Materials TodayPub Date : 2026-03-01Epub Date: 2026-01-30DOI: 10.1016/j.mattod.2026.103202
Kewei Song , Ze Zhang , Zifu Fan , Yifan Pan , Weiyang Wan , Yannan Li , Shinjiro Umezu , Hirotaka Sato
{"title":"Leveraging Multi-Material Ceramic Additive Manufacturing and Intrinsic Material-Based Catalyst Metallization to Realize Robust and Damage-Free 3D Ceramic Electronics","authors":"Kewei Song , Ze Zhang , Zifu Fan , Yifan Pan , Weiyang Wan , Yannan Li , Shinjiro Umezu , Hirotaka Sato","doi":"10.1016/j.mattod.2026.103202","DOIUrl":"10.1016/j.mattod.2026.103202","url":null,"abstract":"<div><div>The fabrication of complex three-dimensional (3D) ceramic electronics is hindered by the lack of metallization methods that can achieve stable coating on curved surfaces and internal cavities without thermal damage. Here, a material-intrinsic catalytic design is implemented on a multi-material vat photopolymerization (MM-VPP) 3D printing platform, in which inert voxels without Pd<sup>2+</sup> and active voxels containing Pd<sup>2+</sup> are directly encoded into the monolithic ceramic structure during the printing stage. After co-sintering, the Pd<sup>2+</sup> is in situ converted into surface Pd(0) nano-anchors, providing autocatalytic sites for subsequent electroless deposition, thereby achieving 3D selective metallization without energy writing. This method is applicable to a variety of systems such as Ni, Cu, and Ag, obtaining dense, continuous metal layers with robust interfaces and showing stable performance in standardized adhesion and electrical characterizations. Long-term thermal aging, damp heat exposure, ozone aging, thermal shock, and thermal cycling tests further confirm that the ceramic–metal interface maintains continuous structure and stable functionality under extended service conditions. Device-level verification shows that the ceramic antenna maintains stable communication at high temperature (short-term conditions), and the ceramic light emitting diode (LED) module exhibits stable conduction at low temperature. The combination of MM-VPP and intrinsic catalytic patterning provides a scalable platform for 3D selective metallization of ceramic architectures and offers compatibility to complement existing processes, particularly for complex ceramic geometries and non-line-of-sight regions.</div></div>","PeriodicalId":387,"journal":{"name":"Materials Today","volume":"93 ","pages":"Article 103202"},"PeriodicalIF":22.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146090239","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials TodayPub Date : 2026-03-01Epub Date: 2026-02-01DOI: 10.1016/j.mattod.2026.103217
Quan Zong , Keyi Chen , Xuelian Liu , Zejie Zhu , Gongxun Bai , Qiaoling Kang , Shuang Zhou , Qilong Zhang , Guoying Wei , Anqiang Pan
{"title":"Advanced amorphous materials for aqueous Zn-ion batteries: mechanisms, design, and future perspectives","authors":"Quan Zong , Keyi Chen , Xuelian Liu , Zejie Zhu , Gongxun Bai , Qiaoling Kang , Shuang Zhou , Qilong Zhang , Guoying Wei , Anqiang Pan","doi":"10.1016/j.mattod.2026.103217","DOIUrl":"10.1016/j.mattod.2026.103217","url":null,"abstract":"<div><div>Aqueous zinc-ion batteries (ZIBs) have emerged as promising candidates for large-scale energy storage owing to their intrinsic safety, cost-effectiveness, and environmental friendliness. Despite these advantages, their practical deployment remains hampered by sluggish ion transport kinetics, cathode dissolution, dendritic zinc growth, and interfacial parasitic reactions. In recent years, amorphous materials have garnered considerable attention as electrode components due to their unique physicochemical characteristics, such as structural isotropy, abundant unsaturated coordination sites, and superior mechanical adaptability, that are distinct from their crystalline counterparts. This review comprehensively discusses the fundamental structure–property relationships of amorphous phases and their roles in facilitating ion diffusion, accommodating structural deformation, and stabilizing electrode/electrolyte interfaces. Recent progress in the rational synthesis, structural design, and functional integration of amorphous materials into both cathodes and zinc anodes is systematically summarized. Furthermore, the correlation between atomic disorder, electrochemical performance, and charge storage mechanisms is critically analyzed. Finally, key challenges and future opportunities of amorphous materials are proposed, offering deep insights into the rational design of amorphous materials toward high-performance and durable aqueous ZIBs, as well as their broader applications for next-generation rechargeable batteries.</div></div>","PeriodicalId":387,"journal":{"name":"Materials Today","volume":"93 ","pages":"Article 103217"},"PeriodicalIF":22.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147400248","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials TodayPub Date : 2026-03-01Epub Date: 2026-01-24DOI: 10.1016/j.mattod.2025.12.034
Soyeon Yoo , Melgious Jin Yan Ang , Amanda M. Murray , Michael J. Mitchell
{"title":"A material toolbox for engineering targeted lipid nanoparticles for RNA therapies","authors":"Soyeon Yoo , Melgious Jin Yan Ang , Amanda M. Murray , Michael J. Mitchell","doi":"10.1016/j.mattod.2025.12.034","DOIUrl":"10.1016/j.mattod.2025.12.034","url":null,"abstract":"<div><div>RNA therapeutics are rapidly redefining the landscape of modern medicine, offering programmable solutions to target diseases at the genetic level. Their success, exemplified by FDA-approved siRNA drugs and mRNA vaccines in clinical use, is primarily enabled by lipid nanoparticles (LNPs), which protect RNA, facilitate its intracellular delivery, and enhance endosomal escape. However, LNPs exhibit limited organ selectivity, often accumulating in the liver, which restricts broader clinical translation. This review presents a materials-centered framework for engineering targeted LNPs that improve therapeutic efficacy in target organs while minimizing off-target effects. We first examine surface functionalization strategies using active targeting ligands such as antibodies, peptides, aptamers, carbohydrates, and small molecules. We then highlight approaches to modulate organ tropism through intrinsic lipid component design, such as rational design of ionizable lipids, use of lipid additives, and tuning of lipid composition. Key analytical methods for evaluating targeting efficiency, including <em>in vitro</em> and <em>in vivo</em> assays, are also discussed. Finally, we examine emerging applications of targeted LNPs across diverse disease areas, including cancer, women’s health disorders and neurological diseases, with an outline on future directions. Overall, this review aims to guide the rational design of next-generation targeted LNPs by presenting a toolbox of material strategies to facilitate the safe and effective application of RNA therapeutics.</div></div>","PeriodicalId":387,"journal":{"name":"Materials Today","volume":"93 ","pages":"Article 103176"},"PeriodicalIF":22.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147400250","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials TodayPub Date : 2026-03-01Epub Date: 2026-01-31DOI: 10.1016/j.mattod.2026.103215
Changdong Liu , Wenzhao Wang , Tiancong Cao , Mohammad A. Islam , Yingjie Xia , Changlin Zheng , Jun Jiang , Zongquan Gu
{"title":"Harnessing ferroelectric domain wall optoelectronics for bitstream data security","authors":"Changdong Liu , Wenzhao Wang , Tiancong Cao , Mohammad A. Islam , Yingjie Xia , Changlin Zheng , Jun Jiang , Zongquan Gu","doi":"10.1016/j.mattod.2026.103215","DOIUrl":"10.1016/j.mattod.2026.103215","url":null,"abstract":"<div><div>The inherent unpredictability of physical property randomness holds great promise for information security applications. A novel encryption approach is devised based on the optoelectronic responses of conducting domain walls (CDWs) in BiFeO<sub>3</sub> thin films, integrating nonlinear transformations with true random secret keys to enhance the overall security. The plaintext is defined by the wavelength-dependent photocurrents at 405, 520 and 635 nm optical excitations and the distortions in each RGB channel are introduced by additional electrical pulsing. The nonlinear transformation makes the characteristic pattern hidden, increasing the image entropy from 2.59 to 6.83. The encryption is then conducted by true random secret keys generated by the stochastic fluctuations of domain wall currents (DWCs) to implement logical encryption operations. The image entropy is further increased to 7.95 with the transition of correlation plots from strong correlations between pixels to aperiodic characteristic pattern. The encryption shows high resistances to attacks by exhaustive method and quantum search, logarithmically extending cracking time with key length bits. The robustness of the scheme is verified by typical differential attacks, noise additions and occlusion interruptions. The approach conveniently embeds a two-step encryption in the optoelectronic responses of conducting domain walls, providing a proof-of-concept solution for data security in AI and IoT.</div></div>","PeriodicalId":387,"journal":{"name":"Materials Today","volume":"93 ","pages":"Article 103215"},"PeriodicalIF":22.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146090373","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials TodayPub Date : 2026-03-01Epub Date: 2026-01-31DOI: 10.1016/j.mattod.2026.103225
Zuoshuai Xi , Xinmeng Xu , Hongyi Gao, Ge Wang
{"title":"LLM-assisted intelligent discovery of metal-organic frameworks for solid-state electrolytes","authors":"Zuoshuai Xi , Xinmeng Xu , Hongyi Gao, Ge Wang","doi":"10.1016/j.mattod.2026.103225","DOIUrl":"10.1016/j.mattod.2026.103225","url":null,"abstract":"<div><div>The development of high-performance solid-state electrolytes has long been hindered by the inefficiency of traditional discovery methods and the lack of systematic design principles. In the October 24, 2025 issue of <em>JACS</em>, Zhang and co-workers leveraged large language models combined with representation clustering to intelligently mine promising metal–organic framework-based electrolytes, offering a transformative approach to materials discovery.</div></div>","PeriodicalId":387,"journal":{"name":"Materials Today","volume":"93 ","pages":"Article 103225"},"PeriodicalIF":22.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146090372","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials TodayPub Date : 2026-03-01Epub Date: 2026-02-03DOI: 10.1016/j.mattod.2026.103224
Byunghyun Do , Hojun Lee , Jonggyu Park , Seongeun Park , Dongwook Shin , Hyeseong Oh , Kyeong-Min Jeong , Kyu-Young Park
{"title":"Scalable and high-rate ultra-thick cathodes enabled by a multifunctional ethyl cellulose additive","authors":"Byunghyun Do , Hojun Lee , Jonggyu Park , Seongeun Park , Dongwook Shin , Hyeseong Oh , Kyeong-Min Jeong , Kyu-Young Park","doi":"10.1016/j.mattod.2026.103224","DOIUrl":"10.1016/j.mattod.2026.103224","url":null,"abstract":"<div><div>Ultra-thick cathodes delivering >10 mAh cm<sup>−2</sup> with high-rate capability remain a central challenge due to severe electronic/ionic transport limitations and structural inhomogeneity introduced during fabrication. Here, we present a multifunctional ethyl-cellulose (EC) additive for conventional slurry processing that enables scalable manufacture of ultra-thick electrodes with exceptional electrochemical performance. A tiny amount of EC (<0.05 wt%) promotes uniform CNT dispersion via noncovalent (CH-π) interactions and drives selective adhesion to oxide surfaces through hydrogen bonding, yielding conformal in situ CNT coatings during slurry processing. The process is fully compatible with industrial roll-to-roll lines and was validated by continuous coating of >150 m of CNT-coated electrodes without loss of processability. In addition, EC suppresses carbon–binder migration during drying, a long-standing issue in slurry fabrication, and enhances electrolyte wettability, thereby lowering tortuosity-limited ionic resistance (i.e., ion-transport resistance from tortuous pores). This strategy enables defect-free electrodes with active-mass loadings up to 97.5 mg cm<sup>−2</sup> (19.5 mAh cm<sup>−2</sup>) using only 0.5 wt% CNT. At 55 mg cm<sup>−2</sup> (≈11 mAh cm<sup>−2</sup>), the electrodes retain 87% and 46% of their 0.1C capacity at 1C and 2C, respectively, demonstrating state-of-the-art performance among ultra-thick electrodes, and they maintain 73% capacity after 200 cycles in full-cell configurations. Li-metal pouch cells achieve a cathode-specific energy density of 734 Wh kg<sup>−1</sup>, demonstrating the industrial viability of the approach. This additive-assisted paradigm provides mechanistic insight into CNT–polymer–oxide interactions and offers a practical route to accelerate commercialization of high-areal-capacity electrodes at industrial scale.</div></div>","PeriodicalId":387,"journal":{"name":"Materials Today","volume":"93 ","pages":"Article 103224"},"PeriodicalIF":22.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147400638","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials TodayPub Date : 2026-03-01Epub Date: 2026-01-24DOI: 10.1016/j.mattod.2026.103195
Han-Wei Fang , Liang-Yu Hou , Chong-Chi Chi , Cheng-Yu Wu , Chia-Ying Wu , Chun-Wei Chang , Jui-Tai Lin , Shang-Cheng Lin , Zong Ying He , Yi Chen , Chia-Shuo Hsu , Chih-Wen Pao , Ming-Yen Lu , Kun-Han Lin , Tung-Han Yang
{"title":"High-index faceted high-entropy-alloy atomic layers with tailored active sites for enhanced catalytic performance","authors":"Han-Wei Fang , Liang-Yu Hou , Chong-Chi Chi , Cheng-Yu Wu , Chia-Ying Wu , Chun-Wei Chang , Jui-Tai Lin , Shang-Cheng Lin , Zong Ying He , Yi Chen , Chia-Shuo Hsu , Chih-Wen Pao , Ming-Yen Lu , Kun-Han Lin , Tung-Han Yang","doi":"10.1016/j.mattod.2026.103195","DOIUrl":"10.1016/j.mattod.2026.103195","url":null,"abstract":"<div><div>High-entropy-alloy (HEA) catalysts have attracted considerable interest for a wide range of catalytic applications. However, the development of high-index faceted HEA catalysts remains rare, due to the synthetic challenge of achieving both atomic-level mixing and precise control over surface facets and atomic arrangements. Here, we report a kinetically controlled two-step synthesis of high-index faceted HEA atomic layers, including {210}, {310}, and {320} facets, epitaxially grown on concave nanocubes with a PtIrRuRhAu composition. Synchrotron X-ray absorption spectroscopy (XAS) confirms inter-element bonding, indicating an atomically mixed multimetallic surface. <em>In situ</em> microscopy analysis demonstrates thermal stability of the high-index faceted HEA atomic layers up to 500 °C. Importantly, they also show excellent hydrogen evolution reaction (HER) activity in 0.5 M H<sub>2</sub>SO<sub>4</sub>, requiring an overpotential of only 41 mV to reach a current density of −10 mA cm<sup>−2</sup> (normalized to the geometric electrode area). <em>Operando</em> XAS analysis reveals electronic modulation under applied potential, with electron gain at Ir sites and loss at Au sites. Density functional theory calculations identify that incorporating weakly hydrogen-binding Au into platinum-group-metal-based HEA surfaces creates sites with near-optimal hydrogen adsorption free energy, effectively tuning adsorption energetics and enabling well-balanced hydrogen binding for enhanced HER activity.</div></div>","PeriodicalId":387,"journal":{"name":"Materials Today","volume":"93 ","pages":"Article 103195"},"PeriodicalIF":22.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147400730","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials TodayPub Date : 2026-03-01Epub Date: 2026-01-30DOI: 10.1016/j.mattod.2026.103214
Meudjeu Tognia , Xinyu Dong , Mengjie Hou , Lin Li , Hua Wang , Yan Li , Peng Zhang , Xingzhong Cao , Runsheng Yu , Tonghua Wang
{"title":"Scaffolded nanopores during carbonization: a strategy for stabilizing nanoporous polymer-derived carbons","authors":"Meudjeu Tognia , Xinyu Dong , Mengjie Hou , Lin Li , Hua Wang , Yan Li , Peng Zhang , Xingzhong Cao , Runsheng Yu , Tonghua Wang","doi":"10.1016/j.mattod.2026.103214","DOIUrl":"10.1016/j.mattod.2026.103214","url":null,"abstract":"<div><div>Porous carbons obtained from pyrolysis of polymer precursors are central to membrane separations, adsorbents, and electrochemical devices, yet their high-temperature carbonization drives densification and pore collapse. Here a thermally guided sacrificial templating with pore scaffolding strategy is introduced using what we named a decomposition-derived scaffoldant (DDS): a templating-scaffolding agent that decomposes to generate additional porosity and subsequently yield nano-carbonaceous residues that skeletonize and stabilize the pore network. Using a phenolphthalein-based cardo poly(arylene ether ketone) (PEK-C) as polymer precursor and [C<sub>2</sub>OHMIM][DCA] as model DDS, we enabled the formation of stabilized interconnected sub-nanometre pore networks while simultaneously suppressing graphitic stacking, and controlling structural densification. As an applied case, we fabricated carbon molecular sieve (CMS) membranes for CO<sub>2</sub> separation. The resulting porous carbons exhibited exceptional CO<sub>2</sub> permeabilities (up to 13665 ± 683 Barrer) and outstanding selectivities (CO<sub>2</sub>/N<sub>2</sub> = 127 ± 9, and CO<sub>2</sub>/CH<sub>4</sub> = 109 ± 8 under optimal conditions) that surpass the 2019 upper bound, alongside long-term stability outperforming current membrane technologies. The concept was validated across multiple polymer systems, establishing a generalizable route to mitigate pore collapse in polymer-derived pyrolyzed materials, using commercially accessible materials and scalable processing.</div></div>","PeriodicalId":387,"journal":{"name":"Materials Today","volume":"93 ","pages":"Article 103214"},"PeriodicalIF":22.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146090376","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials TodayPub Date : 2026-03-01Epub Date: 2026-01-29DOI: 10.1016/j.mattod.2026.103187
Manish Jain , Daniel Vizoso , Alejandro Hinojos , Alejandro Barrios , Kyle R. Dorman , Yichen Yang , David Adams , Khalid Hattar , Doug L. Medlin , Olivier Pierron , Rémi Dingreville , Brad L. Boyce
{"title":"Putting fatigue to rest via solute-pinned boundaries","authors":"Manish Jain , Daniel Vizoso , Alejandro Hinojos , Alejandro Barrios , Kyle R. Dorman , Yichen Yang , David Adams , Khalid Hattar , Doug L. Medlin , Olivier Pierron , Rémi Dingreville , Brad L. Boyce","doi":"10.1016/j.mattod.2026.103187","DOIUrl":"10.1016/j.mattod.2026.103187","url":null,"abstract":"<div><div>All metals have their limit when it comes to enduring fatigue damage. The best commercial alloys can survive 10<sup>7</sup> cycles at cyclic stress amplitudes up to approximately 850 MPa. Here we explore the possibility of exceeding that limit by preventing dislocation-mediated crack nucleation processes. In the current study, a model solute-stabilized nanocrystalline alloy (Pt-10 atom% Au) is shown to sustain no fatigue damage even after 10<sup>10</sup> cycles at stress amplitudes above 1 GPa (corresponding to an applied maximum strain of 0.65% under fully reversed loading). To understand the origins of that remarkable fatigue resistance, atomistic simulations and electron microscopy point to the role of solute-stabilized grain boundaries which prevent the nanostructured alloy from undergoing fatigue-induced grain growth and subsequent dislocation-mediated fatigue damage. Such findings point to new pathways to suppress crack initiation in nanostructured metals, offering a possibility of future metals that are impervious to fatigue failure.</div></div>","PeriodicalId":387,"journal":{"name":"Materials Today","volume":"93 ","pages":"Article 103187"},"PeriodicalIF":22.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146070971","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials TodayPub Date : 2026-03-01Epub Date: 2026-01-17DOI: 10.1016/j.mattod.2026.01.007
Guanghui Yang, En Ma
{"title":"Unconventional sub-grain structures formed in additively manufactured metals","authors":"Guanghui Yang, En Ma","doi":"10.1016/j.mattod.2026.01.007","DOIUrl":"10.1016/j.mattod.2026.01.007","url":null,"abstract":"<div><div>Laser powder bed fusion (LPBF) for additive manufacturing (AM) of metals has garnered significant attention over the past decade, not only for its unique ability to fabricate complex geometries but also for the distinctive microstructural features it imparts, such as hierarchical grain and sub-grain structures. Notably, AM produces unusually rich sub-grain structures, primarily solidification or dislocation cells that lead to only low degrees of crystallographic misorientations yet are effective dislocation barriers. Such microstructural features, distinctly different from conventional thermomechanical processing, are largely responsible for the enhanced strength-ductility frequently reported for AM metals, but remain poorly understood. Key questions persist, including how solute segregation networks form, what mechanisms underlie the generation of dislocation cellular structures, and how the latter correlate with solidification cell structures. In this overview, we delve into the unusual solidification conditions during LPBF, focusing on the mechanisms underlying grain and sub-grain evolution, with the aid of computational simulations to gain insight into the experimental observations available. Overall, this overview aims to improve the foundational understanding of the microstructural evolution in LPBF-fabricated metals, illustrate the new aspects of sub-grain features different from conventional polygonised dislocation cells, and offer an outlook for future advances in the field from a metallurgy standpoint.</div></div>","PeriodicalId":387,"journal":{"name":"Materials Today","volume":"93 ","pages":"Article 103186"},"PeriodicalIF":22.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147400254","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}