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This paper discusses the effect called undesirable extrusion dynamics that occur during material extrusion printing or fused deposition modeling. This effect is revealed during high acceleration and deceleration of printing head and results in over-extrusion on corners of parts and printed layer unevenness. To minimize this effect, modern control systems use Advance algorithms for dynamics control. However, such disadvantages as inertia, reduced printing speed, need for manual calibration, as well as uncertainty of the influence of material, nozzle geometry, and printing process parameters on the algorithm performance do not allow this group of solutions to be applied on an industrial scale. The paper presents a study of the influence of printing characteristics, such as material type, extruder type, printing temperature, layer and nozzle geometry, on extrusion dynamics through a series of experiments. The experiments were carried out on a Creality Ender 3 printer. The obtained experimental data will allow us to deepen the understanding of extrusion dynamics influence in FDM printing; they are also used in the present study to modify existing dynamics control algorithms. The paper proposes a modification of Advance algorithm based on machine learning. It is proposed to implement an algorithm containing two trained neural network models. One model predicts changes in printing head motion to minimize residual defects and increase average print speed. The second model predicts the compensation parameter for specific printing conditions without the need for manual calibration. A neural network model was trained to determine the compensation parameter depending on the type of material, layer thickness, nozzle geometry and printing temperature. The model was trained based on experimental data. The developed algorithm was introduced into Linear Advance algorithm of the Marlin firmware and tested on Creality Ender 3. The experiments showed that the developed model can successfully predict the required compensation and can be applied during the printing process. The proposed algorithm helps to facilitate and automate the process of extrusion dynamics compensation which will expand the possibilities of FDM printers’ application in industrial conditions. The obtained algorithm can improve the accuracy and printing speed which will subsequently help to increase the economic independence and competitiveness of small design organizations and enterprises in Russia that use 3D printers. This research expands the possibilities of rapid prototyping and may help to ensure the rapid creation of pilot batches.

In this paper, a new approach for additive manufacturing metal-matrix composites based on Ti–6Al–4V titanium alloy reinforced with titanium carbide particles, as well as layered structures consisted of such composite and Ti–6Al–4V alloy layers is considered. The approach is based on 3D printing with a conical electron beam using a special cored wire, whose composition corresponds to metal-matrix composite. The issues of production such a wire, the features of the 3D printing process, when using it, as well as the features of formation of the microstructure and phase composition of the printed composite material are described. The issues of titanium-carbide particles’ wetting with Ti–6Al–4V melt during process of 3D printing, as well as possible thermogravitational effects (floating or drowning) for solid TiC particles within the melt are considered in detail with additional experiments. The influence of individual components of the wire composition on the formation of the microstructure and its uniformity over the cross section of the printed layer is shown. The possibility of controlling the formation of homogeneous structural state and obtaining sufficiently high values of the hardness (of above 600 HV) of the metal-matrix composite layer printed on the Ti–6Al–4V baseplate is shown.

Aerospace applications can benefit from additive manufacturing (AM), which is highly advantageous for prototyping and rapid manufacturing. It also offers cost and weight savings, as well as integrated design capabilities. As of now, there are only a few AM standards available, many materials and equipment are involved, resulting in many variables that hinder certification and adoption. As a result, nonstandard testing is making AM in the airborne materials less appealing due to its costly and time-consuming nature. The main objective of this work is to manufacture the Selector Valve Body parts of military and civil aircraft through Laser Powder Bed Fusion (LPBF) process using AlSi10Mg powder. Further, this paper has been carried out the metallurgical properties, non-destructive and destructive testing as well as the clear explanation about the certification procedures. Moreover, this underscores the need for the developing guidelines, and standards that cover all aspects of manufacturing from design to manufacturing to operation. A comprehensive analysis from liquid penetration test shows defects are within the permissible level. In addition, it exhibits higher yield strength, ultimate strength, and elongation of (259±4) MPa, (323±4) MPa, and (12.5±1.5) % respectively, along with factual evidence that the precipitation hardened AlSi10Mg indigenously developed and produced is equal in properties to the equivalent precipitation hardening aluminium alloys produced by internationally renowned manufacturers.

The article discusses the process of using additive technologies in the manufacture of formbuilding equipment. It is supposed to reduce the manufacturing time and labor costs of workers by using non-traditional technological systems in the manufacture of the form-building equipment’s model, which has qualitatively new properties and capabilities and also significantly increases the level of automation and intensification of production processes. When designing a technological process high information and computerization, a certain level of electrification and energy supply are required, therefore, the design of new technologies is based on rational technological processes, using accumulated experience, and a new system approach developed on the basis of the unity of production design technology using CAD/CAE/CAM systems. The extrusion method of three-dimensional printing using the FDM technology with the use of a new modified material of the PA12CF brand was adopted as the basis for the production of form-building equipment. This material is a polyamide-12 composite plastic reinforced with carbon fibers. The use of additive technologies using modern computer modeling based on the unity of technological systems is an urgent task. These technological systems will significantly increase productivity, reduce the production area occupied by equipment, reduce the duration of the production cycle, reduce the number of workers employed in production, and make it possible to switch to technologies that do not require paper-based design documentation. At the same time, additive technologies are open to their further development and have great potential to evolve and be modified in accordance with the changing external conditions on the labor market.