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This study aims to improve the acceleration in the additive manufacturing (AM) process. AM tools, such as extrusion heads, jets, electric arcs, lasers and electron beams (EB), experience negligible forces. However, their speeds are limited by the positioning systems. In addition, a thin tool must travel several kilometers in tiny motions with several turns while realizing the AM part. Hence, acceleration is a more significant limiting factor than the velocity or precision for all except EB.

The sawtooth (ST) scanning strategy presented in this paper minimizes the time by combining three motion features: zigzag scan, 45º or 135º rotation for successive layers in G00 to avoid the CNC interpolation, and modifying these movements along 45º or 135º into sawtooth to halve the turns.

Sawtooth effectiveness is tested using an in-house developed Sand AM (SaAM) apparatus based on the laser–powder bed fusion AM technique. For a simple rectangle layer, the sawtooth achieved a path length reduction of 0.19%–1.49% and reduced the overall time by 3.508–4.889 times, proving that sawtooth uses increased acceleration more effectively than the other three scans. The complex layer study reduced calculated time by 69.80%–139.96% and manufacturing time by 47.35%–86.85%. Sawtooth samples also exhibited less dimensional variation (0.88%) than zigzag 45° (12.94%) along the build direction.

Sawtooth is limited to flying optics AM process.

Development of scanning strategy for flying optics AM process to reduce the warpage by improving the acceleration.

Integrating additive manufacturing (AM) tools in traditional mold-making provides complex yet affordable sand molds and cores. AM processes such as selective laser sintering (SLS) and Binder jetting three-dimensional printing (BJ3DP) are widely used for patternless sand mold and core production. This study aims to perform an in-depth literature review to understand the current status, determine research gaps and propose future research directions. In addition, obtain valuable insights into authors, organizations, countries, keywords, documents, sources and cited references, sources and authors.

This study followed the systematic literature review (SLR) to gather relevant rapid sand casting (RSC) documents via Scopus, Web of Science and EBSCO databases. Furthermore, bibliometrics was performed via the Visualization of Similarities (VOSviewer) software.

An evaluation of 116 documents focused primarily on commercial AM setups and process optimization of the SLS. Process optimization studies the effects of AM processes, their input parameters, scanning approaches, sand types and the integration of computer-aided design in AM on the properties of sample. The authors performed detailed bibliometrics of 80 out of 120 documents via VOSviewer software.

This review focuses primarily on the SLS AM process.

A SLR and bibliometrics using VOSviewer software for patternless sand mold and core production via the AM process.

This study aims to address the limited understanding of the complex correlations among strut size, structural orientation and process parameters in selective laser melting (SLM)-fabricated lattice structures. By investigating the effects of crucial process parameters, strut diameter and angle on the microstructure and mechanical performance of AlSi10Mg struts, the research seeks to enhance the surface morphologies, microstructures and mechanical properties of AM lattice structures, enabling their application in various engineering fields, including medical science and space technologies.

This comprehensive study investigates SLM-fabricated AlSi10Mg strut structures, examining the effects of process parameters, strut diameter and angle on densification behavior and microstructural characteristics. By analyzing microstructure, geometrical properties, melt pool morphology and mechanical properties using optical microscopy, scanning electron microscope, energy dispersive X-ray spectroscopy and microhardness tests, the research addresses existing gaps in knowledge on fine lattice strut elements and their impact on surface morphology and microstructure.

The study revealed that laser energy, power density and strut inclination angle significantly impact the microstructure, geometrical properties and mechanical performance of SLM-produced AlSi10Mg struts. Findings insight enable the optimization of SLM process parameters to produce lattice structures with enhanced surface morphologies, microstructures and mechanical properties, paving the way for applications in medical science and space technologies.

This study uniquely investigates the effects of processing parameters, strut diameter and inclination angle on SLM-fabricated AlSi10Mg struts, focusing on fine lattice strut elements with diameters as small as 200 µm. Unlike existing literature, it delves into the complex correlations among strut size, structural orientation and process parameters to understand their impact on microstructure, geometrical imperfections and mechanical properties. The study provides novel insights that contribute to the optimization of SLM process parameters, moving beyond the typically recommended guidelines from powder or machine suppliers.

Three-dimensional (3D) food printing is an innovative technology used to customize food products through the integration of digital technology and food ingredients. The purpose of this study is to assess the current state of research in the field of 3D food printing, identify trending topics and identify promising future research directions.

This bibliometric review systematically evaluates the field of 3D food printing using data from published literature in the Web of Science database. After reference screening, 812 articles were included in the analysis.

The result reveals that research in 3D food printing primarily focuses on the optimization and characterization of mechanical and rheological properties of food inks and that post-printing processing, such as laser treatment, has emerged recently as an important consideration in 3D food printing. However, extant works lack animal and human studies that demonstrate the functionality of 3D-printed food.

This sophisticated bibliometric analysis uncovered the most studied current research topics and the leading figures in the area of 3D food printing, providing promising future research directions.

This study aims to investigate the relationship between melt pool dimensions and acoustic emission (AE) signal magnitudes obtained during laser powder bed fusion (L-PBF) process of austenitic stainless steel. Specifically, by varying laser power and scan speed, the widths, depths and aspect ratios of melt pools were compared with AE signal magnitudes across a frequency range of 100–200 kHz.

Experiments were conducted under different laser powers at a fixed scan speed and scan speeds at a fixed laser power. Melt pool dimensions were measured from cross-sectional optical images, and AE signals were obtained using a piezoelectric AE sensor installed beneath the build plate. Short-Time Fourier Transform (STFT) was applied to AE signals, and the magnitudes of frequency components were obtained.

A strong correlation between melt pool dimensions and STFT magnitude was obtained. Pearson correlation coefficients between melt pool dimensions and STFT magnitudes were above 0.9 and the p-values were below 0.05. Increasing the laser energy enlarged the volume of melt pool and intensified the oscillation of melt pool. When scan speed exceeded 1,100 mm/s, STFT magnitude showed a slight increase owing to the increase in the vapor pressure.

Previous studies used AE signals to detect defects, but this study found a correlation between STFT magnitude and melt pool dimensions in L-PBF process. It was also found that STFT magnitude was more affected by vapor pressure at higher scan speeds. Monitoring STFT magnitude can help to understand melt pool dynamics, maintain process consistency and identify irregularities in real time.

The ability to use laser powder bed fusion (LPBF) to print parts with tailored surface topography could reduce the need for costly post-processing. However, characterizing the as-built surface topography as a function of process parameters is crucial to establishing linkages between process parameters and surface topography and is currently not well understood. The purpose of this study is to measure the effect of different LPBF process parameters on the as-built surface topography of Inconel 718 parts.

Inconel 718 truncheon specimens with different process parameters, including single- and double contour laser pass, laser power, laser scan speed, build orientation and characterize their as-built surface topography using deterministic and areal surface topography parameters are printed. The effect of both individual process parameters, as well as their interactions, on the as-built surface topography are evaluated and linked to the underlying physics, informed by surface topography data.

Deterministic surface topography parameters are more suitable than areal surface topography parameters to characterize the distinct features of the as-built surfaces that result from LPBF. The as-built surface topography is strongly dependent on the built orientation and is dominated by the staircase effect for shallow orientations and partially fused metal powder particles for steep orientations. Laser power and laser scan speed have a combined effect on the as-built surface topography, even when maintaining constant laser energy density.

This work addresses two knowledge gaps. (i) It introduces deterministic instead of areal surface topography parameters to unambiguously characterize the as-built LPBF surfaces. (ii) It provides a methodical study of the as-built surface topography as a function of individual LPBF process parameters and their interaction effects.

Three-dimensional (3D) casting means using additive manufacturing (AM) techniques to print the mould for casting the cast tool. The printed mould, however, should be checked for its dimensional accuracy. 3D scanning can be used for the same. The purpose of this study is to combine the different AM techniques for 3D casting with 3D scanning to produce parts with close tolerance for preparing electrical discharge machining (EDM) electrodes.

The four processes, namely, stereolithography, selective laser sintering, fused deposition modelling and vacuum casting, are used to print the casting mould. The mould is designed in two halves, assembled to form a complete mould. The mould is 3D scanned in two stages: before and after using it as a casting mould. The mould's average and maximum dimensional deviations are calculated using 3D-scanned results. The eutectic Sn-Bi alloy is cast in the mould. The surface roughness of the mould and the cast tool are measured.

The cast tool is selected from the four processes in terms of dimensional accuracy and surface finish. The same is electroplated with copper. The microstructure of the cast tool (low-melting-point alloy) and deposited copper is analysed using a scanning electron microscope. Energy dispersive spectroscopy and X-ray diffraction techniques are used to verify the composition of the cast and coated alloy. The electroplated tool is finally tested on the EDM setup. The material removal rate and tool wear are measured. The performance is compared with a solid copper tool. The free-form customised EDM mould is also prepared, and the profile is cast out. The same is tested on the EDM. Thus, the developed path can be successfully used for rapid tooling applications.

The eutectic composition of Sn-Bi is cast in the 3D-printed mould using different AM techniques combined with 3D scanning quality to check its feasibility as an EDM electrode, which is a novel work and has not been done previously.

This study aims to evaluate the enhancement in prosthetic supply chain capabilities resulting from the implementation of additive manufacturing (AM) technologies. The study presents an emerging model outlining the key areas that undergo changes when integrating 3D printing technologies into the prosthetic supply chain.

Employing a qualitative approach, data were collected through field observations and 31 in-depth interviews conducted within various Jordanian organizations associated with the prosthetic industry and 3D printing technologies.

The findings suggest that the adoption of 3D printing technologies improves the prosthetic supply chain’s capabilities in terms of customization, responsiveness, innovation, environmental sustainability, cost minimization and patient empowerment. The study sheds light on the specific areas affected in the prosthetic supply chain following the adoption of 3D printing technologies, emphasizing the overall improvement in supply chain capabilities within the prosthetic industry.

This study provides recommendations for governmental bodies and prosthetic organizations to maximize the benefits derived from the use of 3D printing technologies.

This study contributes as the first of its kind in exploring the impact of 3D printing technology adoption in the Jordanian prosthetic industry, elucidating the effects on the supply chain and identifying challenges for decision-makers in an emerging market context.

This paper aims to address the critical labor shortage in the food industry by exploring the potential of 3D food printing technology as a strategic solution. The study investigates how 3D food printing can enhance productivity, reduce labor costs, and offer innovative applications in various sectors of the food industry.

The research employs a comprehensive review of existing literature and case studies to analyze the current state of labor scarcity in the food industry and the technological advancements in 3D food printing. The paper also assesses the technical, operational, regulatory, and ethical challenges of 3D food printing and provides strategic recommendations for stakeholders.

3D food printing technology presents a viable solution by automating labor-intensive tasks, enhancing labor efficiency, and enabling customized food production. The technology’s potential benefits include improved productivity, reduced operational costs, and the ability to meet personalized nutritional needs. However, the adoption of 3D food printing faces challenges such as high initial costs, maintenance requirements, and scalability issues. Additionally, regulatory and consumer acceptance hurdles need to be addressed.

Policymakers are encouraged to support the development and adoption of 3D food printing through funding and clear regulatory frameworks. Business leaders should consider strategic investments in 3D printing technology and training programs to harness its benefits. Technology developers must focus on advancing the capabilities and user-friendliness of 3D food printers. Addressing these aspects can help the food industry overcome labor scarcity and achieve long-term sustainability and efficiency.

This paper provides a comprehensive analysis of 3D food printing technology as a strategic response to labor scarcity in the food industry. It contributes to the existing body of knowledge by highlighting the potential of 3D food printing to revolutionize food production and offering practical recommendations for its adoption and integration.

Additive manufacturing (AM), also known as three-dimensional (3D) printing technology, has been used in the health-care industry for over two decades. It is in high demand in the health-care industry due to its strength to manufacture custom-designed and personalized 3D constructs. Recently, AM technologies are being explored to develop personalized drug delivery systems, such as personalized oral dosages, implants and others due to their potential to design and develop systems with complex geometry and programmed controlled release profile. Furthermore, in 2015, the US Food and Drug Administration approved the first AM medication, Spritam® (Apprecia Pharmaceuticals) which has led to tremendous interest in exploring this technology as a bespoke solution for patient-specific drug delivery systems. The purpose of this study is to provide a comprehensive overview of AM technologies applied to the development of personalized drug delivery systems, including an analysis of the commercial status of AM based drugs and delivery devices.

This review paper provides a detailed understanding of how AM technologies are used to develop personalized drug delivery systems. Different AM technologies and how these technologies can be chosen for a specific drug delivery system are discussed. Different types of materials used to manufacture personalized drug delivery systems are also discussed here. Furthermore, recent preclinical and clinical trials are discussed. The challenges and future perceptions of personalized medicine and the clinical use of these systems are also discussed.

Substantial works are ongoing to develop personalized medicine using AM technologies. Understanding the regulatory requirements is needed to establish this area as a point-of-care solution for patients. Furthermore, scientists, engineers and regulatory agencies need to work closely to successfully translate the research efforts to clinics.

This review paper highlights the recent efforts of AM-based technologies in the field of personalized drug delivery systems with an insight into the possible future direction.