As the world edges closer to sustainable manufacturing practices, researchers at the University of Toronto Engineering have made a groundbreaking discovery that’s poised to revolutionize the metal 3D printing industry. Led by Professor Yu Zou, the team has developed an AI-powered framework called Accurate Inverse process optimization framework in laser Directed Energy Deposition (AIDED). This innovative technology optimizes laser 3D printing to produce higher-quality metal parts for industries such as aerospace, automotive, nuclear, and healthcare.

The challenge facing metal additive manufacturing is the high cost of finding optimal process parameters through trial and error. Xiao Shang, PhD candidate and first author of the new study, explains that their framework quickly identifies the optimal process parameters for various applications based on industry needs. “Our AIDED framework operates in a closed-loop system where machine learning models evaluate suggested process parameter combinations for printing quality,” she says.

The researchers conducted extensive experiments to collect datasets covering a wide range of process parameters. This enabled them to develop a genetic algorithm that mimics natural selection to find optimal solutions. The results were astounding, with the AIDED framework accurately predicting geometries from process parameters and identifying optimal settings in as little as one hour.

Professor Zou is now working on an enhanced autonomous additive manufacturing system, where machines can operate with minimal human intervention. This self-driving laser system will sense potential defects in real-time, predict issues before they occur, and automatically adjust processing parameters to ensure high-quality production.

The AIDED framework has the potential to transform process optimization in industries that use metal 3D printing. “Industries such as aerospace, biomedical, automotive, nuclear, and more would welcome such a low-cost yet accurate solution to facilitate their transition from traditional manufacturing to 3D printing,” Shang says.

By the year 2030, additive manufacturing is expected to reshape manufacturing across multiple high-precision industries. The ability to adaptively correct defects and optimize parameters will accelerate its adoption. As Professor Zou notes, “The AIDED framework is a game-changer for manufacturing industries, and we’re excited to see its impact in the years to come.”

The Beckman Institute for Advanced Science and Technology has revolutionized the world of 3D printing with their innovative “growth printing” method. This groundbreaking technique mimics the natural expansion of tree trunks to print polymer parts quickly and efficiently, outperforming existing methods at a snail’s pace.

Researchers Sameh Tawfick and his colleagues have developed a process that uses frontal ring-opening metathesis polymerization (FROMP) to harden resin into its solid form, poly- dicyclopentadiene (p-DCPD). By pouring amber-colored liquid resin into an open glass container submerged in ice water and heating a center point to 70C, the reaction takes over, radiating heat outward at 1 mm/s. This self-sustained process uses minimal energy to create a growing sphere, which can be manipulated by lifting, dipping, or spinning it like blown glass.

The researchers’ goal was to increase manufacturing speed, size, and material quality while maintaining a low cost. Tawfick said, “Polymer 3D printing equipment has matured, but there are still aspects that make it expensive and very slow.” Their growth printing method speeds past existing methods – at a snail’s pace.

This process is not only fast but also inexpensive, making it an attractive option for various industries. The researchers have fabricated everyday items like pinecones, raspberries, and squash using their new method. They’ve even sculpted a kiwi bird by allowing the spherical body to expand below the surface before pulling it up just in time to create a diminutive head and minute beak.

Philippe Geubelle, co-author on the paper, noted that this method’s limitations are similar to those found in nature. Printing curved objects or complex shapes is theoretically possible but difficult to program mathematically. Tawfick said, “It’s hard to find a perfect cube in nature. I don’t know of any plant or organism that looks like a perfect cube. Similarly, our process cannot make a perfect cube.”

The growth printing method has the potential to revolutionize manufacturing and create large polymer-based products like wind turbine blades. The project is funded through the U.S. Department of Energy Office of Science Basic Energy Sciences program. Tawfick hopes that this transformative manufacturing could lead to significant impacts on our economy.

As Yun Seong Kim, the first author, put it, “It was really a work of true teamwork, because it required expertise in various backgrounds and we all came together to make it happen.”