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The paper focuses on the effect of the scanning strategies on the microstructural evolution, defect formation, and macro-hardness performance of laser-powder bed fusion (L-PBF) produced samples of low alloy 20MnCr5 steel. Respect to the scanning strategies, advanced characterization techniques were employed to study (i) as-built microstructure, (ii) inclusion size and distribution, and (iii) details of compositional variation around porosity and within the build. Microstructural characterization shows that the chessboard scanning strategy can provide a favorable microstructure for the improvement of mechanical performance. However, macro-hardness results show a lower mechanical performance compared to the linear scanning strategy samples, which is contradicted by the improved microstructure. Experimental results reveal that the chessboard scanning strategy promotes the oxidation reaction and in-situ oxide (SiO2) formation in L-PBF, which leads to significant defect formation due to the excessive thermal profile from the overlap of the laser. This has been validated through finite element analysis and thermodynamic computation. The advantages of microstructural improvement using the chessboard strategy can only be realized with strict control of the metallurgical quality during the L-PBF process. Thermal profile optimization and oxygen elimination during the L-PBF process could be critical for the improved metallurgical quality and superior mechanical performance of the as-built components.

Abstract The aim of this study was to identify the effect of material type (matrix and reinforcement) and process parameters, on the mechanical properties of 3D Printed long-fibre reinforced polymer composites manufactured using a commercial 3D Printer (Mark Two). The effect of matrix material (Onyx or polyamide), reinforcement type (Carbon, Kevlar®, and HSHT glass), volume of reinforcement, and reinforcement lay-up orientation on both Ultimate Tensile Strength (UTS) and Flexural Modulus were investigated. For Onyx, carbon fibre reinforcement offered the largest increase in both UTS and Flexural Modulus over unreinforced material (1228 ± 19% and 1114 ± 6% respectively). Kevlar® and HSHT also provided improvements but these were less significant. Similarly, for Nylon, the UTS and Flexural Modulus were increased by 1431 ± 56% and 1924 ± 5% by the addition of carbon fibre reinforcement. Statistical analysis indicated that changing the number of layers of reinforcement had the largest impact on both UTS and Flexural Strength, and all parameters were statistically significant.

An investigation on antenna solutions for expendable origami paper flapping robots is presented. An origami flapping robotic bird that can be produced using standard A4 paper is employed. Antennas resonating at the two commonly used frequency bands, 2.4 GHz and 5.2 GHz, are designed for the limited space available on the folded origami structure. Two developments of the same dual-band monopole antenna are discussed. The first antenna is located on the robot's spine and the second on its tail. A space diversity configuration is also studied. The antennas are printed directly onto a photo paper substrate and then folded into an origami robotic crane's body structure. An ordinary desktop inkjet printer fitted with silver nanoparticle conductive ink cartridges has been employed. CST Microwave StudioTM has been used to design the antennas. A good agreement between the measured and simulated S11 results is achieved with a reasonable -10dB impedance bandwidth realized in the three cases studied. The radiation patterns are omnidirectional in the XZ plane which is desirable for the specific application. The diversity configuration has a mutual coupling of

Low-terahertz (Low-THz, 100 GHz-1.0 THz) technology is expected to provide unprecedented data rates in future generations of wireless system such as the 6th generation (6G) mobile communication system. Increasing the carrier frequencies from millimeter wave to THz is a potential solution to guarantee the transmission rate and channel capacity. Due to the large transmission loss of Low-THz wave in free space, it is particularly urgent to design high-gain antennas to compensate the additional path loss, and to overcome the power limitation of Low-THz source. Recently, with the continuous updating and progress of additive manufacturing (AM) and 3D printing (3DP) technology, antennas with complicated structures can now be easily manufactured with high precision and low cost. In the first part, this paper demonstrates different approaches of recent development on wideband and high gain sub-millimeter-wave and Low-THz antennas as well as their fabrication technologies. In addition, the performances of the state-of-the-art wideband and high-gain antennas are presented. A comparison among these reported antennas is summarized and discussed. In the second part, one case study of a broadband high-gain antenna at 300 GHz is introduced, which is an all-metal model based on the Fabry-Perot cavity (FPC) theory. The proposed FPC antenna is very suitable for manufacturing using AM technology, which provides a low-cost, reliable solution for emerging THz applications.

The mechanical response of steel auxetic structures manufactured using laser-powder bed fusion was explored. The level of control exerted by the key design parameters of vertical strut length (H), re-entrant strut length (L), strut thickness (t) and re-entrant angle (ϴ) on the mechanical response was examined through a design of experiment approach with ANOVA statistical analysis methods applied. The elastic modulus in directions normal to (Ex) and parallel to (Ey) the vertical strut was found to be primarily dependent upon t and L, respectively, whereas yield strength in both test directions (σx and σy) was strongly dependent on t and L. A large variation in modulus was found between the two test directions (Ex / Ey – 1.02 ± 0.07 GPa/ 4.4 ± 0.1 GPa), whereas, yield strength showed little anisotropy (σx / σy–45 ± 6 MPa/ 45 ± 9 MPa). Poisson’s ratio parallel to the vertical strut varied considerably with geometry but not in a direction normal to the vertical strut. Deformation mechanisms were found to be different of compression in the x and y directions, being a combination of stretching of the vertical strut; compression, bending and hinging of the re-entrant strut (x); and vertical strut compression and re-entrant strut stretching and bending (y).

This paper reviews state of the art additive manufactured (AM) IN718 alloy intended for high-temperature applications. AM processes have been around for decades and have gained traction in the past five years due to the huge economic benefit this brings to manufacturers. It is crucial for the scientific community to look into AM IN718 applicability in order to see a step-change in production. Microstructural studies reveal that the grain structure plays a significant role in determining the fatigue lifespan of the material. Controlling IN718 respective phases such as the ϒ’’, δ and Laves phase is seen to be crucial. Literature reviews have shown that the mechanical properties of AM IN718 were very close to its wrought counterpart when treated appropriately. Higher homogenization temperature and longer ageing were recommended to dissolve the damaging phases. Various surface enhancement techniques were examined to find out their compatibility to AM IN718 alloy that is intended for high-temperature application. Laser shock peening (LSP) technology stands out due to the ability to impart low cold work which helps in containing the beneficial compressive residual stress it brings in a high-temperature fatigue environment.

A new practical workflow for the laser Powder Bed Fusion (PBF) process, incorporating topological design, mechanical simulation, manufacture, and validation by computed tomography is presented, uniquely applied to a consumer product (crank for a high-performance racing bicycle), an approach that is tangible and adoptable by industry. The lightweight crank design was realised using topology optimisation software, developing an optimal design iteratively from a simple primitive within a design space and with the addition of load boundary conditions (obtained from prior biomechanical crank force–angle models) and constraints. Parametric design modification was necessary to meet the Design for Additive Manufacturing (DfAM) considerations for PBF to reduce build time, material usage, and post-processing labour. Static testing proved performance close to current market leaders with the PBF manufactured crank found to be stiffer than the benchmark design (static load deflection of 7.0 ± 0.5 mm c.f. 7.67 mm for a Shimano crank at a competitive mass (155 g vs. 175 g). Dynamic mechanical performance proved inadequate, with failure at 2495 ± 125 cycles; the failure mechanism was consistent in both its form and location. This research is valuable and novel as it demonstrates a complete workflow from design, manufacture, post-treatment, and validation of a highly loaded PBF manufactured consumer component, offering practitioners a validated approach to the application of PBF for components with application outside of the accepted sectors (aerospace, biomedical, autosports, space, and power generation).

Purpose - The aim of this study is to demonstrate the benefit of design flexibility afforded by the Arcam free-form fabrication process in the direct manufacture of injection mould inserts with complex cooling channel configurations and the process efficiency and quality gains achieved through using such inserts. Design/methodology/approach - The manufacturing process of a flood cooled injection mould insert using the Arcam EBM S12 layered manufacturing process is presented. The insert is then evaluated against two other inserts (one un-cooled and one traditionally baffle cooled (BC)) in the manufacture of test components, with the temperature of the insert and components recorded. The process conditions were adjusted (reduced cooling time) to increase the core and component temperatures to identify the operational limits of the inserts. Thermal imaging was employed to visualize the thermal distribution within the BC and flood cooled (FC) inserts. Findings - The cooling efficiency of the FC insert was found to be significantly higher than that of the other two inserts, and the homogeneity of the heat distribution of the FC insert was more even than the BC insert. It was possible to manufacture non-deformed components using the FC insert with zero cooling time (ejection immediately after removal of holding pressure), this was not possible with the BC insert. Research limitations/implications - Provides a basis for the development of more efficient and thermally homogeneous inserts through the Arcam EBM process. Practical implications - Provides a technology/process for the manufacture of highly efficient core inserts for injection moulding, offering the industry a competitive advantage through the potential for time and cost savings and higher quality components. Originality/value - This is the first direct comparison of an Arcam EBM manufactured insert with complex cooling geometries against traditionally cooled inserts, particularly novel is the thermal imaging analysis of the cooling efficiency and distribution. [ABSTRACT FROM AUTHOR]