Material shaping and joining are the two fundamental processes that lie at the core of many forms of metal manufacturing techniques, including additive manufacturing. Current metal additive manufacturing processes such as laser/e-beam powder bed fusion and Directed Energy Deposition predominantly use heat and subsequent melt-fusion and solidification to achieve shaping and joining. The energy efficiency of these processes is severely limited due to energy conversion losses before energy is delivered at the point of melt-fusion for shaping and joining, and due to losses through heat transfer to the surrounding environment. This manuscript demonstrates that by using the physical phenomenon of lowered yield stress of metals and enhanced diffusion in the presence of low amplitude high frequency oscillatory strain, metal shaping and joining can be performed in an energy-efficient way. The two performed simultaneously enable a metal additive manufacturing process, namely Resonance-Assisted Deposition (RAD), that has several unique capabilities, like the ability to print net-shape components from hard-to-weld alloys like Al6061 and the ability to print components with a very high aspect ratio. In this study, we show this process\'s capabilities by printing solid components using aluminum-based metal alloys.

Three-dimensional printing is a non-conventional additive manufacturing process. It is different from the conventional subtractive manufacturing process. It offers exceptional rapid prototyping capabilities and results that conventional subtractive manufacturing methods cannot attain, especially in applications involving curved or intricately shaped components. Despite its advantages, metal 3D printing will face porosity, warpage, and surface roughness issues. These issues will affect the future practical application of the parts indirectly, for example, by affecting the structural strength and the parts\' assembly capability. Therefore, this study compares the qualities of the warpage, weight, and surface roughness after milling and grinding processes for the same material (316L stainless steel) between rolled steel and 3D-printed steel. The experimental results show that 3D-printed parts are approximately 13% to 14% lighter than rolled steel. The surface roughness performance of 3D-printed steel is better than that of rolled steel for the same material after milling or grinding processing. The hardness of the 3D-printed steel is better than that of the rolled steel. This research verifies that 3D additive manufacturing can use surface processing to optimize surface performance and achieve the functions of lightness and hardness.

Segmental bone defects of the mandible result in the complete loss of the affected region. We had incorporated the pressure-reducing device (PRD) designs into the customized mandible prostheses (CMP) and conducted a clinical trial to evaluate this approach.
Seven patients were enrolled in this study. We examined the association among the history of radiotherapy, the number of CMP regions, the number of chin regions involved, and CMP exposure.
We included five men and two women with an average age of 55 years. We excised tumors with an average weight of 147.8 g and the average weight of the CMP was 68.5 g. No significant difference between the two weights was noted (p = 0.3882). Three patients received temporary dentures and the CMP remained stable in all patients.
The use of PRD in CMP may address the previous challenges associated with CMP, but further research is necessary.

Metal additive manufacturing (AM) is a layer-by-layer process that makes the direct manufacturing of various industrial parts possible. This method facilitates the design and fabrication of complex industrial, advanced, and fine parts that are used in different industry sectors, such as aerospace, medicine, turbines, and jewelry, where the utilization of other fabrication techniques is difficult or impossible. This method is advantageous in terms of dimensional accuracy and fabrication speed. However, the parts fabricated by this method may suffer from faults such as anisotropy, micro-porosity, and defective joints. Metals like titanium, aluminum, stainless steels, superalloys, etc., have been used-in the form of powder or wire-as feed materials in the additive manufacturing of various parts. The main criterion that distinguishes different additive manufacturing processes from each other is the deposition method. With regard to this criterion, AM processes can be divided into four classes: local melting, sintering, sheet forming, and electrochemical methods. Parameters affecting the properties of the additive-manufactured part and the defects associated with an AM process determine the method by which a certain part should be manufactured. This study is a survey of different additive manufacturing processes, their mechanisms, capabilities, shortcomings, and the general properties of the parts manufactured by them.

The accurate positioning of metal-organic frameworks (MOFs) on the surface of other materials has opened up new possibilities for the development of multifunctional devices. We propose here a postfunctionalization approach for three-dimensional (3D)-printed metallic catalytic flow reactors based on MOFs. The Cu-based reactors were immersed into an acid solution containing an organic linker for the synthesis of MOFs, where Cu2+ ions dissolved in situ were assembled to form MOF crystals on the surface of the reactor. The resultant MOF layer served as a promising interface that enabled the deposition of catalytically active metal nanoparticles (NPs). It also acted as an efficient platform to provide carbonous layers via simple pyrolysis under inert gas conditions, which further enabled functionalization with organic modifiers and metal NPs. Cylindrical-shaped catalytic flow reactors with four different cell densities were used to investigate the effect of the structure of the reactors on the catalytic production of H2 from a liquid-phase hydrogen storage material. The activity increased with an increasing internal surface area but decreased in the reactor with the smallest cell size despite its high internal surface area. The results of fluid dynamics studies indicated that the effect of pressure loss becomes more pronounced as the pore size decreases.

Hemifacial microsomia (HFM), one of the most common congenital facial anomalies, was usually treated with the bilateral sagittal split osteotomy (BSSO) procedure to correct the asymmetric appearance and malocclusion of the mandible. However, the frequent post-operative relapse incidents would lead to the restoration of the mandibular segment to its preoperative position and failure of the BSSO procedure. In this study, a customized asymmetric fixed plate (CAF plate) was developed to resist relapse due to hemifacial microsomia occlusal forces and the different muscular traction forces on both sides of the mandible. For the actual HFM case in this study, the reconstructed mandibular segmental bone model was fixed using BSSO with a rectangular plate (the original CAF plate appearance) in the topology optimization analysis. With the topology optimization technique, the CAF plate was designed with a lightweight profile and excellent structural strength in consideration of the HFM asymmetrical muscle traction and occlusal force. Using biomechanical simulations, the von-Mises stress and CAF plate mandibular segment displacement and the miniplate were compared to evaluate which had superior relapse resistance. In the in-vitro biomechanical test, a fatigue force of 250,000 cycles and a constant muscle traction force were applied to the HFM mandibular model, which was fixed with the CAF plate fabricated using metal 3D printing (selective laser melting, SLM) to obtain the mandibular segment displacement as a relapse assessment. The topology optimization analysis showed that the CAF plate has the best characteristics, light weight and structural strength with 30% volume retention. The biomechanical analysis showed that the maximum von Mises stress of the mini-plate was 2.71 times higher than that of the CAF plate. The relapse displacement of the mandibular segment fixed with the mini-plate was 1.62 times higher than that fixed with the CAF plate. The CAF plate ability to resist relapse was confirmed by the biomechanical testing results so that only 0.29 mm of recurrence displacement was observed in the mandibular segment. The results indicated that the CAF plate structural strength and resistance to relapse was significantly better than that of the mini-plate. This study developed a customized asymmetric fixation plate for hemifacial microsomia, integrating topology optimization, metal 3D printing, and in vitro biomechanical testing to resist occlusal forces and differential muscle traction on both sides of the mandible to reduce relapse and improve fixation stability.

A metal-melting direct writing process, using semi-solid isothermal heat treatment to form high-quality semi-solid components, realized the integrated innovation of semi-solid formation and additive manufacturing. An experimental study was carried out on semi-solid isothermal heat treatment for metal-melting direct-writing technology, using 2A12 aluminum alloy as raw material. The semi-solid isothermal heat treatment was carried out over different temperature ranges, and four-stages evolution mechanism of the semi-solid microstructure in the semi-solid melting direct writing process was investigated. The effects of holding temperature and time on the microstructure of the semi-solid isothermal heat treatment of the alloy were put forward. According to the analysis of the results of the semi-solid-melting direct-writing test, the corresponding relationship between semi-solid microstructure and extrusion formability was found. The results show that when the holding temperature is 640-650 °C and the holding time is 20-25 min, the liquid phase rate can reach about 40%, and the direct-writing forming technology can be carried out stably.

To evaluate the accuracy of metal 3D printed frameworks (MEP group) for removable partial dentures (RPDs) by digital superimposition, in comparison to that of frameworks produced by the conventional (CON group) and resin printing/casting (RPC group) workflows.
A partially edentulous maxillary dentiform was prepared with rest seats and guiding planes on the right canine, left first premolar, and left second molar. Thirty master casts were prepared via repeated impressions of the dentiform. Frameworks were fabricated by three different workflows (n = 10 for each group). The internal discrepancies of the frameworks were assessed at 12 points by digital scanning with an optical triangulation principle-based tabletop scanner and superimposition using a reference best-fit alignment method. First, the master cast was scanned alone. Subsequently, a thin silicone material was applied to the framework and fitted onto the master cast, after which the framework was removed. Finally, the master cast with the silicone material attached was rescanned. The data from the two scans were matched, with the reference being the area not occupied by the silicone.
For the CON, MEP, and RPC groups, respectively, the mean overall internal discrepancies (279.72 µm, 241.02 µm, and 331.70 µm), and the mean internal discrepancies on palate areas (292.92 µm, 250.72 µm, and 355.84 µm) and rest seat areas (240.12 µm, 211.91 µm, and 259.26 µm) did not significantly differ among the three fabrication methods (p = 0.558, 0.542, and 0.774).
The reference best-fit alignment of scan datasets is a useful approach to evaluate the internal discrepancy of frameworks. Metal 3D printing produces RPD frameworks that are comparable to conventional frameworks and meet clinical standards.

The grain size is a determinant microstructural feature to enable the activation of deformation twinning in hexagonal close-packed (hcp) metals. Although deformation twinning is one of the most effective mechanisms for improving the strength-ductility trade-off of structural alloys, its activation is reduced with decreasing grain size. This work reports the discovery of the activation of deformation twinning in a fine-grained hcp microstructure by introducing ductile body-centered cubic (bcc) nano-layer interfaces. The fast solidification and cooling conditions of laser-based additive manufacturing are exploited to obtain a fine microstructure that, coupled with an intensified intrinsic heat treatment, permits to generate the bcc nano-layers. In situ high-energy synchrotron X-ray diffraction allows tracking the activation and evolution of mechanical twinning in real-time. The findings obtained show the potential of ductile nano-layering for the novel design of hcp damage tolerant materials with improved life spans.

Additive manufacturing technologies based on metal are evolving into an essential advanced manufacturing tool for constructing prototypes and parts that can lead to complex structures, dissimilar metal-based structures that cannot be constructed using conventional metallurgical techniques. Unlike traditional manufacturing processes, the metal AM processes are unreliable due to variable process parameters and a lack of conventionally acceptable evaluation methods. A thorough understanding of various diagnostic techniques is essential to improve the quality of additively manufactured products and provide reliable feedback on the manufacturing processes for improving the quality of the products. This review summarizes and discusses various ex-situ inspections and in-situ monitoring methods, including electron-based methods, thermal methods, acoustic methods, laser breakdown, and mechanical methods, for metal additive manufacturing.