Additive manufacturing: technology, applications and research needs

Additive manufacturing (AM) technology has been researched and developed for more than 20 years. Rather than removing materials, AM processes make three-dimensional parts directly from CAD models by adding materials layer by layer, offering the beneficial ability to build parts with geometric and material complexities that could not be produced by subtractive manufacturing processes. Through intensive research over the past two decades, significant progress has been made in the development and commercialization of new and innovative AM processes, as well as numerous practical applications in aerospace, automotive, biomedical, energy and other fields. This paper reviews the main processes, materials and applications of the current AM technology and presents future research needs for this technology.

[1]  Y. Yusuf,et al.  Rapid prototyping technology: applications and benefits for rapid product development , 1999, J. Intell. Manuf..

[2]  Duc Truong Pham,et al.  Rapid prototyping and rapid tooling—the key enablers for rapid manufacturing , 2003 .

[3]  W. Zhong,et al.  Short fiber reinforced composites for fused deposition modeling , 2001 .

[4]  Dichen Li,et al.  Fabrication of artificial bioactive bone using rapid prototyping , 2004 .

[5]  Lijue Xue,et al.  Laser consolidation of net-shape shells for flextensional sonar projectors , 2006 .

[6]  Z. Ji,et al.  Rapid Freezing Prototyping with Water , 1999 .

[7]  Michael Schmidt,et al.  Selective laser sintering of PEEK , 2007 .

[8]  T. Boland,et al.  Cell and organ printing 2: fusion of cell aggregates in three-dimensional gels. , 2003, The anatomical record. Part A, Discoveries in molecular, cellular, and evolutionary biology.

[9]  Xiaofeng Cui,et al.  Application of inkjet printing to tissue engineering , 2006, Biotechnology journal.

[10]  Nicholas X. Fang,et al.  Projection micro-stereolithography using digital micro-mirror dynamic mask , 2005 .

[11]  Jean-Pierre Kruth,et al.  Material incress manufacturing by rapid prototyping techniques , 1991 .

[12]  Vladimir Mironov,et al.  Organ printing: computer-aided jet-based 3D tissue engineering. , 2003, Trends in biotechnology.

[13]  Lars-Erik Rännar,et al.  Efficient cooling with tool inserts manufactured by electron beam melting , 2007 .

[14]  E. Sachlos,et al.  Making tissue engineering scaffolds work. Review: the application of solid freeform fabrication technology to the production of tissue engineering scaffolds. , 2003, European cells & materials.

[15]  Samuel M. Allen,et al.  Three-dimensional printing of metal parts for tooling and other applications , 2000 .

[16]  Ryan B. Wicker,et al.  Fabrication and characterization of reticulated, porous mesh arrays and foams for aerospace applications by additive manufacturing using electron beam melting , 2010 .

[17]  G. K. Lewis,et al.  Practical considerations and capabilities for laser assisted direct metal deposition , 2000 .

[18]  M. Leu,et al.  Fabrication of 13-93 bioactive glass scaffolds for bone tissue engineering using indirect selective laser sintering , 2011, Biofabrication.

[19]  J. Russias,et al.  Fabrication and in vitro characterization of three-dimensional organic/inorganic scaffolds by robocasting. , 2007, Journal of biomedical materials research. Part A.

[20]  Ming-Chuan Leu,et al.  Research on Extrusion Velocity in Freeform Extrusion Fabrication of Aqueous Alumina Paste , 2009 .

[21]  A. Boccaccini,et al.  Biodegradable and bioactive porous polymer/inorganic composite scaffolds for bone tissue engineering. , 2006, Biomaterials.

[22]  Gideon Levy,et al.  RAPID MANUFACTURING AND RAPID TOOLING WITH LAYER MANUFACTURING (LM) TECHNOLOGIES, STATE OF THE ART AND FUTURE PERSPECTIVES , 2003 .

[23]  Peter Greil,et al.  Synthesis of TiC/Ti–Cu composites by pressureless reactive infiltration of TiCu alloy into carbon preforms fabricated by 3D-printing , 2005 .

[24]  Mohsen A. Jafari,et al.  Processing of advanced electroceramic components by fused deposition technique , 2001 .

[25]  Kai Zhang,et al.  Research on the processing experiments of laser metal deposition shaping , 2007 .

[26]  Benjamin M. Wu,et al.  Scaffold fabrication by indirect three-dimensional printing. , 2005, Biomaterials.

[27]  Andrzej Rosochowski,et al.  Rapid tooling: the state of the art , 2000 .

[28]  W Cris Wilson,et al.  Cell and organ printing 1: protein and cell printers. , 2003, The anatomical record. Part A, Discoveries in molecular, cellular, and evolutionary biology.

[29]  Wei Sun,et al.  Precision extruding deposition (PED) fabrication of polycaprolactone (PCL) scaffolds for bone tissue engineering , 2009, Biofabrication.

[30]  Jean-Pierre Kruth,et al.  Composites by rapid prototyping technology , 2010 .

[31]  Dichen Li,et al.  Fabrication of integral ceramic mold for investment casting of hollow turbine blade based on stereolithography , 2009 .

[32]  J. Suwanprateeb,et al.  Mechanical and in vitro performance of apatite–wollastonite glass ceramic reinforced hydroxyapatite composite fabricated by 3D-printing , 2009, Journal of materials science. Materials in medicine.

[33]  David L. Bourell,et al.  Fabrication of modified graphite bipolar plates by indirect selective laser sintering (SLS) for direct methanol fuel cells , 2010 .

[34]  L. Shor,et al.  New developments in fused deposition modeling of ceramics , 2005 .

[35]  David L. Bourell,et al.  Fabrication of electrically conductive, fluid impermeable Direct Methanol Fuel Cell (DMFC) graphite bipolar plates by indirect Selective Laser Sintering (SLS) , 2008 .

[36]  David L. Bourell,et al.  Post‐processing of selective laser sintered metal parts , 1995 .

[37]  Syed H. Masood,et al.  Rheological Properties of a Particulate-Filled Polymeric Composite through Fused Deposition Process , 2010 .

[38]  Robert G. Landers,et al.  Aqueous-Based Extrusion of High Solids Loading Ceramic Pastes: Process Modeling and Control , 2009 .

[39]  M. Domack,et al.  Development of nickel‐titanium graded composition components , 2005 .

[40]  J. Kruth,et al.  Benchmarking of different SLS/SLM processes as Rapid Manufacturing techniques , 2005 .

[41]  M. Cima,et al.  Modeling and designing functionally graded material components for fabrication with local composition control , 1999 .

[42]  Xinhua Wu,et al.  Compositionally graded Ti6Al4V + TiC made by direct laser fabrication using powder and wire , 2007 .

[43]  D. Hutmacher,et al.  Scaffold development using 3D printing with a starch-based polymer , 2002 .

[44]  Christopher B. Williams,et al.  Design and manufacture of a Formula SAE intake system using fused deposition modeling and fiber‐reinforced composite materials , 2010 .

[45]  Amit Bandyopadhyay,et al.  Functionally graded Co-Cr-Mo coating on Ti-6Al-4V alloy structures. , 2008, Acta biomaterialia.

[46]  Andrea Gatto,et al.  3D Printing technique applied to Rapid Casting , 2007 .

[47]  O. Harrysson,et al.  Direct metal fabrication of titanium implants with tailored materials and mechanical properties using electron beam melting technology , 2008 .

[48]  G. K. Lewis,et al.  Direct Laser Metal Deposition Process Fabricates Near-Net-Shape Components Rapidly , 1995 .

[49]  Lijue Xue,et al.  Laser Consolidation - A Novel One-Step Manufacturing Process for Making Net-Shape Functional Components , 2006 .

[50]  R. Crawford,et al.  Solid Freeform Fabrication: A New Direction in Manufacturing , 1997 .

[51]  Ming-Chuan Leu,et al.  Progress in Additive Manufacturing and Rapid Prototyping , 1998 .

[52]  Ralph Müller,et al.  Printability of calcium phosphate powders for three-dimensional printing of tissue engineering scaffolds. , 2012, Acta biomaterialia.

[53]  Kristin L. Wood,et al.  Fabrication of PEM fuel cell bipolar plates by indirect SLS , 2004 .

[54]  Thierry Chartier,et al.  Stereolithography for manufacturing ceramic parts , 2000 .

[55]  Ola L. A. Harrysson,et al.  CHARACTERIZATION OF THIN WALLED Ti-6Al-4V COMPONENTS PRODUCED VIA ELECTRON BEAM MELTING , 2004 .

[56]  David Bak,et al.  Rapid prototyping or rapid production? 3D printing processes move industry towards the latter , 2003 .

[57]  M. Zimmerman,et al.  Three-dimensional printing and porous metallic surfaces: a new orthopedic application. , 2001, Journal of biomedical materials research.

[58]  A. Bandyopadhyay,et al.  Processing of Bulk Alumina Ceramics Using Laser Engineered Net Shaping , 2008 .

[59]  T. Boland,et al.  Human microvasculature fabrication using thermal inkjet printing technology. , 2009, Biomaterials.

[60]  Joseph J. Beaman,et al.  Over‐infiltration mechanisms in selective laser sintered Si/SiC preforms , 2008 .

[61]  Ming-Chuan Leu,et al.  Freeze-Form Extrusion Fabrication of Composite Structures , 2011 .

[62]  Duc Truong Pham,et al.  Selective laser sintering: Applications and technological capabilities , 1999 .

[63]  Neil Hopkinson,et al.  Degree of particle melt in Nylon‐12 selective laser‐sintered parts , 2009 .

[64]  Manfred Geiger,et al.  Rapid Tooling by Laminated Object Manufacturing of Metal Foil , 2005 .

[65]  Minna Kellomäki,et al.  A review of rapid prototyping techniques for tissue engineering purposes , 2008, Annals of medicine.

[66]  Frank W. Liou,et al.  Three Dimensional Die Repair Using a Hybrid Manufacturing System , 2006 .

[67]  James W. Comb,et al.  FDM® Technology Process Improvements , 1994 .

[68]  Richard P. Chartoff,et al.  Direct Fabrication of Polymer Composite Structures with Curved LOM , 1999 .

[69]  Ming-Chuan Leu,et al.  Graphite-based indirect laser sintered fuel cell bipolar plates containing carbon fiber additions , 2011 .

[70]  M. Cima,et al.  Three-Dimensional Printing: Rapid Tooling and Prototypes Directly from a CAD Model , 1990 .

[71]  John W. Halloran,et al.  Freeform Fabrication of Ceramics via Stereolithography , 2005 .

[72]  Jorge Otubo,et al.  Characterization of 150mm in Diameter NiTi SMA Ingot Produced by Electron Beam Melting , 2010 .

[73]  F. Melchels,et al.  A review on stereolithography and its applications in biomedical engineering. , 2010, Biomaterials.

[74]  Ming C. Leu,et al.  Rapid prototyping in dentistry: technology and application , 2006 .

[75]  Colleen L Flanagan,et al.  Bone tissue engineering using polycaprolactone scaffolds fabricated via selective laser sintering. , 2005, Biomaterials.

[76]  Krishna C. R. Kolan,et al.  Selective laser sintering of 13-93 bioactive glass , 2011 .

[77]  Ingomar Kelbassa,et al.  Laser Additive Manufacturing , 2010 .

[78]  F. D. Bryant,et al.  A Study on Effects of Process Parameters in Rapid Freeze Prototyping , 2003 .

[79]  Kristin L. Wood,et al.  Development of SLS fuel cell current collectors , 2006 .

[80]  Robert F. Singer,et al.  Cellular Titanium by Selective Electron Beam Melting , 2007 .

[81]  Stephen C. Danforth,et al.  Fused Deposition of Ceramics and Metals : An Overview , 1996 .

[82]  Detlef Kochan,et al.  Laminated object manufacturing for rapid tooling and patternmaking in foundry industry , 1999 .

[83]  H. Seitz,et al.  Three-dimensional printing of porous ceramic scaffolds for bone tissue engineering. , 2005, Journal of biomedical materials research. Part B, Applied biomaterials.

[84]  Robert P. Mudge,et al.  Laser engineered net shaping advances additive manufacturing and repair , 2007 .

[85]  Stefan Lohfeld,et al.  Effect of Hydroxyapatite on Biodegradable Scaffolds Fabricated by SLS , 2008 .

[86]  Maria J. Troulis,et al.  Hydrogel-β-TCP scaffolds and stem cells for tissue engineering bone , 2006 .

[87]  Feng Wang,et al.  Manufacture of the die of an automobile deck part based on rapid prototyping and rapid tooling technology , 2002 .

[88]  Mohsen A. Jafari,et al.  A novel system for fused deposition of advanced multiple ceramics , 2000 .

[89]  Charles L. Thomas,et al.  Rapid prototyping of large scale aerospace structures , 1996, 1996 IEEE Aerospace Applications Conference. Proceedings.

[90]  Wei Sun,et al.  Freeform fabrication of Ti3SiC2 powder-based structures: Part I—Integrated fabrication process , 2002 .

[91]  Wei Zhang,et al.  An Experimental and Analytical Study of Ice Part Fabrication with Rapid Freeze Prototyping , 2000 .

[92]  J. Kruth,et al.  Selective laser melting of biocompatible metals for rapid manufacturing of medical parts , 2006 .

[93]  Yunn-Shiuan Liao,et al.  Study of laminated object manufacturing with separately applied heating and pressing , 2006 .

[94]  Vamsi Krishna Balla,et al.  Fabrication of compositionally and structurally graded Ti-TiO2 structures using laser engineered net shaping (LENS). , 2009, Acta biomaterialia.

[95]  G. Frommeyer,et al.  Microstructure and mechanical properties of nickel based superalloy IN718 produced by rapid prototyping with electron beam melting (EBM) , 2011 .

[96]  Peter Greil,et al.  Laminated Object Manufacturing (LOM) of SiSiC Composites , 2004 .

[97]  I. Zein,et al.  Fused deposition modeling of novel scaffold architectures for tissue engineering applications. , 2002, Biomaterials.

[98]  C K Chua,et al.  Characterization of a poly-epsilon-caprolactone polymeric drug delivery device built by selective laser sintering. , 2007, Bio-medical materials and engineering.

[99]  Ming-Chuan Leu,et al.  Effect of different graphite materials on the electrical conductivity and flexural strength of bipolar plates fabricated using selective laser sintering , 2012 .

[100]  Duc Truong Pham,et al.  A comparison of rapid prototyping technologies , 1998 .

[101]  Amit Bandyopadhyay,et al.  Application of Laser Engineered Net Shaping (LENS) to manufacture porous and functionally graded structures for load bearing implants , 2009, Journal of materials science. Materials in medicine.

[102]  Thomas Boland,et al.  Rapid prototyping of tissue-engineering constructs, using photopolymerizable hydrogels and stereolithography. , 2004, Tissue engineering.

[103]  Thierry Chartier,et al.  Ceramic suspensions suitable for stereolithography , 1998 .

[104]  J. Mazumder,et al.  Direct materials deposition: designed macro and microstructure , 1998 .

[105]  S. Das,et al.  Producing metal parts with selective laser sintering/hot isostatic pressing , 1998 .

[106]  P. Wright,et al.  Anisotropic material properties of fused deposition modeling ABS , 2002 .

[107]  Philip Dickens,et al.  Rapid Product Development in the USA, Europe and Japan , 1994 .

[108]  Chee Kai Chua,et al.  Modelling of Extrusion Behaviour of Biopolymer and Composites in Fused Deposition Modelling , 2007 .

[109]  F. Klocke,et al.  Consolidation phenomena in laser and powder-bed based layered manufacturing , 2007 .

[110]  Ryan B. Wicker,et al.  Characterization of titanium aluminide alloy components fabricated by additive manufacturing using electron beam melting , 2010 .

[111]  K. Osakada,et al.  The manufacturing of hard tools from metallic powders by selective laser melting , 2001 .

[112]  Chee Kai Chua,et al.  Rapid Prototyping:Principles and Applications , 2010 .

[113]  Saeed Daneshmand,et al.  Design and Production of Wind Tunnel Testing Models with Selective Laser Sintering Technology Using Glass-Reinforced Nylon , 2006 .

[114]  Serge Monneret,et al.  Microstereolithography using a dynamic mask generator and a noncoherent visible light source , 1999, Design, Test, Integration, and Packaging of MEMS/MOEMS.

[115]  Ming-Chuan Leu,et al.  Liquid Phase Migration in Extrusion of Aqueous Alumina Paste for Freeze-Form Extrusion Fabrication , 2009 .

[116]  Ming C. Leu,et al.  Experimental study on the ice pattern fabrication for the investment casting by rapid freeze prototyping (RFP) , 2002, Comput. Ind..

[117]  Ryan B. Wicker,et al.  Characterization of Ti–6Al–4V open cellular foams fabricated by additive manufacturing using electron beam melting , 2010 .

[118]  Chee Kai Chua,et al.  Melt flow behaviour of poly-ε-caprolactone in fused deposition modelling , 2008 .

[119]  K. Osakada,et al.  Flexible manufacturing of metallic products by selective laser melting of powder , 2006 .

[120]  D. Dimitrov,et al.  Advances in three dimensional printing – state of the art and future perspectives , 2006 .

[121]  Frank W. Liou,et al.  Research and Development of a Hybrid Rapid Manufacturing Process , 2001 .

[122]  R. Drew,et al.  Wettability and spreading kinetics of molten aluminum on copper-coated ceramics , 2006 .

[123]  Sanjay Kumar Selective laser sintering: A qualitative and objective approach , 2003 .

[124]  F. E. Wiria,et al.  Poly-ε-caprolactone/hydroxyapatite for tissue engineering scaffold fabrication via selective laser sintering , 2007 .

[125]  Ola L. A. Harrysson,et al.  Characterization of H13 steel produced via electron beam melting , 2004 .

[126]  Ryan B. Wicker,et al.  Stereolithography of Three-Dimensional Bioactive Poly(Ethylene Glycol) Constructs with Encapsulated Cells , 2006, Annals of Biomedical Engineering.

[127]  John W. Halloran,et al.  Stereolithography of ceramic suspensions , 1997 .

[128]  Michael Feygin,et al.  Laminated Object Manufacturing (LOM): A Simpler Process , 1991 .

[129]  Richard P. Chartoff,et al.  Interfacial characteristics of composites fabricated by laminated object manufacturing , 1998 .

[130]  Fu-dong Zhu,et al.  Overview of Rapid Prototyping for Fabrication of Bone Tissue Engineering Scaffold , 2010 .

[131]  M. L. Griffith,et al.  Solidification in direct metal deposition by LENS processing , 2001 .

[132]  K W Dalgarno,et al.  Indirect selective laser sintering of an apatite-mullite glass-ceramic for potential use in bone replacement applications , 2004, Proceedings of the Institution of Mechanical Engineers. Part H, Journal of engineering in medicine.

[133]  M. Wu,et al.  Simulation and Testing of Polymer Electrolyte Membrane Fuel Cell Bipolar Plates Fabricated by Selective Laser Sintering , 2012 .

[134]  Paul F. Jacobs,et al.  Rapid Prototyping & Manufacturing: Fundamentals of Stereolithography , 1992 .

[135]  R. Singer,et al.  Cellular Ti-6Al-4V structures with interconnected macro porosity for bone implants fabricated by selective electron beam melting. , 2008, Acta biomaterialia.

[136]  Allan J. Lightman,et al.  Curved Layer LOM ofCeramics and Composites , 1998 .

[137]  Qingxi Hu,et al.  Fabrication of porous β-TCP scaffolds by combination of rapid prototyping and freeze drying technology , 2008 .

[138]  V Mironov,et al.  Biofabrication: a 21st century manufacturing paradigm , 2009, Biofabrication.

[139]  Stephen C. Danforth,et al.  Powder Processing, Rheology, and Mechanical Properties of Feedstock for Fused Deposition of Si3N4 Ceramics , 2004 .

[140]  Konrad Wissenbach,et al.  Additive manufacturing of ZrO2-Al2O3 ceramic components by selective laser melting , 2013 .

[141]  L. Froyen,et al.  Selective laser melting of iron-based powder , 2004 .

[142]  Steffen Nowotny,et al.  Laser cladding of the titanium alloy TI6242 to restore damaged blades , 2004 .

[143]  Malcolm N. Cooke,et al.  Use of stereolithography to manufacture critical-sized 3D biodegradable scaffolds for bone ingrowth. , 2003, Journal of biomedical materials research. Part B, Applied biomaterials.

[144]  J. Giannatsis,et al.  Additive fabrication technologies applied to medicine and health care: a review , 2009 .

[145]  Chang-Jun Bae,et al.  Integrally cored ceramic investment casting mold fabricated by ceramic stereolithography , 2008 .

[146]  Ingomar Kelbassa,et al.  Laser cladding as a repair technique for BLISKs out of titanium and nickel base alloys used in aero engines , 2004 .

[147]  Chee Kai Chua,et al.  Rapid prototyping and tooling techniques: a review of applications for rapid investment casting , 2005 .

[148]  Huan Qi,et al.  Adaptive toolpath deposition method for laser net shape manufacturing and repair of turbine compressor airfoils , 2010 .

[149]  H Wu,et al.  Rapid casting of hollow turbine blades using integral ceramic moulds , 2009 .

[150]  R. Jamison,et al.  Bone response to 3D periodic hydroxyapatite scaffolds with and without tailored microporosity to deliver bone morphogenetic protein 2. , 2006, Journal of biomedical materials research. Part A.

[151]  P. McHugh,et al.  Dependence of mechanical properties of polyamide components on build parameters in the SLS process , 2007 .

[152]  Gregory E. Hilmas,et al.  Optimization of Selective Laser Sintering Process for Fabrication of Zirconium Diboride Parts , 2010 .

[153]  Wei Sun,et al.  Multi‐nozzle deposition for construction of 3D biopolymer tissue scaffolds , 2005 .

[154]  Jerry Y. H. Fuh,et al.  In situ formation of TiC composite using selective laser melting , 2000 .

[155]  Jerry Y. H. Fuh,et al.  In-situ formation of copper matrix composites by laser sintering , 2002 .

[156]  John N. DuPont,et al.  Fabrication of functionally graded TiC/Ti composites by Laser Engineered Net Shaping , 2003 .

[157]  K. Leong,et al.  Scaffold development using selective laser sintering of polyetheretherketone-hydroxyapatite biocomposite blends. , 2003, Biomaterials.

[158]  L. Froyen,et al.  Binding Mechanisms in Selective Laser Sintering and Selective Laser Melting , 2004 .

[159]  Frank W. Liou,et al.  Applications of a hybrid manufacturing process for fabrication of metallic structures , 2007 .

[160]  David L. Bourell,et al.  Rapid manufacturing of silicon carbide composites , 2005 .

[161]  Gregory E. Hilmas,et al.  Aqueous Based Freeze-Form Extrusion Fabrication of Alumina Components (Preprint) , 2009 .

[162]  K. Lozano,et al.  Nanofiber-reinforced polymers prepared by fused deposition modeling , 2003 .

[163]  H. Thomas Hahn,et al.  Characterization of the laminated object manufacturing (LOM) process , 2000 .

[164]  Thierry Chartier,et al.  Stereolithography of structural complex ceramic parts , 2002 .

[165]  D W Hutmacher,et al.  A comparative analysis of scaffold material modifications for load-bearing applications in bone tissue engineering. , 2006, International journal of oral and maxillofacial surgery.

[166]  Wei Sun,et al.  Biofabrication of a three-dimensional liver micro-organ as an in vitro drug metabolism model , 2010, Biofabrication.

[167]  Emanuel M. Sachs,et al.  Three-Dimensional Printing: The Physics and Implications of Additive Manufacturing , 1993 .

[168]  O. Dufaud,et al.  Stereolithography of PZT ceramic suspensions , 2002 .