Additive manufacturing letters最新文献

{"title":"Aerodynamic fiber deposition: additive manufacturing continuous fiber reinforcement with patternable alignment","authors":"Luochang Wang,&nbsp;Simeng Wu,&nbsp;Paulson Varghese,&nbsp;Jung-Kun Lee,&nbsp;Qihan Liu","doi":"10.1016/j.addlet.2026.100410","DOIUrl":"10.1016/j.addlet.2026.100410","url":null,"abstract":"<div><div>Fiber-reinforced composites (FRC) are high-performance materials whose manufacture is constrained by the difficulty of arranging continuous fibers into complex, spatially varying orientations. This work reports aerodynamic fiber deposition (AFD), a new additive manufacturing technique that uses electrospinning to generate continuous airborne nano/microfibers and a tangent airflow to align them on a conductive target. An insulating mask on the target localizes the aligned deposition. Scanning this deposition window over the target produces fibrous layers with patternable fiber orientation. The deposited polymer fibers can then be pyrolyzed into inorganic fibers, which can be infiltrated with resin to produce high-performance FRC.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"18 ","pages":"Article 100410"},"PeriodicalIF":5.2,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148730329","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Additively manufactured lightweight plate-lattice metamaterials with ultrahigh energy absorption","authors":"Chunlu Zhao,&nbsp;Gan Li,&nbsp;Yuhe Huang,&nbsp;Yaxian Shi,&nbsp;Xinggang Li","doi":"10.1016/j.addlet.2026.100399","DOIUrl":"10.1016/j.addlet.2026.100399","url":null,"abstract":"<div><div>Additively manufactured plate-lattice metamaterials are promising for lightweight protective applications, but they often suffer from high initial peak stress and low specific energy absorption (SEA). Here, we introduce a novel metamaterial design concept based on arched open-cell plates to overcome these limitations. Two architectures—Arch-BCC and Arch-FCC—were designed by placing arched plates on crystallographic-inspired (110) and (111) planes, respectively, followed by rotational patterning. The metamaterials were fabricated by laser powder bed fusion (L-PBF) using a Zr-modified 6061 Al alloy. Quasi-static compression tests and finite element simulations were performed to investigate their mechanical responses. The results show that both architectures exhibit customizable multi-stage stress plateaus, significantly reducing initial peak stress while enhancing energy absorption. Owing to segmented stress transmission, Arch-BCC achieves an exceptional SEA of 29.8 ± 1.2 J/g, and Arch-FCC reaches 23.7 ± 1.5 J/g, substantially surpassing most reported Al-based lattice metamaterials. This work provides a promising design route for high-performance, lightweight protective metamaterials for aerospace and automotive applications.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"18 ","pages":"Article 100399"},"PeriodicalIF":5.2,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148523453","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Towards scalable underwater concrete additive manufacturing for marine and aquatic settings","authors":"Yen-Fang Su,&nbsp;Masoud Pasbani,&nbsp;Khalilullah Taj,&nbsp;Yaxin An","doi":"10.1016/j.addlet.2026.100397","DOIUrl":"10.1016/j.addlet.2026.100397","url":null,"abstract":"<div><div>Underwater concrete underpins marine and aquatic infrastructure, yet its placement remains constrained by limited access and reliance on specialized, diver-dependent methods. Underwater Concrete Additive Manufacturing (UCAM) offers automated, formwork-free placement and access to geometries that conventional underwater concreting cannot reach. Moving extrusion from air to water, however, disrupts the rheology, early-age stability, and interlayer bonding on which printing depends. This mini-review consolidates the small but rapidly expanding UCAM literature into a single framework linking mixture design, process and equipment adaptation, and material characterization. It compares the binder systems, anti-washout and rheology-control admixtures, and aggregate and reinforcement strategies reported to date; maps the printing-process envelope of nozzle geometry, print speed, and flow rate across gantry and robotic systems; and benchmarks fresh- and hardened-state performance against cast and air-printed concrete. Three coupled barriers emerge as specific to UCAM: washout of fresh material, buoyancy acting on deposited filaments, and the influence of hydrostatic pressure on hydration. Interlayer bonding, weakened by water entrapped at layer interfaces, is identified as the principal limit on mechanical reliability. The review contributes a consolidated, comparative basis for mixture and process selection, together with a defined set of standardization and durability gaps that must close before field deployment—structure that the current case-specific literature lacks.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"18 ","pages":"Article 100397"},"PeriodicalIF":5.2,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148523454","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"3D-printed penetrating neural probes with maskless metallization and encapsulation","authors":"Armin Sedighi,&nbsp;Mehedi Hasan,&nbsp;Xiaoce Feng,&nbsp;Yong Xu","doi":"10.1016/j.addlet.2026.100408","DOIUrl":"10.1016/j.addlet.2026.100408","url":null,"abstract":"<div><div>Three‑dimensional (3D) printing offers new design freedoms for neural interfaces, but reliable metallization and selective encapsulation on complex geometries remain challenging. We present a fully 3D-printed penetrating neural probe fabricated by two-photon polymerization, enabled by two maskless approaches: trench-guided metal deposition via line-of-sight evaporation to define electrodes and interconnect traces, and capillary-driven SU-8 encapsulation, which self-limits at convex edges to preserve exposed electrode sites. The resulting probe incorporates a 2-mm shank with four mushroom-shaped electrodes and demonstrates robust metallization, reliable electrical isolation, and controlled encapsulation achieved purely through geometric design without lithographic masking. Electrochemical characterization confirmed the functionality and integrity of the electrodes, while mechanical testing in 0.6% agarose gel confirmed sufficient buckling resistance for insertion. This approach provides a rapid, maskless, and highly customizable route for fabricating penetrating neural probes. More broadly, this approach establishes a scalable, geometry-driven paradigm for functionalizing complex 3D-printed microstructures, extending beyond neural interfaces to a wide range of bioelectronic and microscale devices.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"18 ","pages":"Article 100408"},"PeriodicalIF":5.2,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148640366","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Compositionally graded tungsten–nickel lattices via ionic solution-enabled vat photopolymerization","authors":"Katherine R. Gonzalez,&nbsp;Ana C. Martinez,&nbsp;Penny Hyde,&nbsp;Bor-Rong Chen,&nbsp;Antonio Arribas,&nbsp;Michael Moorehead,&nbsp;Asa Monson,&nbsp;Alexis Maurel","doi":"10.1016/j.addlet.2026.100403","DOIUrl":"10.1016/j.addlet.2026.100403","url":null,"abstract":"<div><div>Vat photopolymerization (VPP) offers unique opportunities for fabricating architected materials with high geometric resolution, however, achieving multi-metal and compositionally graded structures remains a significant challenge. In this work, an ionic solution-enabled VPP approach is introduced to fabricate near-pure tungsten (W + 3% Ni), pure nickel (Ni), and compositionally graded W–Ni lattice structures. First, near-pure W and pure Ni architectures are demonstrated via selective ionic infiltration of printed polymer lattices, followed by a two-step thermal processing route. The process involves polymer removal and oxide formation under air, followed by reduction to metallic phases under H₂/Ar atmosphere. Compositionally graded W–Ni lattices are then prepared by spatially controlled infiltration, where the W + 3% Ni ionic solution is introduced on one side of the lattice and pure Ni ionic solution on the opposite side, enabling a continuous compositional transition. Microstructural and phase analyses using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD) and micro-X-ray fluorescence (µXRF) confirm the successful formation of metallic W-rich and Ni-rich regions and a graded interface. However, differential shrinkage during thermal processing (more pronounced in Ni than in W) initially leads to structural distortion. To address this, a lattice redesign strategy incorporating spatially varying strut thickness is implemented, with thicker struts in Ni-rich regions to partially compensate for higher shrinkage. This approach effectively preserves from major structural distortions after sintering. The proposed method establishes a versatile pathway for fabricating multi-metal and refractory compositionally graded architected materials via VPP, with potential applications in extreme environments and multifunctional systems.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"18 ","pages":"Article 100403"},"PeriodicalIF":5.2,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148523450","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"An experimentally-validated modeling framework for dot-by-dot WAAM process and product set-up: Application to rods","authors":"Michele Palermo,&nbsp;Lidiana Arrè,&nbsp;Arturo Cioni,&nbsp;Lavinia Tonelli,&nbsp;Daniele Carosi,&nbsp;Niccolò Grossi","doi":"10.1016/j.addlet.2026.100404","DOIUrl":"10.1016/j.addlet.2026.100404","url":null,"abstract":"<div><div>Wire Arc Additive Manufacturing (WAAM) enables high deposition rates and large build volumes compared to other Additive Manufacturing (AM) technologies. Further advancements have been achieved through the dot-by-dot (DbD) WAAM strategy, which allows the fabrication of complex geometries, particularly intricate lattice structures, with enhanced control over material properties via thermal cycle regulation. However, DbD WAAM presents significant challenges in geometric accuracy, primarily due to its thermal cycle, where heat buildup and limited interpass temperature control lead to unsatisfactory geometries and defects, requiring manual interventions that compromise repeatability and reliability.</div><div>This work introduces the initial findings of the CIRCULAR WELD research project, focused on developing a comprehensive experimentally-validated modeling framework for DbD WAAM. Designed to set-up both process and product without the need for expensive and unreliable trial-and-error, the framework integrates Geometrical (PG), Thermal (TM), Microstructural-Mechanical (MM), and Mechanical-Structural (MS) digital models. These models investigate mutual interactions to link process parameters with geometrical accuracy, microstructural features, mechanical parameters, and structural performance. This paper presents preliminary results of the framework’s application to single DbD WAAM rods of different nominal diameters (from 4 to 6 mm), focusing on initial model calibration and validation. Experimental results confirmed the efficiency of calibrated geometrical and thermal models, enabling good process repeatability and rods with controlled geometrical features (reduced surface roughness and lack of straightness) and mechanical properties (coefficients of variation &lt;10% for most of them). Overall, the rods demonstrated mechanical and structural performances compliant with steel grade S275, suitable for structural applications.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"18 ","pages":"Article 100404"},"PeriodicalIF":5.2,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148523451","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Melt pool-level multi-output monitoring using an off-the-shelf color camera during multi-layer wire arc additive manufacturing of Alloy 718","authors":"Gala C. Solis,&nbsp;Aaron Rueter,&nbsp;Ilana Lu,&nbsp;Jibrail M. Muhammad,&nbsp;Delphine Duquette,&nbsp;Jonathan A. Malen,&nbsp;Sneha P. Narra","doi":"10.1016/j.addlet.2026.100406","DOIUrl":"10.1016/j.addlet.2026.100406","url":null,"abstract":"<div><div>In this work, two-color thermography using a commercial color camera is applied to directly measure spatially and temporally resolved melt pool temperatures during deposition of Alloy 718 walls via cold metal transfer gas metal arc welding-based additive manufacturing. These measurements are used to extract layer-wise melt pool width and length as well as thermal gradient and cooling rate. Thin walls were fabricated using a wire feed speed 84.67 mm/s, travel speeds of 3.8 and 7.2 mm/s, and interlayer dwell times of 30, 180, and 300 s. The results demonstrate that two-color thermography can directly resolve and quantify layer-wise variations in melt pool geometry and solidification conditions. Shorter dwell time promoted progressive heat accumulation with build height, resulting in increased melt pool dimensions and reduced cooling rates and thermal gradients. In contrast, longer dwell time produced more consistent melt pool dimensions, indicating stabilized solidification conditions. The ability to extract these critical melt pool-level outputs using a single off-the-shelf color camera provides a scalable pathway for in situ monitoring and multi-input multi-output feedback control in wire arc additive manufacturing.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"18 ","pages":"Article 100406"},"PeriodicalIF":5.2,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148651297","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Inverse calibration of a thermal model for Directed Energy Deposition from thermocouple and infrared thermography data","authors":"Markus Schewe,&nbsp;Hamed Dardaei Joghan,&nbsp;Yannis P. Korkolis,&nbsp;Andreas Menzel","doi":"10.1016/j.addlet.2026.100407","DOIUrl":"10.1016/j.addlet.2026.100407","url":null,"abstract":"<div><div>Thermal modelling of metal Directed Energy Deposition (DED) relies on the calibration of parameters that are not directly measurable and often interdependent. Thermocouple measurements are widely used, but their capability to uniquely determine the thermal field remains challenging. In this context, a staged inverse calibration strategy based on Bayesian optimisation and automated Finite Element model generation with separated heating and cooling phases is investigated. Thereby, thermocouple-based optimisation is evaluated against infrared measurements and dilution geometry.</div><div>Thermocouple measurements enable identification of global heat input during heating as well as heat losses during cooling, but provide insufficient information about near-field temperature distributions. In the heating phase, conflicting objectives arise when comparing thermocouple and infrared data, but a correlation analysis identifies the peak-range thermocouple error as suitable measure for heat input calibration. In the cooling phase, both observables are governed by different parameters without strong competition, where the thermocouple error is primarily associated with heat losses, while the thermography data is primarily sensitive to the effective bead-substrate interface conductance. The results highlight that thermocouple-based calibration alone does not fully constrain the thermal field; identifiability can be improved by staged calibration with physically distinct observables, as investigated in this work.</div><div>The source code and calibration data are available at <span><span>https://github.com/InstituteOfMechanics/DEPOQUS_Parameter_Identification</span><svg><path></path></svg></span>.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"18 ","pages":"Article 100407"},"PeriodicalIF":5.2,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148651298","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Physical-modelling–driven process development of laser-induced freeform additive manufacturing for polymer-matrix composites","authors":"Lodovica Casarola,&nbsp;Elisavet Tatsi,&nbsp;Gianmarco Griffini,&nbsp;Ali Gökhan Demir","doi":"10.1016/j.addlet.2026.100400","DOIUrl":"10.1016/j.addlet.2026.100400","url":null,"abstract":"<div><div>This work describes a novel additive manufacturing process able to deposit polymer matrix composites, from conceptualization to proof-of-concept. The process makes use of an indirect curing mechanism induced by laser heating of absorbing reinforcement particles within an optically transparent and colourless polymer matrix to produce self-standing freeform structures. This work presents a model-driven process design framework that constrains process development through first-principles descriptions of the governing optical and thermal laser-matter interactions. The model is used to derive fundamental system requirements in terms of material combination, laser characteristics, and achievable productivity. A cost analysis is also performed to assess the economic feasibility of the process. A proof-of-concept demonstration was provided using a curable polymer blend embedding copper microparticles. Process parameters were extracted from the developed theoretical model, demonstrating that crosslinking and structural solidification could be achieved through localized heating using a low-power blue laser (450 nm, 5 W). The results demonstrate the feasibility of this technological approach, which holds promise for future application in a variety of industrial sectors, from microelectronics to biomedical implant manufacturing.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"18 ","pages":"Article 100400"},"PeriodicalIF":5.2,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148523533","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Stiffness optimized structures with variable density gyroid lattice infill for extrusion additive manufacturing","authors":"Isaac Wegner,&nbsp;Adam Bischoff,&nbsp;Matthew I. Campbell,&nbsp;Devin J. Roach","doi":"10.1016/j.addlet.2026.100398","DOIUrl":"10.1016/j.addlet.2026.100398","url":null,"abstract":"<div><div>Additive manufacturing has enabled the fabrication of sparse lattice structures with complex geometries tailored to specific uses. These lattice infills provide attractive properties while weighing less than a fully solid part and satisfying the strength and stiffness requirements. Historically, variations in infill lattices have altered either the global geometry or the infill wall thickness to increase strength in high load regions of structures. In this work we expand the generation of these lattices to continuously vary the local infill density at each point within the part volume, allowing for further customization of the mechanical properties. Enabled by a modified penalty-based topology optimization method and an adaptation of frequency modulation, this work continuously optimizes the density of lattice infill geometry while maintaining a constant wall thickness to maximize print performance, mechanical properties, and infill continuity throughout the structure with deposition-based fabrication. These stiffness-optimized lattice structures were successfully printed, tested, and compared to equivalent constant density structures, resulting in stiffness increases from up to 15.8% without impact to material usage or fabrication time. By increasing the stiffness to mass ratio of structures through this infill, it allows for increased adoption of 3D printed components in aerospace, medical, and other applications.</div></div>","PeriodicalId":72068,"journal":{"name":"Additive manufacturing letters","volume":"18 ","pages":"Article 100398"},"PeriodicalIF":5.2,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148523452","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}