Accelerating Metal Extrusion Additive Manufacturing Process Development with Citrine Machine Learning Tools

Author(s) Information

Sam Moran, California Polytechnic State University, San Luis ObispoFollow
Andrea Patin, California Polytechnic State University, San Luis ObispoFollow
Tyler Seto, California Polytechnic State University, San Luis ObispoFollow
Cam Sherry, California Polytechnic State University, San Luis ObispoFollow

College - Author 1

College of Engineering

Department - Author 1

Materials Engineering Department

College - Author 2

College of Engineering

Department - Author 2

Materials Engineering Department

College - Author 3

College of Engineering

Department - Author 3

Materials Engineering Department

College - Author 4

College of Engineering

Department - Author 4

Materials Engineering Department

Advisor

Joel Galos, College of Engineering, Materials Engineering Department; Thale Smith, College of Engineering, Materials Engineering Department

Funding Source

Thank you to Jim and Mary Beaver for their generous donation that supported this work.

Acknowledgements

Thank you to Matt Gerboth from Citrine Informatics for his guidance and support.

Date

10-2025

Abstract/Summary

Material Extrusion (MEX) is a low-cost approach to metal additive manufacturing that involves extruding a metal-polymer composite filament to create a part comprised of polymer-bound metal powder, which is subsequently debound and sintered to produce a fully metal component. A major barrier to broader implementation of metal MEX is the time-intensive process for determining printing and sintering process parameters. To consistently produce sintered parts that satisfy geometric and materials properties requirements, trial-and-error experimentation is required to develop process parameters, correct shrinkage variability, and mitigate defects. This project aims to leverage Citrine Informatics’ machine learning (ML) tools to accelerate development of key aspects of the metal MEX process, including defect mitigation, shrinkage behavior, and sintering conditions, while still achieving materials properties that meet metal injection molding (MIM) standards. Successfully integrating ML with metallographic characterization and mechanical testing will enhance industrial viability of metal MEX by using predictive modeling to accelerate process parameter optimization, thereby reducing the number of printing and sintering hours required to produce a component that meets design requirements.

October 1, 2025.