Emerging Materials in Additive Manufacturing Literature Review

This paper provides a comprehensive review of the literature within the Additive Manufacturing (AM) technological designs as well as the study of used materials. It focuses on the ceramic matrix, polymer matrix, fiber reinforced matrix, and metal matrix materials used in AM. The paper also discusses various AM applications and their future advantages, challenges, and work.

Paper Title: Emerging Materials in Additive
Manufacturing
Literature Review
Student’s Names
Course
University
Abstract
Additive Manufacturing has grown into one big production industry that uses complex
shaped materials used in many fields. AM is using various materials such as composites,
polymers, ceramics and metals as its commercially available raw products for the design
process. However, composites and ceramics still are under development and research
improvement. In this paper, there is a comprehensive review of the literature within the
AM technological designs as well as the study of used materials. The ceramic matrix,
polymer matrix, fibre reinforced matrix and metal matrix pieces of literature are reviewed
since they are the most common material matrices being used in this technology. The
paper also constitutes a number of AM applications on various classified materials by
having a look into the different industrial objectives, the importance of the application,
results from designs and processing together with future advantages, challenges and
work.
Keywords: Polymer matrix, Ceramic matrix, Additive Manufacturing, Metal Matrix,
Composite Matrix
1. Introduction
The 3D printing or Additive Manufacturing is a developed field aimed at supporting
designers and engineers in their endeavours when product-process designing for physical
checking on assumptions [1]. To begin with, the AM technology was first developed in
the 1980s for prototype and model production. Its principle lies in manufacturing through
layer-by-layer that starts with designing a 3D object using CAD and later slicing an STL
layer format using a software [2]. Some of the main advantages that the AM process
possess are cost and time reduction, testing capabilities of the product’s life cycle and
human interaction capability. The technology has been pushed too fast technological
improvement by the patent expired and growing demand effects. Thereby, bringing in
numerous AM solutions and manufacturers. Lately, the Am solutions demand is growing
at a very high rate since the discovery of newer materials. Also, its areas of interest
becoming dynamic. For example, the AM technology can be used in automotive
industries, architecture, aeronautics, food, fashion, jewellery, robotics, toys and
pharmaceuticals as in table 1 [3].

Table 1 below shows the different areas of applying AM.
Sectors Application
Medical Developing surgical models that are used
in surgical operations, bridges, dental
fixtures and crowns, custom patient-
specific prostheses and implants
Industry Fixtures, jigs, aero-nautical end-use
industrial parts and automotive spare parts
and prototypes
Food 3D printing and designing of complex-
shaped cookies, pizzas, cakes, candies and
other desserts.
Pharmaceutical Custom drug delivery implants, capsules
and tablets.
Household Cups, plates, holders and spoons.
Fashion Clothes, jewellery and shoes.
Miscellaneous Chemical industrially fabricated complex
compounds and molecules, special built
parts and prototypes in space and scaled
construction models having intricate
architectures.
Through AM technology, there exists a possibility of producing complex shapes as opposed to
classical manufacturing that experience difficulty. Various complex structures and used multi-
materials allow dynamic and static functionalities hence enabling thermal, electrical and
mechanical applications.
2. Literature Review
2.1. Metal Alloys and Matrices
A Metal Matrix Composite is a composite with a ductile metal in its matrix phase [4]. There
exists thermal stability as well as ductility in the composite meal matrix during elevated
temperatures. Additionally, the fibre helps in increasing the stiffness, strength, enhances abrasion
or creep resistance and increase the thermal conductivity. The alloys of aluminium and
aluminium itself, magnesium and titanium are the most used metals in the MMC development as
seen in table 2 [4].
Table 2 below show metallic alloy multi-components used in fabrication.
Alloys Process Type of Laser Composition Property
Ti-based DMD 6kW CO2 laser Ti-6AI-4V About 1045 MPa
tensile strength,
about 1105MPa
yield strength
and about 10.5
ductilities.
Ti-based LMD Nd: YAG lasers Ti-6AI-4V About 1100 MPa

yield strength
and about 1211
MPa tensile
strength
Fe-based LM Fibre laser Inox 904L
stainless steel
A 20 by 20 by 5
mm was
fabricated at 140
micrometres
thick
Fe-based LS CO2 laser High-speed steel Successful
fabrication with
88.2% maximum
density
One effective manufacturing process involves the use of Laser Additives in manufacturing [5].
This technology depends on deriving the peak temperature and cooling rates during the
simulation. The AISI 1030 carbonated steel which is coated with Fe-TiC composites is used in
studying values for the parametric effects in processes for the TiC microstructure and
morphology. There are investigations on the cooling rate whereby cooling rates affect the
microstructure and morphology since the solute material rejection to the melted Fe become
retarded during a cooling rate that is more than 1500K/S. the peak power effect on densities of 2
particle sizes, AL-12Si S20 and AI-12Si S10 is shown in figure 1 and figure 2 below [6].
Figure 1 above shows the peak power effect on densities

Figure 2 above shows the CT scan of SLSM-S10
2.2. Ceramic Matrix and Composites
AM can be used when dealing with materials which do not require part specified tools or molds
[7]. Selective Laser Gelation is applicable in the fabrication of the ceramic matrix composite that
is made up of silica sol and stainless steel powder in a proportionate 35-65 weight %. Metal
particles are embedded with gelled silica before being used in developing a 3D composite
structure and later spread over the layered silica gel through the Nd: YAG lasers method. In this
study, there is less forming energy required in SLG compared to SLS during metal/ceramic
component fabrication. Schematic setup for this study is seen in figure 3 and the product in
figure 4 [7].
Figure 3 above shows the experimental setup.

Figure 4 above shows the CMC parts.
2.3. Polymer Composite Matrices
2.3.1. Hard Polymer
Polymer composites listed in table 3 have the ability to take in shapes that are complex or simple
as shown in figure 5 [1]. Short fibre reinforced ABS composite was developed in 3D printers and
later analyzed using various responses. The responses analyzed include microstructure, the
performance of mechanical properties and processability. This was compared with composites
made through traditional compressions [6]. The AM samples were 700%, 115% and 90.5% for
tensile modulus, tensile strength and yield respectively.
Table 3 below lists synthetic hard polymers used.
Polymers Types Abbreviations Used FDA
examples
Structure
Polycaprolac
tone
Biodegradabl
e polyesters
PCL SmartNail
used in bone
fixation
Polylactic
acid
Biodegradabl
e polyesters
PLA Monocryl
structure
Polydioxane Biodegradabl
e polyesters
PDO Ventrio
Hernai
Patches
Poly(Glycol
acid)
Biodegradabl
e polyesters
PGA Monocryl
structures

Figure 5 above shows some structures made from hard polymers.
2.3.2. Soft Polymer
In selecting a biomaterial to be used in 3D printing, the end product and the structure application
are influential. For example, in orthopaedic applications, biomaterials need to have high stiffness
mechanically and prolonged rates of biodegrading. Table 6 shown below displays the
applications, disadvantages and advantages of using soft polymers. In bioprinting, soft polymers
such as hydrogels are applied in fabricating organs/tissues. Hydrogel polymers mimic
extracellular matrices of living tissue hence easily accommodating cells. Figure 6 below shows
examples of fabrications from soft polymers [8].
Table 6 below displays the advantages, disadvantage and applications of soft polymers.
Type Disadvantages Advantages Applications
Soft polymer Leachable and
degrades
quickly.
Biodegradable,
easily molded
and available
Prostheses,
dental and
orthopaedic
implants

Figure 6 above shows fabricated biomaterials
2.4. Bio-Ink
This is bio-printing in that cell mixtures bioactive molecules and biomaterials are used in
printing to create organs. This review involves describing cell aggregates, polymer hydrogels and
extracellular protein matrices. Bio-inks is made up of hyaluronic acid, elastin, silk protein and
gelatin as the natural polymers while polyphosphazenes and poly(PNIPAAM) make up synthetic
polymers. Figure 7 below shows an example of bio-ink production [8].
Figure 7 above shows a bio-printing process.
3. Future Perspective
There are disadvantages, advantages and opportunities to take in developing and creating designs
using AM technology [6]. Some of the opportunities that lie within the AM technology to be
taken advantage of are: the ability for ceramic composites to increase their properties using
LENS and SLS technologies, possible effective use of structural composites through
microstructure material optimization without changes in physical property and improving SLS
polymer fabrication process from product development with adequate mechanical properties.
More opportunities lie within the technology’s possibility of handling numerous materials in one
AM system [4].
Also, there are disadvantages within Am technology that can be dealt with. For example, the
high cost of AM technology can be reduced by researching on natural materials that are cheaply
and easily for 3D printing. Alternatively, the AM market can be improved in that its
technology’s availability could be increased and user demands met to increase the number of

users [5]. When the users increase, the demand will drop leading to medium or low purchasing
prices. Thickness optimization through layers has to be improved to increase the processing time
and reduce the required data files. The built materials have to improve in their build-up
orientation for enabling easier recyclability [6].
4. Summary
The comprehensive literature review on AM technology in this paper is presented focusing on
development, research and investigation regarding fabrication materials used within the AM
technology. In this review, various types of potential metal alloys and composite materials such
as polymers, metals, composites and ceramics have been researched. The research entailed
investigating the physical properties, mechanical properties, nature and tribological properties of
the developed microstructures [8]. The paper later looks into the challenges, opportunities and
related future work within the AM technology. All in all, AM technology is well implemented
and applied in architecture, biomedicine and building fields [6].

5. References
[1] T. Page, "A Survey of the Use of Additive Fabrication in Component Replacement and
Customised Automotive Modifications," International Journal of Manufacturing, Materials,
and Mechanical Engineering (IJMMME), vol. 8, no. 4, pp. 23-34, 2018.
[2] L. M. Ricles, J. C. C., M. D. P. and S. S. O., "Regulating 3D-printed medical products,"
Science translational medicine, vol. 10, no. 461, p. eaan6521, 2018.
[3] K. S. Prakash, T. Nancharaih and V. V. R. Subba, "Additive Manufacturing Techniques in
Manufacturing-An Overview," Materials Today: Proceedings, vol. 5, no. 2, pp. 3873-3882,
2018.
[4] C. Elanchezhian, B. R. Vijaya, G. Ramakrishnan, R. K. N. Sripada, M. Mithun and V.
Kishore, "Review on metal matrix composites for marine applications," Materials Today:
Proceedings, vol. 5, no. 1, pp. 1211-1218, 2018.
[5] J. Zhang, H. Bastian, S. Julian, M. Gabriele, C. Hauke, S. S. and P. H. Heinz, "Sacrificial-
layer free transfer of mammalian cells using near infrared femtosecond laser pulses," PloS
one, vol. 13, no. 5, p. e0195, 2018.
[6] T. Lieneke, D. Vera, A. A. Guido and Z. Detmar, "Dimensional tolerances for additive
manufacturing: Experimental investigation for Fused Deposition Modeling," Procedia CIRP,
vol. 43, no. 1, pp. 286-291, 2018.
[7] Y. Al-Meslemi, A. Nabil and M. Luc, "Environmental Performance and Key Characteristics
in Additive Manufacturing: A Literature Review," Procedia CIRP , vol. 69, no. 1, pp. 148-
153, 2018.
[8] T. G. Manning, S. O. Jonathan, C. M. P. Daniel, C. Jasamine, C. Jason, M. B. Damien and L.
Nathan, "Three dimensional models in uro-oncology: a future built with additive
fabrication," World journal of urology, vol. 36, no. 4, pp. 557-563, 2018.