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        <title>Frontiers in Manufacturing Technology | Additive Processes section | New and Recent Articles</title>
        <link>https://www.frontiersin.org/journals/manufacturing-technology/sections/additive-processes</link>
        <description>RSS Feed for Additive Processes section in the Frontiers in Manufacturing Technology journal | New and Recent Articles</description>
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        <pubDate>2026-05-04T17:27:55.170+00:00</pubDate>
        <ttl>60</ttl>
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        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmtec.2025.1676365</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmtec.2025.1676365</link>
        <title><![CDATA[WAAM-ViD: towards universal vision-based monitoring for wire arc additive manufacturing]]></title>
        <pubdate>2025-10-29T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Keun Woo Kim</author><author>Alexander Kamerkar</author><author>Tzu-En Chiu</author><author>Ibrahim Abdi</author><author>Jian Qin</author><author>Wojciech Suder</author><author>Seemal Asif</author>
        <description><![CDATA[In the context of Industry 4.0, autonomous and data-driven manufacturing processes are advancing rapidly, with wire arc additive manufacturing (WAAM) emerging as a promising technique for producing large-scale metal components. Ensuring quality control and part traceability in WAAM remains an area of active research, as existing process monitoring systems often require operator intervention and are tailored to specific machine setups and camera configurations, limiting adaptability across industrial environments. This study addresses these challenges by developing an angle-invariant melt pool analysis pipeline capable of recognising bead features in wire-based directed energy deposition from monitoring images captured using various camera qualities, positions, and angles. A new benchmark dataset, WAAM-ViD, is also introduced to support future research. The proposed pipeline integrates two deep learning models: DeepLabv3, fine-tuned through active learning for precise melt pool segmentation (Dice similarity coefficient of 95.90%), and WAAM-ViDNet, a regression-based multimodal model that predicts melt pool width using the segmented images and camera calibration data, achieving 88.71% accuracy. The results demonstrate the pipeline’s effectiveness in enabling real-time process monitoring and control in WAAM, representing a step toward fully autonomous and adaptable additive manufacturing systems.]]></description>
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        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmtec.2025.1572842</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmtec.2025.1572842</link>
        <title><![CDATA[Development of an end-to-end automated production concept for extrusion-based additive manufacturing of personalized medical scaffolds]]></title>
        <pubdate>2025-06-18T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Kai Janning</author><author>Sven König</author><author>Laura Herbst</author><author>Bastian Nießing</author><author>Robert H. Schmitt</author>
        <description><![CDATA[IndroductionPersonalized medical devices, especially scaffold-based implants, are increasingly important in medical care. One established manufacturing method for these products is extrusion-based 3D printing, also called 3D material extrusion (MEX) or extrusion additive manufacturing (EAM). According to the current state of the art, this technique lacks scalability, as many adjacent processes, such as material handling or quality control, are still carried out manually and no holistically automated solutions have been established.MethodsThis work examines the extrusion-based 3D printing process for manufacturing cell-free porous scaffolds. Based on a literature review, relevant process parameters for MEX and quality attributes of polymer-based scaffolds are analyzed to derive functional requirements for holistically automating the manufacturing process. A concept for an end-to-end automated production infrastructure is developed, to allow efficient and scalable manufacture of scaffolds. All process parameters are analyzed for their influence on the quality attributes, and requirements are specified. Based on this, the development of the production concept is systematically carried out.ResultsThe resulting technical system consists of a magnetic planar drive, which is used as an intralogistic transport system, but also forms the horizontal axis plane of the 3D printer. The resulting frictionless levitating print bed increases cleanroom suitability and enables the parallelization of print jobs and quality control steps for improved production flexibility and scalability. The central approaches of the concept are presented in a physical demonstrator.DiscussionAn initial proof of concept for planar drive-based MEX is provided and lays the foundation for further development and validation of the conceptualized production infrastructure.]]></description>
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        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmtec.2025.1558209</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmtec.2025.1558209</link>
        <title><![CDATA[Multifunctional inks in aerosol jet printing: performance, challenges, and applications]]></title>
        <pubdate>2025-05-01T00:00:00Z</pubdate>
        <category>Review</category>
        <author>Rawan Elsersawy</author><author>Arafater Rahman</author><author>Chowdhury Sakib-Uz-Zaman</author><author>Mohammad Abu Hasan Khondoker</author>
        <description><![CDATA[This article comprehensively analyses AJP technology, with a greater focus on the areas that received scant attention in the previously published literature. Whereas various reviews so far discussed the basic principles of AJP and its comparison with other printing techniques, the present article goes further to discuss different types of functional inks being utilized in AJP, including conductive, dielectric, semiconducting, and biological inks. The minimum resolutions of micropatterns achieved with these inks are then reviewed, together with the specific printing recipes enabling their use, to give an overview of the performances of different materials within the AJP process. Furthermore, the article classifies the dimensionality of AJP-printed patterns into 2D-planar, 2D-nonplanar, and 3D parts, underlining the capability of the technology for the fabrication of both planar and non-planar geometries. This makes AJP a tool of major relevance in the newly emerging fields of electronics, sensors, and biotechnology, which strongly demand precise micro-patterning and substrate adaptability. The review, therefore, explains how AJP is bound to change manufacturing processes by exploring its new applications in those sectors. The article also covers the current limitations of AJP, including how to optimize printing processes and generalize them into more industrial uses. Synthesizing state-of-the-art research, this review not only describes the main achievements of AJP technology but also points out likely future tendencies and even disruptions that may occur within this field. This review aims to be an extensive source of information for both researchers and industry representatives interested in finding opportunities for further applications of AJP in various areas.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmtec.2023.1271190</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmtec.2023.1271190</link>
        <title><![CDATA[Imaging systems and techniques for fusion-based metal additive manufacturing: a review]]></title>
        <pubdate>2023-12-21T00:00:00Z</pubdate>
        <category>Methods</category>
        <author>Himanshu Balhara</author><author>Adithyaa Karthikeyan</author><author>Abhishek Hanchate</author><author>Tapan Ganatma Nakkina</author><author>Satish T. S. Bukkapatnam</author>
        <description><![CDATA[This study presents an overview and a few case studies to explicate the transformative power of diverse imaging techniques for smart manufacturing, focusing largely on various in-situ and ex-situ imaging methods for monitoring fusion-based metal additive manufacturing (AM) processes such as directed energy deposition (DED), selective laser melting (SLM), electron beam melting (EBM). In-situ imaging techniques, encompassing high-speed cameras, thermal cameras, and digital cameras, are becoming increasingly affordable, complementary, and are emerging as vital for real-time monitoring, enabling continuous assessment of build quality. For example, high-speed cameras capture dynamic laser-material interaction, swiftly detecting defects, while thermal cameras identify thermal distribution of the melt pool and potential anomalies. The data gathered from in-situ imaging are then utilized to extract pertinent features that facilitate effective control of process parameters, thereby optimizing the AM processes and minimizing defects. On the other hand, ex-situ imaging techniques play a critical role in comprehensive component analysis. Scanning electron microscopy (SEM), optical microscopy, and 3D-profilometry enable detailed characterization of microstructural features, surface roughness, porosity, and dimensional accuracy. Employing a battery of Artificial Intelligence (AI) algorithms, information from diverse imaging and other multi-modal data sources can be fused, and thereby achieve a more comprehensive understanding of a manufacturing process. This integration enables informed decision-making for process optimization and quality assurance, as AI algorithms analyze the combined data to extract relevant insights and patterns. Ultimately, the power of imaging in additive manufacturing lies in its ability to deliver real-time monitoring, precise control, and comprehensive analysis, empowering manufacturers to achieve supreme levels of precision, reliability, and productivity in the production of components.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmtec.2023.1278487</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmtec.2023.1278487</link>
        <title><![CDATA[Editorial: Horizons in manufacturing technology]]></title>
        <pubdate>2023-10-11T00:00:00Z</pubdate>
        <category>Editorial</category>
        <author>Dimitris Kiritsis</author>
        <description></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmtec.2022.964450</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmtec.2022.964450</link>
        <title><![CDATA[Evolution of PEKK crystallization measured in laser sintering]]></title>
        <pubdate>2022-08-30T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>L. Benedetti</author><author>B. Brulé</author><author>N. Decraemer</author><author>K. E. Evans</author><author>O. Ghita</author>
        <description><![CDATA[The rising popularity of laser sintering (LS) technology has increased by the broadening of available materials for this process. Kepstan 6002 poly (ether ketone ketone) (PEKK) was recently launched as a high-performance polymer grade with a lower processing temperature and unique crystallization kinetics. This study aims to understand the progress of crystallization on samples manufactured throughout the laser sintering process. These results were compared with isothermal and dynamic differential scanning calorimetry (DSC) experiments with different cooling rates. Kepstan 6002 PEKK processed by high-temperature laser sintering (HT-LS) presents a kinetics of crystallization in the order of ∼10 times slower than its crystallized samples in the DSC. This result highlights the need for a part-based crystallization investigation rather than isothermal models to describe the crystallization in LS. The transmission electron microscopy (TEM) analysis reveals smaller spherulites in the samples subjected to prolonged cooling times and an almost amorphous structure for the PEKK samples exposed to almost no cooling. This experiment identified the surroundings of laser sintered particles as preferential sites for crystallization initiation, which grows as the particles penetrate the molten layers and spherulites are formed. The slower kinetics of crystallization of Kepstan 6002 PEKK grade improve the adhesion between layers in laser sintering and enable tailoring its properties according to the application. Understanding the relationship between intrinsic material characteristics and the resulting final properties is vital to optimizing the process and controlling the final performance of PEKK for different applications.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmtec.2022.919738</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmtec.2022.919738</link>
        <title><![CDATA[New Trends in Aviation and Medical Technology Enabled by Additive Manufacturing]]></title>
        <pubdate>2022-06-23T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Marie Wegner</author><author>Tobias S. Hartwich</author><author>Emil Heyden</author><author>Lukas Schwan</author><author>Johann Schwenke</author><author>Nadine Wortmann</author><author>Dieter Krause</author>
        <description><![CDATA[In this publication, the potentials of additive manufacturing in the field of sustainability and individualization for aviation and medical technology are presented. Design approaches for each application field as well as examples in the fields are shown. In the field of aviation, structures can be manufactured so that they are load path optimized. This has a great lightweight potential and results in a low resource consumption. The examples contain the design of an aircraft cabin partition using the Direct Energy Deposition process and the optimization of load introduction points directly integrated into the sandwich core. Furthermore, in medical technology, additive manufacturing can be used to produce patient-specific models based on original medical imaging data, which can be used for training of medical treatments, quality assurance or for the validation of new developed medical devices. As examples a stroke simulation model containing a modular aortic model as well as functional stenose models are shown. Furthermore, the use of AM molds to generate a deformable bladder shell and a prostate phantom are described.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmtec.2022.884164</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmtec.2022.884164</link>
        <title><![CDATA[Resilience Analysis of Additive Manufacturing-enabled Supply Chains: An Exploratory Study]]></title>
        <pubdate>2022-05-11T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Pinkesh Patel</author><author>Fantahun Defersha</author><author>Sheng Yang</author>
        <description><![CDATA[Unparalleled level of globalization and fierce competition have made supply chains (SCs) exceedingly complex and fragile as ever before. Increased incidences of natural disasters and unprecedented COVID-19 have highlighted the significance of improving supply chain resilience (SCR) by divulging its susceptibility to the external events. Additive manufacturing (AM) is envisioned as the disruptive technology that allows layer-wised fabrication and has been claimed to be an important contributor to the improved SCR as it could bring new opportunities through expanded design freedom, improved material efficiency, shortened supply chains, and decentralized manufacturing. Nonetheless, rare research has quantitatively measured the impacts of AM on SCR. To fill this research gap, the indices for assessing SCR of AM-enabled supply chains (AM-SCs) are first proposed, and then, the technique for order of preference by similarity to ideal solution (TOPSIS) is employed to derive a quantifiable SCR score that can be used to measure the performance of different SCs. A case study of a gas pedal assembly is presented with three different SC configurations: the original assembly with conventional manufacturing, original assembly with AM, and redesigned assembly with AM. The exploratory study shows that the redesigned assembly with AM considerations could improve the SCR by 200%. Sensitivity analysis also revealed that part count and reaction time of suppliers are influential factors of improving SCR. Last, challenges and limitations of the proposed framework are also deliberated upon alongside future research scope.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmtec.2022.863593</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmtec.2022.863593</link>
        <title><![CDATA[Additive Manufacturing of a Removable Partial Prosthesis in Titanium Using Binder Jetting Technology: A Brief Research Report]]></title>
        <pubdate>2022-04-25T00:00:00Z</pubdate>
        <category>Brief Research Report</category>
        <author>Cecilia Hagman</author><author>Per Svanborg</author>
        <description><![CDATA[Objective: The purpose of this study was to measure the surface roughness and compare the fit of a cobalt-chromium selective laser-melted removable partial denture framework and a titanium binder jetting removable partial denture framework.Materials and methods: A design for a removable partial prosthesis framework was made using 3Shape software, and thereafter, one framework was additively manufactured in cobalt-chromium with selective laser melting and one in titanium using binder jetting technology. The weight of the frameworks was measured, and the surface parameters Sa, Sds, and Sdr were measured by white light interferometry. The fit of the frameworks was analyzed using visual inspection and the pressing test.Results: The weight of the frameworks in their post-printed state was 15.66 g and 7.43 g for cobalt-chromium and titanium, respectively. After finishing and polishing, the cobalt-chromium framework’s outer surface showed a high shine and smooth surface, with lower values in the Sa and Sdr parameters. The visual inspection showed gaps in the titanium framework, and the pressing test detected movement greater than 0.5 mm for the same material.Conclusion: The Ti framework showed higher surface roughness and was left with a lackluster finish after polishing. Also, the fit of the Ti framework was not clinically acceptable. The additive manufacturing binder jetting technology for titanium needs improvement or an adjustment of the settings to be used for clinically removable partial dentures. The cobalt-chromium framework manufactured by selective laser melting showed an acceptable clinical fit and surface roughness.]]></description>
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