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Fused Filament Fabrication (FFF) of Metal-Ceramic Components
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Composition consistency as a critical quality attribute for material extrusion additive manufacturing.

Laurel Hilger1, Alexandra Marnot2, Blair Brettmann1,2

  • 1School of Materials Science and Engineering, Georgia Institute of Technology, Atlanta, GA 30332 USA.

MRS Communications
|July 8, 2026
PubMed
Summary

This study introduces composition consistency as a critical quality attribute for dense paste additive manufacturing (AM) inks. It offers a new framework for assessing the quality of material extrusion AM inks and processes.

Keywords:
3D printingAdditive manufacturingExtrusionPolymer

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Chemical Engineering

Background:

  • Additive manufacturing (AM) of dense pastes is gaining traction in various fields.
  • Designing materials and processes for these heterogeneous systems is challenging.
  • Current printability assessments focus on extrudability and shape retention, neglecting particle-binder separation.

Purpose of the Study:

  • To establish composition consistency as a critical quality attribute for dense paste AM inks.
  • To develop a framework for assessing the quality of material extrusion AM inks and processes.
  • To address the issue of particle-binder separation in dense paste inks.

Main Methods:

  • Focus on assessing composition consistency as a key quality attribute.
  • Development of a framework for quality assessment.
  • Evaluation of material extrusion AM inks and processes.

Main Results:

  • Composition consistency is identified as a critical quality attribute for dense paste AM.
  • A framework for quality assessment of AM inks and processes is proposed.
  • The proposed framework addresses the susceptibility of inks to particle-binder separation.

Conclusions:

  • Composition consistency is essential for reliable dense paste additive manufacturing.
  • The developed framework enhances the quality assessment of material extrusion AM inks.
  • This work provides a new perspective on ensuring ink integrity during AM processes.