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<p>Material extrusion additive manufacturing (AM) with low barriers is an ideal tool for small and medium-sized enterprises to manufacture customized metal parts. However, it has obvious defects, such as low yield and long production cycle of the thick part, which hinders the development of technology. Consequently, the method of filling powder is first proposed to reduce the composite material thickness in material extrusion AM. The 15&#xa0;µm powder is suitable to fill the shell with the composite material consisting of 60 vol% powder to ensure that there are no macroscopic defects in the parts after sintering. Compared with printing, this hybrid AM can shorten 50–60% of the forming time and save 40–60% of the composite material cost. The solvent debinding time of green parts can be shorten by over 75%. More importantly, the ultimate tensile strength of specimen formed along the vertical direction can be improved by more than 48%, which is close to the level of the industry. In the future, large-sized and thick metal parts with high strength can be quickly manufactured by this hybrid AM.</p>

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A hybrid additive manufacturing: filling the metal powder to overcome the limitation of the thickness

  • 期刊论文

  • 发表日期：

    2026年1月28日

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  • Bing He,
  • Jiangtao Li,
  • Zhijie Huang,
  • Xiangyou Li

摘要

Material extrusion additive manufacturing (AM) with low barriers is an ideal tool for small and medium-sized enterprises to manufacture customized metal parts. However, it has obvious defects, such as low yield and long production cycle of the thick part, which hinders the development of technology. Consequently, the method of filling powder is first proposed to reduce the composite material thickness in material extrusion AM. The 15 µm powder is suitable to fill the shell with the composite material consisting of 60 vol% powder to ensure that there are no macroscopic defects in the parts after sintering. Compared with printing, this hybrid AM can shorten 50–60% of the forming time and save 40–60% of the composite material cost. The solvent debinding time of green parts can be shorten by over 75%. More importantly, the ultimate tensile strength of specimen formed along the vertical direction can be improved by more than 48%, which is close to the level of the industry. In the future, large-sized and thick metal parts with high strength can be quickly manufactured by this hybrid AM.