Research and Application of 3D Printed Porous Geometric Structure: a Review
YANG Jianming1,2, TANG Yang1, GU Hai2, LIU Yongjia3, HUANG Dazhi1,2, CHEN Jinsong1,2
1 Marine Resources Development Institute of Jiangsu, Huaihai Institute of Technology, Lianyungang 222005; 2 Jiangsu KeyLaboratory of 3D Printing Equipment and Application Technology, Nantong Institute of Technology, Nantong 226002; 3 Lianyungang Zhenghang Power Energy-Saving Technology Co., Ltd., Lianyungang 222022
Abstract: The materials with porous geometric structure can be used in numerous occasions in industries because of its excellent physical and mechanical performance. At present, various methods are developed to fabricate the porous structure, but a few of them can realize batch production, most of them are of complicated process and are difficult to effectively control the porous geometric structure during the process, thus resulting in the insufficient properties of the porous structures. The development and application of 3D printing technology have introduced a new way of porous structure fabrication. The porous geometric structures fabricated by 3D printing possess both macroscopic and microscopic pore, their framework and macro-pore can be designed according to the demand. 3D printing methods that can be used to fabricate the porous structure mainly include SLS, SLM and LENS (by using laser energy), EBM (by using the electron beam energy), 3DP (by spraying adhesives), FDM and 3DF (classified among material extruding), and indirect 3D printing method. In recent years, numerous studies on fabrication of porous structure by the above 3D printing methods were conducted by scholars at home and abroad, aiming at finding the appropriate 3D printing method fitted for specific requirements and the reaso-nable technical specification corresponding to the method, and then enhance the properties of the fabricated structures. When SLS, SLM, and LENS method are adopted, macropore and micropore can be obtained by controlling laser scanning track and powder sintering degree. There are a wide range of porous structure materials that can be fabricated by SLS. SLM and LENS method are mainly used to fabricate the porous structure of metal. EBM is similar to SLM, but only under the vacuum condition can the formation of products be realized by EBM, therefore, it is appropriate for active metal materials like Ti. There is a wider range of material powders that can be used for 3DP method. The process flexibility of 3DP method is also amazing because different adhesive and corresponding post-processing can be adopted. FDM method generally suits for thermoplastic material with low melting point, and the porous structure with macropore can be formed by extruding and stacking of the molten material. In 3DF method, the formation can be realized by extruding of the powder slurry. There are much more kinds of materials suited for 3DF method than that of FDM method. The porous structures fabricated by 3DF method possess both macropore and micropore. The printing accuracy and pore size in FDM and 3DF method are restricted by the printing ability of the nozzle. In the indirect method, a master mould with porous structure is firstly fabricated by a certain convenient 3D printing method, and then the porous structure of the required material is fabricated by the method like powder metallurgy or pouring using the master mould. The indirect method can overcome the limitations of the direct technique on the structural feature of the fabricated porous structure with some materials. In the above methods, SLM and EBM can obtain a finer porous structure than others thanks to the concentrated energy of laser and electron beam. The pore formation mechanisms in the fabrication of porous structure by 3D printing can be summarized as follows: the designed macropore formed by the area that printing track do not arrive in the fabricated part, the pore formed by the removal of the adhesive in the strut of fabricated part by decomposing after heating or dissolving, the pore formed by the dissolution of gas into the molten metal during sintering, the pore formed by the laser-molten tracks, the pore formed by the gap of the powder particles packing. The research and application status of the fabrication of porous structure by 3D printing is reviewed in this article. Several 3D printing methods for the fabrication of porous structure are briefly introduced. The mechanisms of pore formation are summarized. Then the application status of porous structure fabricated by 3D printing is presented. At last, the further research direction of 3D printing method for porous structure are pointed out.
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2018, Vol. 32 
