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Breakthrough to the pragmatic evolution of direct ink writing: progression, challenges, and future

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Abstract

The potentiality to construct 3D geometries by harnessing multifaceted materials for both conventional and unprecedented methodologies has become a paramount component of the additive manufacturing industry. The direct ink writing (DIW) process, also entitled “Robocasting,” is appertaining to the conventional casting process and facilitates the fabrication of complex architecture made up of peculiar materials, which are to be transformed into ink that procures shear-thinning and viscoelastic properties to be printed in patterns. Several types of research have been carried out on fabricating a variety of components with multifarious materials by employing direct ink writing, but very few articles are present to date pertaining to DIW process parameters and their influence on ink rheology. This review paper is devoted to explicating the DIW technique, appertaining to aggrandized emphasis on preponderate process parameters like nozzle diameter, extrusion rate, nozzle substrate distance, extrusion pressure, layer thickness, and their influence on ink rheology, ink flow, and also broad versatility of the techniques used for printing variety of materials. The delineation of the utilization of newly emerging technologies like machine learning for atomizing the control of process parameters and designing ink rheology models to incipient the accuracy and resolution of DIW is specified. Finally, the future potential of DIW is detailed and elucidated to address future challenges in bio-medical, electronics, and soft robotics applications.

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Acknowledgements

The authors would like to acknowledge Prof. M. S. Sutaone, Director & Professor, College of Engineering Pune, Dr. S. P. Butee, Head of Department, Metallurgy and Materials Technology, College of Engineering Pune, Prof. V. T. Thavale, College of Engineering Pune, and Dr. C. P. Ramanarayanan, Vice Chancellor, DIAT (DU), Pune for their continuous encouragement and support. Authors wish to extend their special thanks to Mr. Jigar Patadiya, Miss Niranjana Jaya Prakash, Miss Alsha Subhash for their unwavering and continuous technical support throughout the review writing.

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Authors and Affiliations

  1. Department of Metallurgy and Materials Science, College of Engineering, Pune, Pune, 411005, India

    Komal Sandeep Pandya

  2. Department of Chemical Engineering, Institute of Chemical Technology, Jalna, Jalna, 431203, India

    Sarang Subhashchandra Shindalkar

  3. Additive Manufacturing Laboratory, Department of Metallurgical and Materials Engineering, Defense Institute of Advanced Technology (DU), Ministry of Defense, Girinagar, Pune, 411025, India

    Balasubramanian Kandasubramanian

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  1. Komal Sandeep Pandya
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Pandya, K.S., Shindalkar, S.S. & Kandasubramanian, B. Breakthrough to the pragmatic evolution of direct ink writing: progression, challenges, and future. Prog Addit Manuf 8, 1303–1328 (2023). https://doi.org/10.1007/s40964-023-00399-7

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