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<p>Additive manufacturing (AM) enables integrated one-piece fabrication of parts, high material utilization efficiency, and unparalleled design freedom. However, problems such as low production efficiency, difficulties in ensuring quality stability and defect control limit the large-scale industrial application of AM. <i>In-situ</i> active modulation for AM enables dynamic regulation of parts during the fabrication process, thereby enhancing the quality of the final fabricated parts without introducing extra processing steps. <i>In-situ</i> active regulation enables direct intervention during defect nucleation, providing better effectiveness than post-printing repairs while avoiding performance degradation risks associated with post-processing. Based on the difference of core factors directly affected during regulation, <i>in-situ</i> active regulation is categorized into the following. (1) Process and path parameter optimization, where regulation directly impacts manufacturing-related procedural rules. It is the simplest method of control and the preferred approach, with widespread attention focused on its effects on microstructure and mechanical properties. (2) Laser beam shaping, where regulation directly influences the energy carrier morphology. To address issues such as edge over-melting and localized energy deficiency caused by non-uniform energy distribution, laser beam shaping should be employed. (3) Additional physical field modulation achieved by superimposing supplementary physical fields. When optimal process and path parameters still fail to obtain the desired microstructure and mechanical properties, additional physical field control may be considered. Meanwhile, this work summarized the effects of different additional physical fields on the mechanical properties of various metallic base materials. The future trends of <i>in-situ</i> modulation in additive manufacturing are also discussed.</p>

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Review on in-situ active modulation technology in metal additive manufacturing processes

  • 期刊论文

  • 发表日期：

    2026年4月9日

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  • Ziyun Long,
  • Yinghao Zhang,
  • Ce Jiang,
  • Puxiang Wang,
  • Jinzhao Zhao,
  • Yangyang Huang,
  • Zhanwei Liu,
  • Wei Feng,
  • Huimin Xie

摘要

Additive manufacturing (AM) enables integrated one-piece fabrication of parts, high material utilization efficiency, and unparalleled design freedom. However, problems such as low production efficiency, difficulties in ensuring quality stability and defect control limit the large-scale industrial application of AM. In-situ active modulation for AM enables dynamic regulation of parts during the fabrication process, thereby enhancing the quality of the final fabricated parts without introducing extra processing steps. In-situ active regulation enables direct intervention during defect nucleation, providing better effectiveness than post-printing repairs while avoiding performance degradation risks associated with post-processing. Based on the difference of core factors directly affected during regulation, in-situ active regulation is categorized into the following. (1) Process and path parameter optimization, where regulation directly impacts manufacturing-related procedural rules. It is the simplest method of control and the preferred approach, with widespread attention focused on its effects on microstructure and mechanical properties. (2) Laser beam shaping, where regulation directly influences the energy carrier morphology. To address issues such as edge over-melting and localized energy deficiency caused by non-uniform energy distribution, laser beam shaping should be employed. (3) Additional physical field modulation achieved by superimposing supplementary physical fields. When optimal process and path parameters still fail to obtain the desired microstructure and mechanical properties, additional physical field control may be considered. Meanwhile, this work summarized the effects of different additional physical fields on the mechanical properties of various metallic base materials. The future trends of in-situ modulation in additive manufacturing are also discussed.