Browse Topic: Additive manufacturing

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Design-Driven Sustainability of Automotive Components: A Comparative LCA from Conventional to Metal and Composite Additive Manufacturing2026-37-0037To be published on 06/09/2026
The increasing pressure to decarbonize manufacturing systems is pushing industry beyond conventional lightweighting strategies toward material and process paradigms, capable of delivering functional performance with radically lower environmental impact. In this context, polymer-based composite Additive Manufacturing (AM) offers an underexplored yet highly promising pathway for sustainable production of load-bearing components. This study presents a preliminary comparative cradle-to-gate Life Cycle Assessment (LCA) of a Formula SAE brake pedal, assessing the environmental transition from conventional CNC machining of Aluminum 7075-T6 to additive manufacturing solutions, with specific focus on Carbon-Fiber-Reinforced Polymer (CFRP) composites. Two topology-optimized designs, respectively for Powder Bed Fusion (PBF) in AlSi10Mg and Material Extrusion (MEX) in PETG-CF are compared to machined aluminum benchmark. The analysis is integrated in the product and process design following ISO
Dalpadulo, Enrico, Russo, Mario, Apté MD, Raphaëlle, Leali, Francesco
Advancing Aerospace Interiors: Evaluation of the In-House Polymer Pellet Additive Manufacturing System2026-26-0765To be published on 06/01/2026
The Elektra printer is an open-source, pellet-based (FGF) 3 axis additive manufacturing system developed by Collins in collaboration with Pollen AM to enable large-scale, cost-efficient 3D printing using standard polymer pellets. In alignment with the Make in India program, Elektra represents a significant step toward localized, industrial-scale additive manufacturing that delivers affordability, flexibility, and performance for aerospace and allied industries. The system provides four major advantages. First, it enables cost-effective part production by leveraging standard injection molding grade thermoplastic pellets instead of expensive proprietary feedstocks. Second, its large build volume (800mm*800mm*400mm) supports the manufacture of tools, fixtures, and structural parts often restricted by conventional systems. Third, Elektra is compatible with a broad range of engineering and high-performance polymers that are flame retardant, ensuring adaptability for multiple use cases
Kini, Aditya Deepak, Sundar, Santosh
System and Method of Strain Emulation using a Beam Load Cell Test Setup2026-26-0743To be published on 06/01/2026
This novel method deals with emulation of Strain of a Structural Measurement System which includes software validation, acceptance tests and training. Current methods for simulating strain and force data for developing and verifying data acquisition (DAQ) software typically rely on costly electronic simulators or specialized hardware, making it challenging and expensive for developers, researchers, and small organizations to test their solutions under realistic conditions. To verify DAQ software, multiple specialized hardware solutions are deployed, that include Electronic Simulators, Commercial DAQ Modules and Hydraulic/Pneumatic test rigs. These technologies pose a challenge with limited flexibility and scalability options for small-scale prototyping, especially in budget-constrained scenarios. The sensors on these equipment may or may not be company approved inducing acceptance challenges. Our invention is an inexpensive, scalable, and mechanically simple alternative. Using a 3D
Murthy, Harsha, Bhat Venkatesh, Aditi, K Padmanabhan, Rahul, Madhu, Sheetal, Garag, Naveen
Zero-shot Classification of Additive Manufacturing Anomalies2026-26-0721To be published on 06/01/2026
Additive Manufacturing (AM) process involves building the part layer by layer. Depending on the AM process, various defects (Anomalies) are possible. These defects adversely affect the strength characteristics of the manufactured part. For any given set of AM process parameters, the melt pool characteristics should be similar (within a range) at any instance of AM printing process. Hence the images of the melt pool taken during the AM printing process are expected to have similar characteristics at any given point of AM printing. So, a melt pool image of an anomaly is different from melt pool images from normal printing process. Hence a zero shot classification of anomaly is done with a vision transformer model and a vector database of created from melt pool images.
Kuppusamy, Balasundar
Reducing Test Campaigns through Advanced Yield Surface Modeling for New Aircraft Metal Grades2026-26-0755To be published on 06/01/2026
Qualification of new aerospace alloys requires extensive mechanical testing to capture anisotropy and ensure reliable performance under complex loading conditions. This process is costly and time-consuming, particularly with emerging manufacturing routes such as additive manufacturing. Advanced yield surface prediction offers a route to reduce test campaigns by linking microstructural features to macroscopic constitutive models. In this work, Digimat is employed as a multi-scale material modeling platform to generate yield surfaces of polycrystalline metals using computational homogenization. Representative volume elements (RVEs) are constructed from experimental texture and grain morphology data, and their response under multiaxial loading is simulated using a crystal plasticity framework. The computed yield loci are then fitted with phenomenological functions (e.g. Barlat2000), enabling calibration of anisotropic yield models from virtual testing. As a case study, an AA6016-T4 sheet
Padhan, Manas, Uppaluri, Rohith, Lemoine, Guerric, Soni, Ganesh
Design and Multi-Faceted Validation of UAV Arm Clamps, Landing Gear and Motor Mounts via Generative Design in Autodesk Fusion 3602026-26-0734To be published on 06/01/2026
The reliability of the entire airframe is essential for Unmanned Aerial Vehicles (UAVs) deployed in critical surveillance and disaster management missions. Performance cannot be compromised, as even minor structural weaknesses can impact flight stability and mission success. This work introduces a thorough "design–simulate–build–test" process that combines advanced simulation, additive manufacturing, AI-driven generative design, and experimental validation to construct an assembly of high-performance UAV structural components. Motor mounts, arm clamps and landing gear were among the important structural components of a custom UAV that were redesigned using the suggested technique. With the use of Autodesk Fusion 360's generative design tools, every component was tailored for Fused Filament Fabrication (FFF) additive manufacturing. Their mechanical performance was first predicted through a detailed Finite Element Analysis (FEA) framework. To experimentally validate these simulations
Krishna Bansal, Vaibhav
Sampling, Conformance Strategies, and Recommended Practices for Closed Loop Processing of Powder for Additive ManufacturingARP7302 (Current)4/8/2026
This SAE Aerospace Recommended Practice (ARP) establishes methods and identifies opportunities to sample used powder feedstock circulating within closed loop equipment of an additive manufacturing (AM) process for the purpose of showing conformance to a powder specification. Powder within the entirety of closed loop equipment cannot be represented by sampling and testing of discrete, in-process lots. Because powder processing (i.e., reconditioning, conveyance, and storage) is asynchronous with a build cycle, individual samples and their associated tests do not represent the totality of powder committed to a machine. Powder consumed as part of an individual build cycle may only represent a subset of feedstock in circulation within such equipment. Therefore, regular testing to substantiate conformance to a powder specification is required to assert conforming feedstock was consumed during individual build cycles of the AM workflow to fabricate parts or preforms. Operation of some
AMS AM Additive Manufacturing Metals
The Development of an Experimental Methodology for the Measurement of Aeroelastic Components2026-01-06484/7/2026
In high-end motorsport engineering, aerodynamic devices such as front and rear wings are prone to aeroelastic deformations under certain conditions, which can be exploited for vehicle performance gains. Considering the complex interactions between the aerodynamics and structures, experimental evaluation can prove to be a time-effective approach for design, optimisation, research and development regarding aeroelastic bodies. This study presents the development and experimental validation of a deformation tracking system using depth-sensing LiDAR (Light Detection and Ranging) camera technology. The system is based on the use of reflective markers mounted on a given model of interest; this project, a front wing model with a flexible, 3D printed flap element was used as a benchmark. Surface deformation is captured by post-processing point cloud data to extract three-dimensional displacement vectors. A series of controlled measurement tests were first conducted to assess accuracy and
Altinbas, Koray, Soares, Renan F.
Design and Simulation Analysis of an Integrated Honeycomb-Filled Front Bumper for a Special Vehicle2026-01-04754/7/2026
In frontal collisions of automobiles, the bumper beam at the front of the vehicle plays a crucial role in absorbing energy and protecting the vehicle body during a collision. To enhance the collision resistance of a specific type of special vehicle with a non-load-bearing body structure, this paper focuses on this type of vehicle and conducts a study on the design and collision performance of an integrated vehicle front bumper - anti-collision beam structure based on aluminum alloy additive manufacturing technology. A novel bumper structure is proposed, which integrates the front bumper and the front anti-collision beam of the vehicle and is integrally formed using aluminum alloy additive manufacturing technology. This integrated structure is directly connected to the vehicle frame. Firstly, based on the appearance of the special vehicle body and the form of the front anti-collision beam of traditional passenger vehicles, an integrated design of the vehicle front bumper- anti-collision
王, Xufan, Yuan, Liu-Kai, Zhang, Tangyun, Wang, Tao, Zhang, Ming, Wang, Liangmo
A Decision-Making Framework for Field Manufacturability of Vehicle Parts in Expeditionary Environments2026-01-01434/7/2026
Expeditionary environments (such as remote exploration missions, forward military operations, and disaster response zones) demand adaptive manufacturing solutions to support vehicle sustainment in the absence of traditional supply chains. This work introduces a conceptual mathematical framework for modeling the constraints and tradeoffs inherent to expeditionary manufacturing, with a focus on vehicle repair and spare parts fabrication using low-energy and simple automated systems including desktop-scale 3D printers and CNC machines. The model integrates key variables such as energy availability, material transport cost, fabrication time, and environmental limitations to support rapid decision-making on part manufacturability and in-field feasibility. A case study involving the on-demand production of some common wear and failure parts on a vehicle, including suspension components and the water pump, is used to demonstrate how this framework can guide the selection of suitable
Mollan, Calahan, Pandey, Vijitashwa, Patterson, Albert E.
Thermal Finite Element Modelling and Prediction of Laser Welded Battery Packs2026-01-03854/7/2026
Battery modules consist of battery cells electrically joined at the terminals by conductive busbars. Laser welds are the most consistent and controllable process to create these connections on a large scale due to their control over power, laser width, speed, wobble, and overlap, and their quality is critical to battery pack performance. Tuning these parameters for an application typically requires weld trials to reach desired weld width, penetration, and strength without overheating the battery cell and weakening the dielectric insulators around the terminals. Poorly welded cells in a module can result in increased electrical resistance, causing greater joule heating and accelerated cell aging, and poorly welded modules can lead to uneven aging and unpredictable performance. To better understand the laser welding process, a modelling approach was developed to predict weld properties to reduce production time, costs, and potential cell damage. The 3D finite element model was calibrated
Contreras, Luis, Hoffmeyer, Matthew, Abidin, Zainal
Anisotropic Mechanical Property Simulation of Fiber Reinforced PEEK Using Composite Theory and Comparison to Experimental Results2026-01-02564/7/2026
The mechanical properties of 3D printed composites have been shown to vary due to the manufacturing infill direction due to artifacts from the printing process. PEEK (Polyether Ether Ketone) and PEEK reinforced with carbon fiber were studied for these experiments because they are widely used for their high strength properties. 3D printed composites that behave with anisotropic characteristics have been evaluated under Laminate Composite Theory (LCT), which can be used to determine the mechanical properties of these 3D printed composites. By changing the orientation of the extruded strands in a 3D printed part, the structure can be optimized in a specific orientation for specific loading conditions, and LCT can be applied for simulating mechanical responses. Three point bending tests were performed on rectangular 3D printed samples and compared to a 3D simulation using LCT for a similar bending load. This allows for the use of LCT in combination with a finite element software such as
Bradley, Coilin, Garcia, Jordan, Sibley, Brian
A Framework for Predicting Mechanical Performance of FFF Printed Parts Using Multimodal Deep Learning on Infrared Images2026-01-01404/7/2026
Fused filament fabrication (FFF) has gained popularity in recent years because it can produce prototypes and functional components with complex geometry. Because of inherent process variability, the components often exhibit defects such as warping, layer delamination, voids, and poor surface finish, as well as issues related to variable material strength and anisotropy. In-situ monitoring (ISM) of the FFF process is a promising technique to predict part performance, which in turn can support accept or reject decisions for printed parts. This paper proposes a framework for incorporating ISM-generated information, with a particular focus on infrared (IR) image analysis for this purpose. IR camera images, in conjunction with numerical features such as infill pattern and extruder nozzle temperature, serve as an input to a multimodal deep learning (MDL) model that predicts the mechanical performance of printed parts. In the framework, convolutional neural nets process image inputs, while a
Mollan, Calahan, Kulkarni, Saurabh, Malik, Ali Ahmad, Patterson, Albert E., Pandey, Vijitashwa
Multi-Objective Topology Optimization for Cost and Time Minimization in Fiber Reinforced Additive Manufacturing2026-01-02574/7/2026
Fiber Reinforced Additive Manufacturing (FRAM) combines the geometric freedom of additive manufacturing with the high stiffness-to-weight advantages of composite materials, making it a promising approach for lightweight automotive components. The mechanical performance of fiber-reinforced composites is strongly influenced by fiber orientation, which highlights the importance of optimization methods that can effectively exploit anisotropic behavior. Existing FRAM optimization research has focused primarily on structural performance and has given limited attention to manufacturability challenges. This gap is significant, as overhangs and the resulting need for support structures can substantially increase print time, material consumption, and production cost, restricting broader industrial uptake. This research introduces a multi-objective topology optimization framework that incorporates Design for Additive Manufacturing (DfAM) principles by minimizing both structural compliance and
Wotten, Erik, Kim, Il Yong
Aerospace & Defense Technology: February 202626AERP022/5/2026
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace Smarter Pyrovalve Alternatives for Modern Missile and Munition Launcher Applications Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight Model-Based Design Is Shaping the Next Phase of eVTOL Systems Development How RF-over-Fiber is Providing the Backbone of Next Generation Mil/Aero Networks NASA Demonstrates a First-of-Its-Kind Space Communications A Rainfield Simulator for Hypersonic Testing The U.S. Army Space and Missile Defense Command Technical Center's Aerophysics Research Facility, (ARF), fired a successful hypersonic shot to test its new rainfield simulator. Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. The Critical Impact Of SAE Aerospace Standards: Certified AS1895/7 and /23 Metal Seals How engineers can ensure safety, reliability
Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research26AERP02_082/1/2026
Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. Auburn University, Auburn, AL In collaboration with Auburn University's Center for Polymers and Advanced Composites (CPAC) and the Department of Aerospace Engineering, the institute recently acquired a CF3D Enterprise Cell - a next-generation 3D carbon fiber composites printer set to define the future of the nation's hypersonic programs. Developed by Idaho-based Continuous Composites, the CF3D system represents a highly specialized advanced manufacturing capability and is the only system of its kind currently operating in Alabama.
3D Printing Method ‘Grows’ Ultra-Strong MaterialsTBMG-544081/1/2026
Researchers have pioneered a 3D printing method that grows metals and ceramics inside a water-based gel, resulting in exceptionally dense, yet intricate constructions for next-generation biomedical technologies.
Nickel Alloy, Corrosion- and Heat-Resistant, Powder for Additive Manufacturing, 50Ni - 20Co - 17Cr - 3.1W - 2.3Ti - 2.1Al - 2.1Mo - 1.8Cb(Nb) - 1.5Ta - 0.04C - 0.005BAMS7075 (Current)12/31/2025
This specification covers a corrosion- and heat-resistant nickel alloy in the form of pre-alloyed powder.
AMS AM Additive Manufacturing Metals
Manufacturing and Industry 4.0 : Vol. 2EPRCOMPV06202512/29/2025
King, Wayne E., Khan, Samir, Abdul Hamid, Umar Zakir
Experimental Investigation of Stress Distribution Characteristics in Surrounding Rock during Unloading in Oblique Upper Crossing Tunnel2025-99-024212/23/2025
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Wu, Hao, Qin, Shuzhen, Li, Guofeng, Dong, Tianwen, Shi, Yongyue
Failure Analysis and Redesign of a 3D Printed Intake Manifold in a Formula SAE Racing Team Using High-Performance Polymers2025-36-023412/18/2025
Fused filament fabrication (FFF) 3D printing has proven to be an affordable method for producing customized and lightweight parts and an accessible method to validate new composite materials. As a rapid prototyping method, it can be used to manufacture and replace defective and/or damaged parts in places with limited infrastructure or logistical support. However, the layer-by-layer deposition inherent to the FFF process introduces anisotropy and residual stresses, which can compromise part performance under high temperatures or vibrational loads. This article aims to analyze the failure of a 3D printed intake runner and address the problems found. The analyzed part was 3D printed in acrylonitrile butadiene styrene (ABS), which had a high volumetric contraction during the printing process. Although ABS exhibits a high heat deflection temperature (HDT) compared to other polymers, prolonged exposure to elevated temperatures during operation led to unintentional embrittlement, reducing
Oliveira, Vinícius de, Horiuchi, Lucas Nao, Magalhaes, Gabriel, Alcantara, Nathan de, Gonçalves, Ana Paula, Souza, Mariana, Polkowski, Rodrigo
Case Study: Nanocomposite-Based 3D Printing and the Implementation of Quality Management to Enhance the Production of Automotive Parts2025-36-020612/18/2025
Additive manufacturing is one of the pillars of technologies of the industry 4.0 and enables rapid prototyping, testing of new materials, and customized manufacturing of parts with personalized design. Poly(lactic acid) (PLA) is a bio-based and biodegradable polymer that is used in packaging, medical applications, and consumer goods. However, it presents low mechanical strength and thermal stability, which limits its use in automotive parts. The use of reinforcement materials such as cellulose nanofibers (CNF) aim to increase the mechanical strength and thermal stability of PLA without reducing its ecological appeal. However, the addition of nanofibers in the 3D printing process can lead to reproducibility problems and constant clogging of the extruder nozzle due to the material’s lower printability. These difficulties may restrict its application to industrial processes due to reduced productivity. To address the challenges in the production of automotive parts with PLA/CNF composites
Oliveira, Vinícius, Horiuchi, Lucas Nao, Gonçalves, Ana Paula, Souza, Mariana, Polkowski, Rodrigo
Design Proposals for the Automotive Sector, Case Study2025-36-010812/18/2025
In recent decades, vehicles have evolved from mere means of individual transportation to something much more meaningful. They are no longer mere metal bodies housing combustion engines, but now play a complex role in people’s lives, encompassing emotional, aesthetic, and symbolic aspects. These factors influence consumers’ choice of a model, brand, or version. Based on a literature review of the global automotive sector, including brand literature, scientific articles, and current automotive news, this study aims to analyze the main design and positioning trends adopted by large multinationals in the market. Using the Jeep Renegade as a case study, three design proposals for the model are illustrated and presented as follows: a “facelift,” a “new generation,” and a “concept vehicle.” Next, these design trends are conceptualized, initially illustrating the respective sketches and drafts, which take into account market positioning and the different options for the models presented in
Camilo, Pedro Gomes, Gamarra Rosado, Victor Orlando, Guidi, Erick Siqueira
Titanium Alloy Preforms from Plasma Arc Directed Energy Deposition Additive Manufacturing on Substrate, Ti-6Al-4V, Stress RelievedAMS7004A (Current)12/17/2025
This specification covers preforms fabricated up through 22.0 inches (560 mm), inclusive, in deposition width thickness (see 2.4) using a wire-fed plasma arc directed energy deposition (PA-DED) additive-manufacturing process on a Ti-6Al-4V substrate that are subjected to post-deposition stress-relief heat treatment. If required by the cognizant engineering organization (CEO), preforms may require subsequent machining to meet requirements for their intended final part application.
AMS AM Additive Manufacturing Metals
Aluminum Alloy Powder 1.1Zr-1.0Fe Aheadd CP1AMS7074 (Current)12/3/2025
This specification covers an aluminum alloy in the form of pre-alloyed powder.
AMS AM Additive Manufacturing Metals
3D Construction of Biologically Derived MaterialsTBMG-5430212/1/2025
NASA has developed a novel approach for macroscale biomaterial production by combining synthetic biology with 3D printing. Cells are biologically engineered to deposit desired materials, such as proteins or metals, derived from locally available resources. The bioengineered cells build different materials in a specified 3D pattern to produce novel microstructures with precise molecular composition, thickness, print pattern, and shape. Scaffolds and reagents can be used for further control over material product. This innovation provides modern design and fabrication techniques for custom-designed organic or organic-inorganic composite biomaterials produced from limited resources.
Metal Powder Feedstock Size ClassificationsAMS7025 (Current)11/26/2025
This specification covers particle size classifications and corresponding particle size distribution requirements for metal powder feedstock conforming to a classification.
AMS AM Additive Manufacturing Metals
Binder Jet Additive Manufacturing (BJAM) ProcessAMS7022 (Current)11/26/2025
This specification establishes process controls for the repeatable production of sintered parts by binder jet additive manufacturing (BJAM). It is primarily intended to be used to manufacture metallic or ceramic aerospace parts, but usage is not limited to such applications.
AMS AM Additive Manufacturing Metals
Electron Beam Directed Energy Deposition-Wire Additive Manufacturing Process (EB-DED-Wire)AMS7027 (Current)11/24/2025
This specification establishes process controls for the repeatable production of aerospace parts by EB-DED-Wire. It is intended to be used for metal aerospace parts produced by additive manufacturing (AM), but usage is not limited to such applications.
AMS AM Additive Manufacturing Metals
Additively Manufactured Aluminum-Lithium Alloys—Advances, Challenges, and Future Directions2025-01-507611/18/2025
Aluminum-lithium alloys are extensively used across various industries due to their exceptional strength-to-weight ratio, excellent fatigue/corrosion resistance and good thermal stability. These attributes, combined with improved weldability and ease of fabrication, make them ideal for lightweight engineering applications in sectors such as aerospace, automotive, and defense. Additive manufacturing (AM) offers unique opportunities to fully leverage the potential of aluminum-lithium alloys by enabling the fabrication of complex geometries, minimizing material waste, and supporting on-demand production. This paper explores the significance of lightweight materials, traces the evolution of aluminum-lithium alloys and provides a comprehensive overview of their AM. It discusses the properties and real-world applications of these alloys and examines various AM techniques employed in their processing. Key advancements in the AM of aluminum-lithium alloys are reviewed, including novel alloy
Santhana Babu, A.V., Antony Benson, B., Danusha, M.
Open-Source Software for 3D Printing with Multiple MaterialsTBMG-5419111/13/2025
3D Printed Injection Molding Tool: An Unique Approach for New Product Development2025-28-032111/6/2025
Automotive industry frequently uses 3D printed plastic proto parts during new product development phases as it bypasses the high tooling investment & development time at early part development stage. However, for some application, 3D printing technique & its limited material options are not fulfilling the required material properties in the part, resulting poor performance during product testing which may mislead the design engineer during validation process. To overcome this, we introduce a novel approach in constructing injection molding tool by 3D printing the core and cavity using Stereolithography (SLA). This enables production of parts with application-recommended material grades, facilitating traditional validation and increasing stakeholder confidence. This paper compares part quality from 3D printed molds against conventional metallic molds for a shifter gear housing cover, demonstrating a 45% reduction in tooling costs and a 75% decrease in tooling development time. Mold life
Gandhi, Sorna Rajendran, Gunduboina, Chaitanya
Strength Analysis of Additive Parts with Variation in Infill Percentage for ABS Materials2025-28-025111/6/2025
Three-dimensional (3D) printing technology has transformed manufacturing by enabling the creation of complex geometries with ease. Yet, optimizing the mechanical performance of printed parts remains a challenge, especially when balancing strength, material usage, and print time. Traditional mechanical testing in additive manufacturing often relies on specimens with 100% infill, overlooking the design potential of variable infill densities. This study introduces a novel approach by explicitly modeling internal infill structures in CAD (Creo Parametric) across a range of densities (10% to 100%) and validating their mechanical behavior through both finite element analysis (FEA) in ANSYS and standardized physical testing (ASTM D638 for tensile, ASTM D695 for compressive, and ASTM D790 for flexural properties). Unlike prior studies that rely on slicer-generated infill patterns, this method enables precise control and repeatability in simulation and testing. The results demonstrate how
Salgar, Manojkumar, Patil, Anup
Influence of Laser Sintered Process Parameters on Crystalline Characteristics and Mechanical Properties of AlSi10Mg Alloy05-19-03-001911/3/2025
The present study examines the influence of process parameters on the effect of strength and crystalline properties of AlSi10Mg alloy with laser sintered process. A detailed work was carried out with the effects of varying the laser power, scan speed, and hatch distance on crystalline structure, hardness, and surface roughness. From the analysis, the improved surface quality and mechanical performance were achieved with a scan speed of 1200 mm/s, a laser power of 370 W, and a hatch distance of 0.1 mm. An increase in hardness, improved surface finish, and reduced porosity was observed with decreased hatch distance. However, the balanced results were obtained for scanning speed of 1200 mm/s and laser power of 370 W. The ideal processing conditions decreased the crystalline size, increasing the overall material strength, when crystalline analysis was carried out. The higher scanning speeds supported improved grain refinement and heat diffusion, with the poor hardness value. With the lower
Shailesh Rao, A.
3D Printed Smart Pen Helps Diagnose Parkinson’sTBMG-5415911/1/2025
Researchers have developed a smart, self-powered magnetoelastic pen that could help detect early signs of Parkinson’s by analyzing a person’s handwriting. The highly sensitive diagnostic pen features a soft, silicon magnetoelastic tip and ferrofluid ink — a special liquid containing tiny magnetic particles.
3D Printed Diamond–Titanium Device Could Lead to Longer-Lasting ImplantsTBMG-5417211/1/2025
RMIT University Melbourne, Australia
Printable Heat Shield Formulations Advance Spacecraft ConstructionTBMG-5412011/1/2025
Innovators at NASA Johnson Space Center have developed additively manufactured thermal protection system (AMTPS) comprised of two printable heat shield material formulations. These formulations are directly applied by 3D printer or other robotic extrusion system and bonded to a spacecraft to devise a heat shield suitable for atmospheric entry. This technology could significantly decrease heat shield or thermal protection system (TPS) fabrication cost and time.
How AI Can Find the Next Groundbreaking PolymerTBMG-5412511/1/2025
Nylon, Teflon, Kevlar. These are just a few familiar polymers — large-molecule chemical compounds — that have changed the world. From Teflon-coated frying pans to 3D printing, polymers are vital to creating the systems that make the world function better.
3D Printed Implant Helps Repair Spinal Cord InjuriesTBMG-5399210/1/2025
A research team at RCSI University of Medicine and Health Sciences has developed a 3D-printed implant to deliver electrical stimulation to injured areas of the spinal cord offering a potential new route to repair nerve damage. Details of the 3D-printed implant and how it performs in lab experiments have been published in the journal Advanced Science.
3D Printed Cardiac Patch Helps Repair Heart DefectsTBMG-5399810/1/2025
ETH Zurich Zurich, Switzerland
Nadcap at 35: Still Defining Excellence in Aviation, Defense and Space Manufacturing25AERP10_0110/1/2025
Celebrating its 35th year, the National Aerospace Defense Contractors Accreditation Program (Nadcap) continues to advance quality assurance and regulatory compliance for aviation, defense, and space OEMs and suppliers. This article summarizes how Nadcap accreditation works, its benefits for manufacturers, and its role in expanding additive manufacturing through industry-wide consensus. The Nadcap program was first established in 1990 by a small group of aerospace and defense OEMs. Their goal was to create an accreditation initiative that provides a common approach to auditing the manufacturing and production processes used by companies supplying parts, components, structures, and services to major aerospace and defense OEMs. This foundation set the stage for Nadcap's continued focus on quality assurance and regulatory compliance in the industry.
3D Printing Lightweight Concrete Structures that Absorb Carbon DioxideTBMG-538449/18/2025
Modernization of Integrated Technologies for Ground Systems (MINT-GS) – Screening OF 17-4PH SS Laser Powder Bed Fusion Additive Manufacturing Process2025-01-04939/16/2025
Additive Manufacturing is currently being utilized to improve military readiness by transforming maintenance operations and the supply chain associated with repairing or replacing parts or components on legacy vehicles. The National Institute for Aviation Research at Wichita State University is collaborating with the Army Ground Vehicle Systems Center in the creation of a rapid qualification framework for various additive manufacturing materials and processes to support the modernization and sustainment of ground vehicles. Currently, a rapid qualification 17-4PH stainless steel material is being executed utilizing Laser Powder Bed Fusion and Direct Energy Deposition additive manufacturing processes. Prior to entering the rapid qualification, pre-qualification screening studies are performed to select the feedstock and develop process control to limit risk within the qualification. An overview of the pre-qualification screening studies performed in selecting the feedstock and heat
Tomblin, John, Andrulonis, Rachael, Saathoff, Brandon, Thomas, Annika, Daharsh, Cole, Lowney, Matthew, Walker, Eric
Synergistic Effects of Notch and Volumetric Defects on Fatigue Performance of Additive Manufactured Parts2025-01-04949/16/2025
The usage of additively manufactured (AM) notched components for fatigue-critical applications presents non-trivial challenges, such as the ubiquitous presence of volumetric defects in AM parts. Volumetric defects accelerate fatigue crack nucleation, impact short crack growth, and are near-impossible to fully eliminate. This study investigated the synergistic effects of volumetric defects and notch geometry on the fatigue behavior of L-PBF AlSi10Mg and 17-4 PH SS notched specimens. The criticality of the defects on fatigue behavior is investigated using a non-destructive evaluation technique. A classical linear elastic fracture mechanics (LEFM) approach was modified and used to quantify the effects of several factors including notch geometry, defects’ size, and location, on the fatigue crack initiation behavior. The modified LEFM approach utilized X-ray computed tomography data and linear elastic finite element analysis of local stresses in different notch geometries; to calculate and
Poudel, Arun, Pegues, Jonathan, Lowney, Matthew, Shao, Shuai, Shamsaei, Nima
Influence of Geometric Parameters on the Performance of TPMS-Based Heat Exchangers2025-24-00159/7/2025
Advancements in additive manufacturing (AM) technology have enabled the use of Triply Periodic Minimal Surface (TPMS) lattice structures to integrate thermal and structural functions into a single component. These structures offer advantages such as weight reduction, compactness and enhanced heat dissipation, making them promising for automotive, aerospace and electronics applications. TPMS structures, characterized by zero mean curvature and periodic crystalline geometry, have recently gained significant research attention thanks to their potential in thermal management. Among various TPMS geometries, the gyroid and diamond structures stand out for their thermal and fluid dynamic performance. This study explores the influence of cell geometry, unit cell size, and wall thickness on the efficiency of TPMS-based heat exchangers, as these parameters are crucial for their technical feasibility. Using Computational Fluid Dynamics (CFD) simulations, a comparative analysis is conducted for a
Cordisco, Ilario, Torri, Federico, Berni, Fabio, Testa, Veronica, Giacalone, Mauro, Fontanesi, Stefano
Dust-Powered 3D PrintingTBMG-537379/2/2025
After 3D printing a habitat designed for Mars and working with NASA on print material made from synthetic Moon dust, AI SpaceFactory Inc. has commercialized two separate 3D printers. The Secaucus, NJ-based company’s latest offering, Starforge, is a large-capacity 3D printer that uses innovative print material inspired by SpaceFactory’s work with NASA’s Kennedy Space Center in Florida under an Announcement of Collaboration Opportunity agreement.
Redefining Modern US Navy Shipbuilding with Additive ManufacturingTBMG-537669/1/2025
Redefining Modern US Navy Shipbuilding with Additive Manufacturing25AERP09_019/1/2025
Additive manufacturing (AM) is no longer just an alternative to traditional manufacturing methods; it's a transformative shift in how parts are designed, built, and qualified. With AM, engineers can create complex internal geometries, lattice structures, and multi-functional components that simply were not possible with traditional manufacturing methods. The design freedom unlocked by AM is advantageous in the next generation of naval innovation, particularly as shipbuilding programs push to meet ambitious construction goals and improve warship readiness. For suppliers, embracing AM isn't just about swapping out tools; it's about rethinking the entire design process. Working to understand and prepare for AM-driven design and qualification changes is necessary to remain competitive in future U.S. Navy shipbuilding programs. This article will explain how new standards are driving qualification, supporting U.S. Navy construction goals and fleet readiness.
3D Printing Self-Heating Microfluidic DevicesTBMG-537149/1/2025
MIT researchers have used 3D printing to produce self-heating microfluidic devices, demonstrating a technique which could someday be used to rapidly create cheap, yet accurate, tools to detect a host of diseases.
Using AI to Perfect the 3D Printing of MetalsTBMG-536708/20/2025
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