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The rapid development of three-dimensional (3D) printing makes it familiar in daily life, especially the fused deposition modeling 3D printers. The process planning of traditional flat layer printing includes slicing and path planning to obtain the boundaries and the filling paths for each layer along the vertical direction. There is a clear division line through the whole fabricated part, inherited in the flat-layer-based printed parts. This problem is brought about by the seam of the boundary in each layer. Hence, the purpose of this paper is to propose a novel helical filling path generation with the ideal surface-plane intersection for a rotary 3D printer.

The detailed algorithm and implementation steps are given with several worked examples to enable readers to understand it better. The adjacent points obtained from the planar slicing are combined to generate each layer's helical points. The contours of all layers are traversed to obtain the helical surface layer and helical path. Meanwhile, the novel rotary four-degree of freedom 3D printer is briefly introduced.

As a proof of concept, this paper presents several examples based on the rotary 3D printer designed in the authors’ previous research and the algorithms illustrated in this paper. The preliminary experiments successfully verify the feasibility and versatility of the proposed slicing method based on a rotary 3D printer.

This paper provides a novel and feasible slicing method for multi-axis rotary 3D printers, making manufacturing thin-wall and complex parts possible. To further broaden the proposed slicing method’s application in further research, adaptive tool path generation for flat and curved layer printing could be applied with a combination of flat and curved layers in the same layer, different layers or even different parts of structures.

Three-dimensional (3D) printing has great potential in the food industry. While 3D printing technology offers customised food products to consumers, it also allows producers to develop new products using a wide variety of alternative food ingredients, modernise the production process and carry out environmentally friendly production. This research aims to determine the attitudes of students towards 3D foods who are studying in the Department of Gastronomy and Culinary Arts, as they are both consumers and examine different food processing systems and use them in the field of application. As a result of the study, it was identified that the participants believed that 3D printing is a great modern technology that allows the development of new foods, that it will bring benefit to us in the future, reduce the cost of food and food waste, increase the sustainability of food and that they see it as environmentally friendly. In addition, it was determined that the participants did not think that 3D-printed foods were disgusting; they found these foods reliable, could try them in the future and were excited to experience them.

The main objective of this paper is to illustrate an analytical view of different methods of 3D bioprinting, variations, formulations and characteristics of biomaterials. This review also aims to discover all the areas of applications and scopes of further improvement of 3D bioprinters in this era of the Fourth Industrial Revolution.

This paper reviewed a number of papers that carried evaluations of different 3D bioprinting methods with different biomaterials, using different pumps to print 3D scaffolds, living cells, tissue and organs. All the papers and articles are collected from different journals and conference papers from 2014 to 2022.

This paper briefly explains how the concept of a 3D bioprinter was developed from a 3D printer and how it affects the biomedical field and helps to recover the lack of organ donors. It also gives a clear explanation of three basic processes and different strategies of these processes and the criteria of biomaterial selection. This paper gives insights into how 3D bioprinters can be assisted with machine learning to increase their scope of application.

The chosen research approach may limit the generalizability of the research findings. As a result, researchers are encouraged to test the proposed hypotheses further.

This paper includes implications for developing 3D bioprinters, developing biomaterials and increasing the printability of 3D bioprinters.

This paper addresses an identified need by investigating how to enable 3D bioprinting performance.

AlSi10Mg alloy is commonly used in laser powder bed fusion due to its printability, relatively high thermal conductivity, low density and good mechanical properties. However, the thermal conductivity of as-built materials as a function of processing (energy density, laser power, laser scanning speed, support structure) and build orientation, are not well explored in the literature. This study aims to elucidate the relationship between processing, microstructure, and thermal conductivity.

The thermal conductivity of laser powder bed fusion (L-PBF) AlSi10Mg samples are investigated by the flash diffusivity and frequency domain thermoreflectance (FDTR) techniques. Thermal conductivities are linked to the microstructure of L-PBF AlSi10Mg, which changes with processing conditions. The through-plane exceeded the in-plane thermal conductivity for all energy densities. A co-located thermal conductivity map by frequency domain thermoreflectance (FDTR) and crystallographic grain orientation map by electron backscattered diffraction (EBSD) was used to investigate the effect of microstructure on thermal conductivity.

The highest through-plane thermal conductivity (136 ± 2 W/m-K) was achieved at 59 J/mm³ and exceeded the values reported previously. The in-plane thermal conductivity peaked at 117 ± 2 W/m-K at 50 J/mm³. The trend of thermal conductivity reducing with energy density at similar porosity was primarily due to the reduced grain size producing more Al-Si interfaces that pose thermal resistance. At these interfaces, thermal energy must convert from electrons in the aluminum to phonons in the silicon. The co-located thermal conductivity and crystallographic grain orientation maps confirmed that larger colonies of columnar grains have higher thermal conductivity compared to smaller columnar grains.

The thermal properties of AlSi10Mg are crucial to heat transfer applications including additively manufactured heatsinks, cold plates, vapor chambers, heat pipes, enclosures and heat exchangers. Additionally, thermal-based nondestructive testing methods require these properties for applications such as defect detection and simulation of L-PBF processes. Industrial standards for L-PBF processes and components can use the data for thermal applications.

To the best of the authors’ knowledge, this paper is the first to make coupled thermal conductivity maps that were matched to microstructure for L-PBF AlSi10Mg aluminum alloy. This was achieved by a unique in-house thermal conductivity mapping setup and relating the data to local SEM EBSD maps. This provides the first conclusive proof that larger grain sizes can achieve higher thermal conductivity for this processing method and material system. This study also shows that control of the solidification can result in higher thermal conductivity. It was also the first to find that the build substrate (with or without support) has a large effect on thermal conductivity.

This study aims to discuss the state-of-the-art digital factory (DF) development combining digital twins (DTs), sensing devices, laser additive manufacturing (LAM) and subtractive manufacturing (SM) processes. The current shortcomings and outlook of the DF also have been highlighted. A DF is a state-of-the-art manufacturing facility that uses innovative technologies, including automation, artificial intelligence (AI), the Internet of Things, additive manufacturing (AM), SM, hybrid manufacturing (HM), sensors for real-time feedback and control, and a DT, to streamline and improve manufacturing operations.

This study presents a novel perspective on DF development using laser-based AM, SM, sensors and DTs. Recent developments in laser-based AM, SM, sensors and DTs have been compiled. This study has been developed using systematic reviews and meta-analyses (PRISMA) guidelines, discussing literature on the DTs for laser-based AM, particularly laser powder bed fusion and direct energy deposition, in-situ monitoring and control equipment, SM and HM. The principal goal of this study is to highlight the aspects of DF and its development using existing techniques.

A comprehensive literature review finds a substantial lack of complete techniques that incorporate cyber-physical systems, advanced data analytics, AI, standardized interoperability, human–machine cooperation and scalable adaptability. The suggested DF effectively fills this void by integrating cyber-physical system components, including DT, AM, SM and sensors into the manufacturing process. Using sophisticated data analytics and AI algorithms, the DF facilitates real-time data analysis, predictive maintenance, quality control and optimal resource allocation. In addition, the suggested DF ensures interoperability between diverse devices and systems by emphasizing standardized communication protocols and interfaces. The modular and adaptable architecture of the DF enables scalability and adaptation, allowing for rapid reaction to market conditions.

Based on the need of DF, this review presents a comprehensive approach to DF development using DTs, sensing devices, LAM and SM processes and provides current progress in this domain.

Fused Filament Fabrication (FFF) is an extrusion-based manufacturing process using fused thermoplastics. Despite its low cost, the FFF is not extensively used in high-value industrial sectors mainly due to parts' anisotropy (related to the deposition strategy) and residual stresses (caused by successive heating cycles). Thus, this study aims to investigate the process improvement and the optimization of the printed parts.

In this work, a meshless technique – the Radial Point Interpolation Method (RPIM) – is used to numerically simulate the viscoplastic extrusion process – the initial phase of the FFF. Unlike the FEM, in meshless methods, there is no pre-established relationship between the nodes so the nodal mesh will not face mesh distortions and the discretization can easily be modified by adding or removing nodes from the initial nodal mesh. The accuracy of the obtained results highlights the importance of using meshless techniques in this field.

Meshless methods show particular relevance in this topic since the nodes can be distributed to match the layer-by-layer growing condition of the printing process.

Using the flow formulation combined with the heat transfer formulation presented here for the first time within an in-house RPIM code, an algorithm is proposed, implemented and validated for benchmark examples.

This study aims to reveal the influences of three-dimensional (3D) printing parameters such as layer heights (0.1 mm, 0.2 mm and 0.4 mm), infill rates (40, 70 and 100%) and geometrical property as tapered angle (0, 0.25 and 0.50) on vibrational behavior of 3D-printed polyethylene terephthalate glycol (PET-G) tapered beams with fused filament fabrication (FFF) method.

In this performance, all test specimens were modeled in AutoCAD 2020 software and then 3D-printed by FFF. The effects of printing parameters on the natural frequencies of 3D-printed PET-G beams with different tapered angles were also analyzed experimentally, and numerically (finite element analysis) via Ansys APDL 16 program. In addition to vibrational properties, tensile strength, elasticity modulus, hardness, and surface roughness of the 3D-printed PET-G parts were examined.

It can be stated that average surface roughness values ranged between 1.63 and 6.91 µm. In addition, the highest and lowest hardness values were found as 68.6 and 58.4 Shore D. Tensile strength and elasticity modulus increased with the increase of infill rate and decrease of the layer height. In conclusion, natural frequency of the 3D-printed PET-G beams went up with higher infill rate values though no critical change was observed for layer height and a change in tapered angle fluctuated the natural frequency values significantly.

The influence of printing parameters on the vibrational properties of 3D-printed PET-G beams with different tapered angles was carried out and the determination of these effects is quite important. On the other hand, with the addition of glass or carbon fiber reinforcements to the PET-G filaments, the material and vibrational properties of the parts can be examined in future works.

As a result of this study, it was shown that natural frequencies of the 3D-printed tapered beams from PET-G material can be predicted via finite element analysis after obtaining material data with the help of mechanical/physical tests. In addition, the outcome of this study can be used as a reference during the design of parts that are subjected to vibration such as turbine blades, drone arms, propellers, orthopedic implants, scaffolds and gears.

It is believed that determination of the effect of the most used 3D printing parameters (layer height and infill rate) and geometrical property of tapered angle on natural frequencies of the 3D-printed parts will be very useful for researchers and engineers; especially when the importance of resonance is known well.

When the literature efforts are scanned in depth, it can be seen that there are many studies about mechanical or wear properties of the 3D-printed parts. However, this is the first study which focuses on the influences of the both 3D printing parameters and tapered angles on the vibrational behaviors of the tapered PET-G beams produced with material extrusion based FFF method. In addition, obtained experimental results were also supported with the performed finite element analysis.

The purpose of this study is, to compare laser-based additive manufacturing and subtractive methods. Laser-based manufacturing is a widely used, noncontact, advanced manufacturing technique, which can be applied to a very wide range of materials, with particular emphasis on metals. In this paper, the governing principles of both laser-based subtractive of metals (LB-SM) and laser-based powder bed fusion (LB-PBF) of metallic materials are discussed and evaluated in terms of performance and capabilities. Using the principles of both laser-based methods, some new potential hybrid additive manufacturing options are discussed.

Production characteristics, such as surface quality, dimensional accuracy, material range, mechanical properties and applications, are reviewed and discussed. The process parameters for both LB-PBF and LB-SM were identified, and different factors that caused defects in both processes are explored. Advantages, disadvantages and limitations are explained and analyzed to shed light on the process selection for both additive and subtractive processes.

The performance of subtractive and additive processes is highly related to the material properties, such as diffusivity, reflectivity, thermal conductivity as well as laser parameters. LB-PBF has more influential factors affecting the quality of produced parts and is a more complex process. Both LB-SM and LB-PBF are flexible manufacturing methods that can be applied to a wide range of materials; however, they both suffer from low energy efficiency and production rate. These may be useful when producing highly innovative parts detailed, hollow products, such as medical implants.

This paper reviews the literature for both LB-PBF and LB-SM; nevertheless, the main contributions of this paper are twofold. To the best of the authors’ knowledge, this paper is one of the first to discuss the effect of the production process (both additive and subtractive) on the quality of the produced components. Also, some options for the hybrid capability of both LB-PBF and LB-SM are suggested to produce complex components with the desired macro- and microscale features.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

This study aims to explore the potential benefits favoring the adaptation of structural optimization techniques in the additive manufacturing (AM) of medical utilities to meet the repetitive demand for functionally precise customized orthoses. Irregularities encountered during the conventional treatment of tendon injuries can be eschewed using advanced structural simulation in design and innovative splint fabrication using 3D printing.

A customized mallet finger splint designed from 3D scans was subjected to ANSYS topological simulation comprising multi-level weight reduction to retain optimal mass (100%, 90%, 80%, 70% and 60%). A batch of the four typical 3D printing materials was chosen to conduct a comparative mechanical and thermal stress analysis, facilitating the selection of the optimal one for fabricating functionally adaptive splints. Assurance of structural safety was accomplished through the experimental validation of simulation results against the testing data set of ASTM D695 and ASTM D638 Type-1 specimens over a universal testing machine (UTM). Fused deposition modeling (FDM) 3D printing processed the optimized splint fabrication to assist evaluation of weight reduction percentage, fitting aesthetics, appearance, comfort, practicality and ventilation ease at the user end.

AM efficacy can efficiently execute the design complexity involved in the topology optimization (TO) results and introduces rehabilitation practicality into the application. Topologically optimized splint provided with favorable comfort, stiffness and strengthening features, offers ventilation ease and structural stability for customized appliances, with 30.52% lighter weight and 121.37% faster heat dissipation than unoptimized one.

The state of art multidisciplinary optimization featured with structural and material optimization attributes can deliberately meet medical necessity for performance-oriented orthotic devices.