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1. Introduction
Layer-based manufacturing is achieved using additive manufacturing (AM) technology, which has been commercially available for over 25 years. AM has progressed a long way from the processes that started on the benches of research institutes over two decades ago. Nowadays, AM exhibits the capability and capacity for advanced manufacturing and is another potential process to produce freeform geometries. AM has experienced extensive growth of almost 30% in the past 5 years (Wohlers, 2018, 2019; Gibson et al., 2020). It shows the reality of being able to transfer three-dimensional (3D) designs created on computers to a machine that can replicate the geometry into a physical object. This can all be done almost regardless of the geometrical complexity and without determining how each feature must be made and in what order (Murtezaoglu et al., 2018; Maurya et al., 2020; Izadi et al., 2020).
Various industries have been using AM profitably for many years. High-tech industries, such as aerospace, enjoy the geometric freedom that allows them to make lightweight, high-performance components. Many AM-produced parts are already incorporated into aerospace engines and vehicles (Yakout et al., 2020). Volume production industries, such as the automotive sector, benefit from AM being able to prototype their models earlier and bring their products to the market as fast as possible. Medical companies value the ability of AM to convert patient-specific data for customized products and medical interventions (Gibson et al., 2006).
Large aerospace companies such as General Electric (GE), Boeing and Airbus are conducting wide research programs that are taking advantage of the opportunities that AM technologies provide (Najmon et al., 2019). A well-known example of AM in aerospace is the fuel nozzle for the GE LEAP engine, which was tested on the Airbus A320neo in April 2016. Production of this component increased to 3,000 parts during the 2 years from its release. Airbus planned to use over 120,000 AM parts in 2020. The feasibility of using nickel alloys for gas turbine blades produced by laser-based powder bed fusion (LB-PBF) has been examined for full load engine tests under a real working temperature (1,250°F) and speed of 13,000 rpm by Siemens Company. This project showed that when using AM, lead-time can be considerably reduced compared to conventional...