Index

A classification of, 120

Acrylonitrile butadiene styrene (ABS), 4, 13, disadvantages, 120
163, 319 dynamic mechanical properties, 262
Additive manufacturing file easier, 30
format (AMF), 192 extrusion, 108
Additive manufacturing (AM) processes, 2 faster, 29
ability of, 181 features, 31, 113
add-on, 113 green part, 84
advantages, 3, 85, 106 harmonization
attributes of, 56 modification of, 190
beta alloys, 270 standardization, 189
better, 30 hybridization, 152
bigger, 29 indirect methods
biological materials 3DAM, 151
3D scaffold printing, 318 advantages, 120
biological polymer printing, 320 disadvantages, 120
cell printing, 321 ink jetting, 41, 47
feedstocks, 318 laser-based, 112
synthetic polymer printing, 319 layer-by-layer approach, 191
biomedical applications, 262 market survey
birth of, 3 conventional ceramic industry, 118
BJ, 42, 45, 47 niche technology providers, 118
ceramic injection molding, 109 perspectives of, 120
challenges, 315 printing service providers, 118
characteristics of, 312, 313 razor-sharp business model, 119
cheaper, 30 research/universities, 118
CoCr alloys specialized ceramic providers, 118
biomedical applications, 284 structure of, 119
functional characteristics, 283 system/material providers, 114
mechanical characteristics, 283 material extrusion, 1
PFM, 287 material jetting, 1
complex, 31 medical devices
complex ceramic objects, 208 biocompatibility, 315
DED, 1, 42, 44 electrospinning, 323
definition, 261 fabrics, 325
development of, 48 immunology, 315
directed energy deposition, 82 metals, 330
direct energy deposition, 85 microelectromechanical systems, 328
direct methods, 120 microfluidics, 328
advantages, 120 molding, 326
346 Index

Additive manufacturing (AM) inspection techniques, 185

processes (cont.) medical device industries, 182
polytetrafluoroethylene, 314 roadmap action plan, 197
soft robots, 329 robust methods, 185
toxicology, 315 strategies, 186
metal ink, 58 surveillance, 182
metal material systems technology and measurement
metal powders, 206 challenges, 186, 209
powder bed melting, 205 quasi-static, 262
printed and studied, 204 questi, 32
printing techniques, 204 sheet lamination, 1, 42, 46
residual stresses, 206 slip casting, 108
metal microdroplet stainless steels
laser-based printing, 93 austenitic, 279
nozzle-based method, 86 functional characteristics, 278
Mg alloy martensitic, 281
biomedical applications, 292 mechanical characteristics, 278
functional characteristics, 292 precipitation hardening, 281
mechanical characteristics, 292 stereolithography, 40, 48
optimization process, 293 strengths of, 113
nanoparticle jetting, 85 synopsis, 317
NiTi alloys, 272 tantalum
distinctive functional properties, 272 biomedical applications, 288
physical properties, 273 functional characteristics, 288
problems, 275 mechanical characteristics, 288
property of, 275 selective laser melting, 289
opportunities, 316 tape casting, 108
PBF, 42 three-dimensional (3D) printing
polymer material systems applications, 22
soft polymers, 203 binder jetting, 8, 9, 47, 121, 125
thermoplastic polymer, 202 deposition, 149
UV curable polymer, 203 directed energy deposition, 82
polymers, 114 direct melting, 149
powder bed fusion, 1 direct printing, 139
production challenges fused deposition modeling, 3, 140
manufacturing, 333 hybrid, 18
packaging, 330 inkjet, 121
sterility, 330 laminated object manufacturing, 136
PSD, 208 layer-wise slurry deposition, 140
qualification and certification material jetting, 6
aerospace products, 183 metal, 8
affordable methods, 184 nanoparticles, 84
aircraft industries, 183 next generation, 10
application, 182 powder bed fusion, 76
barriers, 209 precursor-based processes, 148
conventional manufacturing methods, 185 pressure assisted, 129
decision, 182 robocasting, 138
evaluation, 182 screen, 143
guidelines, 186, 197 selective laser melting, 127
Index 347
selective laser sintering, 5, 125
sheet lamination, 5
stencil, 143
stereolithography, 131
thermoplastic, 145
titanium alloys, 263, 264
biomedical applications, 272
functional characteristics, 263
mechanical characteristics, 263
two-dimensional (2D) printing
comparison of, 63, 65
laser transfer, 72
metallic particle ink, 58
microfabrication processes, 57
nanoparticles, 59
roll-to-roll printing, 61
screen printing, 57
uniaxial pressing, 107
valid data, 200
vat photopolymerization, 1
weaknesses of, 110, 113
Augmented reality (AR), 13
Austenite, 281
B D
Beer-Lambert law, 134
Biocompatibility, 262
Biopolymer
3D scaffold printing
extrusion, 319
inkjet printing, 318
inorganic materials, 318
Boltzmann constant, 59
C Directed energy deposition (DED), 9, 82, 194
CAD. See Computer aided design (CAD)
Carbon’s Continuous Liquid Interface
Production (CLIP), 11
Casting
cores, 24
molds, 24
patterns, 24
Center for Disease Control (CDC), 332
Ceramic injection molding (CIM), 109
limitations, 110
pros and cons of, 110, 111
shaping process, 109
thermoplastic feedstocks, 109
Ceramic stereolithography (CSL), 132
Chemical vapour deposition (CVD), 288
CMYK color model, 7
Cobalt chromium (CoCr) alloys, 298
biomedical applications, 284
functional characteristics, 283
mechanical characteristics, 283
PFM, 287
Cold isostatic pressing (CIP), 126
Composite-based additive manufacturing
(CBAM), 10
Computed tomography (CT), 315
Computer aided design (CAD), 39, 163,
285, 315
Computer numerical control (CNC), 10, 312
COMSOL Multiphysics, 232
Continuous liquid interface production
(CLIP), 40
Continuous wave (CW), 66
Crystal structure
body-centered cubic structure, 263
hexagonal close-packed, 263
CTE, 170, 172
DED. See Directed energy deposition (DED)
Defense Advanced Research Projects
Agency (DARPA), 8
Deformable mirror device (DMD), 132
Demineralized bone matrix (DBM), 319
Digital light projection (DLP), 131, 132
Digital printing
laser-based technologies, 63
nozzle-based technologies, 63
advantages, 83
disadvantages, 83
hybrid systems, 83
laser beam, 196
LENS, 82
machine operation, 196
PBF systems, 83
powder bed fusion techniques, 83
process documentation, 196
Direct metal laser sintering (DMLS), 3, 263
DEM simulation, 229
design parametric study, 254
distortion analyses, 251
348 Index

Direct metal laser sintering (DMLS) (cont.) Fused deposition modeling (FDM), 3, 140,
hatch spacing, 240 163, 202, 319
laser power, 236 ABS, 163
laser scan, 237 adoption of, 164
particle flow model, 231 anisotropic character, 165
powder deposition, 229 applications of, 163
properties of, 229 building speed, 165
recoating process, 229 CAD, 163
residual stress, 251 CTE, 170, 172
sequential schematics, 235 environmental conditions, 165
temperature distributions, 235 fabrication process, 169
thermal analysis, 248 Fiber Bragg grating, 166
Direct methods, 120 fiber embedment process, 167
advantages, 120 infill, 165
classification of, 120 mechanical characterization
disadvantages, 120 flexural tests, 173
Discrete element modeling (DEM), 216, 229 tensile tests, 174, 175
platform, 166
E porosity, 164
printing process, 164, 167
EBM. See Electron beam melting (EBM)
printing temperature, 165
Electrical discharge machining (EDM), 194
Fused filament fabrication (FFF), 145
Electron Beam Freeform Fabrication (EBF3),
44, 292
G
Electron beam melting (EBM), 3, 76, 80,
194, 263 Gibbs–Thomson equation, 59
CoCr alloys, 286 Good Manufacturing Practices (GMP), 319
Electro Optical Systems (EOS), 8 Governing equations, 230, 244
Electrospinning, 323 Green body, 111
Embedded-atom method (EAM), 217 Green technology, 317
Extracellular matrix (ECM), 316
Extrusion, 108 H
Harmonization
F modification of, 190
standardization, 189
Fabrics, 325
Hot isostatic pressing (HIP), 84, 85, 262
Face centered cubic (FCC), 218
Human mesenchymal stem cells (hMST), 276
FDM. See Fused deposition modeling (FDM)
Hybrid. See also Three-dimensional (3D)
Federal aviation administration (FAA), 183
printing
Fiber Bragg grating (FBG), 166
additive construction, 21
stress–strain curves, 176, 177
bioprinting, 20
tensile test, 176
electronics, 19
Finite element model (FEM), 215, 232
food printing, 21
boundary conditions, 245
in space, 22
governing equations, 244
Hybridization, 152
materials properties, 246
model geometry, 245
I
simulation analyses, 247
SLS process, 243 Indirect methods
Functionally graded materials (FGM), 269 3DAM, 151
Index 349

advantages, 120 M
disadvantages, 120 Magnesium (Mg) alloys, 299
Indium Thin Oxides (ITO), 71 biomedical applications, 292
Inkjet technology functional characteristics, 292
advantages, 63 mechanical characteristics, 292
electrohydrodynamic, 63 optimization process, 293
laser-based methods, 63 Magnetic resonance imaging (MRI), 315
piezoelectric, 63 Maxwell–Boltzmann distribution, 219
small-volume reservoir, 63 Mean-squared displacement (MSD), 219
Medical devices, 312
L
biocompatibility, 315
Laminated object manufacturing (LOM), 6, definition, 312
7, 46, 136 electrospinning, 323
Large-scale atomic/molecular massively fabrics, 325
parallel simulator (LAMMPS), 217 immunology, 315
Laser-assisted bioprinting (LAB), 48 metals, 330
Laser beam (LB), 196 microelectromechanical systems, 328
Laser Cladding (LC), 292 microfluidics, 328
Laser engineered net shaping (LENS), 44, molding, 326
82, 288, 289 polytetrafluoroethylene, 314
Laser engineered net shaping (LENSTM), 284 soft robots, 329
Laser induced forward transfer (LIFT), 55, toxicology, 315
72, 93 Metal. See also Three-dimensional (3D)
bubble formation, 74 printing
liquids, 74 DED, 9
material/substrate interface, 73 powder bed fusion, 10
pixel, 73 Microelectromechanical systems (MEMS),
release layer, 73 40, 328
transfer pastes, 74 Microextrusion, 84
transfer printing, 75 Microfluidics, 328
Laser metal deposition (LMD), 278 Microwaves (MW), 66
Laser powder bed fusion (LPBF), 76, 215, 263 Molecular dynamics (MD), 216
advantages, 80, 81 EAM, 217
disadvantages, 80, 81 governing equations, 230
nitrogen, 79 LAMMPS, 217
rule of thumb, 79 model validation, 247
ytterbium, 78 model validations
Laser sintering, 66 DMLS process model, 233
ITO, 71 heat transfer model, 232
TCC, 71 particle flow model, 231
TCO, 71 Ni–Ni nanoparticle pair
Layer-wise slurry deposition (LSD), 140 atomistic model, 218
LENS. See Laser engineered net shaping configuration change, 221
(LENS) diffusion of, 219, 222
Lithography-based Ceramic Manufacturing solid state sintering, 219
(LCM), 153 stress strain curve, 228
LOM. See Laminated object manufacturing temperature change, 221
(LOM) SHS, 217
LPBF. See Laser powder bed fusion (LPBF) SOFC, 217
350 Index

Molecular dynamics (MD) (cont.) Polyethylene glycol (PEG), 320

tensile test
atomistic model, 220
configurational change, 227
sintered structure, 220
YSZ, 217
Multi Jet Fusion (MJF), 12
Multi Jet Printing (MJP), 9
Polylactic acid (PLA), 4
Polymers, 73
Polytetrafluoroethylene (PTFE), 314
Porcelainfused-to-metal (PFM), 287
Powder-based 3D printing (P-3DP), 191
Prepreg, 10
Printed circuit boards (PCBs), 13

N R
Nanoparticle Rapid electrical sintering (RES), 65
atomic bonds, 59 Rapid prototyping (RP), 39, 324
binder jetting, 84 RepRap Project, 6
delamination, 66 Roadmap, 188, 197
jetting closed-loop process control, 198
advantages, 86 Robocasting, 207
disadvantages, 86 Round robin testing, 198
kinetics of, 59 Rule of thumb, 79
microextrusion, 84
organics sintering, 66 S
plasma sintering, 65
Scanning electron microscope (SEM),
posttreatment sintering, 64
42, 80
preparation of, 59
Screen printing, 143
sintering temperature, 59
Selective lamination composite object
thermodynamics, 59
manufacturing (SLCOM), 10
Next generation, 10
Selective laser melting (SLM), 3, 127, 204,
FDM, 12
263, 289
low-cost plastic, 11
ceramic materials, 129
multi jet fusion, 14
CoCr alloy, 284
new metals, 16
EBM, 3
sheet lamination, 12
hMST, 276
vat photopolymerization, 13
limitations of, 127
NiTi alloys, 272, 297
multi-stage shape recovery, 276
distinctive functional properties, 272
Selective laser sintering (SLS), 5, 125,
physical properties, 273
202
problems, 275
advantages of, 127
property of, 275
akermanite scaffold, 126
CIP, 126
O
disadvantages of, 127
Offset printing, 61 inorganic/organic binders, 127
Shape memory alloys (SMAs), 262,
P 275
Packaging, 330 biomedical applications, 275
Photopolymer, 3 damping capacity, 274
Polycaprolactone (PCL), 316, 323 shape recovery, 273
Poly-d, l-lactide (PDLLA), 319 superelastic effect, 273
Polyetherimide (PEI), 5 transformation temperature, 273
Polyetherketoneketone (PEKK), 7, 10, 11 two-way memory effect, 273
Index 351

Sintering, 64 T
argon, 69 Tantalum, 298
copper NP inks, 69 biomedical applications, 288
direct-write laser, 70 functional characteristics, 288
electrical, 65 mechanical characteristics, 288
equilibrium, 221 selective laser melting, 289
HIP, 84 Tape casting, 108
laser, 66 Tensile testing, 174, 175
laser irradiance, 69 atomistic model, 220
mechanical response, 224 configurational change, 227
microwaves, 66 sintered structure, 220
organics, 66 Thermoplastic elastomers (TPEs), 203
photonic, 65, 66 Three-dimensional (3D) printing
RES, 65 binder jet, 121, 125
scan velocity, 69 binder jetting, 8
simulations, 220 casting, 24
tensile test simulations, 221 deposition, 149
SL. See Stereolithography (SL) directed energy deposition, 82
Slip casting, 108 direct melting, 149
SLM. See Selective laser melting (SLM) direct printing, 139
SLS. See Selective laser sintering (SLS) functional prototypes, 23
Soft robotics, 329 fused deposition modeling, 3, 140
Solid oxide fuel cell (SOFC), 217 hybrid
Stainless steels, 297 additive construction, 21
austenitic, 279 bioprinting, 20
functional characteristics, 278 electronics, 19
martensitic, 281 food printing, 21
mechanical characteristics, 278 in space, 22
precipitation hardening, 281 inkjet, 121
Standardization, 189. See also Additive laminated object manufacturing, 136
manufacturing (AM) processes layer-wise slurry deposition, 140
design, 192 material jetting, 6
materials, 194 metal
processes, 194 DED, 9
terminology, 192 powder bed fusion, 10
test methods, 196 nanoparticles, 84
Stencil printing, 143 next generation
Stereolithography (SL), 40, 48, 191 FDM, 12
Stereolithography (STL), 318 low-cost plastic, 11
Stereolithography apparatus (SLA), 131, 329 multi jet fusion, 14
advantages, 135 new metals, 16
CLIP, 40 sheet lamination, 12
disadvantages, 135 vat photopolymerization, 13
optimal parameters, 40 powder bed fusion, 76
properties of, 40 precursor-based processes, 148
Sterility, 330 pressure assisted, 129
Sterility assurance level (SAL), 332 robocasting, 138
Stratasys, 9, 10 screen, 143
Synopsis, 317 selective laser melting, 127
352 Index
Molecular dynamics (MD) (cont.)
selective laser sintering, 5, 125
sheet lamination, 5
stencil, 143
stereolithography, 131
thermoplastic, 145
tooling, 24
visual prototypes, 23
Ti6Al4V, 204
EBM Ti6Al4V material, 266
heat treatments of, 269
lattice structures, 269
mechanical properties, 266
nitrogen pick-up, 267
oxygen pick-up, 267
reliability, 266
repeatability, 266
residual stresses, 267
SLM Ti6Al4V material, 266
stress-relief, 269
Tissue engineered medical device products
(TEMPs), 319
Titanium (Ti) alloys, 263, 264, 296
biomedical applications, 272
functional characteristics, 263
mechanical characteristics, 263
Ti6Al4V
EBM Ti6Al4V material, 266
heat treatments of, 269
lattice structures, 269
mechanical properties, 266
nitrogen pick-up, 267
oxygen pick-up, 267
reliability, 266
repeatability, 266
residual stresses, 267
SLM Ti6Al4V material, 266
stress-relief, 269
Traditional manufacturing (TM), 312
Transparent conductive coatings (TCC), 71
Transparent conductive oxides (TCO), 71
Two-dimensional (2D) printing
comparison of, 63, 65
laser transfer, 72
metallic particle ink, 58
microfabrication processes, 57
nanoparticles, 59
roll-to-roll printing, 61
screen printing, 57
U
Ultimate tensile strength (UTS), 266
Ultrasonic additive manufacturing
(UAM), 46
Ultraviolet (UV), 40, 318
W
Wide and High Additive Manufacturing
(WHAM), 10
Y
Yield strength (YS), 266
Yttria-stabilized zirconia (YSZ), 217