Integrating stereolithography and direct print technologies for 3D structural electronics fabrication

Rapid vacuum casting has been proven to be a successful method in producing high-quality parts in small series. However, a challenge lies in the selection of proper Additive Manufacturing (AM) technologies for the development of a master pattern for the vacuum casting process. Each AM technologies differ from one another in terms of dimensional accuracy, surface finish, cost and lead times. The aim of this study is to investigate the performance of casting mating parts based on different additive manufacturing patterns for small batch. Three types of AM-based patterns: Fused Deposition Modeling (FDM), Stereolithography (SLA) and Multi-Jet Fusion (MJF) were compared. The Taguchi method, Signal to Noise ratio (S/N), Analysis of Variance (ANOVA) and T-test were conducted in determining the optimized parameters. From the findings, curing time is shown to be a significant parameter for dimensional accuracy and surface finish. Dimensional deviation varies in different directions of parts. For surface finish, there was only a slight change from the master pattern whereas the surface roughness of casting parts decreased within the range 0.23% to 2.85%. Tolerance grades for the selected dimensions of the parts were in the permissible range, based on ISO286-1:2010. When using distinct kinds of AM patterns to create replacement components, design tolerance is needed. It was suggested to select AM technology similar to that had been used for the original components. Battery cover was selected as a case study to represent the mating application parts.

The Adoption of Additive Manufacturing Technology in Sweden

This paper investigates the feasibility of manufacturing hydraulic fittings using additive manufacturing (AM) technologies, specifically Fused Deposition Modeling (FDM) and Stereolithography (SLA). The study addresses the environmental challenge of material waste in conventional fitting production by exploring 3D printing as an alternative manufacturing method. Hydraulic fittings were designed using CAD software: SolidWorks 2022 and fabricated using FDM with PETG (Polyethene Terephthalate Glycol) material and SLA with UV-sensitive photopolymer resin. In present studies, on-destructive leak testing was conducted in accordance with PN-EN 1254-4 and PN-EN 1254, at pressures ranging from 0.1 to 1.0 bar. Dimensional accuracy analysis revealed shrinkage of approximately 1% for SLA-printed parts and 2% for FDM-printed parts. Microscopic examination at 50× and 80× magnification showed superior thread quality in SLA samples compared to FDM, which exhibited visible layer separation and material porosity. Leak testing demonstrated that while the brass reference fitting maintained complete seal integrity, both 3D-printed variants failed to achieve leak tightness under operational pressures, with structural failure occurring at 1.0 bar during tightening. The study showed that FDM with PETG material and SLA with UV-sensitive photopolymer resin, despite achieving acceptable dimensional tolerances (±1-2%), do not meet hydraulic leak tightness requirements at pressures exceeding 0.5 bar in their raw state after printing. The results suggest that alternative material formulations (e.g., carbon fiber-reinforced PEEK for FDM or epoxy engineering resins for SLA) warrant further investigation. Potential avenues for improvement include advanced surface treatment, optimization of printing parameters, and modifications to thread geometry to reduce interthread gaps.

Chapter 1 - Overview of additive manufacturing technology and materials

Fundamentals of Mechanical Design and Analysis for AM Fabricated Parts

Additive manufacturing (AM) technologies continuously evolve in materials and operational processes. However, challenges related to energy consumption, material reuse efficiency, and the integration of Circular Economy (CE) principles may impede the overall sustainability of AM processes. As many industrial sectors adopt AM technologies, there is a growing need for innovative tools, methods, and frameworks that guide companies toward more sustainable and circular production practices. This shift involves improving resource efficiency and fostering new Circular Business Models that emphasize material recovery, product lifecycle extension, and waste minimization. This study assesses current and future trends in the development of sustainable AM technologies for processing metal feedstock, based on a comprehensive patent analysis covering the period from 2004 to 2024. We specifically focus on the sustainability impacts of Electron and Laser Beam Powder Bed Fusion (PBF-EB, PBF-LB) and Direct Energy Deposition (DED), given their widespread industrial applications. Patents were categorized into three groups: materials, processes, and components. Furthermore, AM technologies were analyzed according to their role within the production cycle: materials preparation, pre-processing, manufacturing, and post-processing. This categorization allows for a detailed understanding of how innovations in AM contribute to more sustainable production and consumption practices by improving energy efficiency, material usage, circularity, and overall environmental impact.

Purpose Manufacturing companies still struggle to integrate additive manufacturing (AM) technologies with existing traditional manufacturing technologies. This paper explores AM technology integration into a global manufacturing company from an operational capability perspective. Design/methodology/approach The research was conducted using a single case study in collaboration with a global heavy-duty vehicle manufacturer. Data were collected through a focus group and interviews representing management and engineering roles. Additional data were collected from meetings, company documents, field notes and observations. Subsequently, the collected data were analyzed thematically. Findings The findings reveal that, despite the company embarking on its AM technology integration journey, it encountered challenges, including cognitive fixation, manufacturing fixation, situational awareness, ambiguous ownership and the make-or-buy dilemma. Furthermore, the findings showed that the company developed operational capabilities – such as developing proficiency in AM know-how, continuous use of AM technology, operational practices for AM technology, cross-collaboration for AM initiatives and business cases for AM technology – to address these challenges. A facilitation model was developed, outlining essential actions prioritized for the short-term, mid-term and long-term. These actions leverage the operational capabilities to address challenges in AM technology integration. Originality/value This paper offers an in-depth exploration of AM technology integration in a global heavy-duty vehicle manufacturer. It introduces a novel application of operational capability theory and proposes a facilitation model for managers and academics in pursuit of achieving AM technology integration.

Additive manufacturing (AM) technologies can be used to fabricate 3D-printed interim dental restorations. The aim of this review is to report the manufacturing workflow, its chemical composition, and the mechanical properties that may support their clinical application. These new 3D-printing provisional materials are typically composed of monomers based on acrylic esters or filled hybrid material. The most commonly used AM methods to manufacture dental provisional restorations are stereolithography (SLA) and material jetting (MJ) technologies. To the knowledge of the authors, there is no published article that analyzes the chemical composition of these new 3D-printing materials. Because of protocol disparities, technology selected, and parameters of the printers and material used, it is notably difficult to compare mechanical properties results obtained in different studies. Although there is a growing demand for these high-tech restorations, additional information regarding the chemical composition and mechanical properties of these new provisional printed materials is required. Additive manufacturing technologies are a current option to fabricate provisional dental restorations; however, there is very limited information regarding its chemical composition and mechanical properties that may support their clinical application.

Additive manufacturing of cementitious composites: Materials, methods, potentials, and challenges

Additive manufacturing (AM) technologies provide the possible method to manufacture the new suspension for ultra-weight green vehicles. In spite of traditional suspension system with a large amount of small components, Additive Manufacturing technologies allow the manufacturers to manufacture complicated mechanical structure in single piece which could efficiently decrease the number of components, the mass of new suspensions and the time for assembling. With the support of the modelling software, such as Creo® and AutoCAD®, the design concepts can be easily presented departments and made modifications when it is necessary. Finite element analysis software, such as ANSYS®, will provide the platform to do structural analysis by simulation without physically making the prototypes. Integrating these tools and technologies, time for products development will be dramatically reduced and ready-to-make products can be achieved. In this research, various concepts of the wishbones for the new suspension system will be designed based on the design constraints and the new designs will then be analysed by finite element analysis (FEA) in terms of stress distribution and total deformation of the model under a defined load. Creo® will be used to create the models of wishbones and ANSYS Workbench® will be employed for the structural analysis. Prototypes will also be built by Selective laser melting (SLM).Additive manufacturing (AM) technologies provide the possible method to manufacture the new suspension for ultra-weight green vehicles. In spite of traditional suspension system with a large amount of small components, Additive Manufacturing technologies allow the manufacturers to manufacture complicated mechanical structure in single piece which could efficiently decrease the number of components, the mass of new suspensions and the time for assembling. With the support of the modelling software, such as Creo® and AutoCAD®, the design concepts can be easily presented departments and made modifications when it is necessary. Finite element analysis software, such as ANSYS®, will provide the platform to do structural analysis by simulation without physically making the prototypes. Integrating these tools and technologies, time for products development will be dramatically reduced and ready-to-make products can be achieved. In this research, various concepts of the wishbones for the new suspension system wil...

PurposeIn this era of Fourth Industrial Revolution, also known as Industry 4.0, additive manufacturing (AM) has been recognized as one of the nine technologies of Industry 4.0 that will revolutionize different sectors (such as manufacturing and industrial production). Therefore, this study aims to focus on “Additive Manufacturing Education” and the primary aim of this study is to investigate the impacts of AM technology at selected South African universities and develop a proposed framework for effective AM education using South African universities as the case study.Design/methodology/approachQuantitative research approach was used in this study, that is, a survey (questionnaire) was designed specifically to investigate the impacts of the existing AM technology/education and the facilities at the selected South African universities. The survey was distributed to several students (undergraduate and postgraduate) and the academic staffs within the selected universities. The questionnaire contained structured questions based on five factors/variables and followed by two open-ended questions. The data were collected and analyzed using statistical tools and were interpreted accordingly (i.e. both the closed and open-ended questions). The hypotheses were stated, tested and accepted. In conclusion, the framework for AM education at the universities was developed.FindingsBased on different literature reviewed on “framework for AM technology and education”, there is no specific framework that centers on AM education and this makes it difficult to find an existing framework for AM education to serve as a landscape to determine the new framework for AM education at the universities. Therefore, the results from this study made a significant contribution to the body of knowledge in AM, most especially in the area of education. The significant positive responses from the respondents have shown that the existing AM in-house facilities at the selected South African universities is promoting AM education and research activities. This study also shows that a number of students at the South African universities have access to AM/3D printing lab for design and research purposes. Furthermore, the findings show that the inclusion of AM education in the curriculum of both the science and engineering education is South Africa will bring very positive results. The introduction of a postgraduate degree in AM such as MSc or MEng in AM will greatly benefit the South African universities and different industries because it will increase the number of AM experts and professionals. Through literature review, this study was able to identify five factors (which includes sub-factors) that are suitable for the development of a framework for AM education, and this framework is expected to serve as base-line or building block for other universities globally to build/develop their AM journey.Research limitations/implicationsThe survey was distributed to 200 participants and 130 completed questionnaires were returned. The target audience for the survey was mainly university students (both undergraduate and postgraduate) and the academics who have access to AM machines or have used the AM/3D printing lab/facilities on their campuses for both academic and research purposes. Therefore, one of the limitations of the survey is the limited sample size; however, the sample size for this survey is considered suitable for this type of research and would allow generalization of the findings. Nevertheless, future research on this study should use larger sample size for purpose of results generalization. In addition, this study is limited to quantitative research methodology; future study should include qualitative research method. Irrespective of any existing or developed framework, there is always a need to further improve the existing framework, and therefore, the proposed framework for AM education in this study contained only five factors/variables and future should include some other factors (AM commercialization, AM continuous Improvement, etc.) to further enhance the framework.Practical implicationsThis study provides the readers and researchers within the STEM education, industry or engineering education/educators to see the importance of the inclusion of AM in the university curriculum for both undergraduate and postgraduate degrees. More so, this study serves as a roadmap for AM initiative at the universities and provides necessary factors to be considered when the universities are considering or embarking on AM education/research journey at their universities. It also serves as a guideline or platform for various investors or individual organization to see the need to invest in AM education.Originality/valueThe contribution of this study towards the existing body of knowledge in AM technology, specifically “AM education research” is in the form of proposed framework for AM education at the universities which would allow the government sectors/industry/department/bodies and key players in AM in South Africa and globally to see the need to invest significantly towards the advancement of AM technology, education and research activities at various universities.

Metal Powder Production for Additive Manufacturing

Cranial reconstruction: 3D biomodel and custom-built implant created using additive manufacturing

Additive manufacturing (AM) technologies can enable the direct fabrication of customized physical objects with complex shapes, based on computer-aided design models. This technology is changing the digital manufacturing industry and has become a subject of considerable interest in digital implant dentistry. Personalized dentistry implant treatments for individual patients can be achieved through Additive manufacturing. Herein, we review the applications of Additive manufacturing technologies in oral implantology, including implant surgery, and implant and restoration products, such as surgical guides for implantation, custom titanium meshes for bone augmentation, personalized or non-personalized dental implants, custom trays, implant casts, and implant-support frameworks, among others. In addition, this review also focuses on Additive manufacturing technologies commonly used in oral implantology. Stereolithography, digital light processing, and fused deposition modeling are often used to construct surgical guides and implant casts, whereas direct metal laser sintering, selective laser melting, and electron beam melting can be applied to fabricate dental implants, personalized titanium meshes, and denture frameworks. Moreover, it is sometimes required to combine Additive manufacturing technology with milling and other cutting and finishing techniques to ensure that the product is suitable for its final application.

Background: Mandibular defects caused by trauma or tumor resection pose significant challenges in both functional and aesthetic reconstruction. Additive manufacturing (AM) technologies offer promising solutions for surgical planning and personalized treatment. Objectives: This review aims to evaluate current trends in the application of AM technologies for mandibular resection and reconstruction, with a particular focus on material selection, clinical integration, and technology-specific advantages. Methods: A structured literature review was performed using PubMed, Scopus, Web of Science, and Google Scholar. Studies published between January 2020 and May 2025 were screened using the following inclusion criteria: original peer-reviewed English-language research involving AM in mandibular surgery. The exclusion criteria included review articles, non-English sources, and non-mandibular studies. A total of 77 studies met the inclusion criteria and were analyzed in this review. Results: Based on the literature review conducted from 2020 to 2025, the most common restorative methods for the mandible using additively manufactured models include reconstruction with a titanium surgical plate bent to the curvature of the edges and angle of the mandible or a personalized titanium or PEEK surgical plate made directly based on the patient’s diagnosis. Implants made of Ti-6AL-4V ELI and bioceramic scaffolds are also used in the reconstruction process. They are developed based on patient diagnostic data and effectively replace the loss of mandibular bone structure. In addition, based on models and surgical guides created using additive manufacturing techniques, the performance of autogenous grafts from the fibula or iliac crest has improved significantly when used with a titanium implant plate. Conclusions: Additive manufacturing supports highly personalized and accurate mandibular reconstruction. The advantages of these methods include a reduced overall duration of procedures, a lower health risk for patients due to less reliance on general anesthesia, a near perfect match between the implant and the remaining hard tissues, and satisfactory aesthetic outcomes. However, success depends on the appropriate selection AM technology and material, particularly in load-bearing applications.