A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

Ayush Verma; Angshuman Kapil; Damjan Klobčar; Abhay Sharma

doi:10.3390/ma16155246

A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

Materials (Basel). 2023 Jul 26;16(15):5246. doi: 10.3390/ma16155246.

Authors

Ayush Verma¹, Angshuman Kapil², Damjan Klobčar³, Abhay Sharma²

Affiliations

¹ Department of Mechanical Engineering, Netaji Subhas University of Technology, New Delhi 110078, India.
² Department of Materials Engineering, Faculty of Engineering Technology, KU Leuven, Campus De Nayer, 2860 Sint-Katelijne Waver, Belgium.
³ Faculty of Mechanical Engineering, University of Ljubljana, Aškerčeva 6, 1000 Ljubljana, Slovenia.

Abstract

Additive manufacturing (AM) has experienced exponential growth over the past two decades and now stands on the cusp of a transformative paradigm shift into the realm of multi-functional component manufacturing, known as multi-material AM (MMAM). While progress in MMAM has been more gradual compared to single-material AM, significant strides have been made in exploring the scientific and technological possibilities of this emerging field. Researchers have conducted feasibility studies and investigated various processes for multi-material deposition, encompassing polymeric, metallic, and bio-materials. To facilitate further advancements, this review paper addresses the pressing need for a consolidated document on MMAM that can serve as a comprehensive guide to the state of the art. Previous reviews have tended to focus on specific processes or materials, overlooking the overall picture of MMAM. Thus, this pioneering review endeavors to synthesize the collective knowledge and provide a holistic understanding of the multiplicity of materials and multiscale processes employed in MMAM. The review commences with an analysis of the implications of multiplicity, delving into its advantages, applications, challenges, and issues. Subsequently, it offers a detailed examination of MMAM with respect to processes, materials, capabilities, scales, and structural aspects. Seven standard AM processes and hybrid AM processes are thoroughly scrutinized in the context of their adaptation for MMAM, accompanied by specific examples, merits, and demerits. The scope of the review encompasses material combinations in polymers, composites, metals-ceramics, metal alloys, and biomaterials. Furthermore, it explores MMAM's capabilities in fabricating bi-metallic structures and functionally/compositionally graded materials, providing insights into various scale and structural aspects. The review culminates by outlining future research directions in MMAM and offering an overall outlook on the vast potential of multiplicity in this field. By presenting a comprehensive and integrated perspective, this paper aims to catalyze further breakthroughs in MMAM, thus propelling the next generation of multi-functional component manufacturing to new heights by capitalizing on the unprecedented possibilities of MMAM.

Keywords: 3D printing; additive manufacturing; multi-material; multiplicity.

Publication types

Review

Grants and funding

A part of the investigation was carried out under the project “Fundamental Study on Next Generation Multi-Material Wire-Arc Additive Manufacturing”, grant number 3E210629, funded by CELSA. This work was also partly supported by the Slovenian Research Agency, research program P2-0270, and by the European Union project ERASMUS+ Strategic Partnership Key Action 2, number: 2021-1-RO01-KA220-VET-000028028, DIGIGREEN.