Additive manufacturing (AM) is replacing traditional fabrication methods, offering nearly unlimited possibilities
in part design, while allowing precise control across the whole geometry. The automated just-in-time nature of
the process, user customization and tailored properties are beneficial for products in aerospace, pharmaceutical
and biomedical industries. A variety of AM techniques are employed based on different physical mechanisms
with appropriate domains of applicability in terms of materials and scale.
In this talk, we will first review AM approaches, systems and applications, with a focus on current capability gaps.
We will then introduce Vibration Assisted Printing (VAP), which is a new direct-write technique for rapid
processing of extremely viscous precursor mixtures to fabricate propellants, food, ceramics and metal
composites at high resolution. A suite of advanced diagnostics based on X-rays and image magnification will be
demonstrated that are used to quantify nozzle structural characteristics and material rheology in-situ during the
VAP process, as well as the resulting part structure and properties.