Common Imperfections and Mechanical Performance of Additively Manufactured Scaffolds

Direct Ink Writing (DIW) manufacturing technique enables the fabrication of metal-ceramic composite structures. This study examined core-shell filaments composed of 316L stainless steel and Al₂O₃ ceramic, produced through co-axial DIW followed by reactive sintering within the MULTIFUN3D project. Scaffolds made of pure ceramic filaments are also considered. Fabrication-induced imperfections, including porosity, non-circular cross-sections, and filament penetration are observed. Their influence on structural performance is evaluated by interpreting the experimental results obtained from mechanical tests with the aid of corresponding numerical simulations. The final goal is to identify the most effective improvements to be introduced into the manufacturing process to ensure consistency between design and actual production performance.