Additive manufacturing of materials: Opportunities and challenges

Abstract

Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. This article discusses the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performance computational tools to address each of these challenges. Emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5-20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.