A roadmap for the next generation of additive manufacturing materials and processes

Materials currently used in 3D printing are costly, not readily available, and limited
March 16, 2016

The Strategic Roadmap for the Next Generation of Additive Manufacturing Materials offers a strategy for building the fundamental knowledge necessary to accelerate the design and application of additive manufacturing (AM) materials over the next 10 years. It organizes research and activities for developing additive manufacturing materials into five strategic thrusts: enabling integrated design methodologies for materials, processes and parts; developing AM process-structure-property relationships; establishing part and feedstock testing protocols; building AM process analytics capabilities; and exploring next-generation AM materials and processes. (credit: Penn State)

Penn State University researchers have released a roadmap for developing future additive manufacturing (3D printing) materials and processes.

It’s much needed. Most of the feedstock materials currently used in 3D printing are costly, not readily available, and limited, according to the researchers. The first additive manufacturing (AM) processes were actually developed 30 years ago. All of the metal alloys currently used, for example, were developed to be processed using casting and forging processes.

There is also a limited understating and inadequate compatibility with current AM processing technologies, the researchers say.

Funded by the U.S. National Institute of Standards and Technology, the new roadmap offers “a strategy for building the fundamental knowledge necessary to accelerate the design and application of additive manufacturing (AM) materials over the next 10 years.”

An example of a radical new additive-manufacturing process: JPL’s prototype of a compositionally graded mirror mount made by a new metal-based AM powder deposition technique. The gradient alloy component design — which contains a nickel and nickel-iron alloy at the top of the part and stainless steel at the base — replaces epoxy bonding techniques and mitigates the effects of thermal expansion caused by the extreme temperatures of outer space. (credit: NASA JPL)

The roadmapping effort involved more than 120 participants from industry, government and academia, according to Todd Palmer, Penn State associate professor of materials science and engineering and senior research associate with the Applied Research Lab (ARL), principal investigator on the roadmapping project.

The roadmap organizes research and activities into five strategic thrusts: enabling integrated design methodologies for materials, processes and parts; developing AM process-structure-property relationships; establishing part and feedstock testing protocols; building AM process analytics capabilities; and exploring next-generation AM materials and processes.

The researchers have also been coordinating their roadmapping efforts with America Makes, the National Additive Manufacturing Innovation Institute, which helps transition research and development in AM into the marketplace.

The researchers are also hoping that the roadmap generates enough interest from academia, research institutions, government labs, and industry partners so that they can launch the Consortium for Additive Manufacturing Materials (CAMM).

Additive manufacturing (3D printing) could affect a wide range of industries, including defense, energy, aerospace, automotive, medical and metals manufacturing.


editor’s comments: It will be interesting to see what cool new products, materials, and processes for the maker community become available. What would you make if you had the ideal 3D printer and ideal materials?