Background In laser powder bed fusion (LPBF) additive manufacturing, 20–30% of metal powder feedstock becomes unusable after multiple cycles of sieving and reclaiming. This is due to deviations in particle size and geometry, which can lead to build defects and failures. These out-of-spec powders are typically stored, creating logistical, cost,...

Background 3D printing has rapidly advanced to a highly accessible technology, revolutionizing industries by enabling the creation of everything from custom prosthetics to entire homes. Its ability to accelerate production by streamlining prototyping has empowered inventors and manufacturers alike to develop highly customized, unique, and innovative...

Background Additive manufacturing, also known as 3D printing, is a fabrication process to build 3D objects layer by layer based on computer aided design (CAD) models, or digital 3D models. Current filament or wire feedstock-based technologies, including the fused filament fabrication (FFF), are desirable for printing thermal plastic materials due to...

Fused filament fabrication (FFF) is a 3D printing process that adds material layer-by-layer to form a 3D object. Today, 3D printing can produce a range of objects from simple children’s toys to fully-functioning human hearts. However, the products created by FFF still contain a significant amount of error in terms of structural variability during...