Shoufeng Yang

Shoufeng Yang
KU Leuven | ku leuven · Department of Mechanical Engineering

Professor of Additive Manufacturing

About

209
Publications
113,635
Reads
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13,238
Citations
Introduction
My major research interest is powder bed based (SLM/SLS/EBM/3DP etc.) multi-materials Additive Manufacturing, in which both complex materials composition and shape could be controlled in 3D. This is achieved by home-developed dry powder micro dispensing devices, mounted on powder bed AM systems using gantry or robotic arm. This micro dispensing device can dispense various dry powders at "drop on demand" style using open loop control (no weighing feedback needed), with high consistent (RSD
Additional affiliations
October 2016 - present
KU Leuven
Position
  • Professor (Full)
September 2010 - present
University of Southampton
Position
  • Professor (Full)
August 2013 - present
Nanyang Technological University
Position
  • Professor

Publications

Publications (209)
Article
Full-text available
To balance the manufacturing cost and customizability of automotive parts, a hybrid manufacturing process combining die-casting and selective laser melting (SLM) is proposed: starting with a conventional cast substrate, SLM is utilized to add additional geometric elements on top of it. For this hybrid process, the first priority is to prepare a sub...
Article
Full-text available
Potential applications of steel/nickel bimetals in corrosive environments are of increasing interest. In this study, bimetallic 316L/Hastelloy X was processed via laser powder bed fusion (L-PBF) using different parameters. Results indicated that the rapid cooling of L-PBF reduced the element segregation and carbide formation, thus leading to an int...
Article
Full-text available
Titanium alloys of near-α Ti–6Al–2Sn–4Zr–2Mo (Ti-6242) and intermetallic γ-TiAl (Ti–48Al–2Cr–2Nb) are commonly served as turbine blade materials operating at elevated temperatures. This study investigated the feasibility of using laser powder bed fusion (L-PBF) to fabricate two Ti–6Al–4V-based bimetals, i.e., Ti–6Al–4V/γ-TiAl and Ti–6Al–4V/Ti-6242,...
Article
Full-text available
For the first time, the interfacial microstructures and hardening mechanisms of a multi-material (MM) 316L stainless steel/Inconel 718 (316L SS/IN 718) interface fabricated by a novel multi-material selective laser melting (MM SLM) additive manufacturing (AM) system have been investigated in this study. MM 316L SS/IN 718 parts were successfully bui...
Preprint
Full-text available
Due to low productivity hence high costs, additive manufacturing is rarely used to automobile sector for volume production. This study proposes a hybrid solution combining die casting and selective laser melting (SLM) to balance the auto-part manufacturing cost and customizability. The top priority for such hybrid manufacturing is to prepare the ca...
Article
Full-text available
Additive manufacturing offers a revolutionary pathway for customising patient-specific metal implants. However, clinical practice calls for balanced material properties besides a patient-matched geometry, including good biocompatibility, low elastic modulus, good material strength and enhanced wear resistance. This study demonstrates an in-situ mic...
Article
Additive manufacturing has received tremendous attention in the manufacturing and materials industry in the past three decades. Zirconia-based advanced ceramics have been the subject of substantial interest related to structural and functional ceramics. NanoParticle Jetting (NPJ), a novel material jetting process for selectively depositing nanopart...
Article
Patient-specific mandibular reconstruction plates (PSMRPs) are being widely used to bridge segmental defects of the mandible after tumor resection or trauma as a result of their superior performance in mandibular reconstruction. Two structural optimized PSMRPs were created to boost the biomechanical behavior in patient-specific mandibular reconstru...
Preprint
Full-text available
Due to low productivity hence high costs, additive manufacturing is rarely used to automobile sector for volume production. This study proposes a hybrid solution combining die casting and selective laser melting (SLM) to balance the auto-part manufacturing cost and customizability. The top priority for such hybrid manufacturing is to prepare the ca...
Article
Fabricating microfluidics directly onto a printed circuit board (PCB) is a promising method to produce integrated systems. Here, we applied stereolithography (SLA) to 3D print microfluidic components directly onto PCBs. Current SLA resins suffer from significant thermal expansion, which leads to adhesion issues during temperature cycling. Photocura...
Article
Full-text available
Ti-Mo alloys/composites are expected to be the next-generation implant material with low modulus but without toxic/allergic elements. However, synthesis mechanisms of Ti-Mo biomaterials in Selective Laser Melting (SLM) vary according to raw materials and fundamentally influence material performance, due to its inhomogeneous chemical composition and...
Article
Full-text available
SLM) has evidenced deleterious effects on interfacial bonding reliability, but its fundamental understanding is less revealed. Therefore, this work vertically prepared MM parts of H13 tool steel and IN625 superalloy by SLM, as an example, to explore the interfacial macrosegregation mechanism. According to the mechanism, a liquid layer of unmixed H1...
Article
Full-text available
Background A combination of short titanium plates fabricated using additive manufacturing (AM) provides multiple advantages for complete mandible reconstruction, such as the minimisation of inherent implant deformation formed during AM and the resulting clinical impact, as well as greater flexibility for surgical operation. However, the biomechanic...
Article
Full-text available
In-situ preparation of particle reinforced Al matrix composites (PRAMCs) by laser powder bed fusion (LPBF) is a promising strategy to strengthen Al-based alloys. The laser-driven thermite reaction can be a practical mechanism to in-situ synthesise PRAMCs. However, the introduction of elements oxygen by adding Fe2O3 makes the powder mixture highly s...
Article
Patient-specific mandibular reconstruction plate (PSMRP), as one of the patient-specific implants (PSIs), offers a host of benefits to mandibular reconstruction. Due to the limitation of fabricating screw hole threads in the PSMRP, 3D printed PSMRP is applied to the non-locking system directly in the mandibular reconstruction with bone graft regard...
Article
Full-text available
Ti–6Al–2Sn–4Zr–2Mo (Ti-6242), a near-[Formula: see text] titanium alloy explicitly designed for high-temperature applications, consists of a martensitic structure after selective laser melting (SLM). However, martensite is thermally unstable and thus adverse to the long-term service at high temperatures. Hence, understanding martensite decompositio...
Article
For the first time, the tribological behaviour of 316 L stainless steel (316 L SS) additively manufactured via laser powder bed fusion (L-PBF) with ultrafine- and nano-grains obtained from high-pressure torsion (HPT) processing has been investigated. The pin-on-disk dry sliding wear test results demonstrate enhancement wear performance after HPT pr...
Article
Full-text available
Fatigue fracture of titanium alloys fabricated by Selective Laser Melting (SLM) in engineering has been studied in recent years, but an underlying understanding of the in-vivo fatigue fracture of SLM-fabricated titanium patient-specific implants (PSIs) is rarely revealed due to the complex in-vivo biomechanical behaviour and biological environment...
Article
In this study, the interfacial region of multi-material 316L stainless steel/Inconel 718 (316L SS/IN718) fabricated by laser powder bed fusion (L-PBF) is investigated in detail for the first time. The interfacial region consists of a fusion zone (FZ) with intermixed fused Fe and Ni, and individual 316L SS and IN 718 regions. Solid metallurgical bon...
Article
Background: Due to the limitation of conventional cancer treatment using chemotherapy, the nanoparticle therapeutics showed enhanced efficacy with alleviating side effects. Objective: The superparamagnetic iron oxide nanoparticles (T-C-SPION) would be prepared for doxorubicin (DOX) loading and delivery. Methods: Here, we reported a simple green s...
Article
Hydroxyapatite (HA) is a promising biomaterial for tissue engineering scaffolds due to its similar performance and composition to natural bone. However, the brittleness and poor toughness of pure HA limit its clinical application. Therefore, a lot of HA composites have been prepared to improve their mechanical performance. Fabricating complex and c...
Article
The influence of laser surface melting and Al–SiC cladding on the microstructure, mechanical, and electrochemical properties of Mg-Gd-Y-Zn-Zr alloys was studied. The presence of α-Mg, Mg5(Gd,Y,Zn) and Mg10(Y,Gd)Zn phases in the melted layer and Al4C3, SiC, Si, Mg2Si and Mg17Al12 phases in cladded layer were confirmed from XRD results. Microstructur...
Article
This study reported for the first time the selective laser melting of Ti–6Al–2Sn–4Zr–2Mo (Ti-6242), a near-α titanium alloy specifically designed for high-temperature services. The microstructural stability under standard aging (595 °C/8h) was assessed after fabrication. With increasing laser scan speeds, an increase of relative density to 99.5% wa...
Article
Full-text available
Fabrication of reinforced scaffolds for bone regeneration remains a significant challenge. The weak mechanical properties of the chitosan (CS)-based composite scaffold hindered its further application in clinic. Here, to obtain hydroxyethyl CS (HECS), some hydrogen bonds of CS were replaced by hydroxyethyl groups. Then, HECS-reinforced polyvinyl al...
Article
Full-text available
For the first time, the plastic deformation behavior of additively manufactured material processed by severe plastic deformation (SPD) is investigated. Herein, high‐pressure torsion (HPT) is applied on 316L stainless steel (316L SS) fabricated by laser powder bed fusion (LPBF) to produce ultrafine‐grained (UFG) and nanograined (NG) microstructures....
Article
Full-text available
In this work Macadamia nutshell (MS) was used as filler in fused deposition modeling (FDM) of Poly (lactic acid) (PLA) composites filaments. Composites containing MS both treated and untreated with alkali and silane were investigated by means of Fourier transform infrared spectroscopy (FTIR), X-Ray diffraction (XRD), Thermogravimetry (TG), scanning...
Article
Triply Periodic Minimal Surface (TPMS) porous structures are recognized as the most promising bionic artificial structures for tissue engineering. The fatigue properties of additive manufactured porous structures are essential for long-term use in a dynamical bio-skeletal environment. The aim of this study is to study the compression-compression fa...
Article
Biomineralized tissue is considered the final product of successful cell culture in bone tissue engineering. Dulbecco’s modified Eagle’s medium (DMEM) with fetal bovine serum (FBS) not only is used as a common culture medium but also provides a natural biomineralization environment, due to having similar ionic concentrations as blood plasma. Here,...
Article
Full-text available
p>Triply Periodic Minimal Surface (TPMS) porous structures are recognized as the most promising bionic artificial structures for tissue engineering. The fatigue properties of additive manufactured porous structures are essential for long-term use in a dynamical bio-skeletal environment. The aim of this study is to study the compression–compression...
Article
Full-text available
This paper presents the study of the properties of objects that were fabricated with fused deposition modeling technology while using Poly (lactic acid)/Walnut shell powder (PLA/WSP) biocomposite filaments. The WSP was treated while using NaOH followed by silane. The infrared spectrum of treated and untreated WSP was characterized. The result was t...
Article
Full-text available
A strategy for the preparation of bioactive poly-ether-ether-ketone/hydroxyapatite (PEEK/HA) composites was proposed in this study with the aim of controlling the biological and mechanical properties of different parts of the composites. The strategy integrated solvent-based extrusion freeforming 3D printing technology in order to print high-resolu...
Article
The microstructural evolution and deformation mechanisms of 316L stainless steel fabricated by Selective Laser Melting (SLM) and then processed by high-pressure torsion (HPT) were investigated by optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and x-ray diffraction (XRD). TEM observations and XRD...
Article
Here, the micropatterned gold nanoparticles (AuNPs) on graphene oxide (GO) nanosheet ([email protected]) was fabricated via thiol-Michael addition click reaction under ultraviolet (UV) light. First, AuNPs and GO were both functionalized by acrylamide and dithiothreitol, respectively, which were characterized by transmission electron microscope (TEM...
Article
Full-text available
The traditional aim of materials science is to establish the causal relationships between composition, processing, structure, and properties with the intention that, eventually, these relationships will make it possible to design materials to meet specifications. This paper explores another approach. If properties are related to structure at differ...
Article
Laser powder bed fusion (LPBF) is a proven additive manufacturing (AM) technology for producing metallic components with complex shapes using layer-by-layer manufacture principle. However, the fabrication of crackfree high-performance Ni-based superalloys such as Hastelloy X (HX) using LPBF technology remains a challenge because of these materials’...
Preprint
Full-text available
Triply Periodic Minimal Surface (TPMS) porous structures are recognized as the most promising bionic artificial structures for tissue engineering. The fatigue properties of additive manufactured porous structures are essential for long-term use in a dynamical bio-skeletal environment. The aim of this study is to study the compression-compression fa...
Conference Paper
Compared to limited complexity capacity in traditional fabrication and assembly techniques, Additive Manufacturing(AM)-based hybrid fabrication was widely used in the electronics industry for the advantages of fabricating complex structures and simplifying the assembly steps. In this study, the fabrication process of the Electrical-Mechanical Integ...
Article
The chitosan/gelatin hydrogel incorporated with biphasic calcium phosphate nanoparticles (BCP-NPs) as scaffold (CGB) for bone tissue engineering was reported in this paper. Such nanocomposite hydrogels were fabricated by using cycled freeze-thawing method, of which physicochemical and biological properties were regulated by adjusting the weight rat...
Article
Full-text available
Triply periodic minimal surfaces (TPMSs) have attracted increasing attention for their high manufacturability, biocompatibility, and mechanical properties. In this work, graded Gyroid cellular structures (GCSs) with varying gradient directions were mathematically designed and manufactured via selective laser melting (SLM). The effect of gradients o...
Article
Full-text available
Metal additive manufacturing, despite of offering unique capabilities e.g. unlimited design freedom, short manufacturing time, etc., suffers from raft of intrinsic defects. Porosity is of the defects which can badly deteriorate a part’s performance. In this respect, enabling one to observe and predict the porosity during this process is of high imp...
Conference Paper
Full-text available
Optical preforms and fibres manufacturing face numerous challenges with the demand for novel fibre designs with complex geometries using single or multiple materials. The multi-step approach currently followed to produce complex structures can endanger the mechanical integrity of the preform and add optical losses to the fibre. Often these complex...
Article
The multi-material selective laser melting (SLM) technology has been widely studied in recent years. In this paper, 316L stainless steel (316SS) and Inconel 718 (IN718) multi-material parts were manufactured by SLM and their interfacial characteristics and mechanical properties were investigated by optical microscopy, scanning electron microscopy,...
Article
Selective Laser Melting (SLM) was used to process a powder mixture of CP Ti, 6.5 wt% Mo and 3.5 wt% Mo 2 C. The process parameters were optimized to obtain full-density, crack free parts. After the in situ decomposition of Mo 2 C in favor of the formation of TiC, the material consisted of a homogeneous dispersion of submicrometer sized TiC platelet...
Article
The chip-level bare die direct liquid impingement jet cooling is regarded as a highly efficient cooling solution for high-performance applications. Furthermore, it shows potential to be integrated inside the chip package. In previous studies, we demonstrated this cooling concept using a prototype fabricated with mechanical micromachining using poly...
Article
The occurrence of keyhole porosity in selective laser melting (SLM) has so far not been quantified systematically using X-ray computed tomography (X-CT). In this study, keyhole porosity in selective laser molten Ti-6Al-4V grade 23 parts was analyzed using post-process characterizations. Single tracks were produced with optimum, high volumetric ener...
Poster
Full-text available
The occurrence of keyhole porosity in Ti-6Al-4V parts manufactured by selective laser melting (SLM) has not been systematically quantified using post-process characterizations. The X-ray computed tomography (X-CT) technique is capable to analyse the size, shape, location, and number of keyhole pores in SLM parts. In this study, keyhole porosity in...
Conference Paper
Full-text available
The occurrence of keyhole porosity in selective laser melting (SLM) has so far not been quantified systematically using X-ray computed tomography (X-CT). In this study, keyhole porosity in selective laser molten Ti-6Al-4V grade 23 parts was analyzed using post-process characterizations. Single tracks were produced with optimum, high volumetric ener...
Article
Full-text available
This paper presents the influence of an inorganic Al2O3 layer over MoS2 particles on the tribological performance of electroless Ni–P–MoS2/Al2O3 composite coatings fabricated without using surfactants. The Al2O3-coated MoS2 particles were prepared by a heterogeneous nucleation process. The dry sliding tests of the composite coatings were tested aga...
Article
Although metal matrix composites (MMCs) possess high mechanical properties for wide potential applications, there are limited kinds of ex-situ MMCs fabricated via selective laser melting (SLM) until now. In this study, TiN/AISI 420 stainless steel (SS) MMCs samples were fabricated by SLM. Densification behavior, microstructure, hardness and wear pe...
Article
Full-text available
The laser polishing technique offers an adaptable, accurate, and environmentally friendly solution to enhance the surface quality of additive manufactured metallic components. Recent work has shown that the surface roughness of laser additive manufactured metallic alloys can be significantly reduced via the laser polishing method. This paper examin...
Article
Full-text available
Functional graded cellular materials (FGCMs) have attracted increasing attentions for their improved properties when compared to uniform cellular structures. In this work, graded Gyroid cellular structures (GCSs) with varying gradient directions were designed and manufactured via selective laser melting (SLM). As a reference, uniform structures wer...
Article
The inorganic coating of Al2O3 was introduced on nanoparticles to weaken their tendency of agglomeration in electroless plating bath. The influence of the coating on interaction energy and interaction forces between the coated particles was evaluated in this study. The Al2O3-coated diamond particles were prepared by the heterogeneous nucleation pro...
Article
Full-text available
The traditional machine tool design method with metal materials makes large-scale moving structures very heavy, which seriously impacts dynamic performance and results in significant energy consumption. Using sandwich structures of composite materials to replace metal materials is an important strategy for lightweight large-scale moving structures....
Article
Materials used for hard tissue replacement should match the elastic properties of human bone tissue. Therefore, cellular structures are more favourable for the use of implants than solid materials for their custom-designed mechanical properties. The superimposed load from various directions in vivo makes uniaxial compression testing insufficient fo...
Article
Cellular structures with controllable mechanical properties and porous architecture are the most promising candidates for many applications such as bone implants. Selective laser melting (SLM), one of the additive manufacturing (AM) technologies, enables manufacturing of space filling lattice structures with exceptional load bearing efficiency, cus...
Conference Paper
In this work, a slurry-based laser sintering process is investigated. Laser sintering allows for a broad palette of materials to be used. Since the binder content is only about 16 vol% with respect to the ceramic powder load, the debinding process is faster and less susceptible to crack formation and part warping compared to lithography-based manuf...
Article
Extracellular matrix stiffness has a profound effect on the behavior of many cell types. Adherent cells apply contractile forces to the material on which they adhere and sense the resistance of the material to deformation-its stiffness. This is dependent on both the elastic modulus and the thickness of the material, with the corollary that single c...
Conference Paper
Liquid jet impingement cooling is a very efficient cooling technology for high performance devices. Previous studies demonstrated that polymers can be used as a cost effective alternative for Si for the fabrication of impingement coolers. The recent developments in additive manufacturing or 3D printing technology enable the potential to fabricate l...
Article
For the first time, the novel combination of severe plastic deformation (SPD) and Additive Manufacturing (AM) in a single process sequence was explored. 316L stainless steel (316L SS) alloy was firstly fabricated by Selective Laser Melting (SLM) AM process and subsequently processed by high-pressure torsion (HPT) SPD technique under a constant pres...
Preprint
Extracellular matrix stiffness has a profound effect on the behaviour of many cell types. Adherent cells apply contractile forces to the material on which they adhere, and sense the resistance of the material to deformation – its stiffness. This is dependent on both the elastic modulus and the thickness of the material, with the corollary that sing...
Chapter
Different fabrication methods from traditional chemical engineering methods to advanced additive manufacturing (AM) are used for fabrication of tissue engineering (TE) scaffolds. The traditional techniques are subjected to limitations such as manual intervention, and inconsistent and inflexible processing procedures. In addition, the traditional te...
Article
Full-text available
The present study proposes a back propagation artificial neural network (BPANN) to provide improved precision for predicting the material removal rate (MRR) in ultrasonic machining. The BPANN benefits from the advantage of artificial neural networks (ANNs) in dealing with complex input-output relationships without explicit mathematical functions. I...
Article
Full-text available
Purpose This paper aims to provide a review on the process of additive manufacturing of ceramic materials, focusing on partial and full melting of ceramic powder by a high-energy laser beam without the use of binders. Design/methodology/approach Selective laser sintering or melting (SLS/SLM) techniques are first introduced, followed by analysis of...
Article
Full-text available
Three-dimensional printing of cell-laden hydrogels has evolved as a promising approach on the route to patient-specific or complex tissue engineered constructs. However, it is still challenging to print structures with both, high shape fidelity and cell vitality. Herein, we used a synthetic nanosilicate clay, called Laponite, to build up scaffolds...
Article
The present study proposes a characterization approach for the extrusion process of hydroxyapatite (HA) paste considering the nonlinear characteristics of bioceramics materials with the aim of printing high-resolution ceramic scaffolds using low-temperature extrusion 3D printing technology. A novel method named the three-point experimental extrapol...
Conference Paper
The ReDSHIFT (Revolutionary Design of Spacecraft through Holistic Integration of Future Technologies) project has been approved by the European Community in the framework of the H2020 Protec 2015 call, focused on passive means to reduce the impact of Space Debris by prevention, mitigation and protection. In ReDSHIFT these goals will be achieved thr...