The processes utilized for Additive Manufacturing (AM) production of metallic parts usually entail the use of hazardous feedstocks, expensive production equipment, and high energy consumption. Metal Material Extrusion AM (MEX/M) presents an alternative multi-step approach that addresses these challenges by additively extruding polymer-metal composite filaments, constructing a green part. This green part undergoes transformation into a fully functional (white) part through successive debinding and sintering processes.

The promising potential of MEX/M has spurred research efforts aimed at enhancing mechanical strength, controlling volumetric shrinkage, and minimizing distortion in the final parts. These efforts aim to position MEX/M as a viable option for the serial manufacturing of metal near-net shape parts, since it currently lacks the capability to meet the quality level required to be a fully competitive industrial alternative.

In line with this purpose, this project introduces a scientific hypothesis proposing the improvement of dimensional and geometric quality in MEX/M parts through a synergistic approach involving geometry compensation and data-driven process optimization. Consequently, its main objective is to develop and evaluate a methodology to enhance the accuracy of industrial components produced via MEX/M.

Specially developed optimization algorithms will fine-tune process configuration and adjust input geometry to minimize dimensional and geometric errors, relying on the information within a Space-Timely Enhanced Information Model (STEIM). Additionally, the STEIM will continuously update, enabling early anomaly detection and the prompt application of corrective measures.

The proposed methodology will be employed to reduce manufacturing errors in MEX/M/AISI316L stainless steel parts, with the goal of elevating MEX/M to a quality level comparable to Metal Injection Moulding (MIM) and superior to Binder Jetting of metallic parts (BJT/M). The choice of AISI 316L, extensively used in MEX/M, is based on its industrial relevance.

The accomplishment of the proposed objective will be evaluated by producing and verifying batches of AISI 316L components, encompassing both optimized and non-optimized versions, on a sensorized test bench. The focus will be on three critical quality aspects: the dimensions of geometric features, the intrinsic geometry of these features, and the achieved density. A set of quality indicators will be utilized to precisely measure the improvements achieved through the application of the proposed methodology. A conclusive case study will be conducted in collaboration with an industrial producer of MEX/M parts.

If successful, this approach has the potential to establish MEX/M as a practical and competitive choice for serially producing 316L stainless steel components with industrial-grade quality, and could foster the utilization of the developed methodology for other metals.