Freedom of design, mass customisation, waste minimisation and the ability to manufacture complex structures, as well as fast prototyping, are the main benefits of additive manufacturing (AM) or 3D printing. A comprehensive review of the main 3D printing methods, materials and their development in trending applications was carried out. In particular, the revolutionary applications of AM in biomedical, aerospace, buildings and protective structures were discussed. The current state of materials development, including metal alloys, polymer composites, ceramics and concrete, was presented. In addition, this paper discussed the main processing challenges with void formation, anisotropic behaviour, the limitation of computer design and layer-by-layer appearance. Overall, this paper gives an overview of 3D printing, including a survey on its benefits and drawbacks as a benchmark for future research and development.

Additive manufacturing (3D printing): A review of materials, methods, applications and challenges

The use of 3D printing for rapid tooling and manufacturing has promised to produce components with complex geometries according to computer designs. Due to the intrinsically limited mechanical properties and functionalities of printed pure polymer parts, there is a critical need to develop printable polymer composites with high performance. 3D printing offers many advantages in the fabrication of composites, including high precision, cost effective and customized geometry. This article gives an overview on 3D printing techniques of polymer composite materials and the properties and performance of 3D printed composite parts as well as their potential applications in the fields of biomedical, electronics and aerospace engineering. Common 3D printing techniques such as fused deposition modeling, selective laser sintering, inkjet 3D printing, stereolithography, and 3D plotting are introduced. The formation methodology and the performance of particle-, fiber- and nanomaterial-reinforced polymer composites are emphasized. Finally, important limitations are identified to motivate the future research of 3D printing.

3D printing of polymer matrix composites: A review and prospective

Additive manufacturing (AM) is poised to bring about a revolution in the way products are designed, manufactured, and distributed to end users. This technology has gained significant academic as well as industry interest due to its ability to create complex geometries with customizable material properties. AM has also inspired the development of the maker movement by democratizing design and manufacturing. Due to the rapid proliferation of a wide variety of technologies associated with AM, there is a lack of a comprehensive set of design principles, manufacturing guidelines, and standardization of best practices. These challenges are compounded by the fact that advancements in multiple technologies (for example materials processing, topology optimization) generate a "positive feedback loop" effect in advancing AM. In order to advance research interest and investment in AM technologies, some fundamental questions and trends about the dependencies existing in these avenues need highlighting. The goal of our review paper is to organize this body of knowledge surrounding AM, and present current barriers, findings, and future trends significantly to the researchers. We also discuss fundamental attributes of AM processes, evolution of the AM industry, and the affordances enabled by the emergence of AM in a variety of areas such as geometry processing, material design, and education. We conclude our paper by pointing out future directions such as the "print-it-all" paradigm, that have the potential to re-imagine current research and spawn completely new avenues for exploration. The fundamental attributes and challenges/barriers of Additive Manufacturing (AM).The evolution of research on AM with a focus on engineering capabilities.The affordances enabled by AM such as geometry, material and tools design.The developments in industry, intellectual property, and education-related aspects.The important future trends of AM technologies.

The status, challenges, and future of additive manufacturing in engineering

The past few decades have seen substantial growth in Additive Manufacturing (AM) technologies. However, this growth has mainly been process-driven. The evolution of engineering design to take advantage of the possibilities afforded by AM and to manage the constraints associated with the technology has lagged behind. This paper presents the major opportunities, constraints, and economic considerations for Design for Additive Manufacturing. It explores issues related to design and redesign for direct and indirect AM production. It also highlights key industrial applications, outlines future challenges, and identifies promising directions for research and the exploitation of AM's full potential in industry.

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Design for additive manufacturing: trends, opportunities, considerations, and constraints

3D printing, more formally known as Additive Manufacturing (AM), is already being adopted for rapid prototyping and soon rapid manufacturing. This review provides a brief discussion about AM and also the most employed AM technologies for polymers. The commonly-used ASTM and ISO mechanical test standards which have been used by various research groups to test the strength of the 3D-printed parts have been reported. Also, a summary of an exhaustive amount of literature regarding the mechanical properties of 3D-printed parts is included, specifically, properties under different loading types such as tensile, bending, compressive, fatigue, impact and others. Properties at low temperatures have also been discussed. Further, the effects of fillers as well as post-processing on the mechanical properties have also been discussed. Lastly, several important questions to consider in the standardization of mechanical test methods have been raised.

Mechanical characterization of 3D-printed polymers

In new product development, time to market (TTM) is critical for the success and profitability of next generation products. When these products include sophisticated electronics encased in 3D packaging with complex geometries and intricate detail, TTM can be compromised - resulting in lost opportunity. The use of advanced 3D printing technology enhanced with component placement and electrical interconnect deposition can provide electronic prototypes that now can be rapidly fabricated in comparable time frames as traditional 2D bread-boarded prototypes; however, these 3D prototypes include the advantage of being embedded within more appropriate shapes in order to authentically prototype products earlier in the development cycle. The fabrication freedom offered by 3D printing techniques, such as stereolithography and fused deposition modeling have recently been explored in the context of 3D electronics integration - referred to as 3D structural electronics or 3D printed electronics. Enhanced 3D printing may eventually be employed to manufacture end-use parts and thus offer unit-level customization with local manufacturing; however, until the materials and dimensional accuracies improve (an eventuality), 3D printing technologies can be employed to reduce development times by providing advanced geometrically appropriate electronic prototypes. This paper describes the development process used to design a novelty six-sided gaming die. The die includes a microprocessor and accelerometer, which together detect motion and upon halting, identify the top surface through gravity and illuminate light-emitting diodes for a striking effect. By applying 3D printing of structural electronics to expedite prototyping, the development cycle was reduced from weeks to hours.

3D Printing for the Rapid Prototyping of Structural Electronics

3D Printing of Electro Mechanical Systems

Recent advances in the field of 3D printing have utilized embedded electronic interconnects in order to construct advanced electronic devices. This work builds on these advances in order to construct and characterize arbitrarily formed capacitive sensors using fine-pitch copper mesh and embedded copper wires. Three varieties of sensors were fabricated and tested, including a small area wire sensor (320μm width), a large area mesh sensor (2cm2), and a fully embedded demonstration model. In order to test and characterize these sensors in FDM materials, three distinct tests were explored. Specifically, the sensors were able to distinguish between three metallic materials and distinguish salt water from distilled water. These capacitive sensors have many potential sensing applications, such as biomedical sensing, human interface devices, material sensing, electronics characterization, and environmental sensing. As such, this work specifically examines optimum mesh/wire capacitive parameters as well as potential applications such as 3D printed integrated material sensing.

3D printed capacitive sensors

The ability to access individual layers of a part as they are being printed has allowed additive manufacturing (AM) researchers to experiment with the in situ placement of components, thereby creating multi-process parts with additional functionality, such as customized printed electronics. As AM has evolved to become an established method for creating end-use parts, this interest in multi-process printing has increased. Although progress has been made in developing multi-process hardware, which can combine AM with other technologies, holistic design software, capable of readily integrating these processes, is developing at a slower rate. In this paper, an integrated software solution capable of supporting multi-process 3D printing from design through manufacture is described, featuring the integration of electronic components and circuits interconnected by copper wires. This solution features automated generation of the cavities that accommodate electronic components as well as toolpath generation for a multi-process 3D printer capable of automated wire embedding. As a case study of the developed technology, a hexagonal 3D printed body, which included a microcontroller, four LEDs, a USB connector, two resistors, and a Zener diode, all interconnected by embedded copper wires, was fabricated within a short cycle time: 5.75 h from design to fabricated part. Short cycle times allow multiple design iterations to be realized and printed within the same day.

Efrain Aguilera

Papers

3D Printing for the Rapid Prototyping of Structural Electronics

3D Printing of Electro Mechanical Systems

3D printed capacitive sensors

Augmenting Computer-Aided Design Software With Multi-Functional Capabilities to Automate Multi-Process Additive Manufacturing

Characterization of a capacitive voltage divider