Purpose A key characteristic of powder bed fusion for polymers is that also the non-processed powder in the powder bed is exposed to elevated temperatures. This alters the properties of the remaining powder, which is compensated by refreshing the used powder with new powder. Nonetheless, it is discarded after a certain number of process iterations, which is economically and ecologically highly disadvantageous. Research works intensively to analyse and reduce the concurring effects responsible for powder ageing. This study aims to give a comprehensive overview of the cumulative changes in the powder and the printed parts when conducting several subsequent build cycles. Design/methodology/approach New polyamide powder (PA12) was used in a total of nine subsequent build cycles with constant sintering parameters and without powder refreshing. After each iteration, the powder and parts were tested for their morphological, thermal and rheological properties. Findings The results are related to three main changes in the powder during the build cycles: decreasing bulk density (through agglomeration), increasing melt viscosity (through polyamide post-condensation) and increasing melting peak and onset temperatures (through thermal annealing of the powder). Originality/value Even though the ageing of PA12 powder in powder bed fusion is well-known, it is not yet fully understood. Studies are not complete and due to different ageing conditions only partially comparable. The detailed study aims to help understand the related effects of powder ageing for process-relevant properties and to show which factors require control to limit the powder ageing.

Purpose This study aims to investigate the tensile strength and compressive behaviour of two thermoplastic polyurethane (TPU) filaments produced via material extrusion (ME): TPU 95A and Reciflex (recycled). Design/methodology/approach Tensile strength and compressive behaviour are assessed. The influence of extrusion temperature and infill pattern on these properties is examined, supported by thermal characterization, surface morphology analyses and a comprehensive comparison with existing literature. An analytical method is presented for estimating the solid ratio of ME parts, using an ellipse model to describe the material bead geometry. Findings Reciflex is generally stiffer than TPU 95A in both tensile and compressive tests. Specimens loaded orthogonally in compression tests exhibited stiffer behaviour than those loaded parallelly, and higher tensile properties were typically observed when material beads were deposited parallel to the load direction. Unlike TPU 95A, Reciflex is sensitive to extrusion temperature variations. Social implications By comparing recycled and virgin TPU filaments, this research addresses waste management concerns and advocates for environmentally sustainable production practices in the broadly used filament/based ME technique. Originality/value This study provides an extensive comparison of computed values with existing literature, offering insights into how different materials may behave under similar processing conditions. Given ongoing challenges in controlling melt flow during extrusion, these results may offer insights for optimizing the production of ME parts made with thermoplastic elastomers.

PurposeThe purpose of this paper is to propose a design method for additive manufacturing (AM) hydraulic valves based on valve body structural decomposition. The method aims to achieve the design of a hydraulic valve with minimum mass or maximum stiffness or minimum pressure loss that also satisfies the structural strength requirements.Design/methodology/approachDecompose the hydraulic valve into typical feature structures and functional structures. Generative design (GD) tools are used to perform GD on the typical feature structures while considering loads and constraints. Based on the GD results, automatically design flow channels with variable wall thickness driven by fluid pressure. The GD results under different design objectives are combined with the automatically designed variable wall thickness channels to obtain hydraulic valves with different performance characteristics.FindingsThe case study section redesigned and manufactured a minimum mass fuel regulator valve. Compared to the conventional fuel regulator valve, the mass of the redesigned valve was reduced by 77%, the pressure loss was reduced by 40% and the flow rate was increased by 38%.Originality/valueThe value of this work is the combination of structural and flow optimization, as well as the design of flow channels with variable wall thickness. The proposed method contributes a novel solution to the design of AM hydraulic valves.

PurposeIn laser powder bed fusion (L-PBF) additive manufacturing, spatter particles are ejected from the melt pool and can be detrimental to material performance and powder recycling. Quantifying spatter generation with respect to processing conditions is a step toward mitigating spatter and better understanding the phenomenon. This paper reveals process insights of spatter phenomena by automatically annotating spatter particles in high-speed video observations using machine learning.Design/methodology/approachA high-speed camera was used to observe the L-PBF process while varying laser power, laser scan speed and scan strategy on a constant geometry on an EOSM290 using Ti-6Al-4V powder. Two separate convolutional neural networks were trained to segment and track spatter particles in captured high-speed videos for spatter characterization.FindingsSpatter generation and ejection angle significantly differ between keyhole and conduction mode melting. High laser powers lead to large ejections at the beginning of scan lines. Slow and fast build rates produce more spatter than moderate build rates at constant energy density. Scan strategies with more scan vectors lead to more spatter. The presence of powder significantly increases the amount of spatter generated during the process.Originality/valueWith the ability to automatically annotate a large volume of high-speed video data sets with high accuracy, an experimental design of observed parameter changes reveals quantitively stark changes in spatter morphology that can aid process development to mitigate spatter occurrence and impacts on material performance.

PurposeThis paper aims to offer a comprehensive review and categorization of production optimization throughout the additive manufacturing lifecycle in a cloud environment. It aims to provide a structured approach to identifying and addressing issues.Design/methodology/approachThis paper systematically reviews 75 technical papers on cloud manufacturing, nesting, scheduling and postprocessing in additive manufacturing. This includes a detailed discussion of the key issues.FindingsThis paper introduces a production framework for the entire lifecycle of additive manufacturing in a cloud environment. This framework aids in problem identification and decision-making based on the process flow. It provides an integrated view from cloud to postprocessing, examining decision interdependencies and enhancing problem identification and organization.Originality/valueTo the best of the authors’ knowledge, this paper is the first to review the complete lifecycle of additive manufacturing, emphasizing the often-overlooked aspects of postprocessing and cloud manufacturing. It offers a comprehensive study of lifecycle optimization challenges and suggests ways to streamline the production process.

PurposeThis paper aims to study the influence of bed temperature on the properties of printed parts and their structural stability.Design/methodology/approachMaterial extrusion is a manufacturing technique in which a part is completed layer by layer with molten filament. The first layer is deposited on a build platform called bed, which is usually at a controlled temperature above room temperature. The density, coefficient of thermal expansion and Young’s modulus were determined as a function of the bed temperature. The complex permittivity was determined at different temperatures, with the aim of analyzing the influence of the bed temperature and isothermal treatments on the characteristics of the amorphous phase.FindingsThe Young’s modulus presented a non-monotonic behavior, while the coefficient of thermal expansion did not present a clear dependence on the bed temperature. However, a contraction of the dimensions of the parts was observed after heating at temperatures above the glass transition. With treatments at temperatures lower than the glass transition temperature, no changes were observed. However, with treatments at temperatures higher than this, changes in the mobile amorphous region were inferred.Originality/valueIssues related to the use of parts manufactured by 3D printing after a posterior heating were analyzed: an improvement in the Young’s modulus and a slight variation of the coefficient of thermal expansion were observed. However, a significant variation in dimensions was detected, mainly for the lowest bed temperatures. This is important for possible applications at temperatures above 60°C.

PurposeA 3D finite element (FE) model based on the double ellipsoidal heat source was developed to investigate the evolution of temperature and stress fields during the multilayer and multi-pass wire and arc additive manufacturing (WAAM) process. This paper aims to investigate the evolution of temperature and stress fields during the multilayer and multi-pass wire and arc additive manufacturing (WAAM) process by developing a 3D finite element (FE) model based on the double ellipsoidal heat source.Design/methodology/approachExperimental thermal cycle curves and residual stresses were obtained by thermocouples and X-ray diffraction, respectively. The validity of the model was verified by the corresponding experimental results.FindingsThe deposition process of the upper pass led to the partial remelting of the lower deposited pass. The thermal process of the current-deposited pass alleviated the stress concentration in the previous-formed passes. A more uniform temperature distribution could be obtained by using the reciprocating deposition path. Compared to the reciprocating deposition path, the peak values of the transverse and longitudinal tensile residual stresses of the deposited sample under the unidirectional deposition path were reduced by 15 MPa and increased by 13 MPa, respectively. The heat conduction in the deposited passes could be improved by extending the inter-pass cooling time appropriately. With an increase in the inter-pass cooling time, the longitudinal residual stress in the middle region of sample along longitudinal and transverse directions showed increase and decrease–increase trends, respectively, while the transverse residual stress exhibited decrease trend.Originality/valueThis study enhances the understanding of temperature and stress fields evolution during the multilayer and multi-pass cold metal transfer-WAAM processes of magnesium alloy and provides the reference for parameter optimization.

PurposeThe effects of climate change have been contributing to coral reef degradation. Artificial reefs are one method being used to counteract this destruction. However, the most common artificial approaches, such as sunken vehicles and prefabricated cement reefs, do not allow adequate coral development. This paper aims to demonstrate how designers, using additive manufacturing and computational design techniques, can create artificial reefs that better mimic natural reef structures.Design/methodology/approachThis research focuses on developing three-dimensional matrices through computational design using additive manufacturing to achieve better coral settlement. A “Nature Centered Design” approach was followed, with the corals at the center of the design project. Samples with different geometries and roughness, produced using paste-based extrusion with porcelain and porcelain with oyster shell, were tested in a controlled environment to investigate the settlement preference of soft corals.FindingsThe rapid prototyping of samples confirmed the preference of corals to settle to complex surfaces compared to smooth surfaces. Porcelain showed comparable results to Portland cement, suggesting further testing potential. A closer resemblance to the natural and intricate forms found in coral reefs was achieved through computational design.Originality/valueThis paper proposes a new approach combining rapid prototyping with coral’s biological responses to enhance the understanding of their surface settlement preference. The Nature Centered Design approach, with additive manufacturing and computational design, made it possible to create an innovative working model that could be customized depending on the implementation area or intended coral species, validating the design approach as a method to support environmental conservation.

PurposeAdditive lamination manufacturing (ALM), as a novel additive manufacturing technology, builds up the geometry via the lamination of fiber-reinforced polymer (FRP) fabric laterally, rendering it suitable for fabricating large-scale Stay-in-Place concrete formwork. This paper aims to investigate the control parameters and structure performance of ALM and assess its application for the fabrication of large-scale concrete formwork.Design/methodology/approachBased on previous feasibility studies, this research systematically investigates the control and material parameters that influence horizontal and vertical extrusion speeds, as well as the overall quality of ALM. Once the system parameters are established, a series of prototypes are fabricated and tested to validate the tensile strength of the formwork and its reinforcement capabilities. In addition, this study assesses the potential geometric freedom and implementation constraints of ALM.FindingsThis research identifies the essential control parameters for path planning in ALM and examines their impact on fabrication. In addition, this paper evaluates ALM’s strengths and limitations in producing concrete formwork for large-scale concrete structures, comparing these to industry benchmarks.Originality/valueA critical challenge in additive manufacturing lies in its scalability and compatibility with existing construction processes. In comparison to concrete, FRP offers advantages such as being lighter, easier to handle and providing surface protection and reinforcement. These qualities make FRP superior for formwork and compatible with existing building standards. Despite its advantages and potential, the current path planning and control model in 3D printing do not apply to ALM due to its novel build-up process. Also, the performance of fabricated parts as part of integrated large-scale structures is yet to be studied.

PurposeThis paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects.Design/methodology/approach304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size.FindingsCompared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part.Originality/valueTo the best of the authors’ knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.