Head-to-Head Evaluation of FDM and SLA in Additive Manufacturing: Performance, Cost, and Environmental Perspectives

Applied Sciences, Год журнала: 2025, Номер 15(4), С. 2245 - 2245

Опубликована: Фев. 19, 2025

This paper conducts a comprehensive experimental comparison of two widely used additive manufacturing (AM) processes, Fused Deposition Modeling (FDM) and Stereolithography (SLA), under standardized conditions using the same test geometries protocols. FDM parts were printed with both Polylactic Acid (PLA) Acrylonitrile Butadiene Styrene (ABS) filaments, while SLA general-purpose photopolymer resin. Quantitative evaluations included surface roughness, dimensional accuracy, tensile properties, production cost, energy consumption. Additionally, environmental considerations process reliability assessed by examining waste streams, recyclability, failure rates. The results indicate that achieves superior quality (Ra≈2μm vs. 12–13μm) tolerances (±0.05mm ±0.15–0.20mm), along higher strength (up to 70MPa). However, provides notable advantages in cost (approximately 60% lower on per-part basis), speed, efficiency. Moreover, from an perspective, is more favorable when biodegradable PLA or recyclable ABS, whereas resin hazardous. Overall, study highlights no single universally superior. offers rapid, cost-effective solution for prototyping, excels precision finish. By presenting detailed, data-driven comparison, this work guides engineers, product designers, researchers choosing most suitable AM technology their specific needs.

Язык: Английский

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Effect of Surface Finishing and Nitriding on the Wetting Properties of Hot Forging Tools

Materials, Год журнала: 2025, Номер 18(1), С. 172 - 172

Опубликована: Янв. 3, 2025

Lubrication is a critical aspect of the metal forming process and it strongly influenced by surface texture tool-forming surfaces. This study focused on determining effect finish heat treatment wettability involving commonly used lubrication agents. Three different finishing states are evaluated (as-ground, as-polished as-nitrided). Surface topography was measured using focus variation microscope. Parametric evaluation carried out according to ISO 25178, including fractal methods. The functional relations between state wettability, lubricating agent selected parameters as well parameters, were designated. results showed that treatments, particularly nitriding, both roughness with varying effects observed across lubricants droplet sizes. findings provide valuable insights into optimization strategies for processes, highlighting importance tailored treatments enhanced tool performance longevity.

Язык: Английский

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Surface Quality and Compressive Properties of Mortise and Tenon Lattice Structures Fabricated by Fused Deposition Modeling

Materials, Год журнала: 2025, Номер 18(3), С. 628 - 628

Опубликована: Янв. 30, 2025

To address the anisotropy of mechanical properties and challenge removing support materials in lattice structures fabricated using fused deposition modeling (FDM), this study is inspired by traditional woodworking mortise tenon joints. A hexagonal interlocking structure was designed, (MTLSs) with various parameters were fabricated. Compared integrated forming (IFLS), MTLS exhibits maximum reductions side surface roughness (Ra), printing time, material consumption 74.87%, 25.55%, 52.21%, respectively. In addition to enhancing quality efficiency, also exhibited superior properties. The uniaxial compression test results show that specific strength, energy absorption (EA), (SEA) exhibit increases 51.22%, 894.59%, 888.39%, respectively, compared IFLS. Moreover, effects strut angle thickness on analyzed. Smaller angles larger thicknesses endowed greater while smaller contributed higher absorption. This proposes a novel approach for designing additive manufacturing.

Язык: Английский

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A Mechanics Model for Contact with Rough Surface Considering the Interaction of Micro-Asperity Bodies

Lubricants, Год журнала: 2025, Номер 13(3), С. 96 - 96

Опубликована: Фев. 20, 2025

In order to evaluate contact characteristics, a modified model was proposed considering the deformation characteristics of asperity bodies, and variation rules wear rate with fractal dimension, material property constant debris probability were established. The results show that actual area increases an increase in load when surface topography is constant, whereas decreases characteristic scale coefficient if dimension or constant. For running-in wear, profile parameters under same area. addition, parameter Regarding abrasive smallest 1.6. coefficient, but area, smaller larger higher rate. establishment this provides basis for further study tribological properties surface.

Язык: Английский

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Three-Dimensional-Printed Biomimetic Structural Ceramics with Excellent Tribological Properties

Materials, Год журнала: 2025, Номер 18(6), С. 1376 - 1376

Опубликована: Март 20, 2025

Inspired by the ventral scale structure of oriental sand boa, this study successfully fabricated multiscale bioinspired alumina (Al2O3) ceramics combining excellent mechanical properties, high-temperature resistance, and high hardness ceramic composites with direct ink writing (DIW) 3D printing technology femtosecond laser processing. A MoS2 thin film was then deposited on surface via radio frequency magnetron sputtering (PVD) to systematically investigate impact structures tribological properties under both dry lubricated conditions. Experimental results demonstrated that at different scales exhibited significant friction-reducing wear-resistant characteristics compared blank structures. Specifically, room-temperature conditions, friction coefficients solid lubricants oil lubrication were 0.3 0.148, respectively, indicating performance. These findings confirm synergistic effect between structures, two-dimensional lubricants, lubricating oil, which significantly enhanced components. Therefore, design provides an innovative strategy for advanced application

Язык: Английский

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Comparing the Effectiveness of R and S Roughness Parameters on Surfaces Lubricated with Standardized Nominal Particle Size Lubricants

Lubricants, Год журнала: 2025, Номер 13(4), С. 148 - 148

Опубликована: Март 27, 2025

The aim of this article is to simulate the distribution oil or lubricants on surface by characterization R and S roughness parameters. It considered that undesirable particles may appear in due friction, wear parts, dirt lubrication circuit. One problems can generate appearance poor along surface, using standards, standardised particle sizes, following standard. This research aims implement effective algorithms for calculation profile parameters existing as well development a morphological filter will surface. analysis contact with lubricant help decide maximum size permissible system; therefore, analysing when it necessary replace lubricant. carried out form geometrical point view effect. paper represents first approach researching all standardized As result, only selection has been chosen from full range available ones, order improve effectiveness.

Язык: Английский

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A Systematic Review of Innovative Advances in Multi-Material Additive Manufacturing: Implications for Architecture and Construction

Materials, Год журнала: 2025, Номер 18(8), С. 1820 - 1820

Опубликована: Апрель 16, 2025

Additive manufacturing (AM) has made rapid progress in most industries; however, the construction sector lags behind, despite substantial potential for growth. This study aims to evaluate recent innovations AM, with a focus on multi-material additive (MMAM), identify transferable knowledge and technologies industry. A systematic Boolean search reviewing Scopus Web of Science databases identified 33 relevant articles out 368 papers published English over last five years. Material properties, processes, design approaches were collectively as key interdisciplinary factors; these included thermal mechanical property gradation techniques from materials science, multi-scale optimization engineering, real-time monitoring systems manufacturing, which are each architectural applications. Bibliometric analysis demonstrated growing research trajectories AI-driven methods functionally graded that could bridge implementation gap construction. article identifies significant gaps scaling laboratory-proven MMAM applications, including material interface challenges, environmental durability concerns, absence tools specific building-scale components. We provide critical roadmap researchers prioritizes development integrated frameworks; multiscale modeling techniques; novel combinations suitable environments; standardized protocol bases Equipment Design, Process Control, Design Integration, Digital Tools, Materials Research evaluating long-term performance safety building

Язык: Английский

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Preparation and Post-Processing of Three-Dimensional Printed Porous Titanium Alloys

Materials, Год журнала: 2025, Номер 18(8), С. 1864 - 1864

Опубликована: Апрель 18, 2025

Ti6Al4V is widely utilized in orthopedic implants due to its excellent mechanical properties, corrosion resistance, and biocompatibility. However, traditional solid titanium exhibit an elastic modulus (90–115 GPa) significantly higher than that of human bone (10–30 GPa), leading stress shielding implant loosening. To address this, porous alloys have been developed better match elasticity. Additive manufacturing, particularly selective laser melting (SLM), enables precise control over pore size porosity, thereby tuning properties. Nevertheless, SLM-produced structures often suffer from powder adhesion, which compromises integration patient safety. In this study, bulk samples were fabricated via SLM with a fixed power 200 W varying scanning speeds (800–1400 mm/s). Density measurements surface defect analysis identified 1200 mm/s as the optimal speed. Cubic unit cell scaffolds different diameters (400, 600, 800 μm) porosities (60%, 80%) subsequently designed. Compression tests revealed 400 μm diameter 60% porosity exhibited highest compressive strength (794 MPa) fracture strain (41.35%). Chemical polishing using diluted HF-HNO3 solution (1:2:97) effectively removed adhered without significant structural degradation, 40 min duration.

Язык: Английский

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Fabrication of a Composite Groove Array Surface with Gradient Wettability Which Delivers Enhanced Lubrication Performance

Lubricants, Год журнала: 2025, Номер 13(5), С. 193 - 193

Опубликована: Апрель 23, 2025

A novel composite groove array surface was fabricated using femtosecond laser ablation technology to enhance self-replenishment capability. Initially, the driving efficiency of droplets on tested a high-speed droplet transportation system, characterizing effect this lubricant backflow characteristics. Simultaneously, measurement lubricating film thickness utilized explore lubrication enhancement oil formation under reciprocating motion. The multidimensional gradient wettability, engineered through surface, demonstrated excellent in replenishment within track. Oil testing that which induced wettability at boundary, attained maximum speed 123.5 mm/s. This innovative design significantly reduced barriers associated with backflow, particularly those by cavitation expansion during high-frequency Furthermore, results film-forming capabilities were enhanced, thereby optimizing overall performance.

Язык: Английский

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