Suhuan Guo , Gaoqi Wang , Ziqiang Yin , Hao Li , Jinxu Zhang , Yujing Sun
{"title":"A precision polishing method for 3D-printed complex internal flow channel components with composite magnetic field control","authors":"Suhuan Guo , Gaoqi Wang , Ziqiang Yin , Hao Li , Jinxu Zhang , Yujing Sun","doi":"10.1016/j.jmapro.2025.09.034","DOIUrl":"10.1016/j.jmapro.2025.09.034","url":null,"abstract":"<div><div>Advancements in 3D printing technology provide designers with unprecedented freedom, allowing them to prioritize fluid performance when designing flow channels for aerospace, biomedical, and other applications. This has led to increasingly complex geometries with arbitrarily shaped cross-sections and axial dimensional variations. However, traditional magnetic abrasive polishing processes often struggle to accurately control the trajectory and polishing force of abrasives when dealing with such complex flow channels, thereby compromising polishing accuracy. To address this challenge, this study proposes an innovative magnetically controlled polishing system. This system integrates four electromagnetic solenoid coils and two annular electromagnetic coils to generate a composite magnetic field, comprising an alternating gradient magnetic field across the cross-section and an oscillating magnetic field along the axial direction. The magnetic abrasives are driven to execute a combined motion that integrates circumferential motion with axial reciprocating motion. By establishing a mathematical model correlating magnetic field force with input current in each coil, precise control over the motion trajectory, speed, and polishing force of the abrasives is achieved. The inner walls of various complex flow channels were thoroughly polished through the combined motion of abrasive particles (with the roughness of each flow channel decreasing by approximately 50 % after polishing). Additionally, comparisons of roughness at different positions within the same flow channel demonstrated the uniformity of the polishing effect. This study confirms that the proposed magnetically controlled polishing system offers a feasible and effective solution for achieving efficient and precise polishing of the inner surfaces of complex flow channels.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 557-572"},"PeriodicalIF":6.8,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106580","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"An improved method for assessing fillet weld fusion quality based on phased array ultrasonic testing","authors":"Dazhao Chi, Xin Li","doi":"10.1016/j.jmapro.2025.09.027","DOIUrl":"10.1016/j.jmapro.2025.09.027","url":null,"abstract":"<div><div>L-shaped fillet welds are widely used in shipbuilding, automotive industry, and energy sectors. The load-bearing capacity of fillet welds is directly determined by their fusion state. When lack-of-fusion defects exist between the base metal and filler metal, the mechanical properties of the joint can be significantly compromised. Moreover, such internal defects are often undetectable by visual inspection. Therefore, non-destructive testing of fusion quality in L-shaped fillet welds is essential for quality assurance and safety evaluation. Phased array ultrasonic testing (PAUT) has been extensively employed for fusion quality evaluation due to its high resolution and sensitivity. However, compared to electronic focusing, the phased array probe beam diverges along the length of the element. This results in severe dimensional distortion along the lateral axis of the inspection images and reduced resolution, compromising measurement reliability. To address this issue, an ultrasonic acoustic lens was designed for linear phased array probes. It enables ultrasonic waves to converge at designated positions within the workpiece through multiple refractions. The acoustic field after applying the acoustic lens was simulated using COMSOL, and the results demonstrate that the ultrasonic waves converge, with the main beam width reduced. For experimental validation, a straight weld with observable full morphology was fabricated and inspected using two methods. With the acoustic lens, the inspection images exhibited enhanced resolution, and the mean squared errors (MSE) for weld dimensions significantly decreased: Weld width MSE reduced from 1.4785 to 0.0141. Weld length MSE reduced from 13.4813 to 0.1128. Finally, the improved method with the acoustic lens was applied to inspect L-shaped fillet welds in test specimens, demonstrating its effectiveness.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 588-601"},"PeriodicalIF":6.8,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106646","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yu Long , Tao Wang , Yan Wang , Xiaolong Huang , Yu Lei , Jianguan Hua , Biwei Deng , Yan Li
{"title":"Tuning the stiffness of two-photon polymerized elastomer by controlling the sparsity and helicity of printing paths","authors":"Yu Long , Tao Wang , Yan Wang , Xiaolong Huang , Yu Lei , Jianguan Hua , Biwei Deng , Yan Li","doi":"10.1016/j.jmapro.2025.09.032","DOIUrl":"10.1016/j.jmapro.2025.09.032","url":null,"abstract":"<div><div>Two-photon polymerization (TPP) is one of the emerging technologies for manufacturing high-precision micro-nano 3D structures. Common resin materials used in TPP are limited to, for example, acrylates or epoxy oligomers. The mechanical properties of these resins are difficult to tune after exposure, limiting their applications in advanced fields such as biomedicine, soft robotics, and microelectronics. In this work, an elastomer photoresist based on polyurethane acrylate (PUA) is designed, which combines the flexibility of polyurethane with the rapid curing characteristics of acrylates. Microstructures with good self-supporting properties are prepared by TPP-3D printing, and the mechanical properties of the elastomer photoresist are tuned by controlling the line spacing and rotation angle. Through in-situ compression tests, it is found that the modulus of the elastomer photoresist could be tuned from 284 MPa to 665 MPa, the yield strength from 43 MPa to 59 MPa, and the initial cycle energy absorption from 18 MJ/m<sup>3</sup> to 27 MJ/m<sup>3</sup>, showcasing an effective strategy of tuning mechanical properties through printing parameters. Finally, three types of recoverable structures are designed and printed, validating the potential of this elastomer photoresist for applications in flexible electronics and microelectronic device protection. This study provides an effective approach for the design of elastomer photoresist and the tunable mechanical properties of TPP-3D printed structure.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 547-556"},"PeriodicalIF":6.8,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106579","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Achieving high-strength 2195-T8 AlLi alloy double-wire VPPA cladding welded joint by Ag-Nb-Ti-Zr alloying induced grain refinement and T1-Ω phase synergistic strengthening","authors":"Guihan Cui , Chunli Yang","doi":"10.1016/j.jmapro.2025.09.030","DOIUrl":"10.1016/j.jmapro.2025.09.030","url":null,"abstract":"<div><div>The prevalent strength degradation in fusion welded joints of Al-Cu-Li alloys poses significant challenges in achieving base metal (BM) matching properties like high-strength steel welds. This limitation stems from coarse dendritic structures, eutectic segregation, and insufficient strengthening phases. This study employed double -wire variable polarity plasma arc (VPPA) cladding welding process to weld 2195 Al<img>Li alloy coupled with Ag/In-Nb-Ti-Zr alloying for microstructural and property regulation. With aging treatment, superior strength VPPA welded joints exceeding BM were obtained. A systematic investigation was conducted on grain morphology and precipitation behavior, elucidating microstructural evolution and strengthening mechanisms. The results showed that double-wire feed and arc cladding reduced heat input and suppressed coarse grain growth. Nb-Ti-Zr alloying induced Al₃(Ti, Zr, Nb, V) and β<sub>v</sub>' phase. These phases refined grains through peritectic reactions, enhanced nucleation rates, and pinning effect, resulting in fine equiaxed cellular and dendritic grains. θ' phase dominated aged Nb-Ti-Zr alloying welds due to low Cu<img>Li vacancy binding energy, yielding minimal T1 phase formation. Indium (In) addition captured quenched vacancies, promoting θ' nucleation via In-Cu-vacancy complexes. Complete T1 phase suppression and PFZ widening degraded strength and elongation. Silver (Ag) addition promoted Mg<img>Ag co-cluster formation, providing alternative T1 nucleation sites beyond quenching vacancies and promoting precipitation kinetics. The Mg<img>Ag riched {111}<sub>Al</sub> GP zones evolved into the T1-like Ω phase. This dual-phase system achieved breakthrough weld properties in strength (maximum 572 MPa, 101.2 % BM) and hardness (187.9 HV<sub>0.2</sub>, 129.9 % BM), exceeding BM for the first time. T1 and Ω phases eliminated universal PFZ at conventional boundaries and enhanced maximum elongation to 6.9 %. Precipitation strengthening from T1/Ω phases contributed 41.2 % of total yield strength enhancement.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 573-587"},"PeriodicalIF":6.8,"publicationDate":"2025-09-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106581","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yichen Yan , Gaiyun He , Chenglin Yao , Sitong Wang , Zhi Tan
{"title":"A precision reconstruction method based on refined and adjusted multilevel T-spline for complex surface manufacturing","authors":"Yichen Yan , Gaiyun He , Chenglin Yao , Sitong Wang , Zhi Tan","doi":"10.1016/j.jmapro.2025.08.070","DOIUrl":"10.1016/j.jmapro.2025.08.070","url":null,"abstract":"<div><div>Precision reconstruction is a critical technology in complex part manufacturing and measurement. The rapid development of data acquisition systems, represented by the 3D laser scanner and Coordinate Measuring Machine (CMM), requires simulation and reconstruction capabilities for large-scale, dense, and non-uniform point clouds. Moreover, advancements in T-spline theory enable a significant reduction in control points while maintaining high accuracy. This paper proposes a Refined and Adjusted Multilevel T-spline method based on the point-to-surface shortest Distance (D-RAMT) to reconstruct surfaces from measured point clouds. Reconstruction performance is significantly improved via alternating cycles of multilevel adjustment and refinement. Point-to-surface shortest distances are computed as reconstruction errors using a proposed algorithm combining Random points, Set-inherited search, and Parallel computation (RSP). Additionally, an Improved B-spline Approximation (IBA) method for solving control points and an adaptive T-mesh local refinement strategy are developed. Machined workpieces with complex surfaces are utilized to verify the proposed method. Results show that the D-RAMT has better reconstruction capability with high accuracy, acceptable convergence times, and fewer control points (37–62 %) than other methods.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 531-546"},"PeriodicalIF":6.8,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106645","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Shuai Zhang , Zhifen Zhang , Jie Wang , Jing Huang , Rui Qin , Hao Qin , Zhiwen Li , Guangrui Wen , Qi Zhang , Xuefeng Chen
{"title":"A graph neural network integrating physical prior knowledge for defect monitoring in laser powder bed fusion","authors":"Shuai Zhang , Zhifen Zhang , Jie Wang , Jing Huang , Rui Qin , Hao Qin , Zhiwen Li , Guangrui Wen , Qi Zhang , Xuefeng Chen","doi":"10.1016/j.jmapro.2025.08.082","DOIUrl":"10.1016/j.jmapro.2025.08.082","url":null,"abstract":"<div><div>The complex physical interactions between the laser and the powder during the laser powder bed fusion (LPBF) process significantly affect the consistency and stability of the component quality. Existing online monitoring technologies predominantly employ Convolutional Neural Networks (CNNs) to achieve defect monitoring within a single time window, which struggle to capture the complex coupling relationships and synergies caused by spatial knowledge in additive manufacturing. This study presents a graph structure construction algorithm that integrates physical priors to reflect heat transfer effects, aiming to explicitly model spatial structural information and utilizing Graph Convolutional Networks (GCNs) to capture acoustic information in the adjacent spatial regions of the melt pool across the melt pool. The algorithm utilizes spatial prior knowledge to construct a graph structure that corresponds to the spatial relationships of real components. Furthermore, the graph structure is established utilizing two indicators that possess significant physical meanings: PatchSize and LinkMode. PatchSize refers to the quantity of melt channels and the length of the single melt channels incorporated within the graph structure, while LinkMode signifies the mode of heat transfer occurring between the melt pool and its surrounding area. Experimental results indicate that, in comparison to non-graph structures and traditional graph structures, the method enhances accuracy by an average of 3.56 % and 2.42 % on acoustic datasets with different porosity levels respectively. Finally, this study explores the impact of different physical knowledge on GCNs by changing the graph construction indicators, providing new solutions to improve the reproducibility and quality stability of LPBF technology.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 516-530"},"PeriodicalIF":6.8,"publicationDate":"2025-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145061206","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Sang-Hyun Ahn , Inyoung Song , Junsung Bae , Gwang-Ho Jeong , Dae-Won Cho , Young Whan Park
{"title":"A novel heat source model for welding and additive manufacturing: The traveling steady pool approach","authors":"Sang-Hyun Ahn , Inyoung Song , Junsung Bae , Gwang-Ho Jeong , Dae-Won Cho , Young Whan Park","doi":"10.1016/j.jmapro.2025.09.012","DOIUrl":"10.1016/j.jmapro.2025.09.012","url":null,"abstract":"<div><div>Numerical simulation is essential in solving complex problems in welding and additive manufacturing (AM). However, conventional finite element analysis (FEA) models require repeated parameter tuning due to their inability to capture fluid behavior, while computational fluid dynamics (CFD) is often impractical for industrial applications. To address this, a Traveling Steady Pool (TSP) model was developed based on the observation that the molten pool stabilizes after a critical time. The steady pool geometry was extracted from CFD results, segmented into longitudinal sections, fitted with polynomial functions, and interpolated to construct a three-dimensional profile. This geometry was applied in FEA as a moving Dirichlet boundary at the melting temperature. The TSP model was validated against conventional heat source models and experimental data, including thermal images and bead cross-sections. Thermo-elasto-plastic simulations under various inclination angles further confirmed its predictive capability in deformation analysis. The model also provided physical insights into key phenomena, such as the enlarged CGHAZ at 45° and minimal deformation at 30°, based on the heat transfer characteristics of the molten pool geometry.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 471-486"},"PeriodicalIF":6.8,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145046926","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Effects of pre-weld 6061 base metal composition and post-weld heat treatment on microstructure and mechanical properties of 7075/6061 dissimilar aluminum alloy FSW joints","authors":"Yongjun Ren , Sheng Liu , Xinbin Hu","doi":"10.1016/j.jmapro.2025.09.021","DOIUrl":"10.1016/j.jmapro.2025.09.021","url":null,"abstract":"<div><div>This study systematically investigates the influence of four different 6061 base metal compositions and post-weld heat treatment (PWHT) processes on the microstructure and mechanical properties of 7075/6061 dissimilar aluminum alloy friction stir welded (FSW) joints. The results indicate: Prior to PWHT, the position and size of the “elliptical onion ring” structures formed in the stir zone (SZ) of 7075/6061 FSW joints varied significantly depending on the 6061 base metal composition, with notable differences in material mixing and flow behavior. Joints made with 6061 base metals having either high Mg/Si ratio with low total alloy content or low Mg/Si ratio with high total alloy content exhibited superior metal flow characteristics. All as-welded joints developed fine equiaxed grains through dynamic recrystallization in the SZ, with no significant difference in average grain size. The joint made with high Mg/Si ratio and low alloy content 6061 base metal demonstrated tensile strength and elongation of 214 MPa and 6.11 %, respectively. After PWHT, abnormal grain growth (AGG) occurred in the SZ of all joints. Joints with high Mg/Si ratio 6061 developed grains exceeding 500 μm in maximum dimension, showing strong texture. PWHT significantly improved the mechanical properties of joints with low Mg/Si ratio 6061 base metal (BM). In particular, the joint with high alloy content showed reprecipitation of dissolved Si-rich phases and Mg<sub>2</sub>Si phases, which were uniformly distributed in the Al matrix with weaker texture. Its tensile strength increased from 207 MPa to 290 MPa, and elongation improved from 2.49 % to 3.07 %, respectively. For 6061 BM with high Mg/Si ratio and low Si content, PWHT failed to enhance joint mechanical properties. The combination of pre-weld 6061 base metal with low Mg/Si ratio and high total alloy content, coupled with appropriate PWHT, can significantly improve the microstructural stability and mechanical properties of 7075/6061 FSW joints, demonstrating the greatest potential for performance enhancement.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 452-470"},"PeriodicalIF":6.8,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145046974","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Dan-Yang Wen, Min Wan, Shao-Cong Linghu, Wei-Hong Zhang, Deng-Hui Li
{"title":"Modeling the cutting force with emphasis on the exiting stage of metal cutting","authors":"Dan-Yang Wen, Min Wan, Shao-Cong Linghu, Wei-Hong Zhang, Deng-Hui Li","doi":"10.1016/j.jmapro.2025.09.010","DOIUrl":"10.1016/j.jmapro.2025.09.010","url":null,"abstract":"<div><div>While many existing cutting force models achieve high predictive precision near the peak force, they frequently show substantial discrepancies in estimating the exiting moment during the tool’s exiting stage. Despite its significance, this issue has garnered little attention and remains poorly understood. To address this knowledge gap, this study introduces a theoretical framework to explain these discrepancies, attributing them to the interplay of negative shearing effects, flank face interference, and workpiece deformation during the exiting stage of the cutting process. In the proposed model, the minimum energy principle is employed as the criterion for determining whether a negative or regular shearing effect occurs. A slip-line field is developed to model the negative shearing effect and its generated cutting forces. Flank interference, caused by the rapid elastic recovery of deflected cutters during the exiting stage of the cut, along with its induced interference force, is found and modeled using a combination of force equilibrium principles and constraints related to friction and acceleration limitations. The deformed workpiece, which is associated with burrs, is treated to follow the volume invariance principle and rotate around the intersection point of the instantaneous negative shearing plane and the workpiece boundary. The final cutting forces corresponding to different exiting instants together with the actual exiting moment are successfully determined by combining the effects of the negative shearing-induced component and flank interference-related component. The proposed model is validated through a series of cutting tests.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 487-504"},"PeriodicalIF":6.8,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145046927","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Nathaniel Heathman , Michael DeLay , Mehran Tehrani
{"title":"Five-axis material extrusion of high-performance structural parts with continuous carbon fiber-reinforced LM-PAEK","authors":"Nathaniel Heathman , Michael DeLay , Mehran Tehrani","doi":"10.1016/j.jmapro.2025.08.084","DOIUrl":"10.1016/j.jmapro.2025.08.084","url":null,"abstract":"<div><div>Utilizing continuous fiber-reinforced polymer composites in additive manufacturing (AM) enables end-use components with weight-specific mechanical performance that can surpass that of metals. In this paper, five-axis continuous fiber material extrusion (ME) was used to manufacture specimens from carbon fiber reinforced low-melt polyaryletherketone™ (LM-PAEK™) composite filaments. Mechanical testing revealed that the LM-PAEK matrix resolves typical challenges with high-performance thermoplastic polymers used in ME. Printed parts achieved an impressive short beam strength (SBS) of 60 MPa, flexural strength of 943 MPa, and inter-raster tensile strength of 62 MPa in curved regions. These samples also achieved a low void content and high crystallinity. Detailed thermal analysis via differential scanning calorimetry (DSC) showed that samples could achieve near-maximum crystallinity (∼25 %) in regions close to the heated print bed or after a brief post-annealing cycle (210 °C), underscoring the importance of spatial temperature control in ME. X-ray micro-computed tomography (μCT) confirmed a void content as low as 1.6 % for flat coupons, while systematic analysis of curved specimens quantified how steering radii below 10 mm induce fiber folding, wrinkling, and voids. A custom geometric bracket was fabricated to illustrate the capabilities of out-of-plane continuous fiber deposition and showcased similar defects due to tight curvatures as well as downward nozzle travel. Together, findings of this paper establish LM-PAEK as a promising matrix for continuous fiber AM and provide the first empirical design rules for fiber steering in multi-axis extrusion, advancing the field toward true load-bearing structural applications.</div></div>","PeriodicalId":16148,"journal":{"name":"Journal of Manufacturing Processes","volume":"153 ","pages":"Pages 505-515"},"PeriodicalIF":6.8,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145046928","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}