Foreword xiii Preface xv Acknowledgements xix 1 Review of Processing Techniques in Large-Format Additive Manufacturing of Polymers and Composites 1 Ahmed Arabi Hassen, Alex Roschli, Daniel Moreno, Vlastimil Kunc, and Brian Post 1.1 Introduction 1 1.2 Auxiliary Systems and Equipment Configurations for Enhanced Functionality 6 1.2.1 Material Drying, Conveyance, and Control Systems 6 1.2.2 Machining and Postprocessing 7 1.2.
3 Multimaterials Printing 7 1.2.4 Pick-and-Place System 8 1.2.5 Heated Enclosures 9 1.2.6 Integration of Automated Fiber Placement 10 1.2.
7 Coextrusion of Wires 11 1.2.8 Continuous Fiber Printing 12 1.2.9 Build Table 12 1.2.10 Improving Layer Adhesion 14 1.2.
11 Slicing Software and Printing Algorithms 15 1.3 Cost Efficiency, Industrialization, and Market Adoption 18 1.3.1 Market Adoption 20 1.4 Choosing the Optimal Motion Platform for LFAM Systems 21 1.5 Conclusions 24 References 24 2 Polymer and Composite Materials for Extrusion-Based Additive Manufacturing 29 Daniel Moreno Sánchez, Alberto Sanz de León, Ahmed Arabi Hassen, Halil Tekinalp, and Sergio I. Molina 2.1 Introduction 29 2.
2 Polymers Used in LFAM Systems 32 2.2.1 Thermoplastics and Thermoplastic Composites 32 2.2.2 Thermoset Polymers and Reactive Chemistries 40 2.2.3 Sustainable and Bio-Based Materials 41 2.2.
4 Speciality Polymers 47 2.2.4.1 Magnetic Materials 48 2.2.4.2 Dissolvable Materials 48 2.2.
4.3 Foamed Materials 50 2.2.4.4 Nano-additivated Materials 50 2.3 Fundamental Materials Aspects for LFAM 51 2.3.1 Influence of the Rheological Behavior 52 2.
3.2 Influence of Thermo-Mechanical Behavior 55 2.4 Recommendations for the Development of New Materials for LFAM 57 2.5 Conclusion 59 References 59 3 Characterization of Polymers and Polymer-Based Composites for Material Extrusion Additive Manufacturing 69 Alberto Sanz de León and Mirko Maturi 3.1 Introduction 69 3.2 Rheology of Polymers and Polymer-Based Composites for Material Extrusion 70 3.3 Mechanical Properties of Polymers and Polymer-Based Composites for Material Extrusion 74 3.4 Thermal and Thermo-Mechanical Properties of Polymers and Polymer-Based Composites for Material Extrusion 79 3.
5 Microstructural Analysis of Polymers and Polymer-Based Composites for Me 84 References 87 4 Large-Format Additive Manufacturing with Polymeric Materials. Molds and Dies "Tooling" 93 Daniel Moreno Nieto, Pedro Burgos Pintos, María de las Nieves Pizarro Ruiz, Sergio I. Molina, and Ahmed Arabi Hassen 4.1 Introduction 93 4.1.1 The Need for Molds and Dies 95 4.2 Large-Format Additive Manufacturing of Molds and Dies 96 4.3 Design and Operation Requirements for Mold and Dies 113 4.
3.1 Vacuum-Assisted Resin Transfer Molding and Lay-Up Tooling 114 4.3.2 Trim Tools and Fixtures 114 4.3.3 Out-of-Autoclave Molds 114 4.3.4 Autoclave Molds 115 4.
3.5 Compression Molding Molds 115 4.3.6 Stamping Dies 115 4.3.7 Concrete Casting Molds 116 4.4 Material Selection Criteria for Molds and Dies 116 4.5 Final Parts Materials 118 4.
6 Large-Format AM Mold PostProcessing and Machining 120 4.6.1 Release Agents and Mold Coating 121 4.6.2 Machining Strategies 121 4.7 Conclusions 123 References 124 5 Direct Part Production Through Polymer Large-Format Additive Manufacturing 129 Eric MacDonald, Lonnie Love, Brian Post, Alex Roschli, Daniel Moreno Sánchez, and Ahmed Arabi Hassen 5.1 Introduction 129 5.2 Main Application Sectors of Polymeric LFAM 130 5.
2.1 Automotive 130 5.2.2 Aerospace 130 5.2.3 Architecture 131 5.2.4 Marine Applications 134 5.
2.5 Energy Applications 137 5.2.6 Interior Design and Furniture 138 5.3 Design Considerations for Polymeric LFAM 141 5.3.1 Layer Configuration and Resolution of Printed Parts 141 5.3.
2 Deposition Nozzle 142 5.3.3 Layer Time Dependence 143 5.3.4 Geometrical Design Considerations 143 5.3.4.1 Minimum Wall Thicknesses and Slim Elements 144 5.
3.4.2 Overhang Areas and Bridges 145 5.3.4.3 Contour Configuration and Filling 147 5.3.5 Topological Optimization 148 5.
4 Conclusion and Future Trends 150 References 150 6 Large-Format Additive Manufacturing with Cement and Clays: Process Review 155 Leonardo Santana and Jorge Lino Alves 6.1 Introduction 155 6.2 Contextualization 155 6.3 LFAM Technologies for Cement- and Clay-Based Materials Processing 158 6.3.1 LFAM Technologies Based on Powder Bed and Material Jetting 159 6.3.2 Extrusion-Based LFAM Technologies 163 6.
3.3 Other LFAM Technologies 169 6.4 Final Consideration 170 References 171 7 Large-format Additive Manufacturing with Cement and Clays: Materials Review 177 Jorge Lino Alves and Leonardo Santana 7.1 Introduction 177 7.2 Contextualization 177 7.3 Cement- and Clay-Based Materials for LFAM: A Review 180 7.3.1 Cement-Based Materials 180 7.
3.2 Clay-Based Materials 187 7.4 Final Consideration 192 References 192 8 Large-Format Additive Manufacturing with Cement and Clays: Characterization Methods 199 Ana Guerrero, Eloy Asensio, and Fernando Fernández 8.1 Introduction 199 8.2 Specific Requirements for 3D Printing Materials 203 8.2.1 Extrudability 203 8.2.
2 Buildability 203 8.2.3 Mechanical Behavior 204 8.3 Tests for Evaluating the Specific Requirements of 3D Printing Materials 204 8.3.1 Flow Table 204 8.3.2 Slump Test 205 8.
3.3 Squeezing Test 206 8.3.4 V-Funnel Test 207 8.3.5 Open Time 208 8.3.6 Rheometer Testing 208 8.
3.7 Density 210 8.3.8 Pastry Bag and Caulking Gun 210 8.3.9 Setting Time 211 8.3.10 Shape Retention Test 214 8.
3.11 Visual Inspection 215 8.3.12 Hardened Mechanical Properties 218 8.4 Conclusions 221 References 221 9 Large Format Additive Manufacturing with Cementitious and Geo Materials. General Considerations, Drivers, and Context 227 Mohammed Alnaggar 9.1 Why Large Format Additive Manufacturing in Construction 227 9.1.
1 LFAM Copes with the Custom Nature of Construction Projects 227 9.1.2 Social Drivers for Construction LFAM 228 9.1.3 Economic Drivers for Construction LFAM 229 9.1.4 Environmental Impacts of Construction LFAM 229 9.2 Components of a Construction LFAM System 229 9.
2.1 Foundation 230 9.2.2 Material 230 9.2.3 Material Delivery System 232 9.2.4 Reinforcement 232 9.
2.5 Motion System 234 9.2.5.1 Gantry Motion Systems 235 9.2.5.2 Robotic Motion Systems 236 9.
2.5.3 Cable-Driven Motion Systems 236 9.2.6 Process Control Software 237 9.3 Construction LFAM Process Steps 237 9.3.1 Structural Design 237 9.
3.2 Acquiring a Construction Permit 239 9.3.3 Site Preparation 239 9.3.4 Construction LFAM Operation 239 9.3.5 Quality Control and Quality Assurance 240 9.
3.6 Equipment Removal, Structure Curing, and Site Restoration 241 9.3.7 Building Finishing Up 241 9.4 Concluding Remark and Future Direction 242 References 242 10 Large Format Additive Manufacturing with Cement and Clay Applications 245 João Teixeira, Manuel Jesus, Elis Ribeiro, Bárbara Rangel, Jorge Lino Alves, and Lino Maia 10.1 Introduction 245 10.2 Applications of LFAM with Cement-Based Materials 246 10.2.
1 Artificial Reefs 246 10.2.2 Urban Furniture 247 10.2.3 Buildings 248 10.2.3.1 In Situ Applications 248 10.
2.3.2 Off-Site Applications 248 10.3 Applications of LFAM with Clay-Based Materials 250 10.3.1 Art and Design 251 10.3.2 Structures 251 10.
4 Exploring the Design Possibilities of LFAM with Cement and Clay for Facade Applications 252 10.5 Opportunities 255 10.6 Challenges 258 10.7 A Showcase of LFAM Capabilities: Panel Concept 259 10.7.1 Project Definition 259 10.7.2 Design for LFAM 259 10.
7.3 3D Print Test and Validation 261 10.8 Conclusions 264 Acknowledgments 264 References 264 11 LFAM with Metallic Materials--Technology Review 269 E. Aldalur, F. Veiga, and A. Suárez 11.1 Introduction 269 11.2 AM Technology Classification 271 11.
3 LFAM with Metallic Material 274 11.4 Ded 275 11.4.1 L-ded 278 11.4.1.1 Laser Powder-Based DED 279 11.4.
1.2 Laser Wire Based-DED 280 11.4.2 Eb-ded 281 11.4.3 Arc-DED 282 11.5 Cold Spray Additive Manufacturing 285 11.6 Friction-Based AM 287 11.
7 Metallic LFAM Solutions 288 References 290 12 Large-Format Additive Manufacturing with Metallic Materials - Materials Review 301 Yukinori Yamamoto, Peeyush Nandwana, Vanshika Singh, Wei Tang, Rangasayee Kannan, and Saket Thapliyal 12.1 Introduction 301 12.2 Deposition Process 301 12.2.1 Solidification 303 12.2.2 As-deposited Microstructure 306 12.2.
3 Postprocess Heat Treatment 309 12.2.3.1 Ferrous Alloys 311 12.2.3.2 Nonferrous Materials 315 12.3 Mechanical Properties 317 12.
3.1 Room-Temperature Mechanical Properties 317 12.3.