Additive Manufacturing Technologies and Post-processing, Design Optimization, and Material Considerations for Reliable Printing

Abstract

Additive manufacturing (AM) is a process of making three-dimensional components through the CAD model by depositing the materials layer-by-layer, feeding the material in the form of either powder or wire, and using various melting sources available like a laser beam or an electron beam. Over the last few years, because of extensive research by academic institutions, companies, and research organizations around the world, AM technology has reached its pinnacle in both research and commercial production. Subtractive manufacturing methods have been replaced by the AM process because of waste reduction and production flexibility. Nowadays, AM technologies are capable of making sophisticated and almost net-shaped parts in materials such as polymers, metals, ceramics, and composites that may be used directly as functioning parts. When a part is fabricated from an AM process, it may need to go through a few more steps before it can be regarded suitable for use, which is referred to as “post-processing.” Post-processing refers to any process or activity like coating, subtractive manufacturing, and material treatments that must be performed on a printed item as well as any technique used to improve the part further. AM coupled with design optimization allows the computational enhancement of mechanical system performance and also optimizes the structure for the desired outcome. To minimize material costs and improve sustainability, cellular structures are interesting candidates for AM to design lightweight and complicated parts. The potential materials are essential for successful AM, and various processes necessitate different preparation methods. We also go for the various AM materials like polymers, metals, ceramics, and composites. In this chapter, we discussed the different AM technologies, post-processing techniques, design optimization, and considerations of materials for reliable printing. © 2023 Wiley-VCH GmbH, Boschstr. 12, 69469 Weinheim, Germany.