Composition consistency as a critical quality attribute for material extrusion additive manufacturing

Additive manufacturing (AM) of dense pastes is attracting interest across many fields and while the combination of a high loading of functional particles with a flowable continuous phase is promising, the heterogeneous system makes material and process design difficult. Prior work has focused on assessing printability by examining their extrudability and shape retention. However, for dense pastes, the inks are susceptible to separation of particles from binder, so we consider composition consistency as a critical quality attribute. This composition consistency attribute provides a framework for quality assessment of material extrusion AM inks and processes. Supplementary Information: The online version contains supplementary material available at 10.1557/s43579-026-00936-9.