The quality control of 3D printed structures is significant for the reliability of additively manufactured objects. A novel remote sensing technique for characterizing 3D printed structures was developed by non-destructive ultrasonic imaging of a commonly used thermoplastic object such as acrylonitrile butadiene syrene (ABS). The quality of the additively manufactured ABS slab printed by fused deposition modeling (FDM) technique was evaluated by imaging effective density technique. The infill density of the FDM printed structures were modified by varying the motor speed of the printing extruder. An ultrasonic raster scan of the 3D printed structure using the novel effective density imaging technique distinguished the contrast in density with a very high resolution in the density variation. In addition to the lateral scanning, the density characterization was also effective when applied axially and can probe deep inside the additively manufactured object. The experimentally measured density variation agrees well with the theoretically calculated density values as a function of flow rate. The combined lateral and axial capabilities of the imaging technique make it a promising diagnostic tool for an in situ inspection method of optimizing FDM printing and quality control of 3D printed objects.

Practically applied techniques for ultrasonic biomedical imaging employ delay-and-sum (DAS) beamforming which can resolve two objects down to 2.1λ within the acoustic Fresnel zone. Here, we demonstrate a phononic metamaterial lens (ML) for detection of laterally subwavelength object features in tissue-like phantoms beyond the phononic crystal evanescent zone and Fresnel zone of the emitter. The ML produces metamaterial collimation that spreads 8x less than the emitting transducer. Utilizing collimation, 3.6x greater lateral resolution beyond the Fresnel zone limit was achieved. Both hard objects and tissue approximating masses were examined in gelatin tissue phantoms near the Fresnel zone limit. Lateral dimensions and separation were resolved down to 0.50λ for hard objects, with tissue approximating masses slightly higher at 0.73λ. The work represents the application of a metamaterial for spatial characterization, and subwavelength resolution in a biosystem beyond the Fresnel zone limit.

The temperature dependence of the mechanical properties of polyvinyl alcohol-based poly n-isopropyl acrylamide (PVA-PNIPAm) hydrogel was studied from the static and dynamic bulk modulus of the material. The effect of the temperature-induced volumetric phase transition on Young’s Modulus, Poisson’s ratio, and the density of PVA-PNIPAm was experimentally measured and compared with a non-thermo-responsive Alginate hydrogel as a reference. An increase in the temperature from 27.5 to 32 °C results in the conventional temperature-dependent de-swelling of the PVA-PNIPAm hydrogel volume of up to 70% at the lower critical solution temperature (LCST). However, with the increase in temperature, the PVA-PNIPAm hydrogel showed a drastic increase in Young’s Modulus and density of PVA-PNIPAm and a corresponding decrease in the Poisson’s ratio and the static bulk modulus around the LCST temperature. The dynamic bulk modulus of the PVA-PNIPAm hydrogel is highly frequency-dependent before the LCST and highly temperature-sensitive after the LCST. The dynamic elastic properties of the thermo-responsive PVA-PNIPAm hydrogel were compared and observed to be significantly different from the thermally insensitive Alginate hydrogel.

Additive manufacturing technologies based on metal are evolving into an essential advanced manufacturing tool for constructing prototypes and parts that can lead to complex structures, dissimilar metal-based structures that cannot be constructed using conventional metallurgical techniques. Unlike traditional manufacturing processes, the metal AM processes are unreliable due to variable process parameters and a lack of conventionally acceptable evaluation methods. A thorough understanding of various diagnostic techniques is essential to improve the quality of additively manufactured products and provide reliable feedback on the manufacturing processes for improving the quality of the products. This review summarizes and discusses various ex-situ inspections and in-situ monitoring methods, including electron-based methods, thermal methods, acoustic methods, laser breakdown, and mechanical methods, for metal additive manufacturing.