Industrial Strategies and Solutions for 3D Printing

Hamid Reza Vanaei is an Associate Professor at Ecole Supérieure d’Ingénieurs Léonard de Vinci (ESILV), Léonard de Vinci University in Paris, France. Sofiane Khelladi is a Full Professor at Arts et Métiers Institute of Technology in Paris, France. Abbas Tcharkhtchi is a Full Professor at Arts et Métiers Institute of Technology in Paris, France.

• List of Contributors xvPreface xxi1 3D Printing as a Multidisciplinary Field 1Hamid Reza Vanaei, Sofiane Khelladi, and Abbas Tcharkhtchi1.1 Introduction 11.2 Unveiling the Foundations: Grasping the Essential Features of 3D Printing 21.2.1 Historical Review 21.2.2 Potential of 3D Printing from Lab to Industry 51.2.3 Challenges and Potential Roadmap Toward Solving them in 3D Printing 61.2.3.1 High Building Rate 3D Printing Process 91.2.3.2 Big Area Additive Manufacturing (BAAM) System 91.2.3.3 Faster FFF 3D Printing System 101.2.3.4 Improvement of Interfacial Bonding and Strength in Z-Direction 111.2.4 Role of Controlling Factors in 3D Printing 121.3 Multiphysics Behavior in 3D Printing Process 131.3.1 Physicochemical and Mechanical Phenomena of 3D-printed Parts 131.3.2 Thermal Features of 3D-printed Parts 141.3.3 Rheological Evaluations in 3D Printing 151.3.3.1 Mastering the Flow: Essential Fundamentals of Rheology 151.3.3.2 Optimizing with Rheological Insights 161.3.4 In-process Temperature Monitoring in 3D Printing 171.4 3D Printing Perfection: Unveiling the Power of Optimization 181.4.1 Importance of Multiphysics Evaluation in 3D Printing 181.4.2 Optimizing the Controlling Factors and Characteristics of 3D-printed Parts 201.4.3 Role of Machine Learning in 3D Printing 211.5 Future Outlook 221.5.1 Emerging Horizons in Multidisciplinary 3D Printing 221.5.2 Building Life with Precision 221.5.3 Architectural Revolution: Design and Construction Reimagined 231.5.4 Sustainable Manufacturing: A Green Revolution 231.6 Summary and Outlooks: Pioneering a Multidisciplinary Renaissance 23References 242 Potential of 3D Printing from Lab to Industry 25Zohreh Mousavi Nejad, Nicholas J. Dunne, and Tanya J. Levingstone2.1 Introduction 252.2 Architecture and Construction Industry 262.3 Healthcare and Medical Industry 282.3.1 Dental and Craniomaxillofacial 292.3.2 Medical Devices 302.3.3 Drug Delivery and Pharmaceutical 312.3.4 Tissue Engineering 322.3.5 Personalized Treatment 352.4 Textile and Fashion Industry 352.5 Food Industry 372.6 Aerospace Industry 392.7 Conclusions and Future Perspectives 40References 403 Applicable Materials and Techniques in 3D Printing 43Saeedeh Vanaei and Mohammad Elahinia3.1 Introduction 433.2 Materials in 3D Printing 453.2.1 Metals 453.2.1.1 Aluminum Alloys 453.2.1.2 Stainless Steel 453.2.1.3 Titanium Alloys 463.2.1.4 Nickel-based Shape Memory Alloys 463.2.1.5 Cobalt Chrome Alloys 463.2.2 Polymers 473.2.2.1 Polylactide 473.2.2.2 Acrylonitrile Butadiene Styrene 473.2.2.3 Polyamide 473.2.2.4 Polycarbonate 483.2.3 Ceramics 483.2.4 Composites 483.2.4.1 Fiber Reinforced Composites 493.2.4.2 Particle Reinforced Composites 493.3 Techniques in 3D Printing 493.3.1 Fused Deposition Modeling 523.3.2 Powder Bed Fusion 523.3.3 Direct Energy Deposition 523.3.4 Binder Jetting 533.3.5 Material Jetting 533.3.6 Sheet Lamination 543.3.7 Vat Photopolymerization 543.4 Summary and Outlook 54References 554 Diverse Application of 3D Printing Process 59Shohreh Vanaei and Nader Zirak4.1 Introduction 594.2 3D Printing: Transforming Manufacturing Landscapes 604.3 Application of 3D Printing: Different Manufacturing Technology 614.3.1 Fused Deposition Modeling 614.3.1.1 Revolutionizing Prototyping with Fused Deposition Modeling (fdm) 614.3.1.2 Functional End-Use Parts in Manufacturing 614.3.1.3 Medical Advancements Through FDM 614.3.1.4 Education and Conceptual Learning 624.3.1.5 Sustainability and Customization 624.3.2 Stereolithography 624.3.2.1 Precision Prototyping and Beyond with Stereolithography (sla) 624.3.2.2 Tailoring the Medical Landscape 634.3.2.3 Architectural and Design Elegance 634.3.2.4 Jewelry and Fashion Innovation 634.3.2.5 Educational Enrichment and Research 634.3.3 Binder Jetting 644.3.3.1 Redefining Metal Fabrication with Binder Jetting Technology 644.3.3.2 Ceramic Applications and Engineering Advancements 644.3.3.3 Transforming Customization and Product Design 644.3.3.4 Architectural and Artistic Exploration 654.3.3.5 Promoting Sustainable Practices and Material Efficiency 654.3.4 Power Bed Fusion 654.3.4.1 Empowering Aerospace Innovation with Powder Bed Fusion 654.3.4.2 Medical Advancements Through PBF Techniques 654.3.4.3 High-Performance Components in Automotive Engineering 664.3.4.4 Unlocking Design Possibilities with Customization 664.3.5 Selective Laser Sintering 664.3.5.1 Elevating Manufacturing Precision with Selective Laser Sintering (SLS) 664.3.5.2 Aerospace Innovation Through SLS 674.3.5.3 Medical Devices and Prosthetics 674.3.5.4 Automotive Engineering and Rapid Prototyping 674.3.5.5 Tooling and Manufacturing Efficiency 674.3.6 Direct Energy Deposition (DED) 674.3.6.1 Empowering Large-Scale Manufacturing with DED 674.3.6.2 Aerospace Advancements with DED 684.3.6.3 Oil and Gas Infrastructure Enhancement 684.3.6.4 Tooling and Mold Manufacturing 684.3.6.5 Repair and Refurbishment 684.4 Application of 3D Printing: Industrial Sector 694.4.1 Automotive Innovation Driven by 3D Printing 694.4.2 Aerospace Advancements Through 3D Printing 704.4.3 3D Printing in Turbomachinery 714.4.4 Food Industry 724.4.5 Medical Breakthroughs with 3D Printing 734.4.6 Electronic Industry 744.4.7 Construction Industry: Architecture and Building 754.4.8 Fashion Industry 764.5 Summary 78References 785 Redefining Fabrication: Emerging Challenges in the Evaluation of 3D-printed Parts 81Xiaofan Luo, Mengxue Yan, Kaddour Raissi, and Amrid Mammeri5.1 Introduction: Scope and Definition 815.2 Historical Review 825.3 Technological Challenges in ME-3DP 855.3.1 The Symptoms of ME-3DP 865.3.1.1 Poor Process Reliability 865.3.1.2 Low Printing Speed 885.3.1.3 Part Distortion 895.3.1.4 Unpredictable Properties 905.3.2 The Root Cause 915.3.2.1 Process Complexity: ME-3DP vs Injection Molding 915.3.2.2 The Extrusion Process 925.3.2.3 Anisotropy and the Poor Strength in Z-direction of 3D-printed Parts 935.3.2.4 The Lower Building Rate of ME-3DP 965.4 Future Perspective: Potential Roadmaps Toward Solving the Key Challenges of ME-3DP 965.5 High Building Rate ME-3DP Process 985.6 Big Area Additive Manufacturing (BAAM) System 985.7 Faster FFF 3D Printing System 995.8 Improvement of Interfacial Bonding and Strength in Z-direction 1005.9 Conclusions 101References 1026 Importance of Multi-objective Evaluation in 3D Printing 105Kasin Ransikarbum and Namhun Kim6.1 Introduction 1056.2 The Current State of Multi-Objective Evaluation of 3DP 1076.2.1 Part Orientation Problem in 3DP 1086.2.2 Printer Selection Problem in 3DP 1096.2.3 Part-to-Printer Assignment Problem in 3DP 1106.3 Decision Support System for 3DP Under Multi-Objective Evaluation 1116.3.1 Part Orientation 1116.3.1.1 Data Envelopment Analysis (DEA) 1146.3.1.2 Analytic Hierarchy Process (AHP) 1146.3.1.3 Linear Normalization (LN) 1156.3.1.4 Illustrative Case Study for Part Orientation 1156.3.2 Printer Selection 1206.3.2.1 Fuzzy Analytic Hierarchy Process (FAHP) 1206.3.2.2 Technique for Order of Preference by Similarity to Ideal Solution (topsis) 1216.3.2.3 Illustrative Case Study for Printer Selection 1226.3.3 Part-to-Printer Scheduling 1226.3.3.1 Multi-objective Optimization 1236.3.3.2 Illustrative Case Study for Part-to-Printer Assignment 1246.4 Discussion and Managerial Implication 1256.5 Conclusion 126References 1277 Role of Controlling Factors in 3D Printing 129Shahriar Hashemipour and Amrid Mammeri7.1 Introduction 1297.2 FFF Process Parameters 1307.3 Controlling Factors as a Source of Heat Transfer 1337.4 Impact of Controlling Factors on Mechanical Features of 3D-Printed Parts 1357.5 Role of Controlling Factors on Interfacial Bonding of 3D-Printed Parts 1367.6 Role of Controlling Factors on Optimization of 3D-Printed Parts 1377.7 Summary and Outlook 141References 1428 Physico-chemical Features of 3D-printed Parts 145Wuzhen Huang and Yi Xiong8.1 Introduction 1458.2 Fused Filament Fabrication 1468.3 Different Types of Applicable Materials in FFF 1478.3.1 Classification of Polymers 1498.3.1.1 Amorphous Polymers 1498.3.1.2 Semi-crystalline Polymers 1528.3.2 Classification of Polymer Composites 1558.3.2.1 Structural Polymer Matrix Composites 1568.3.2.2 Functional Polymer Matrix Composites 1578.4 Physicochemical Characterization of 3D-printed Parts 1578.4.1 Physical Properties of 3D-printed Parts 1588.4.1.1 Mechanical Properties 1588.4.1.2 Thermal Properties 1618.4.1.3 Electrical and Optical Properties 1648.4.2 Chemical Properties 1648.4.2.1 Molecular Weight 1648.4.2.2 Chemical Permeability 1658.4.2.3 Chemical Resistance 1658.4.2.4 Chemical Degradability 1658.5 Effect of Phase Change on the Quality of 3D-Printed Parts 1668.5.1 The Factors that Affect the Crystallization of 3D-Printed Parts 1668.5.2 The Effect of Crystallinity on Physical Properties 1668.5.2.1 Optical Properties 1668.5.2.2 Thermal Properties 1678.5.2.3 Water Absorption and Wear Resistance 1678.5.2.4 Mechanical Properties 168References 1689 3D Printing Optimization: Importance of Rheological Evaluation in 3D Printing 171Abbas Tcharkhtchi, Reza Eslami Farsani, and Hamid Reza Vanaei9.1 Introduction 1719.2 Fundamentals of Viscosity 1729.3 Resistance of Materials to Flow 1739.3.1 Modulus 1739.3.2 Viscosity 1749.3.3 Relaxation Time 1759.4 Materials with Different Rheological Behaviors 1769.4.1 Elastic Materials 1779.4.2 Viscous Materials 1779.4.3 Plastic Materials 1789.5 Different Rheological Behaviors at Constant Pressure and Temperature 1819.5.1 Newtonian Liquids 1819.5.2 Time-independent Non-Newtonian Liquids 1819.6 Viscoelastic Behavior 1829.7 3D Printing of Thermoplastic Polymers 1849.7.1 Temperature Evolution as an Indicator for Viscosity Measurement 1859.7.2 Interphase Formation Between the Filaments During 3D Printing Process 1889.8 Rheology and Optimization in 3D Printing Process 1899.9 Summary 190References 19110 Investigating the Mechanical Performance of 3D-printed Parts 193Hamid Reza Javadinejad, Abdoulmajid Eslami, and Hamid Reza Vanaei10.1 Introduction 19310.2 Mechanical Properties of 3D-Printed Parts 19410.2.1 Modula of 3D-Printed Parts 19410.2.2 Tensile Properties of 3D-Printed Parts 19410.2.3 Compressive Properties of 3D Printed Parts 19610.2.4 Flexural Properties of 3D Printed Parts 19710.2.5 Impact Strength Properties of 3D Printed Parts 19910.2.6 Shear Properties of 3D Printed Parts 20110.2.7 Hardness Properties of 3D Printed Parts 20210.2.8 Fatigue Properties of 3D Printed Parts 20310.2.9 Creep Properties of 3D Printed Parts 20410.3 Conclusion 205References 20511 Thermal Modeling of Material Extrusion Additive Manufacturing (MEX) 211José A. Covas, Sidonie F. Costa, and Fernando M. Duarte11.1 Introduction 21111.2 Thermal Modeling of MEX 21211.3 A Thermal Model for Heat Transfer and Bonding 21811.4 Printing a Tensile Test Specimen 22511.5 Conclusions 228References 22912 In-Process Temperature Monitoring in 3D Printing 233Saeedeh Vanaei and Michael Deligant12.1 Introduction 23312.2 Heat Transfer in 3D Printing 23412.3 The Impact of Cyclic Temperature Profile in 3D-Printing Process 23712.3.1 In-Process Monitoring of Temperature Variation in 3D-Printing Process 24012.3.1.1 Global Monitoring – Temperature Recording on the External Surface of Deposited Layers 24112.3.1.2 Local Monitoring – Temperature Recording at the Interfaces of Adjacent Layers 24312.4 Advantages and Disadvantages of Global–Local In-Process Monitoring 24712.5 Summary and Outlook 247References 24813 Optimizing the Controlling Factors and Characteristics of 3D-printed Parts 253Anouar El Magri and Sébastien Vaudreuil13.1 Introduction 25313.2 Controlling Factors of FFF Process 25413.3 Overview of Optimization 25613.3.1 What Is “Optimization of 3D-Printing Parameters”? 25613.3.2 Response Surface Methodology (RSM) 25713.3.3 Equation of Regression and ANOVA 25813.3.4 Main Effect Diagram and Pareto Chart 25913.3.5 Contour Plots, 3D Surface Plots, and Optimization Diagram 26113.4 Advantages and Disadvantages of the Optimization 26213.5 Optimization in 3D-Printing Perspective 26413.6 Optimization of 3D-Printing FFF Controlling Factors 26413.6.1 Nozzle Temperature 26413.6.2 Layer Thickness 26613.6.3 Printing Speed 26713.6.4 Infill Density 268References 26914 Machine Learning in 3D Printing 273Mohammadali Rastak, Saeedeh Vanaei, Shohreh Vanaei, and Mohammad Moezzibadi14.1 Introduction 27314.2 Literature Review 27414.3 3D Printing: Applications and Obstacles 27814.4 AI/ML and 3D Printing 27914.4.1 Role of AI/ML in 3D Printing 27914.4.2 ML Algorithms Review 28214.4.3 Application of AI/ML in 3D Printing: A Roadmap from Defect Detection to Optimization Purposes 28414.4.3.1 Defect Detection 28414.4.3.2 Processing Parameter Optimization 28614.4.3.3 Geometric Control Using Deep Learning 28714.4.3.4 Cost Estimation 288References 290Index 295