Processes and materials used for direct writing technologies: A review

Abstract

Direct Writing (DW), also known as Robocasting, is an extrusion-based layer-by-layer manufacturing technique suitable for manufacturing complex geometries. Different types of materials such as metals, composites, ceramics, biomaterials, and shape memory alloys can be used for DW. The simplicity and cost-efficiency of DW makes it convenient for different applications, from biomedical to optics. Recent studies on DW show a tendency towards the development of new materials and applications. This represents the necessity of a deep understanding of the principles and parameters of each technique, material, and process challenge. This review highlights the principles of many DW techniques, the recent advancements in material development, applications, process parameters, and challenges in each DW process. Since the quality of the printed parts by DW highly depend on the material extrusion, the focus of this review is mainly on the ceramic extrusion process and its challenges from rheological and material development point of view. This review delivers an insight into DW processes and the challenges to overcome for development of new materials and applications. The main objective of the review is to deliver necessary information for non-specialist and interdisciplinary researchers.