Additive manufacturing (AM) technology has revolutionized the way goods are developed and produced, with numerous uses in aerospace, automotive, medical, and consumer goods industries. Its significance within the context of the fourth industrial revolution, characterized by digitalization, automation, and interconnected systems, is imperative. This paper provides a comprehensive overview of the current state of AM, including its background, underlying concepts, processes, materials, implicit benefits, and inherent limitations. It also examines the various applications of AM for the manufacture and remanufacture of parts, components, and products. This study assesses current advances in AM, such as progress in multi-material and large-scale 3D printing, improvements in speed and efficacy, precision and accuracy, automation, and sustainability. Likewise, the study investigates some of the present issues confronting AM, such as material limits, cost, intellectual property, and sustainability. Furthermore, by analyzing the review articles on various aspects of AM, this paper provides a more comprehensive overview of the subject. Finally, the study concludes with highlights of future prospects and emerging AM trends. This comprehensive review is intended to offer readers a clear grasp of AM, its inherent processes, and recent advances, as well as the challenges that must be addressed in order to fully realize the possibilities it holds. 

Revolutionizing manufacturing: A comprehensive overview of additive manufacturing processes, materials, developments, and challenges

This general review paper presents a condensed view of recent inventions in the Additive Manufacturing (AM) field. It outlines factors affecting the development and commercialization of inventions via research collaboration and discusses breakthroughs in materials and AM technologies and their integration with emerging technologies. The paper explores the impact of AM across various sectors, including the aerospace, automotive, healthcare, food, and construction industries, since the 1970s. It also addresses challenges and future directions, such as hybrid manufacturing and bio-printing, along with socio-economic and environmental implications. This collaborative study provides a concise understanding of the latest inventions in AM, offering valuable insights for researchers, practitioners, and decision makers in diverse industries and institutions. 

Recent Inventions in Additive Manufacturing: Holistic Review

Printed circuit assemblies (PCAs) are an integral part of most modern electronic devices. With the significant supply chain issues affecting the electronics industry there has been renewed interest in new ways to reshoring and revitalising the electronics manufacturing sectors. A PCA is composed of a substrate, interconnections, passive and/or active components which when combined allow an electronic device to function. These constituents are made of a variety of materials including conductive, insulating and semiconductor. In considering the application of 3D printing (3DP) to the manufacture of PCAs a necessary criterion would be the need for multi-material 3D printing (MM3DP). The aim of this review is to report on the recent progress in the application of MM3DP technologies for the manufacture of PCAs. Emphasis is placed on the realisation of fully automated, standalone MM3DP systems. The review identifies the dominant MM3DP technologies utilised in the industry as well as the limitations of the currently available technologies. Finally, the review proposes five characteristics of the ideal MM3DP system for manufacturing PCAs and discusses the important opportunities for future research in each of the areas. • Aerosol jet printing (AJP) and ink jet printing (IJP) processes dominate multi-material 3D printing (MM3DP) applications for the manufacture of printed circuit assemblies (PCAs). • Implementations of MM3DP PCAs are primarily planar and do not make effective use of the z-axis. • The realisation of 3DP embedded active and passive electronic components is lacking. • The recycling of MM3DP PCAs can be a significant environmental concern for the electronics industry. 

Multi-material 3D printed electronic assemblies: A review

In this paper, a microfluidic sensor is proposed using a microwave planar multiple split-ring resonator (MSRR). The main objective of this real time non-destructive microfluidic sensor is to detect and analyse the dielectric properties of materials using extremely small amount of liquid volumes $(2.5\mu \mathrm {L})$. The sensing mechanism of the proposed microfluidic sensor is based on frequency shifting and amplitude changing of material under test. An MSRR is employed using a Rogers RT/Duroid 5880 substrate. Then, a microcapillary made from glass material is loaded on the outer ring slot to observe the perturbation response. The microcapillary is filled with several common solvents and the ideal value of those solvents are used as a reference result. The resonant frequency of the structure with microcapillary is observed to be 2.1 GHz. The functionality and reliability of the proposed sensor are successfully demonstrated through full-wave simulations and measurements. The resonant frequency of the loaded microcapillary showed a shift of 125.5 MHz and 25 MHz when compared to empty microfluidic. Our proposed microfluidic sensor is nondestructive and reliable. Furthermore, it is low cost and fabricated using simple and easy design procedures.

Complex Permittivity Measurement Based on Planar Microfluidic Resonator Sensor

In the era of Industry 4.0, 3D printing, or additive manufacturing (AM), has revolutionized product design and manufacturing across various sectors. This review explores the evolution of 3D printing technology and its impact on industrial innovation, highlighting advancements in aeronautics, the automotive industry, and biomedicine. Various AM processes, such as binder jetting, direct energy deposition, and powder bed fusion, and materials like metals, polymers, ceramics, and composites, are discussed. Innovations like high-speed sintering, continuous liquid interface production, and bioprinting demonstrate ongoing advancements. The potential of 3D printing in personalized medical applications is emphasized due to its flexibility in geometry and materials. Despite progress, challenges like standardization, material quality, recycling, sustainability, and economic feasibility hinder widespread adoption. Overcoming these challenges is crucial for optimizing 3D printing technologies, ensuring high-quality, efficient, and affordable production. The review also addresses the future prospects of 4D and 5D printing technologies and their potential applications in various industries. This overview underscores 3D printing’s role in shaping the future of manufacturing within the context of Industry 5.0, emphasizing human–machine collaboration and sustainability. 

Printing the Future Layer by Layer: A Comprehensive Exploration of Additive Manufacturing in the Era of Industry 4.0

3D printing technologies (3DP) leverage the benefits of additive manufacturing across many areas including electronics, food, medicine and optics. These technologies allow varying materials to be precision deposited, forming structures ranging from simple to complex composites such as organs and satellites. One important application for 3DP is printed electronics which is expected to exceed USD10 billion in market value by 2030. However, while considerable work has been reported in areas including inter alia: mechanical, thermal and multiple aspects, there has been less emphasis on the critical electromagnetic (EM) domain. In the EM domain, related work for 3DP encompasses interrelated EM studies of materials, processes and built structures and examines material characteristics including permittivity, permeability, electrical conductivity, which are foundational to 3D printed electronics design and fabrication. This paper presents a comprehensive report of 3DP technologies as applied to EM research & development (R&D) and end applications in order to inspire exploratory work in related areas by providing sufficient breadth for newcomers and depth for experts. The paper contributions include: summarization of the major R&D and applications areas for 3DP, thereby quantifying the prevalence of EM related work; examination of mainstream 3DP technologies applied to EM related R&D and end applications based on their materials, technology highlights and known issues; examination of relevant research which incorporates traditional printing, proprietary methods and composite 3DP methods; and classification of 3DP built EM structures as reported by research teams. Finally, the key challenges and opportunities for future research are identified and discussed.

/pdf/a-survey-of-3d-printing-technologies-as-applied-to-printed-24174ek4.pdf

A Survey of 3D Printing Technologies as Applied to Printed Electronics

Globally, chronic kidney disease (CKD) burden healthcare systems. Current treatment systems in many countries have presented a serious socioeconomic situation for low- to middle-income countries. As such, monitoring mechanisms present a clinical need for effective diagnosis, prevention and treatment of numerous non communicable diseases, such as CKD. Non-invasive, continuous monitoring of renal function using a complementary split ring resonator (CSRR) microwave sensor confers potential benefits to meeting this clinical need. The sensor was sensitive to changes in the relative permittivity of a material under test with the electrical properties of blood, for the frequency range investigated in COMSOL Multiphysics®. The correlation of the electrical parameters with relative permittivity changes highlights the applicability of CSRRs as a sensor module for CKD monitoring.

CSRR-based microwave sensor for noninvasive, continuous monitoring of renal function

This paper explores whether engaging embedded electronic systems students in the creation of, as opposed to simply the use of, lab equipment improves their motivation to practice, and thereby their ability to acquire, discipline-specific skills. The specific piece of laboratory equipment considered is the Microchip In Circuit Debugger, inclusive of header, for PIC16F mid-range micro-controllers. A printed circuit board related teaching activity guided students through design of the ICD header (both 2011/12 and 2013/14), and physical assembly of a pre-designed ICD unit (2011/12 only). Three student cohorts subsequently used the in-house I CDs. Increased availability of units allowed each student to take the equipment outside of the lab and conduct studies at their convenience. The impact of the intervention was measured through the use of a survey; the survey instrument and response summaries are presented. Deliberate use of equipment construction as teaching activity could be an innovative way to improve skills acquisition by leveraging student motivation. Follow-up work will establish whether such activities yield reduction in time to minimal skill levels, and/or an improvement in final skill levels.

Leveraging student motivation in engineering skills acquisition

One challenge faced in the engineering education, is the need to imbue both technical competence and critical thinking skills within the bounds of academic program delivery. While technical competence can be built and assessed using structured and/or quantitative exercises, critical thinking is a skill that is both difficult to cultivate and to assess. Critical thinking involves the possession of both an expert mental model as well as the ability to leverage this model in various tasks. In engineering education, these tasks include making and justifying design choices, system optimization, and predicting system performance. Prior work, by one of the authors, explored the role of graphic organizers in the development of student's mental models. This paper describes action research underway, to explore the use of the argument map, as a structured means of leveraging mental models to promote critical thinking. In this paper, interactive small-group tasks based on argument maps are presented, and outputs generated by the initial cohort of undergraduate senior learners on these tasks are examined for evidence of critical thinking. These items form the basis of a longer-term longitudinal study in which the most effective means of deploying argument maps for promoting critical thinking will be examined.

Use of argument maps to promote critical thinking in engineering education

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