Analysis of Density, Roughness, and Accuracy of the Atomic Diffusion Additive Manufacturing (ADAM) Process for Metal Parts

Atomic Diffusion Additive Manufacturing (ADAM) is a recent layer-wise process patented by Markforged for metals based on material extrusion. ADAM can be classified as an indirect additive manufacturing process in which a filament of metal powder encased in a plastic binder is used. After the fabrication of a green part, the plastic binder is removed by the post-treatments of washing and sintering (frittage). The aim of this work is to provide a preliminary characterisation of the ADAM process using Markforged Metal X, the unique system currently available on the market. Particularly, the density of printed 17-4 PH material is investigated, varying the layer thickness and the sample size. The dimensional accuracy of the ADAM process is evaluated using the ISO IT grades of a reference artefact. Due to the deposition strategy, the final density of the material results in being strongly dependent on the layer thickness and the size of the sample. The density of the material is low if compared to the material processed by powder bed AM processes. The superficial roughness is strongly dependent upon the layer thickness, but higher than that of other metal additive manufacturing processes because of the use of raw material in the filament form. The accuracy of the process achieves the IT13 grade that is comparable to that of traditional processes for the production of semi-finished metal parts.