturing methods. This review provides a comprehensive analysis of AM processes, materials, and applications for sensors that are either fully or partially produced by AM. The review highlights key challenges in material development and processes that limit the production of fully 3D-printed sensors. It also explores the role of AM sensors in green technology. The review aims to provide researchers with a comprehensive understanding of the processes and materials used to produce sensors for various applications.
Sensors are widely used to detect environmental changes and for condition monitoring, with broad applications in modern devices and systems requiring data acquisition and processing. Advances in technology have led to various methods for manufacturing sensors. AM, also known as 3D printing, is an advanced manufacturing process that enables fabrication capabilities previously unachievable by conventional methods. The ISO/ASTM 52,900 standard defines AM as the process of joining materials to make parts from 3D model data, usually layer by layer. This standard provides a consistent language and framework for the AM industry.
AM technologies used for this purpose can generally be classified into several processes, such as material extrusion (MEX), vat photopolymerization (VPP), powder bed fusion (PBF), sheet lamination (SHL), binder jetting (BJT), material jetting (MJT), and directed energy deposition (DED). A variety of materials can be 3D-printed, including polymers, ceramics, metals, and their composites in different states such as liquid or solid.
AM technologies have been widely used for fabricating sensing components, molds, and sensor housing. Because various parts of a sensor are often made from different materials, it is necessary to develop AM systems capable of fabrication with multiple materials. As not many AM systems are currently capable of fulfilling this requirement, it has been challenging to produce an entire sensor by AM. The hybrid manufacturing process combines AM with other manufacturing methods as a secondary process to improve the accuracy of the fabricated parts, their physical properties, and their architecture.
This review aims to provide a detailed analysis of fully 3D-printed sensors and hybrid 3D-printed sensors by comparing their performance, functionality, and potential applications. This article is expected to be helpful for researchers, engineers, and manufacturers aiming to develop fully 3D-printed sensors. Additionally, this review has also attempted to clarify and understand the various contributions related to the use of AM technologies in the development and fabrication of sensors specifically designed for applications in the realm of sustainable and green technologies.