Introduction

Additive manufacturing (AM), also known as 3D printing, has emerged as a transformative technology across various industries. This mini-review examines recent advancements in AM over the past five years, focusing on microstructure control, process optimization, and sustainable practices. The analysis is based solely on the provided list of papers.

Microstructure Control in Metal Additive Manufacturing

A significant area of research in AM focuses on controlling the microstructure of additively manufactured parts to achieve desired mechanical properties. Several studies have investigated the influence of process parameters and post-processing techniques on microstructure evolution.

Early work by Wentao Yan's group explored the origin of high-density dislocations in additively manufactured metals (Ge Wang et al., 2020, Materials Research Letters). Minh-Son Pham examined the role of side-branching in microstructure development in laser powder-bed fusion (LPBF) (Minh‐Son Pham et al., 2020, Nature Communications). Takayoshi Nakano's research group investigated unique crystallographic texture formation in Inconel 718 by LPBF and its effect on mechanical anisotropy (Ozkan Gokcekaya et al., 2021, Acta Materialia). Tao Yang and colleagues demonstrated the in-situ design of advanced titanium alloys with concentration modulations using AM (Tianlong Zhang et al., 2021, Science). Furthermore, Wen Chen's group achieved strong yet ductile nanolamellar high-entropy alloys by AM (Jie Ren et al., 2021, Nature, Jie Ren et al., 2022, Nature).

More recently, T. DebRoy's group reviewed the control of grain structure, phases, and defects in AM of high-performance metallic components (T. Mukherjee et al., 2023, Progress in Materials Science). Ma Qian's team developed strong and ductile titanium–oxygen–iron alloys by AM (Tingting Song et al., 2023, Nature). Kaiyu Luo and Jinzhong Lu demonstrated tailoring the microstructure of additively manufactured Ti6Al4V titanium alloy using hybrid AM technology (Haifei Lu et al., 2023, Additive manufacturing). Changjun Han's group explored the role of heterogeneous microstructure and deformation behavior in achieving superior strength-ductility synergy in zinc fabricated via LPBF (Zhi Dong et al., 2024, International Journal of Extreme Manufacturing) and manipulated stacking fault energy to achieve crack inhibition and superior strength–ductility synergy in an additively manufactured high‐entropy alloy (Pengda Niu et al., 2024, Advanced Materials). Lai-Chang Zhang and Liqiang Wang investigated the deformation mechanisms of additively manufactured TiNbTaZrMo refractory high-entropy alloy (Changxi Liu et al., 2024, International Journal of Plasticity). Robert O. Ritchie's group achieved high fatigue resistance in a titanium alloy via near-void-free 3D printing (Zhan Qu et al., 2024, Nature).

These studies highlight the increasing sophistication in controlling microstructure during AM to achieve specific performance characteristics.

Process Optimization and Monitoring

Optimizing AM processes and monitoring them in-situ are crucial for ensuring part quality and reducing defects. Research in this area spans various AM techniques and materials.

Amir Mostafaei and Markus Chmielus reviewed process parameters, materials, properties, modeling, and challenges in binder jet 3D printing (Amir Mostafaei et al., 2020, Progress in Materials Science). Davoud Jafari's group provided insights into opportunities and challenges in controlling the quality and accuracy of parts manufactured by wire and arc additive manufacturing (WAAM) (Davoud Jafari et al., 2020, Materials & Design, Davoud Jafari et al., 2021, Materials & Design). Dong-Gyu Ahn presented the state-of-the-art in Directed Energy Deposition (DED) processes (Dong-Gyu Ahn et al., 2020, International Journal of Precision Engineering and Manufacturing-Green Technology, Dong-Gyu Ahn et al., 2021, International Journal of Precision Engineering and Manufacturing-Green Technology). R. McCann's group reviewed in-situ sensing, process monitoring, and machine control in LPBF (R. McCann et al., 2021, Additive manufacturing). John D. Kechagias reviewed key parameters controlling surface quality and dimensional accuracy in Fused Filament Fabrication (FFF) (John D. Kechagias et al., 2022, Materials and Manufacturing Processes). Yuze Huang investigated keyhole fluctuation and pore formation mechanisms during LPBF (Yuze Huang et al., 2022, Nature Communications). Hanjun Gao's group reviewed residual stresses in metal AM (Shuguang Chen et al., 2022, Journal of Materials Research and Technology).

More recently, Tao Sun's group developed machine learning–aided real-time detection of keyhole pore generation in LPBF (Zhongshu Ren et al., 2023, Science). Farazila Yusof's group discussed research challenges, quality control, and monitoring strategy for WAAM (Mohd Rozaimi Zahidin et al., 2023, Journal of Materials Research and Technology). Kai Zhang's group investigated pore evolution mechanisms during DED (Kai Zhang et al., 2024, Nature Communications). Emanoil Linul's group studied the effect of multiple process parameters on optimizing tensile properties for material extrusion-based AM (Cristina Vălean et al., 2024, Construction and Building Materials).

These studies demonstrate the ongoing efforts to understand and control AM processes for improved part quality and performance.

Advancements in Material Extrusion

Material extrusion, particularly Fused Filament Fabrication (FFF), has seen significant advancements in recent years, focusing on material properties, multi-material printing, and sustainable practices.

Xia Gao and Yunlan Su reviewed the interlayer bond in FFF of polymer materials (Xia Gao et al., 2020, Additive manufacturing). Asma Perveen and Didier Talamona provided a critical review of the optimization of strength properties of FDM printed parts (Daniyar Syrlybayev et al., 2021, Polymers (Basel)). Jennifer A. Lewis's group demonstrated rotational multimaterial printing of filaments with subvoxel control (Natalie Larson et al., 2023, Nature).

Joshua M. Pearce's group explored multi‐material distributed recycling via material extrusion using recycled high density polyethylene and poly(ethylene terephthalate) mixture (Catalina Suescun Gonzalez et al., 2024, Polymer Engineering and Science). Pouyan Ghabezi's group investigated circular economy innovation through 3D printing of industrial waste polypropylene and carbon fibre composites (Pouyan Ghabezi et al., 2024, Resources Conservation and Recycling).

These studies showcase the increasing versatility and sustainability of material extrusion-based AM.

Conclusion

The field of additive manufacturing has witnessed significant advancements in recent years. Research efforts have focused on achieving precise microstructure control for enhanced mechanical properties, optimizing process parameters for improved part quality, and promoting sustainable practices through material recycling and innovative material extrusion techniques. These advancements are paving the way for wider adoption of AM across diverse industries.

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