Advancements and Challenges in Additive Manufacturing: Future Directions and Implications for Sustainable Engineering
DOI:
https://doi.org/10.26877/asset.v7i1.1079Keywords:
Metal 3D Printing, Industry 4.0, Sustainable Manufacturing, Additive Manufacturing Applications, Manufacturing Technology AdvancementsAbstract
This study explores the recent advancements in additive manufacturing (AM) and its significant effects on various industries such as aerospace, automotive, medical, and casting. The research investigates how AM has the potential to enhance design flexibility, reduce weight, and optimize material performance through developments like adaptive algorithms, topology-based process planning, and multi-objective optimization techniques. These advancements have resulted in near-net-shape casting, improved surface finishes, and enhanced structural integrity. However, the widespread adoption of AM in the commercial sector faces challenges such as high costs, limited material compatibility, and inconsistent build quality. This paper assesses these limitations and suggests solutions such as enhanced design algorithms, AI-driven process monitoring, and the creation of sustainable materials to address them. By overcoming these barriers, AM can smoothly integrate into industrial environments and revolutionize manufacturing processes. The study emphasizes the importance of further exploration of AM's potential to drive innovation, sustainability, and productivity across different sectors.
References
[1] Gibson, Ian, et al. "Design for additive manufacturing." Additive manufacturing technologies (2021): 555-607. [HTML]
[2] Kumar, M. B. and Sathiya, P. "Methods and materials for additive manufacturing: A critical review on advancements and challenges." Thin-Walled Structures, 2021. [HTML]
[3] Vafadar, A., Guzzomi, F., Rassau, A., and Hayward, K. "Advances in metal additive manufacturing: a review of common processes, industrial applications, and current challenges." Applied Sciences, 2021. mdpi.com
[4] Zhang, C., Li, Y., Kang, W., Liu, X., and Wang, Q. "Current advances and future perspectives of additive manufacturing for functional polymeric materials and devices." SusMat, 2021. wiley.com
[5] Al Rashid, A., Khan, S. A., Al-Ghamdi, S. G., and Koç, M. "Additive manufacturing: Technology, applications, markets, and opportunities for the built environment." Automation in Construction, 2020. sciencedirect.com
[6] Liu, Zhiyuan, et al. "Additive manufacturing of metals: Microstructure evolution and multistage control." Journal of Materials Science & Technology 100 (2022): 224-236. [HTML]
[7] Rathod, D. W. "Comprehensive analysis of gas tungsten arc welding technique for Ni-base weld overlay." Advanced welding and deforming, 2021. [HTML]
[8] ADEDAYO, S. M. "OPTIMAL APPLICATION OF MATERIALS JOINING TOWARDS RAPID NATIONAL DEVELOPMENT." unilorin.edu.ng, unilorin.edu.ng
[9] Prashar, Gaurav, Hitesh Vasudev, and Dharam Bhuddhi. "Additive manufacturing: expanding 3D printing horizon in industry 4.0." International Journal on Interactive Design and Manufacturing (IJIDeM) 17.5 (2023): 2221-2235. springer.com
[10] Vora, H. D. and Sanyal, S. "A comprehensive review: metrology in additive manufacturing and 3D printing technology." Progress in additive manufacturing, 2020. [HTML]
[11] Vahia, I. V., Jeste, D. V., and Reynolds III, C. F. "Older adults and the mental health effects of COVID-19." Jama, 2020. jamanetwork.com
[12] Barca, Giuseppe MJ, et al. "Recent developments in the general atomic and molecular electronic structure system." The Journal of chemical physics 152.15 (2020). aip.org
[13] Kladovasilakis, Nikolaos, et al. "Impact of metal additive manufacturing parameters on the powder bed fusion and direct energy deposition processes: A comprehensive review." Progress in Additive Manufacturing 6 (2021): 349-365. [HTML]
[14] Raffi Mohammed, Irfan Anjum Badruddin, Abdul Saddique Shaik, Sarfaraz Kamangar, and Abdul Azeem Khan, Experimental Investigation on Mechanical Characterization of Epoxy-E-Glass Fiber-Particulate Reinforced Hybrid Composites, ACS Omega 2024 9 (23), 24761-24773, DOI: 10.1021/acsomega.4c01365
[15] Bourell, D. L. and Wohlers, T. "Introduction to additive manufacturing." 2020. [HTML]
[16] Liu, Guo, et al. "Additive manufacturing of structural materials." Materials Science and Engineering: R: Reports 145 (2021): 100596. sciencedirect.com
[17] Rich, S. I., Jiang, Z., Fukuda, K., and Someya, T. "Well-rounded devices: the fabrication of electronics on curved surfaces–a review." Materials Horizons, 2021. [HTML]
[18] Wu, Hao, et al. "Fabrication techniques for curved electronics on arbitrary surfaces." Advanced Materials Technologies 5.8 (2020): 2000093. researchgate.net
[19] Singh, Riya, et al. "Powder bed fusion process in additive manufacturing: An overview." Materials Today: Proceedings 26 (2020): 3058-3070. academia.edu
[20] Singh, D. D., Mahender, T., and Reddy, A. R. "Powder bed fusion process: A brief review." Materials Today: Proceedings, 2021. researchgate.net
[21] Popov, Vladimir V., et al. "Powder bed fusion additive manufacturing using critical raw materials: A review." Materials 14.4 (2021): 909. mdpi.com
[22] Gibson, Ian, et al. "Material jetting." Additive manufacturing technologies (2021): 203-235. [HTML]
[23] Elkaseer, Ahmed, et al. "Material jetting for advanced applications: A state-of-the-art review, gaps and future directions." Additive Manufacturing 60 (2022): 103270. sciencedirect.com
[24] Sarabia-Vallejos, Mauricio A., et al. "Innovation in additive manufacturing using polymers: a survey on the technological and material developments." Polymers 14.7 (2022): 1351. mdpi.com
[25] Mora, S., Pugno, N. M., and Misseroni, D. "3D printed architected lattice structures by material jetting." Materials Today, 2022. [PDF]
[26] Piscopo, Gabriele, and Luca Iuliano. "Current research and industrial application of laser powder directed energy deposition." The International Journal of Advanced Manufacturing Technology 119.11 (2022): 6893-6917. springer.com
[27] Mohammed, R.; Reddy, B. R.; Sridhar, K.; Manoj, A. Fabrication, Mechanical Characterization and Selection of Hybrid Composites by TOPSIS. Int. J. Recent Technol. Eng. 2019, 8 (1), 3118– 3125
[28] Svetlizky, David, et al. "Directed energy deposition (DED) additive manufacturing: Physical characteristics, defects, challenges and applications." Materials Today 49 (2021): 271-295. sciencedirect.com
[29] Svetlizky, David, et al. "Laser-based directed energy deposition (DED-LB) of advanced materials." Materials Science and Engineering: A 840 (2022): 142967. sciencedirect.com
[30] Mohammed, R.; Reddy, B. R.; Manoj, A. Synthetic Fibers of Polymer Matrix Composites- A Review. J. Adv. Res. Dyn. Control Syst. 2018, 10 (9), 2733– 2743
[31] Dezaki, Mohammadreza Lalegani, et al. "A review on additive/subtractive hybrid manufacturing of directed energy deposition (DED) process." Advanced powder materials 1.4 (2022): 100054. sciencedirect.com
[32] Lin, Z. and Hong, M. "Femtosecond laser precision engineering: from micron, submicron, to nanoscale." Ultrafast Science, 2021. science.org
[33] Mayana, P.; Raviprakash, A. V.; Mohamed Ali, S.; Mohammed, R. Effect of industrial wastes as epoxy modifiers on mechanical characteristics of E-glass fiber reinforced hybrid composites. Mater. Today: Proc. 2022, 65, 416– 422, DOI: 10.1016/j.matpr.2022.07.200
[34] Sefene, E. M. "State-of-the-art of selective laser melting process: A comprehensive review." Journal of Manufacturing Systems, 2022. researchgate.net
[35] Javaid, Mohd, et al. "Role of additive manufacturing applications towards environmental sustainability." Advanced Industrial and Engineering Polymer Research 4.4 (2021): 312-322. sciencedirect.com
[36] Guzzi, E. A. and Tibbitt, M. W. "Additive manufacturing of precision biomaterials." Advanced materials, 2020. [HTML]
[37] Mohammed, R.; Reddy, B. R.; Kakarla, S.; Krishna, B. B.; Khan, M. P. Mechanical Characterization & TOPSIS Ranking of Glass Fiber Reinforced particulate filled Epoxy based Hybrid Composites. J. Chem. Pharm. Sci. 2017, 10 (2), 1075– 1081.
[38] Jafari D, Vaneker THJ, Gibson I. Wire and arc additive manufacturing: Opportunities and challenges to control the quality and accuracy of manufactured parts. Materials & Design. 2021. sciencedirect.com
[39] Khorasani M, Ghasemi A, Rolfe B, Gibson I. Additive manufacturing a powerful tool for the aerospace industry. Rapid prototyping journal. 2022 Jan 3;28(1):87-100. [HTML]
[40] Vafadar A, Guzzomi F, Rassau A, Hayward K. Advances in metal additive manufacturing: a review of common processes, industrial applications, and current challenges. Applied Sciences. 2021. mdpi.com
[41] Ashima R, Haleem A, Bahl S, Javaid M, Mahla SK, Singh S. Automation and manufacturing of smart materials in Additive Manufacturing technologies using Internet of Things towards the adoption of Industry 4.0. Materials Today: Proceedings. 2021 Jan 1;45:5081-8. [HTML]
[42] Bandyopadhyay A, Traxel KD, Lang M, Juhasz M, Eliaz N, Bose S. Alloy design via additive manufacturing: Advantages, challenges, applications and perspectives. Materials Today. 2022 Jan 1;52:207-24. sciencedirect.com
[43] Kumar MB, Sathiya P. Methods and materials for additive manufacturing: A critical review on advancements and challenges. Thin-Walled Structures. 2021. [HTML]
[44] Blakey-Milner B, Gradl P, Snedden G, Brooks M, Pitot J, Lopez E, Leary M, Berto F, Du Plessis A. Metal additive manufacturing in aerospace: A review. Materials & Design. 2021 Nov 1;209:110008. sciencedirect.com
[45] Svetlizky D, Das M, Zheng B, Vyatskikh AL, Bose S, Bandyopadhyay A, Schoenung JM, Lavernia EJ, Eliaz N. Directed energy deposition (DED) additive manufacturing: Physical characteristics, defects, challenges and applications. Materials Today. 2021 Oct 1;49:271-95. sciencedirect.com
[46] Mohammed, R.; Reddy, B. R. G.; Reddy, V. S.; Ali, A. Effect of epoxy modifiers (bagasse fiber/ bagasse ash/ coal powder/ coal fly ash) on mechanical properties of epoxy/ glass fiber hybrid composites. Int. J. Appl. Eng. Res. 2015, 10 (24), 45625– 45630
[47] Beaman, J. J., et al. "Additive manufacturing review: early past to current practice." Journal of Manufacturing Science and Engineering 142.11 (2020): 110812. [HTML]
[48] Ramachandran, K. K., et al. "Machine learning and role of artificial intelligence in optimizing work performance and employee behavior." Materials Today: Proceedings 51 (2022): 2327-2331. [HTML]
[49] Mohammed, R.; Reddy, B. R.; Manoj, A. Fabrication & Erosion wear Response of E-Glass-Epoxy Based Hybrid Composites filled with CFA/CFACP. Int. J. Eng. Adv. Technol. 2019, 8 (3), 522– 528
[50] Zohuri, B. and Rahmani, F. M. "Artificial intelligence driven resiliency with machine learning and deep learning components." Japan Journal of Research, 2023. sciencexcel.com
[51] Leonard D. Tijing et. al., 3D-Printed Absorbers for Solar-Driven Interfacial Water Evaporation: A Mini-Review, Advance Sustainable Science, Engineering and Technology (ASSET), Vol. 3, No.1, April 2021, pp. 0210103-1 ~ 0210103-9 ISSN: 2715-4211 DOI: https://doi.org/10.26877/asset.v3i1.8367
[52] Alboro, R., Acain, L., Rivera, C., C. Rivera, A., Roxas-Buce, S., Aguilar, R., M. Delda, R., & C. Dizon, J. (2022). Assessment of the Viability of using 3D printing for the Design and Prototyping of Historical Artifacts as Replicas. Advance Sustainable Science, Engineering and Technology, 4(2), 0220201. doi: https://doi.org/10.26877/asset.v4i2.13004.
[53] Alboro, R., Acain, L., Rivera, C., C. Rivera, A., Roxas-Buce, S., Aguilar, R., M. Delda, R., & C. Dizon, J. (2022). Assessment of the Viability of using 3D printing for the Design and Prototyping of Historical Artifacts as Replicas. Advance Sustainable Science, Engineering and Technology, 4(2), 0220201. doi: https://doi.org/10.26877/asset.v4i2.13004.
[54] Crisostomo, J., & Dizon, J. (2021). 3D Printing Applications in Agriculture, Food Processing, and Environmental Protection and Monitoring. Advance Sustainable Science, Engineering and Technology, 3(2), 0210201. doi: https://doi.org/10.26877/asset.v3i2.9627
[55] Tijing, L., Dizon, J., & Cruz Jr., G. (2021). 3D-Printed Absorbers for Solar-Driven Interfacial Water Evaporation: A Mini-Review. Advance Sustainable Science, Engineering and Technology, 3(1), 0210103. doi: https://doi.org/10.26877/asset.v3i1.8367
