3d printing presentation pdf

3D printing for ultra-precision machining: current status, opportunities, and future perspectives

• Review Article
• Open access
• Published: 16 August 2024
• Volume 19 , article number  23 , ( 2024 )

Cite this article

You have full access to this open access article

• Wai Sze Yip 1 ,
• Edward Hengzhou Yan 1 ,
• Jiuxing Tang 1 ,
• Muhammad Rehan 1 ,
• Long Teng 2 ,
• Chi Ho Wong 3 ,
• Linhe Sun 1 ,
• Baolong Zhang 1 ,
• Feng Guo 1 ,
• Shaohe Zhang 4 &
• Suet To 1  

121 Accesses

1 Altmetric

Explore all metrics

Additive manufacturing, particularly 3D printing, has revolutionized the manufacturing industry by allowing the production of complex and intricate parts at a lower cost and with greater efficiency. However, 3D-printed parts frequently require post-processing or integration with other machining technologies to achieve the desired surface finish, accuracy, and mechanical properties. Ultra-precision machining (UPM) is a potential machining technology that addresses these challenges by enabling high surface quality, accuracy, and repeatability in 3D-printed components. This study provides an overview of the current state of UPM for 3D printing, including the current UPM and 3D printing stages, and the application of UPM to 3D printing. Following the presentation of current stage perspectives, this study presents a detailed discussion of the benefits of combining UPM with 3D printing and the opportunities for leveraging UPM on 3D printing or supporting each other. In particular, future opportunities focus on cutting tools manufactured via 3D printing for UPM, UPM of 3D-printed components for real-world applications, and post-machining of 3D-printed components. Finally, future prospects for integrating the two advanced manufacturing technologies into potential industries are discussed. This study concludes that UPM is a promising technology for 3D-printed components, exhibiting the potential to improve the functionality and performance of 3D-printed products in various applications. It also discusses how UPM and 3D printing can complement each other.

Article PDF

Download to read the full article text

Similar content being viewed by others

3D Printing and CNC Machining: Materials, Technologies, and Process Parameters

3D Printing Technology: Materials, Application and Current Trends in Process Improvement

Investigating the Dimensional Accuracy and Surface Roughness for 3D Printed Parts Using a Multi-jet Printer

Avoid common mistakes on your manuscript.

Abbreviations

Acrylonitrile butadiene styrene

Artificial intelligence

Additive manufacturing

Artificial neural network

Binder jetting

Computer numerical control

Direct energy deposition

Depth of cut

Direct laser metal forming

Direct laser metal sintering

Electron beam melting

Finite element modeling

Fused decomposition modeling

Focused ion beam

Focused ion beam induced deposition

Integrated circuit

Laser-engineered net shaping

Laminated object manufacturing

Micro-electromechanical system

Molecular dynamics

Powder bed fusion

Polydimethylsiloxane

Polylactic acid

Single crystal silicon

Stereolithography

Selective laser melting

Selective laser sintering

Single-point diamond turning

Ultra-precision machining

Ultra-precision grinding

Ultraviolet

Vat photo-polymerization

Markopoulos A P. Preface to “Precision Machining”. MDP-Multidisciplinary Digital Publishing Institute. 2022, 10–12

Google Scholar  

Li M, Yuan J L, Wu Z, Lyu B H, Sun L, Zhao P. Progress in ultra-precision machining methods of complex curved parts. Journal of Mechanical Engineering, 2015, 51(5): 178–191

Article   Google Scholar  

Yuan J L, Lyu B H, Hang W, Deng Q F. Review on the progress of ultra-precision machining technologies. Frontiers of Mechanical Engineering, 2017, 12(2): 158–180

Dornfeld D, Min S, Takeuchi Y. Recent advances in mechanical micromachining. CIRP Annals, 2006, 55(2): 745–768

Brinksmeier E, Preuss W. Micro-machining. Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences, 2012, 370(1973): 3973–3992

Liu X L, Zhang X D, Fang F Z, Zeng Z. Prrformncee-controllable manufacture of optical surfaces by ultra-precision machining. The International Journal of Advanced Manufacturing Technology, 2018, 94(9–12): 4289–4299

Ding X, Lim G C, Cheng C K, Butler D L, Shaw K C, Liu K, Fong W S. Fabrication of a micro-size diamond tool using a focused ion beam. Journal of Micromechanics and Microengineering, 2008, 18(7): 075017

Chen G D, Liang Y C, Sun Y Z, Chen W Q, Wang B. Volumetric error modeling and sensitivity analysis for designing a five-axis ultra-precision machine tool. The International Journal of Advanced Manufacturing Technology, 2013, 68(9–12): 2525–2534

Yip W S, To S. Sustainable ultra-precision machining of titanium alloy using intermittent cutting. International Journal of Precision Engineering and Manufacturing-Green Technology, 2020, 7(2): 361–373

Yip W S, To S, Zhou H T. Social network analysis for optimal machining conditions in ultra-precision manufacturing. Journal of Manufacturing Systems, 2020, 56: 93–103

Yip W S, To S. Identification of stakeholder related barriers in sustainable manufacturing using social network analysis. Sustainable Production and Consumption, 2021, 27: 1903–1917

Precision engineering machines market size, share & trends analysis report by end-use (automotive, non-Automotive), by region (North America, Europe, Asia Pacific, Latin America, Middle East and Africa), and segment forecasts, 2023–2030. Available at the website of Grand View Research

G G, Malayath G, Mote R G. A review of cutting tools for ultra-precision machining. Machining Science and Technology, 2022, 26(6): 923–976

Lucca D A, Klopfstein M J, Riemer O. Ultra-precision machining: cutting with diamond tools. Journal of Manufacturing Science and Engineering, 2020, 142(11): 110817

Jung H J, Hayasaka T, Shamoto E. Study on process monitoring of elliptical vibration cutting by utilizing internal data in ultrasonic elliptical vibration device. International Journal of Precision Engineering and Manufacturing-Green Technology, 2018, 5(5): 571–581

Zhang S J, To S, Zhang G Q. Diamond tool wear in ultra-precision machining. The International Journal of Advanced Manufacturing Technology, 2017, 88(1–4): 613–641

Osman Zahid M N, Case K, Watts D. End mill tools integration in CNC machining for rapid manufacturing processes: simulation studies. Production & Manufacturing Research, 2015, 3(1): 274–288

Zhang S J, To S, Wang S J, Zhu Z W. A review of surface roughness generation in ultra-precision machining. International Journal of Machine Tools & Manufacture, 2015, 91: 76–95

Simoneau A, Ng E, Elbestawi M A. Surface defects during microcutting. International Journal of Machine Tools & Manufacture, 2006, 46(12–13): 1378–1387

Wang S J, To S, Cheung C F. An investigation into material-induced surface roughness in ultra-precision milling. The International Journal of Advanced Manufacturing Technology, 2013, 68(1–4): 607–616

Zhang S J, To S, Zhang G Q, Zhu Z W. A review of machine-tool vibration and its influence upon surface generation in ultra-precision machining. International Journal of Machine Tools & Manufacture, 2015, 91: 34–42

Marie N. Optical components: market shares, strategies, and forecasts, worldwide, 2013 to 2019. Global License Report. 2013

Childs T H C, Dornfeld D, Lee D E, Min S, Sekiya K, Tezuka R, Yamane Y. The influence of cutting edge sharpness on surface finish in facing with round nosed cutting tools. CIRP Journal of Manufacturing Science and Technology, 2008, 1(2): 70–75

Liu K, Melkote S N. Finite element analysis of the influence of tool edge radius on size effect in orthogonal micro-cutting process. International Journal of Mechanical Sciences, 2007, 49(5): 650–660

Ngo T D, Kashani A, Imbalzano G, Nguyen K T Q, Hui D. Additive manufacturing (3D printing): a review of materials, methods, applications and challenges. Composites Part B: Engineering, 2018, 143: 172–196

Zhang S J, To S. A theoretical and experimental study of surface generation under spindle vibration in ultra-precision raster milling. International Journal of Machine Tools and Manufacture, 2013, 75: 36–45

Wang H, To S, Chan C Y, Cheung C F, Lee W B. A theoretical and experimental investigation of the tool-tip vibration and its influence upon surface generation in single-point diamond turning. International Journal of Machine Tools & Manufacture, 2010, 50(3): 241–252

Cheng M N, Cheung C F, Lee W B, To S, Kong L B. Theoretical and experimental analysis of nano-surface generation in ultra-precision raster milling. International Journal of Machine Tools & Manufacture, 2008, 48(10): 1090–1102

Kong L B, Cheung C F, To S, Lee W B. An investigation into surface generation in ultra-precision raster milling. Journal of Materials Processing Technology, 2009, 209(8): 4178–4185

He C L, Zong W J, Zhang J J. Influencing factors and theoretical modeling methods of surface roughness in turning process: state-of-the-art. International Journal of Machine Tools & Manufacture, 2018, 129: 15–26

Zhao L, Zhang J J, Zhang J G, Dai H F, Hartmaier A, Sun T. Numerical simulation of materials-oriented ultra-precision diamond cutting: review and outlook. International Journal of Extreme Manufacturing, 2023, 5(2): 022001

Zhao C Y, Cheung C F, Liu M Y. Modeling and simulation of a machining process chain for the precision manufacture of polar microstructure. Micromachines, 2017, 8(12): 345

Shi C K, Luo H H, Xu Z W, Fang F Z. Nitrogen-vacancy color centers in diamond fabricated by ultrafast laser nanomachining. In: Zhang J, Guo B, and Zhang J, eds. Simulation and Experiments of Material-Oriented Ultra-Precision Machining. Singapore: Springer, 2019, 277–305

Chapter   Google Scholar  

Dai H F, Hu Y, Wu W L, Yue H X, Meng X S, Li P, Duan H G. Molecular dynamics simulation of ultra-precision machining 3C-SiC assisted by ion implantation. Journal of Manufacturing Processes, 2021, 69: 398–411

Guo X G, Li Q, Liu T, Kang R K, Jin Z J, Guo D M. Advances in molecular dynamics simulation of ultra-precision machining of hard and brittle materials. Frontiers of Mechanical Engineering, 2017, 12(1): 89–98

Guo B, Wu M T, Zhao Q L. The FEM simulation of ultra-precision grinding of optical glass with micro-structured coarsegrained diamond wheels. In: Proceedings of Optical Design and Fabrication 2017. Optica Publishing Group, 2017, 1–2

Khalil A. K, Yip W S, To S. Theoretical and experimental investigations of magnetic field assisted ultra-precision machining of titanium alloys. Journal of Materials Processing Technology, 2022, 300: 117429

Shao Y Z, Adetoro O B, Cheng K. Development of multiscale multiphysics-based modelling and simulations with the application to precision machining of aerofoil structures. Engineering Computations, 2021, 38(3): 1330–1349

Hu K, Lo S L, Wu H, To S. Study on influence of ultrasonic vibration on the ultra-precision turning of Ti6Al4V alloy based on simulation and experiment. IEEE Access: Practical Innovations, Open Solutions, 2019, 7: 33640–33651

Huang W W, Tang J Y, Zhou W H, Wen J, Yi M H. Molecular dynamics simulations of ultrasonic vibration-assisted grinding of polycrystalline iron: nanoscale plastic deformation mechanism and microstructural evolution. Applied Surface Science, 2023, 640: 158440

Basheer A C, Dabade U A, Joshi S S, Bhanuprasad V V, Gadre V M. Modeling of surface roughness in precision machining of metal matrix composites using ANN. Journal of Materials Processing Technology, 2008, 197(1–3): 439–444

Chapman G. Ultra- precision machining systems: an enabling technology for perfect surfaces. In: Moore Nanotechnology Systems. Nanotech, 2001, 1–9

Meng S T, Yin Z Q, Guo Y W, Yao J H, Chai N. Ultra-precision machining of polygonal Fresnel lens on roller mold. The International Journal of Advanced Manufacturing Technology, 2020, 108(7–8): 2445–2452

Elton J. A light to lighten our darkness: lighthouse optics and the later development of Fresnel’s revolutionary refracting lens 1780–1900. The International Journal for the History of Engineering & Technology, 2009, 79(2): 183–244

Khamooshi M, Salati H, Egelioglu F, Hooshyar Faghiri A, Tarabishi J, Babadi S. A review of solar photovoltaic concentrators. International Journal of Photoenergy, 2014, 2014(1): 958521

Li J Y, Zhu J B, Zhu X, Zhang D M, Li X G, Liu J H, Xu C Y. XU C. Processing behavior and surface quality control of the engine fuel nozzle precision machining by AFM containing magnetic particles. The International Journal of Advanced Manufacturing Technology, 2021, 113(5–6): 1577–1590

Shahrubudin N, Lee T C, Ramlan R. An overview on 3D printing technology: technological, materials, and applications. Procedia Manufacturing, 2019, 35: 1286–1296

Liu G, Zhang X, Chen X, He Y, Cheng L, Huo M, Yin J, Hao F, Chen S, Wang P, Yi S, Wan L, Mao Z, Chen Z, Wang X, Cao Z, Lu J. Additive manufacturing of structural materials. Materials Science and Engineering: R Reports, 2021, 145: 100596

Jandyal A, Chaturvedi I, Wazir I, Raina A, Irfan Ul Haq M. 3D printing—a review of processes, materials and applications in Industry 4.0. Sustainable Operations and Computers, 2022, 3: 33–42

Bikas H, Stavropoulos P, Chryssolouris G. Additive manufacturing methods and modelling approaches: a critical review. The International Journal of Advanced Manufacturing Technology, 2016, 83(1–4): 389–405

Sing S L, Tey C F, Tan J H K, Huang S, Yeong W Y. 3D printing of metals in rapid prototyping of biomaterials: techniques in additive manufacturing. In: Narayan R, ed. Rapid Prototyping of Biomaterials. 2nd ed. Sawston: Woodhead Publishing. 2020, 17–40

Lee J Y, An J, Chua C K. Fundamentals and applications of 3D printing for novel materials. Applied Materials Today, 2017, 7: 120–133

King W E, Anderson A T, Ferencz R M, Hodge N E, Kamath C, Khairallah S A, Rubenchik A M. Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges. Applied Physics Reviews, 2015, 2(4): 041304

Li J, Monaghan T, Nguyen T T, Kay R W, Friel R J, Harris R A. Multifunctional metal matrix composites with embedded printed electrical materials fabricated by ultrasonic additive manufacturing. Composites Part B: Engineering, 2017, 113: 342–354

Bagaria V, Bhansali R, Pawar P. 3D printing—creating a blueprint for the future of orthopedics: current concept review and the road ahead! Journal of Clinical Orthopaedics and Trauma, 2018, 9(3): 207–212

Rouf S, Malik A, Singh N, Raina A, Naveed N, Siddiqui M I H, Haq M I U. Additive manufacturing technologies: industrial and medical applications. Sustainable Operations and Computers, 2022, 3: 258–274

Mohanraj T, Jegadeeshwaran R. Introduction to Industry 4.0. In: Jena H, Katiyar J K, Patnaik A, eds. Tribology of Polymer and Polymer Composites for Industry 4.0. Singapore: Springer, 2021, 113–127

Kwon S B, Nagaraj A, Xi D L, Du Y Y, Kim D N, Kim W K, Min S. Studying crack generation mechanism in single-crystal sapphire during ultra-precision machining by MD simulation-based slip/fracture activation model. International Journal of Precision Engineering and Manufacturing, 2023, 24(5): 715–727

Paszkiewicz A, Bolanowski M, Budzik G, Przeszlowski Ł, Oleksy M. Process of creating an integrated design and manufacturing environment as part of the structure of industry 4.0. Processes, 2020, 8(9): 1019

Hao B T, Lin G M. 3D printing technology and its application in industrial manufacturing. IOP Conference Series: Materials Science and Engineering, 2020, 782(2): 022065

Eyers D R, Potter A T. Industrial additive manufacturing: a manufacturing systems perspective. Computers in Industry, 2017, 92–93: 208–218

Petrovic V, Vicente Haro Gonzalez J, Jordá Ferrando O, Delgado Gordillo J, Ramón Blasco Puchades J, Portolés Griñan L. Additive layered manufacturing: sectors of industrial application shown through case studies. International Journal of Production Research, 2011, 49(4): 1061–1079

Praveena B A, Lokesh N, Buradi A, Santhosh N, Praveena B L, Vignesh R. A comprehensive review of emerging additive manufacturing (3D printing technology): methods, materials, applications, challenges, trends and future potential. Materials Today: Proceedings, 2022, 52(3): 1309–1313

Irfan Ul Haq M, Khuroo S, Raina A, Khajuria S, Javaid M, Farhan Ul Haq M, Haleem A. 3D printing for development of medical equipment amidst coronavirus (COVID-19) pandemic—review and advancements. Research on Biomedical Engineering, 2022, 38(1): 305–315

Ahn S H, Yoon H S, Jang K H, Kim E S, Lee H T, Lee G Y, Kim C S, Cha S W. Nanoscale 3D printing process using aerodynamically focused nanoparticle (AFN) printing, micro-machining, and focused ion beam (FIB). CIRP Annals, 2015, 64(1): 523–526

Yamazaki T. Development of a hybrid multi-tasking machine tool: integration of additive manufacturing technology with CNC machining. Procedia CIRP, 2016, 42: 81–86

Raina A, Haq M I U, Javaid M, Rab S, Haleem A. 4D printing for automotive industry applications. Journal of the Institution of Engineers: Series D, 2021, 102(2): 521–529

Anonymous. Cyclists take industrial 3D printing for a spin. Metal Powder Report, 2013, 68 (3): 26–29

Bozkurt Y, Karayel E. 3D printing technology; methods, biomedical applications, future opportunities and trends. Journal of Materials Research and Technology, 2021, 14: 1430–1450

Zolfaghari A, Chen T T, Yi A Y. Additive manufacturing of precision optics at micro and nanoscale. International Journal of Extreme Manufacturing, 2019, 1(1): 012005

Muldoon K, Song Y H, Ahmad Z, Chen X, Chang M W. High precision 3D printing for micro to nano scale biomedical and electronic devices. Micromachines, 2022, 13(4): 642

Dai J T, Li P, Spintzyk S, Liu C F, Xu S L. Influence of additive manufacturing method and build angle on the accuracy of 3D-printed palatal plates. Journal of Dentistry, 2023, 132: 104449

Behera D, Cullinan M. Current challenges and potential directions towards precision microscale additive manufacturing – part I: direct ink writing/jetting processes. Precision Engineering, 2021, 68: 326–337

Johnson L K, Richburg C, Lew M, Ledoux W R, Aubin P M, Rombokas E. 3D printed lattice microstructures to mimic soft biological materials. Bioinspiration & Biomimetics, 2018, 14(1): 016001

Kim J, Cao Y S, Eddy C, Deng Y Y, Levine H, Rappel W J, Sun B. The mechanics and dynamics of cancer cells sensing noisy 3D contact guidance. Proceedings of the National Academy of Sciences of the United States of America, 2021, 118(10): e2024780118

Liu X F, George M N, Park S, Miller A L II, Gaihre B, Li L L, Waletzki B E, Terzic A, Yaszemski M J, Lu L C. 3D-printed scaffolds with carbon nanotubes for bone tissue engineering: fast and homogeneous one-step functionalization. Acta Biomaterialia, 2020, 111: 129–140

Chizari S, Shaw L A, Behera D, Roy N K, Zheng X M, Panas R M, Hopkins J B, Chen S C, Cullinan M A. Current challenges and potential directions towards precision microscale additive manufacturing – part III: energy induced deposition and hybrid electrochemical processes. Precision Engineering, 2021, 68 174–186

Jiang S, Guo D L, Zhang L, Li K, Song B, Huang Y A. Electropolishing-enhanced, high-precision 3D printing of metallic pentamode metamaterials. Materials & Design, 2022, 223: 111211

Müller M, Wings E. An architecture for hybrid manufacturing combining 3D printing and CNC machining. International Journal of Manufacturing Engineering, 2016, 2016(1): 8609108

Kapil S, Legesse F, Negi S, Karunakaran K P, Bag S. Hybrid layered manufacturing of a bimetallic injection mold of P20 tool steel and mild steel with conformal cooling channels. Progress in Additive Manufacturing, 2020, 5(2): 183–198

Behera D, Chizari S, Shaw L A, Porter M, Hensleigh R, Xu Z P, Zheng X M, Connolly L G, Roy N K, Panas R M, Saha S K, Zheng X Y, Hopkins J B, Chen S C, Cullinan M A. Current challenges and potential directions towards precision microscale additive manufacturing – part IV: future perspectives. Precision Engineering, 2021, 68: 197–205

Berger U. Aspects of accuracy and precision in the additive manufacturing of plastic gears. Virtual and Physical Prototyping, 2015, 10(2): 49–57

Behera D, Chizari S, Shaw L A, Porter M, Hensleigh R, Xu Z P, Zheng X M, Connolly L G, Roy N K, Panas R M, Saha S K, Zheng X Y, Hopkins J B, Chen S C, Cullinan M A. Current challenges and potential directions towards precision microscale additive manufacturing – part II: laser-based curing, heating, and trapping processes. Precision Engineering, 2021, 68: 301–318

Singh S, Ramakrishna S, Singh R. Material issues in additive manufacturing: a review. Journal of Manufacturing Processes, 2017, 25: 185–200

Valino A D, Dizon J R C, Espera A H, Chen Q Y, Messman J, Advincula R C. Advances in 3D printing of thermoplastic polymer composites and nanocomposites. Progress in Polymer Science, 2019, 98: 101162

Wu J J, Zhang S H, Qu F L, Zhou H, Tang J. Matrix material for a new 3D-printed diamond-impregnated bit with grid-shaped matrix. International Journal of Refractory Metals & Hard Metals, 2019, 82: 199–207

Grzesik W. Hybrid manufacturing of metallic parts integrated additive and subtractive processes. Mechanik, 2018, 91(7): 468–475

Mochizuki T, Kawamura T. 3D printer of five-axis laminate-shaping with FDM method and its application. In: Proceedings of the 18th International Conference on Geometry and Graphics. Cham: Springer, 2019, 903–911

Ghibaudo C, Maculotti G, Gobber F, Saboori A, Galetto M, Biamino S, Ugues D. Information-rich quality controls prediction model based on non-destructive analysis for porosity determination of AISI H13 produced by electron beam melting. The International Journal of Advanced Manufacturing Technology, 2023, 126(3–4): 1159–1173

Rajaguru K, Karthikeyan T, Vijayan V. Additive manufacturing – state of art. Materials Today: Proceedings, 2020, 21: 628–633

Adel M, Abdelaal O, Gad A, Nasr A B, Khalil A M. Polishing of fused deposition modeling products by hot air jet: evaluation of surface roughness. Journal of Materials Processing Technology, 2018, 251: 73–82

Thrasher C J, Schwartz J J, Boydston A J. Modular elastomer photoresins for digital light processing additive manufacturing. ACS Applied Materials & Interfaces, 2017, 9(45): 39708–39716

Cong W L, Ning F D. A fundamental investigation on ultrasonic vibration-assisted laser engineered net shaping of stainless steel. International Journal of Machine Tools & Manufacture, 2017, 121: 61–69

Senthilkumaran K, Pandey P M, Rao P V M. Influence of building strategies on the accuracy of parts in selective laser sintering. Materials & Design, 2009, 30(8): 2946–2954

Bhushan B, Caspers M. An overview of additive manufacturing (3D printing) for microfabrication. Microsystem Technologies, 2017, 23(4): 1117–1124

Karunakaran R, Ortgies S, Tamayol A, Bobaru F, Sealy M P. Additive manufacturing of magnesium alloys. Bioactive Materials, 2020, 5(1): 44–54

Gan J, Gao H, Wen S F, Zhou Y, Tan S C, Duan L C. Simulation, forming process and mechanical property of Cu–Sn–Ti/diamond composites fabricated by selective laser melting. International Journal of Refractory Metals and Hard Materials, 2020, 87: 105144

Wu J J, Zhang S H, Liu L L, Qu F L, Zhou H, Su Z. Rock breaking characteristics of a 3D printing grid-matrix impregnated diamond bit. International Journal of Refractory Metals and Hard Materials, 2020, 89: 105212

Durão L F C S, Barkoczy R, Zancul E, Lee Ho L, Bonnard R. Optimizing additive manufacturing parameters for the fused deposition modeling technology using a design of experiments. Progress in Additive Manufacturing, 2019, 4(3): 291–313

Bakar N S A, Alkahari M R, Boejang H. Analysis on fused deposition modelling performance. Journal of Zhejiang University-Science A, 2010, 11(12): 972–977

Hwang S, Reyes E I, Moon K S, Rumpf R C, Kim N S. Thermomechanical characterization of metal/polymer composite filaments and printing parameter study for fused deposition modeling in the 3D printing process. Journal of Electronic Materials, 2015, 44(3): 771–777

Gong H J, Snelling D, Kardel K, Carrano A. Comparison of stainless steel 316L parts made by FDM- and SLM-based additive manufacturing processes. The Journal of the Minerals, Metals & Materials Society, 2019, 71(3): 880–885

Wu H D, Liu W, Xu Y R, Lin L F, Li Y H, Wu S H. Vat photopolymerization-based 3D printing of complex-shaped and high-performance Al2O3 ceramic tool with chip-breaking grooves: cutting performance and wear mechanism. Journal of Asian Ceramic Societies, 2023, 11(1): 159–169

Zhou M P, Liu W, Wu H D, Song X, Chen Y, Cheng L X, He F P, Chen S X, Wu S H. Preparation of a defect-free alumina cutting tool via additive manufacturing based on stereolithography – optimization of the drying and debinding processes. Ceramics International, 2016, 42(10): 11598–11602

Yang Y, Chen Y H, Wei Y, Li Y T. 3D printing of shape memory polymer for functional part fabrication. The International Journal of Advanced Manufacturing Technology, 2016, 84(9–12): 2079–2095

Deja M, Zieliński D, Kadir A Z A, Humaira S N. Applications of additively manufactured tools in abrasive machining—a literature review. Materials, 2021, 14(5): 1318

Maekawa K, Yokoyama Y, Ohshima I. Fabrication of metal-bonded grinding/polishing tools by greentape laser sintering method. Key Engineering Materials, 2001, 196: 133–140

Denkena B, Krödel A, Harmes J, Kempf F, Griemsmann T, Hoff C, Hermsdorf J, Kaierle S. Additive manufacturing of metal-bonded grinding tools. The International Journal of Advanced Manufacturing Technology, 2020, 107(5–6): 2387–2395

Ai Q F, Khosravi J, Azarhoushang B, Daneshi A, Becker B. Digital light processing-based additive manufacturing of resin bonded SiC grinding wheels and their grinding performance. The International Journal of Advanced Manufacturing Technology, 2022, 118(5–6): 1641–1657

Chen B, Chen P, Huang Y J, Xu X X, Liu Y B, Wang S X. Blade segment with a 3D lattice of diamond grits fabricated via an additive manufacturing process. Chinese Journal of Mechanical Engineering, 2020, 33(1): 73

Traxel K D, Bandyopadhyay A. Diamond-reinforced cutting tools using laser-based additive manufacturing. Additive Manufacturing, 2021, 37: 101602

Skrzyniarz M, Nowakowski L, Blasiak S. Geometry, structure and surface quality of a maraging steel milling cutter printed by direct metal laser melting. Materials, 2022, 15(3): 773

He T, Zhang S H, Kong X W, Wu J J, Liu L L, Wu D Y, Su Z. Influence of diamond parameters on microstructure and properties of copper-based diamond composites manufactured by fused deposition modeling and sintering (FDMS). Journal of Alloys and Compounds, 2023, 931: 167492

Su Z, Zhang S H, Liu L L, Wu J J. Microstructure and performance characterization of co-based diamond composites fabricated via fused deposition molding and sintering. Journal of Alloys and Compounds, 2021, 871: 159569

Kong X W, Su Z, He T, Wu J J, Wu D Y, Zhang S H. Development and properties evaluation of diamond-containing metal composites for fused filament fabrication of diamond tool. Diamond and Related Materials, 2022, 130: 109423

Sandhu K, Singh G, Singh S, Kumar R, Prakash C, Ramakrishna S, Królczyk G, Pruncu C I. Surface characteristics of machined polystyrene with 3D printed thermoplastic tool. Materials, 2020, 13(12): 2729

He T, Zhang S H, Yip W S, To S, Wu J J, Liu L L, Wu D Y, Kong X W, Rong L L. Investigation on the machining performance of copper-based diamond ultra-thin dicing blades manufactured by fused deposition modeling and sintering (FDMS). Tribology International, 2023, 187: 108702

Zhang L, Yi A Y, Yan J W. Flexible fabrication of Fresnel microlens array by off-spindle-axis diamond turning and precision glass molding. Precision Engineering, 2022, 74: 186–194

Georgiadis K. The failure mechanisms of coated precision glass molding tools. Dissertation for the Doctoral Degree. Aachen: RWTH Aachen University, 2015

Zhang Y Y, Liang R G, Spires O J, Yin S H, Yi A, Milster T D. Precision glass molding of diffractive optical elements with high surface quality. Optics Letters, 2020, 45(23): 6438–6441

Xu Z Q, Wang J, Yin S H, Wu H, Yi L Y. Compound machining of tungsten alloy aspheric mould by oblique-axis grinding and magnetorheological polishing. International Journal of Precision Engineering and Manufacturing, 2021, 22(9): 1487–1496

Altaf K, Qayyum J A, Rani A M A, Ahmad F, Megat-Yusoff P S M, Baharom M, Aziz A R A, Jahanzaib M, German R M. Performance analysis of enhanced 3D printed polymer molds for metal injection molding process. Metals, 2018, 8(6): 433

Boros R, Kannan Rajamani P, Kovács J G. Combination of 3D printing and injection molding: overmolding and overprinting. eExpress Polymer Letters, 2019, 13(10): 889–897

Gohn A M, Brown D, Mendis G, Forster S, Rudd N, Giles M. Mold inserts for injection molding prototype applications fabricated via material extrusion additive manufacturing. Additive Manufacturing, 2022, 51: 102595

Yang X X, Wu T, Liu D S, Wu J Y, Wang Y X, Lu Y Z, Ji Z Y, Jia X, Jiang P, Wang X L. 3D printing of release-agent retaining molds. Additive Manufacturing, 2023, 71: 103580

Assefa B G, Pekkarinen M, Partanen H, Biskop J, Turunen J, Saarinen J. Imaging- quality 3D-printed centimeter-scale lens. Optics Express, 2019, 27(9): 12630–12637

Luo N N, Zhang Z M. Fabrication of a curved microlens array using double gray-scale digital maskless lithography. Journal of Micromechanics and Microengineering, 2017, 27(3): 035015

Asadollahbaik A, Thiele S, Weber K, Kumar A, Drozella J, Sterl F, Herkommer A M, Giessen H, Fick J. Highly efficient dualfiber optical trapping with 3D printed diffractive fresnel lenses. ACS Photonics, 2020, 7(1): 88–97

Seniutinas G, Weber A, Padeste C, Sakellari I, Farsari M, David C. Beyond 100 nm resolution in 3D laser lithography—post processing solutions. Microelectronic Engineering, 2018, 191: 25–31

Sung Y L, Jeang J, Lee C H, Shih W C. Fabricating optical lenses by inkjet printing and heat-assisted in situ curing of polydimethylsiloxane for smartphone microscopy. Journal of Biomedical Optics, 2015, 20(4): 047005

Zhu Y Z, Tang T T, Zhao S Y, Joralmon D, Poit Z, Ahire B, Keshav S, Raje A R, Blair J, Zhang Z L, Li X J. Recent advancements and applications in 3D printing of functional optics. Additive Manufacturing, 2022, 52: 102682

Yuan C, Kowsari K, Panjwani S, Chen Z C, Wang D, Zhang B, Ng C J X, Alvarado P V Y, Ge Q. Ultrafast three-dimensional printing of optically smooth microlens arrays by oscillation-assisted digital light processing. ACS Applied Materials & Interfaces, 2019, 11(43): 40662–40668

Guo P, Wei Z P, Zhang S J, Xiong Z W, Liu M Y. Feature-adaptive toolpath planning with enhanced surface texture uniformity for ultra-precision diamond milling of freeform optics. Journal of Materials Processing Technology, 2024, 323: 118220

Lim J, Kim Y K, Won D J, Choi I H, Lee S, Kim J. 3D printing of freestanding overhanging structures utilizing an in situ light guide. Advanced Materials Technologies, 2019, 4(8): 1900118

Wang S, Zhao Q L, Pan Y C, Guo B. Ultra- precision raster grinding biconical optics with a novel profile error compensation technique based on on-machine measurement and wavelet decomposition. Journal of Manufacturing Processes, 2021, 67: 128–140

Liu C X, Oriekhov T, Lee C, Harvey C M, Fokine M. Rapid fabrication of silica microlens arrays via glass 3D printing. 3D Printing and Additive Manufacturing, 2024, 11(2): 460–466

Lin C B, Huang P J, Chen G C. Integrating a fused deposition modeling 3D printing design with computer numerical control milling machines. The International Journal of Advanced Manufacturing Technology, 2023, 125(7–8): 3869–3880

Durna A, Fries J, Hrabovsky L, Sliva A, Zarnovsky J. Research and development of laser engraving and material cutting machine from 3D printer. Management Systems in Production Engineering, 2020, 28(1): 47–52

Kostakis V, Papachristou M. Commons- based peer production and digital fabrication: the case of a RepRap-based, Lego-built 3D printing-milling machine. Telematics and Informatics, 2014, 31(3): 434–443

Feng K P, Zhao T C, Lyu B H, Zhou Z Z. Ultra-precision grinding of 4H-SiC wafer by PAV/PF composite sol-gel diamond wheel. Advances in Mechanical Engineering, 2021, 13(9): 16878140211044929

Yan J W, Syoji K, Tamaki J. Some observations on the wear of diamond tools in ultra-precision cutting of single-crystal silicon. Wear, 2003, 255(7–12): 1380–1387

Zhang Y X, Wang D, Gao W, Kang R K. Residual stress analysis on silicon wafer surface layers induced by ultra-precision grinding. Rare Metals, 2011, 30(3): 278–281

Tao H F, Liu Y H, Zhao D W, Lu X C. The material removal and surface generation mechanism in ultra-precision grinding of silicon wafers. International Journal of Mechanical Sciences, 2022, 222: 107240

Li C, Li X L, Huang S Q, Li L Q, Zhang F H. Ultra-precision grinding of Gd 3 Ga 5 O 12 crystals with graphene oxide coolant: material deformation mechanism and performance evaluation. Journal of Manufacturing Processes, 2021, 61: 417–427

Huo F W, Kang R K, Li Z, Guo D M. Origin, modeling and suppression of grinding marks in ultra precision grinding of silicon wafers. International Journal of Machine Tools & Manufacture, 2013, 66: 54–65

Young H T, Liao H T, Huang H Y. Surface integrity of silicon wafers in ultra precision machining. The International Journal of Advanced Manufacturing Technology, 2006, 29(3–4): 372–378

Ayomoh M, Abou-El-Hossein K. Surface finish in ultra-precision diamond turning of single-crystal silicon. In: Bentley J L, Stoebenau S, eds. Optifab 2015. Rochester: SPIE, 2015, 96331I

Wu W L, Hu Y, Meng X S, Liao B K, Dai H F. Molecular dynamics analysis of the influence of ion implantation parameters on ultra-precision machining of silicon carbide. Journal of Manufacturing Processes, 2022, 82: 174–191

Wang M H, Wang W, Lu Z S. Critical cutting thickness in ultra-precision machining of single crystal silicon. The International Journal of Advanced Manufacturing Technology, 2013, 65(5–8): 843–851

Park Y G, Yun I, Chung W G, Park W, Lee D H, Park J U. High-resolution 3D printing for electronics. Advanced Science, 2022, 9(8): 2270046

Zong W, Ouyang Y, Miao Y E, Liu T X, Lai F L. Recent advances and perspectives of 3D printed micro-supercapacitors: from design to smart integrated devices. Chemical Communications, 2022, 58(13): 2075–2095

Zhang W, Liu H Z, Zhang X, Li X J, Zhang G H, Cao P. 3D printed micro-electrochemical energy storage devices: from design to integration. Advanced Functional Materials, 2021, 31(40): 2104909

Park Y G, Yun I, Chung W G, Park W, Lee D H, Park J U. High-resolution 3D printing for electronics. Advanced Science, 2022, 9(8): 2104623

Waldbaur A, Rapp H, Länge K, Rapp B E. Let there be chip - towards rapid prototyping of microfluidic devices: one-step manufacturing processes. Analytical Methods, 2011, 3(12): 2681–2716

Gross B C, Erkal J L, Lockwood S Y, Chen C P, Spence D M. Evaluation of 3D printing and its potential impact on biotechnology and the chemical sciences. Analytical Chemistry, 2014, 86(7): 3240–3253

Alapan Y, Hasan M N, Shen R C, Gurkan U A. Three-dimensional printing based hybrid manufacturing of microfluidic devices. Journal of Nanotechnology in Engineering and Medicine, 2015, 6(2): 021007

Sochol R D, Sweet E, Glick C C, Wu S Y, Yang C, Restaino M, Lin L W. 3D printed microfluidics and microelectronics. Microelectronic Engineering, 2018, 189: 52–68

Khanna N, Zadafiya K, Patel T, Kaynak Y, Rahman Rashid R A, Vafadar A. Review on machining of additively manufactured nickel and titanium alloys. Journal of Materials Research and Technology, 2021, 15: 3192–3221

Pragana J P M, Sampaio R F V, Bragança I M F, Silva C M A, Martins P A F. Hybrid metal additive manufacturing: a state-of-the-art review. Advances in Industrial and Manufacturing Engineering, 2021, 2: 100032

Grossi N, Scippa A, Venturini G, Campatelli G. Process parameters optimization of thin-wall machining for wire arc additive manufactured parts. Applied Sciences, 2020, 10(21): 7575

Ming W W, Dang J Q, An Q L, Chen M. Chip formation and hole quality in dry drilling additive manufactured Ti6Al4V. Materials and Manufacturing Processes, 2020, 35(1): 43–51

Dang J Q, Zhang H, Ming W W, An Q L, Chen M. New observations on wear characteristics of solid Al 2 O 3 /Si 3 N 4 ceramic tool in high speed milling of additive manufactured Ti6Al4V. Ceramics International, 2020, 46(5): 5876–5886

Rein C, Toner M, Sevenler D. Rapid prototyping for high-pressure microfluidics. Scientific Reports, 2023, 13(1): 1232

Unger M A, Chou H P, Thorsen T, Scherer A, Quake S R. Monolithic microfabricated valves and pumps by multilayer soft lithography. Science, 2000, 288(5463): 113–116

Shikida M, Sato K, Tokoro K, Uchikawa D. Differences in anisotropic etching properties of KOH and TMAH solutions. Sensors and Actuators A: Physical, 2000, 80(2): 179–188

Golonka L. Technology and applications of low temperature co-fired ceramic (LTCC) based sensors and microsystems. Bulletin of the Polish Academy of Sciences: Technical Sciences, 2006, 54: 221–231

Walczak R. Inkjet 3D printing—towards new micromachining tool for MEMS fabrication. Bulletin of the Polish Academy of Sciences: Technical Sciences, 2018, 66(2): 179–186

Mehta V, Rath S N. 3D printed microfluidic devices: a review focused on four fundamental manufacturing approaches and implications on the field of healthcare. Bio-Design and Manufacturing, 2021, 4(2): 311–343

Phung S C, Zhu Q F, Plevniak K, He M. 3D printed microfluidic devices and applications. In: Li X J, Zhou Y, eds. Microfluidic Devices for Biomedical Applications. 2nd ed. Sawston: Woodhead Publishing, 2021, 659–679

Razavi Bazaz S, Rouhi O, Raoufi M A, Ejeian F, Asadnia M, Jin D Y, Ebrahimi Warkiani M. 3D printing of inertial microfluidic devices. Scientific Reports, 2020, 10(1): 5929

Comina G, Suska A, Filippini D. PDMS lab-on-a-chip fabrication using 3D printed templates. Lab on a Chip, 2014, 14(2): 424–430

Su R T, Wang F J, McAlpine M C. 3D printed microfluidics: advances in strategies, integration, and applications. Lab on a Chip, 2023, 23(5): 1279–1299

Au A K, Lee W, Folch A. Mail-order microfluidics: evaluation of stereolithography for the production of microfluidic devices. Lab on a Chip, 2014, 14(7): 1294–1301

Behroodi E, Latifi H, Bagheri Z, Ermis E, Roshani S, Salehi Moghaddam M. A combined 3D printing/CNC micro-milling method to fabricate a large-scale microfluidic device with the small size 3D architectures: an application for tumor spheroid production. Scientific Reports, 2020, 10(1): 22171

Oyelola O, Crawforth P, M’Saoubi R, Clare A T. On the machinability of directed energy deposited Ti6Al4V. Additive Manufacturing, 2018, 19: 39–50

Sun Z G, Tian Y B, Fan Z H, Qian C, Ma Z, Li L, Yu H L, Guo J. Experimental investigations on enhanced alternating-magnetic field-assisted finishing of stereolithographic 3D printing zirconia ceramics. Ceramics International, 2022, 48(24): 36609–36619

Ni C B, Zhu L D, Zheng Z P, Zhang J Y, Yang Y, Yang J, Bai Y C, Weng C, Lu W F, Wang H. Effect of material anisotropy on ultra-precision machining of Ti-6Al-4V alloy fabricated by selective laser melting. Journal of Alloys and Compounds, 2020, 848: 156457

Varghese V, Mujumdar S. Micromilling-induced surface integrity of porous additive manufactured Ti6Al4V alloy. Procedia Manufacturing, 2021, 53: 387–394

Aldesoki M, Keilig L, Dörsam I, Evers-Dietze B, Elshazly T M, Bourauel C. Trueness and precision of milled and 3D printed root-analogue implants: a comparative in vitro study. Journal of Dentistry, 2023, 130: 104425

Wu Y Y, Qian S Q, Zhang H, Zhang Y, Cao H B, Huang M Y. Experimental study on three-dimensional microstructure copper electroforming based on 3D printing technology. Micromachines, 2019, 10(12): 887

Martin J J, Fiore B E, Erb R M. Designing bioinspired composite reinforcement architectures via 3D magnetic printing. Nature Communications, 2015, 6(1): 8641

Mehta S, Suresh A, Nayak Y, Narayan R, Nayak U Y. Hybrid nanostructures: versatile systems for biomedical applications. Coordination Chemistry Reviews, 2022, 460: 214482

Miyoshi H, Adachi T, Ju J, Lee S M, Cho D J, Ko J S, Uchida G, Yamagata Y. Characteristics of motility-based filtering of adherent cells on microgrooved surfaces. Biomaterials, 2012, 33(2): 395–401

Liu H F, He L M, Kuzmanovic M, Huang Y T, Zhang L, Zhang Y, Zhu Q, Ren Y, Dong Y C, Cardon L, Gou M L. Advanced nanomaterials in medical 3D printing. Small Methods, 2024, 8(3): 2301121

Cheng K, Niu Z C, Wang R C, Rakowski R, Bateman R. Smart cutting tools and smart machining: development approaches, and their implementation and application perspectives. Chinese Journal of Mechanical Engineering, 2017, 30(5): 1162–1176

Selvaraj V, Xu Z C, Min S K. Intelligent operation monitoring of an ultra-precision CNC machine tool using energy data. International Journal of Precision Engineering and Manufacturing-Green Technology, 2023, 10(1): 59–69

Ren Z S, Gao L, Clark S J, Fezzaa K, Shevchenko P, Choi A, Everhart W, Rollett A D, Chen L Y, Sun T. Machine learning-aided real-time detection of keyhole pore generation in laser powder bed fusion. Science, 2023, 379(6627): 89–94

Shevchik S, Le-Quang T, Meylan B, Farahani F V, Olbinado M P, Rack A, Masinelli G, Leinenbach C, Wasmer K. Supervised deep learning for real-time quality monitoring of laser welding with X-ray radiographic guidance. Scientific Reports, 2020, 10(1): 3389

Xu Z C, Selvaraj V, Min S. Intelligent G-code-based power prediction of ultra-precision CNC machine tools through 1DCNN-LSTM-Attention model. Journal of Intelligent Manufacturing, 2024: 1–24

Download references

Acknowledgements

This research was jointly supported by the State Key Laboratories in Hong Kong, China, from the Innovation and Technology Commission (project code: BBR3) of the Government of the Hong Kong Special Administrative Region, China; the Research Office (project codes: BBXM and BBX) of The Hong Kong Polytechnic University, China; the Project of Strategic Importance (project codes: 1-ZE0G and SBBD) of The Hong Kong Polytechnic University, China; and the Research Committee (project code: RMAC) of The Hong Kong Polytechnic University, China.

Author information

Authors and affiliations.

State Key Laboratory of Ultra-precision Machining Technology, Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong, China

Tao He, Wai Sze Yip, Edward Hengzhou Yan, Jiuxing Tang, Muhammad Rehan, Linhe Sun, Baolong Zhang, Feng Guo & Suet To

Department of Industrial and Systems Engineering, The Hong Kong Polytechnic University, Hong Kong, China

Department of Physics, The Hong Kong University of Science and Technology, Hong Kong, China

Chi Ho Wong

School of Geosciences and Info-Physics, Central South University, Changsha, 410083, China

Shaohe Zhang

You can also search for this author in PubMed   Google Scholar

Corresponding authors

Correspondence to Wai Sze Yip or Suet To .

Ethics declarations

Conflict of Interest The authors declare that they have no conflict of interest.

Rights and permissions

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution, and reproduction in any medium or format, as long as appropriate credit is given to the original author(s) and source, a link to the Creative Commons license is provided, and the changes made are indicated.

The images or other third-party material in this article are included in the article’s Creative Commons license, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons license and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.

Visit https://creativecommons.org/licenses/by/4.0/ to view a copy of this license.

Reprints and permissions

About this article

He, T., Yip, W.S., Yan, E.H. et al. 3D printing for ultra-precision machining: current status, opportunities, and future perspectives. Front. Mech. Eng. 19 , 23 (2024). https://doi.org/10.1007/s11465-024-0792-4

Download citation

Received : 12 December 2023

Accepted : 21 March 2024

Published : 16 August 2024

DOI : https://doi.org/10.1007/s11465-024-0792-4

Share this article

Anyone you share the following link with will be able to read this content:

Sorry, a shareable link is not currently available for this article.

Provided by the Springer Nature SharedIt content-sharing initiative

• ultra-precision machining
• 3D printing
• additive manufacturing
• future perspectives
• start-of-the-art-review

Advertisement

• Find a journal
• Publish with us
• Track your research

• Engineering
• Manufacturing Engineering
• 3D Printing

Artificial Intelligence in 3D Printing

• In book: Enabling Machine Learning Applications in Data Science (pp.77-88)

• Kafrelsheikh University

• Faculty of computer and information science

Abstract and Figures

Discover the world's research

• 25+ million members
• 160+ million publication pages
• 2.3+ billion citations

• J INTELL MANUF

• COMPUT AIDED DESIGN

• Elena M. Blinova
• Igor I. Bezukladnikov

• Heming Zhang
• Zhaojing Zhang

• Kai-Yin Fok

• Recruit researchers
• Join for free
• Login Email Tip: Most researchers use their institutional email address as their ResearchGate login Password Forgot password? Keep me logged in Log in or Continue with Google Welcome back! Please log in. Email · Hint Tip: Most researchers use their institutional email address as their ResearchGate login Password Forgot password? Keep me logged in Log in or Continue with Google No account? Sign up

Information

• Author Services

Initiatives

You are accessing a machine-readable page. In order to be human-readable, please install an RSS reader.

All articles published by MDPI are made immediately available worldwide under an open access license. No special permission is required to reuse all or part of the article published by MDPI, including figures and tables. For articles published under an open access Creative Common CC BY license, any part of the article may be reused without permission provided that the original article is clearly cited. For more information, please refer to https://www.mdpi.com/openaccess .

Feature papers represent the most advanced research with significant potential for high impact in the field. A Feature Paper should be a substantial original Article that involves several techniques or approaches, provides an outlook for future research directions and describes possible research applications.

Feature papers are submitted upon individual invitation or recommendation by the scientific editors and must receive positive feedback from the reviewers.

Editor’s Choice articles are based on recommendations by the scientific editors of MDPI journals from around the world. Editors select a small number of articles recently published in the journal that they believe will be particularly interesting to readers, or important in the respective research area. The aim is to provide a snapshot of some of the most exciting work published in the various research areas of the journal.

Original Submission Date Received: .

• Active Journals
• Find a Journal
• Proceedings Series
• For Authors
• For Reviewers
• For Editors
• For Librarians
• For Publishers
• For Societies
• For Conference Organizers
• Open Access Policy
• Institutional Open Access Program
• Special Issues Guidelines
• Editorial Process
• Research and Publication Ethics
• Article Processing Charges
• Testimonials
• Preprints.org
• SciProfiles
• Encyclopedia

Article Menu

• Subscribe SciFeed
• Recommended Articles
• Google Scholar
• on Google Scholar
• Table of Contents

Find support for a specific problem in the support section of our website.

Please let us know what you think of our products and services.

Visit our dedicated information section to learn more about MDPI.

JSmol Viewer

The effect of 3d printing layer thickness and post-polymerization time on the flexural strength and hardness of denture base resins.

1. Introduction

2. materials and methods, 2.1. specimens preparation, 2.2. specimens testing, 2.2.1. flexural strength, 2.2.2. hardness, 2.3. statistical analysis, 4. discussion, 5. conclusions, author contributions, institutional review board statement, informed consent statement, data availability statement, conflicts of interest.

• Witkowski, S. (CAD-)/CAM in dental technology. Quintessence Dent. Technol. 2005 , 28 , 169–184. [ Google Scholar ]
• Revilla-León, M.; Özcan, M. Additive Manufacturing Technologies Used for Processing Polymers: Current Status and Potential Application in Prosthetic Dentistry. J. Prosthodont. 2019 , 28 , 146–158. [ Google Scholar ] [ CrossRef ]
• Jawahar, A.; Maragathavalli, G. Applications of 3D printing in dentistry—A review. J. Pharm. Sci. Res. 2019 , 11 , 1670–1675. [ Google Scholar ]
• Gad, M.M.; Fouda, S.M. Factors affecting flexural strength of 3D-printed resins: A systematic review. J. Prosthodont. 2023 , 32 , 96–110. [ Google Scholar ] [ CrossRef ]
• Alshamrani, A.A.; Raju, R.; Ellakwa, A. Effect of Printing Layer Thickness and Postprinting Conditions on the Flexural Strength and Hardness of a 3D-Printed Resin. BioMed Res. Int. 2022 , 2022 , 8353137. [ Google Scholar ] [ CrossRef ]
• Barazanchi, A.; Li, K.C.; Al-Amleh, B.; Lyons, K.; Waddell, J.N. Additive Technology: Update on Current Materials and Applications in Dentistry. J. Prosthodont. 2017 , 26 , 156–163. [ Google Scholar ] [ CrossRef ]
• Kim, D.; Shim, J.S.; Lee, D.; Shin, S.H.; Nam, N.E.; Park, K.H.; Shim, J.S.; Kim, J.E. Effects of Post-Curing Time on the Mechanical and Color Properties of Three-Dimensional Printed Crown and Bridge Materials. Polymers 2020 , 12 , 2762. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Scotti, C.K.; Velo, M.M.A.C.; Rizzante, F.A.P.; Nascimento, T.R.L.; Mondelli, R.F.L.; Bombonatti, J.F.S. Physical and surface properties of a 3D-printed composite resin for a digital workflow. J. Prosthet. Dent. 2020 , 124 , 614.e1–614.e5. [ Google Scholar ] [ CrossRef ]
• KEßLER, A.; Hickel, R.; Ilie, N. In vitro investigation of the influence of printing direction on the flexural strength, flexural modulus and fractographic analysis of 3D-printed temporary materials. Dent. Mater. J. 2021 , 40 , 641–649. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Pagac, M.; Hajnys, J.; Ma, Q.P.; Jancar, L.; Jansa, J.; Stefek, P.; Mesicek, J. A Review of Vat Photopolymerization Technology: Materials, Applications, Challenges, and Future Trends of 3D Printing. Polymers 2021 , 13 , 598. [ Google Scholar ] [ CrossRef ]
• Figueiredo-Pina, C.G.; Serro, A.P. 3D Printing for Dental Applications. Materials 2023 , 16 , 4972. [ Google Scholar ] [ CrossRef ]
• Srinivasan, M.; Kalberer, N.; Kamnoedboon, P.; Mekki, M.; Durual, S.; Özcan, M.; Müller, F. CAD-CAM complete denture resins: An evaluation of biocompatibility, mechanical properties, and surface characteristics. J. Dent. 2021 , 114 , 103785. [ Google Scholar ] [ CrossRef ]
• Chen, S.; Yang, J.; Jia, Y.G.; Lu, B.; Ren, L. A Study of 3D-Printable Reinforced Composite Resin: PMMA Modified with Silver Nanoparticles Loaded Cellulose Nanocrystal. Materials 2018 , 11 , 2444. [ Google Scholar ] [ CrossRef ]
• Perea-Lowery, L.; Gibreel, M.; Vallittu, P.K.; Lassila, L.V. 3D-Printed vs. Heat-Polymerizing and Autopolymerizing Denture Base Acrylic Resins. Materials 2021 , 14 , 5781. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Bayarsaikhan, E.; Lim, J.H.; Shin, S.H.; Park, K.H.; Park, Y.B.; Lee, J.H.; Kim, J.E. Effects of Postcuring Temperature on the Mechanical Properties and Biocompatibility of Three-Dimensional Printed Dental Resin Material. Polymers 2021 , 13 , 1180. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Aati, S.; Akram, Z.; Shrestha, B.; Patel, J.; Shih, B.; Shearston, K.; Ngo, H.; Fawzy, A. Effect of post-curing light exposure time on the physico-mechanical properties and cytotoxicity of 3D-printed denture base material. Dent. Mater. 2022 , 38 , 57–67. [ Google Scholar ] [ CrossRef ]
• Li, P.; Lambart, A.L.; Stawarczyk, B.; Reymus, M.; Spintzyk, S. Postpolymerization of a 3D-printed denture base polymer: Impact of post-curing methods on surface characteristics, flexural strength, and cytotoxicity. J. Dent. 2021 , 115 , 103856. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Gad, M.M.; Al-Harbi, F.A.; Akhtar, S.; Fouda, S.M. 3D-Printable Denture Base Resin Containing SiO 2 Nanoparticles: An In Vitro Analysis of Mechanical and Surface Properties. J. Prosthodont. 2022 , 31 , 784–790. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Tahayeri, A.; Morgan, M.; Fugolin, A.P.; Bompolaki, D.; Athirasala, A.; Pfeifer, C.S.; Ferracane, J.L.; Bertassoni, L.E. 3D printed versus conventionally cured provisional crown and bridge dental materials. Dent. Mater. 2018 , 34 , 192–200. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Alharbi, N.; Osman, R.; Wismeijer, D. Effects of build direction on the mechanical properties of 3D-printed complete coverage interim dental restorations. J. Prosthet. Dent. 2016 , 115 , 760–767. [ Google Scholar ] [ CrossRef ]
• Osman, R.B.; Alharbi, N.; Wismeijer, D. Build Angle: Does It Influence the Accuracy of 3D-Printed Dental Restorations Using Digital Light-Processing Technology? Int. J. Prosthodont. 2017 , 30 , 182–188. [ Google Scholar ] [ CrossRef ]
• Seelbach, P.; Brueckel, C.; Wöstmann, B. Accuracy of digital and conventional impression techniques and workflow. Clin. Oral. Investig. 2013 , 17 , 1759–1764. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Mangal, U.; Seo, J.Y.; Yu, J.; Kwon, J.S.; Choi, S.H. Incorporating Aminated Nanodiamonds to Improve the Mechanical Properties of 3D-Printed Resin-Based Biomedical Appliances. Nanomaterials 2020 , 10 , 827. [ Google Scholar ] [ CrossRef ]
• Aati, S.; Akram, Z.; Ngo, H.; Fawzy, A.S. Development of 3D printed resin reinforced with modified ZrO 2 nanoparticles for long-term provisional dental restorations. Dent. Mater. 2021 , 37 , e360–e374. [ Google Scholar ] [ CrossRef ]
• Kwon, J.S.; Kim, J.Y.; Mangal, U.; Seo, J.Y.; Lee, M.J.; Jin, J.; Yu, J.H.; Choi, S.H. Durable Oral Biofilm Resistance of 3D-Printed Dental Base Polymers Containing Zwitterionic Materials. Int. J. Mol. Sci. 2021 , 22 , 417. [ Google Scholar ] [ CrossRef ]
• Shim, J.S.; Kim, J.E.; Jeong, S.H.; Choi, Y.J.; Ryu, J.J. Printing accuracy, mechanical properties, surface characteristics, and microbial adhesion of 3D-printed resins with various printing orientations. J. Prosthet. Dent. 2020 , 124 , 468–475. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Derban, P.; Negrea, R.; Rominu, M.; Marsavina, L. Influence of the Printing Angle and Load Direction on Flexure Strength in 3D Printed Materials for Provisional Dental Restorations. Materials 2021 , 14 , 3376. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Väyrynen, V.O.; Tanner, J.; Vallittu, P.K. The anisotropicity of the flexural properties of an occlusal device material processed by stereolithography. J. Prosthet. Dent. 2016 , 116 , 811–817. [ Google Scholar ] [ CrossRef ]
• Unkovskiy, A.; Bui, P.H.; Schille, C.; Geis-Gerstorfer, J.; Huettig, F.; Spintzyk, S. Objects build orientation, positioning, and curing influence dimensional accuracy and flexural properties of stereolithographically printed resin. Dent. Mater. 2018 , 34 , e324–e333. [ Google Scholar ] [ CrossRef ]
• Perea-Lowery, L.; Gibreel, M.; Vallittu, P.K.; Lassila, L. Evaluation of the mechanical properties and degree of conversion of 3D printed splint material. J. Mech. Behav. Biomed. Mater. 2021 , 115 , 104254. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Sabbah, A.; Romanos, G.; Delgado-Ruiz, R. Impact of Layer Thickness and Storage Time on the Properties of 3D-Printed Dental Dies. Materials 2021 , 14 , 509. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Kalberer, N.; Mehl, A.; Schimmel, M.; Müller, F.; Srinivasan, M. CAD-CAM milled versus rapidly prototyped (3D-printed) complete dentures: An in vitro evaluation of trueness. J. Prosthet. Dent. 2019 , 121 , 637–643. [ Google Scholar ] [ CrossRef ]
• Gad, M.M.; Fouda, S.M.; Abualsaud, R.; Alshahrani, F.A.; Al-Thobity, A.M.; Khan, S.Q.; Akhtar, S.; Ateeq, I.S.; Helal, M.A.; Al-Harbi, F.A. Strength and Surface Properties of a 3D-Printed Denture Base Polymer. J. Prosthodont. 2022 , 31 , 412–418. [ Google Scholar ] [ CrossRef ]
• Al-Dulaijan, Y.A.; Alsulaimi, L.; Alotaibi, R.; Alboainain, A.; Akhtar, S.; Khan, S.Q.; Al-Ghamdi, M.; Gad, M.M. Effect of Printing Orientation and Postcuring Time on the Flexural Strength of 3D-Printed Resins. J. Prosthodont. 2023 , 32 , 45–52. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Kim, T.; Lee, S.; Kim, G.B.; Hong, D.; Kwon, J.; Park, J.W.; Kim, N. Accuracy of a simplified 3D-printed implant surgical guide. J. Prosthet. Dent. 2020 , 124 , 195–201.e2. [ Google Scholar ] [ CrossRef ]
• Prpić, V.; Schauperl, Z.; Ćatić, A.; Dulčić, N.; Čimić, S. Comparison of Mechanical Properties of 3D-Printed, CAD/CAM, and Conventional Denture Base Materials. J. Prosthodont. 2020 , 29 , 524–528. [ Google Scholar ] [ CrossRef ]
• Jeong, M.; Radomski, K.; Lopez, D.; Liu, J.T.; Lee, J.D.; Lee, S.J. Materials and Applications of 3D Printing Technology in Dentistry: An Overview. Dent. J. 2023 , 12 , 1. [ Google Scholar ] [ CrossRef ] [ PubMed ]
• Al-Dulaijan, Y.A.; Alsulaimi, L.; Alotaibi, R.; Alboainain, A.; Alalawi, H.; Alshehri, S.; Khan, S.Q.; Alsaloum, M.; AlRumaih, H.S.; Alhumaidan, A.A.; et al. Comparative Evaluation of Surface Roughness and Hardness of 3D Printed Resins. Materials 2022 , 15 , 6822. [ Google Scholar ] [ CrossRef ]
• Borella, P.S.; Alvares, L.A.S.; Ribeiro, M.T.H.; Moura, G.F.; Soares, C.J.; Zancopé, K.; Mendonça, G.; Rodrigues, F.P.; das Neves, F.D. Physical and mechanical properties of four 3D-printed resins at two different thick layers: An in vitro comparative study. Dent. Mater. 2023 , 39 , 686. [ Google Scholar ] [ CrossRef ]

Click here to enlarge figure

Share and Cite

AlRumaih, H.S.; Gad, M.M. The Effect of 3D Printing Layer Thickness and Post-Polymerization Time on the Flexural Strength and Hardness of Denture Base Resins. Prosthesis 2024 , 6 , 970-978. https://doi.org/10.3390/prosthesis6040070

AlRumaih HS, Gad MM. The Effect of 3D Printing Layer Thickness and Post-Polymerization Time on the Flexural Strength and Hardness of Denture Base Resins. Prosthesis . 2024; 6(4):970-978. https://doi.org/10.3390/prosthesis6040070

AlRumaih, Hamad S., and Mohammed M. Gad. 2024. "The Effect of 3D Printing Layer Thickness and Post-Polymerization Time on the Flexural Strength and Hardness of Denture Base Resins" Prosthesis 6, no. 4: 970-978. https://doi.org/10.3390/prosthesis6040070

Article Metrics

Article access statistics, further information, mdpi initiatives, follow mdpi.

Subscribe to receive issue release notifications and newsletters from MDPI journals