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Design, Processes and Materials for Additive Manufacturing: 2nd Edition
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Design, Processes and Materials for Additive Manufacturing: 2nd Edition

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 31 July 2025 | Viewed by 1717

Special Issue Editor

Prof. Dr. Panagiotis Stavropoulos

E-Mail Website
Guest Editor
Laboratory for Manufacturing Systems and Automation, University of Patras, 26504 Patras, Greece
Interests: advanced manufacturing processes; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) has several advantages over traditional manufacturing technologies and has grown very quickly in recent years. However, there are still technological issues preventing the industry from utilizing its full potential, which can be categorized under three pillars, namely design, processes, and materials.

Such challenges include design and redesign for AM aiming to improve manufacturability, productivity, and quality, and the encapsulation of post-processing for AM into the design phase. These can be expanded towards techniques for the utilization of AI towards AM design optimization, as well as design aspects/considerations for multi-material AM and 4D printing.

Regarding process-related AM challenges, there is still a need for methodologies to mitigate the quality issues with AM parts and the optimization of process parameters for the improvement in specific key performance indicators (KPIs) related to quality and productivity, either experimentally or through simulation. Another aspect is connected to strategies and applications for in situ monitoring, defect detection, and process control, especially for metal-based AM, as well as decision support systems for AM process selection. Additionally, there is an exigency of practical and innovative modeling/simulation approaches for AM (nano-, micro-, macro-, multi-scale), as well as digital twins for AM, utilizing a holistic solution approach. Process optimization for improved surface quality and reduced post-processing is another important challenge, which will reduce the costs of AM and further increase its appeal for many industrial applications. Finally, other important topics include innovative AM processes allowing for higher productivity and a minimized need for post-processing and the design and validation of innovative hybrid AM systems.

As far as the materials pillar is concerned, there is still a need to further investigate the impact of process parameters on microstructure and mechanical properties, both experimentally and through simulations, as well as for the development of efficient quality assessment applications of mechanical properties of metal AM components. Additionally, material-related aspects of 4D printing, such as the testing and validation of 4D printing materials and methodologies for 4D printing using conventional AM equipment and materials, should be further investigated. Additional challenges include the development of techniques and methodologies for the utilization of multi-material AM for high-added-value products, as well as new materials for AM, including their testing and validation (metals, polymers, ceramics, composites, cement-based, biomaterials).

The focus and goal of this Special Issue is to address the design-, process-, and material-related challenges of AM, which include, but are not limited to, the aforementioned ones, and to propose improvements in aspects related to those three pillars to avail the wider industrial adoption of AM.

Prof. Dr. Panagiotis Stavropoulos
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing
  • AM design optimization
  • post-processing for AM
  • process optimization
  • in situ monitoring, defect detection, and process control for metal-based AM
  • material-related aspects of 4D printing
  • utilization of multi-material AM
  • new materials for AM

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Related Special Issue

Published Papers (3 papers)

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Research

13 pages, 3162 KiB  
Article
Effect of Varying Layer Thickness by Interlayer Machining on Microstructure and Mechanical Properties in Wire Arc Additive Manufacturing
by G. Ganesan, Neel Kamal Gupta, S. Siddhartha, Shahu R. Karade, Henning Zeidler, K. Narasimhan and K. P. Karunakaran
J. Manuf. Mater. Process. 2025, 9(4), 135; https://doi.org/10.3390/jmmp9040135 - 18 Apr 2025
Viewed by 101
Abstract
This study investigates the influence of varying layer thickness through interlayer machining in Wire Arc Additive Manufacturing (WAAM) and its impact on microstructural evolution, mechanical properties, and residual stress distribution. It compares four types of WAAM samples: As-built with uneven layer thickness without [...] Read more.
This study investigates the influence of varying layer thickness through interlayer machining in Wire Arc Additive Manufacturing (WAAM) and its impact on microstructural evolution, mechanical properties, and residual stress distribution. It compares four types of WAAM samples: As-built with uneven layer thickness without interlayer machining and uniform layer thicknesses of 2 mm, 1.5 mm, and 1 mm achieved through interlayer machining. As-built components exhibited coarse columnar grains and uneven deposition, adversely affecting hardness and strength. Interlayer machining at reduced layer thickness refined grains, restricted growth, and induced plastic deformation, leading to enhanced mechanical properties. Grain refinement achieved reductions of 62.7% (top), 77.6% (middle), and 64.3% (bottom), significantly improving microstructural uniformity. Microhardness increased from 150 to 180 HV (as-built) to 210 to 230 HV (machined to maintain 1 mm layer thickness), marking a 40–43% improvement. Tensile strength was enhanced, with UTS increasing from 494.72 MPa to 582.11 MPa (17.6%) and YS from 371 MPa to 471 MPa (26.9%), although elongation decreased from 59% to 46% (22% reduction). Residual stress was reduced by 55–60%, improving structural integrity. These findings highlight interlayer machining as a key strategy for optimizing WAAM-fabricated components while balancing mechanical performance and manufacturing efficiency. Full article
(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing: 2nd Edition)
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15 pages, 4776 KiB  
Article
Stack and Structure: Ultrafast Lasers for Additive Manufacturing of Thin Polymer Films for Medical Applications
by Dominic Bartels, Yvonne Reg, Mahboobeh Borandegi, Maximilian Marschall, Alexander Sommereyns and Michael Schmidt
J. Manuf. Mater. Process. 2025, 9(4), 125; https://doi.org/10.3390/jmmp9040125 - 8 Apr 2025
Viewed by 285
Abstract
Overcoming the limitations of powder-based additive manufacturing processes is a crucial aspect for the manufacturing of patient-specific sophisticated implants with tailored properties. Within this work, a novel manufacturing process for the fabrication of polymer-based implants is proposed. This manufacturing process is inspired by [...] Read more.
Overcoming the limitations of powder-based additive manufacturing processes is a crucial aspect for the manufacturing of patient-specific sophisticated implants with tailored properties. Within this work, a novel manufacturing process for the fabrication of polymer-based implants is proposed. This manufacturing process is inspired by the laminated object manufacturing technology and is based on using thin films as raw material, which are processed using an ultrafast laser source. Utilizing thin films as a starting material helps to avoid powder contamination during additive manufacturing, thus supporting the generation of internal cavities that can be filled with secondary phases. Additionally, the use of medical materials mitigates the burden of a later certification of potential implants. Furthermore, the ultrafast laser supports the generation of highly resolved structures smaller than the average layer thickness (from 50 to 100 µm) through material ablation. These structures can be helpful to obtain progressive part properties or a targeted stress flow, as well as a specified release of secondary phases (e.g., hydrogels) upon load. Within this work, first investigations on the joining, cutting, and structuring of thin polymer films with layer thickness of between 50 and 100 µm using a ps-pulsed laser are reported. It is shown that thin film sizes of around 50 µm could be structured, joined, and cut successfully using ultrafast lasers emitting in the NIR spectral range. Full article
(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing: 2nd Edition)
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22 pages, 9226 KiB  
Article
Design for Additive Manufacturing of Lattice Structures for Functional Integration of Thermal Management and Shock Absorption
by Enrico Dalpadulo, Mattia Pollon, Alberto Vergnano and Francesco Leali
J. Manuf. Mater. Process. 2025, 9(1), 24; https://doi.org/10.3390/jmmp9010024 - 14 Jan 2025
Viewed by 1026
Abstract
Design optimization through the integration of multiple functions into a single part is a highly effective strategy to reduce costs, simplify assembly, improve performance, and reduce weight. Additive manufacturing facilitates the production of complex structures by allowing parts consolidation, resulting in optimized designs, [...] Read more.
Design optimization through the integration of multiple functions into a single part is a highly effective strategy to reduce costs, simplify assembly, improve performance, and reduce weight. Additive manufacturing facilitates the production of complex structures by allowing parts consolidation, resulting in optimized designs, where multiple functions are integrated into a single component. This study presents a design for additive manufacturing method for integrating multiple lattice structures to achieve thermal management and shock absorption functions. The method follows modeling and simulation phases for dimensioning and optimizing solutions to deliver the design functions at different macro- and mesoscale levels. Hierarchical complexity was leveraged to design the two-levels structure in a single part, each delivering a specific function. Specifically, the external layer addresses energy absorption and thermal insulation, while the internal layer acts as a thermal battery by incorporating a phase change material. The design of a container carried by an unmanned aerial vehicle for the transport of healthcare and biological materials is presented. The container is shock-resistant and can maintain the content at 4 ± 2 °C for at least 1 h. As it operates passively without the need for additional energy-consuming devices, it is easy to operate and contributes to increased flight autonomy. A flight mission experiment for urgent transport of blood bags confirmed the capability of the container to preserve blood integrity. This case study demonstrates that the two-layer lattice structure design represents a highly efficient approach to multifunctional design optimization. Full article
(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing: 2nd Edition)
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