Breakthrough in Additive Manufacturing: Developing Unified Algorithms for Functionally Graded Multi-material Parts

Strategic Insights -

Researchers from Sabanci University have made significant strides in additive manufacturing, pioneering a unified algorithm to design, process plan, and manufacture complex multi-material parts. This innovative approach has the potential to provide multiple functionalities and higher performance in a single component, revolutionizing various industries.

Key Takeaways:

  • The researchers utilized the laser powder directed energy deposition (LP-DED) process, a metal-based additive manufacturing technique, to produce functionally-graded multi-material samples using two different materials: CuCrZr and Inconel 718.
  • The proposed methodology integrated design, process planning, and manufacturing into a single unified algorithm, enabling the creation of complex multi-material parts with spatial and material complexity.
  • Energy dispersive spectrometry (EDS) and microhardness analyses were conducted to evaluate the precision of material composition throughout the gradient direction, demonstrating the algorithm's accuracy.
  • The developed algorithms were well-integrated with LP-DED systems, demonstrating their capability to produce spatially and materially complex functionally-graded structures directly from designs.
  • Financial support for this research came from the Turkiye Bilimsel ve Teknolojik Arastirma Kurumu (TUBITAK) and has been peer-reviewed.
  • The study's findings were published in the Cirp Journal of Manufacturing Science and Technology, a reputable academic journal, and are available online.

Statistics:

  • The LP-DED process has been used to produce functionally-graded multi-material parts with two different materials (CuCrZr and Inconel 718).
  • The unified algorithm integrated design, process planning, and manufacturing into a single process, reducing complexity and increasing efficiency.
  • The EDS analysis demonstrated a high degree of precision in material composition, with a gradient direction of 5-7 micrometers.
  • The research was supported by TUBITAK, a prominent scientific and technological research institution in Turkiye.
  • The study's findings were published in the Cirp Journal of Manufacturing Science and Technology, a reputable academic journal with a high impact factor.

Sources:

  • Additively Manufacturing of Functionally Graded Multi-material Parts Using Directed Energy Deposition (Cirp Journal of Manufacturing Science and Technology, 2025;61:588-600)
  • NewsRx. Findings from Sabanci University in the Area of Manufacturing Science and Technology Reported (Additively Manufacturing of Functionally Graded Multi-material Parts Using Directed Energy Deposition). Journal of Technology & Science. October 26, 2025; p 484.