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Journal of Manufacturing and Materials Processing, Volume 9, Issue 12

December 2025 - 35 articles

Cover Story: Drilling remains one of the most critical operations in manufacturing, particularly in aerospace assembly, where thousands of holes must meet stringent structural requirements. This review explores the evolution of drilling from a parameter-based operation to an intelligent, data-driven process through the integration of sensors and artificial intelligence. Cutting forces, acoustic emission, vibrations, power, thermal, and vision-based signals are analyzed in relation to tool condition, defect formation, and hole quality. Recent advances in artificial intelligence-based monitoring, predictive modeling, and adaptive control are discussed, highlighting current limitations and future research directions toward reliable and industrially deployable intelligent drilling systems. View this paper
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Articles (35)

  • Article
  • Open Access
317 Views
26 Pages

Influence of Vibration-Assisted Dynamic Solidification on Microstructure and Mechanical Properties of Permanent Mold Cast Aluminum Alloy 2024 with Conformal Cooling

  • Muhammad Waqas Ali Khan,
  • Rauf Ahmad,
  • Syed Masood Arif Bukhari,
  • Muhammad Sultan,
  • Naveed Husnain,
  • Muhammad Tuoqeer Anwar,
  • Umer Bin Nooman,
  • Hassan Raza,
  • Abid Latif and
  • Sajjad Ahmad
  • + 1 author

Aluminum alloy 2024 (AA2024) is widely used in the aerospace sector, where a fine, uniform, and equiaxed grain structure is crucial for achieving enhanced mechanical properties. This study examines the effect of dynamic solidification, assisted by me...

  • Article
  • Open Access
310 Views
14 Pages

Influence of Cutting Parameters and Tool Surface Texturing on Surface Integrity in Face Milling of AISI 1050 Carbon Steel

  • Serafino Caruso,
  • Maria Rosaria Saffioti,
  • Vincenzina Siciliani,
  • Giulia Zaniboni,
  • Domenico Umbrello,
  • Leonardo Orazi and
  • Luigino Filice

Machining of medium-carbon steels, such as AISI 1050, poses a significant challenge in terms of achieving stable cutting conditions, controlled chip evacuation and high surface integrity, in particular when full-face milling is performed under elevat...

  • Article
  • Open Access
227 Views
20 Pages

Effect of MEX Process Parameters on the Mechanical Response of PLA Structures for Orthopedic Applications

  • Stelios Avraam,
  • Demetris Photiou,
  • Theodoros Leontiou and
  • Loucas Papadakis

The advancement of polymeric materials for orthopedic applications has enabled the development of lightweight, adaptable structures that support patient-specific solutions. This study focuses on the design, fabrication, and mechanical characterizatio...

  • Article
  • Open Access
291 Views
13 Pages

Mechanism Governing the Effect of Roller Straightening of a Pure Magnesium Strip on the Tensile Stress–Strain Curve Shape

  • Stanislav O. Rogachev,
  • Viacheslav E. Bazhenov,
  • Eugene S. Statnik,
  • Vladimir A. Andreev,
  • Anatoly E. Shelest and
  • Nikita A. Ershov

A roller straightening process of a pure magnesium strip, accompanied by alternating elastic-plastic deformation, was performed through one and three passes, where one pass corresponded to 19 bending events. It was discovered that roller straightenin...

  • Review
  • Open Access
602 Views
43 Pages

Material Extrusion (ME) is a layer-by-layer additive manufacturing technique that has gained prominence due to its simplicity, cost-effectiveness, design freedom, and adaptability to a wide range of thermoplastic materials. However, the mechanical pe...

  • Article
  • Open Access
389 Views
17 Pages

The progress in metal additive manufacturing (AM) technology has enabled the printing of parts with intricate geometries. Predicting and reducing geometrical deviations (i.e., the difference between the printed part and the design) in metal AM parts...

  • Article
  • Open Access
370 Views
22 Pages

Tube hydroforming is a versatile forming process widely used in lightweight structural applications, where accurate characterization of the hoop mechanical behavior is crucial for reliable design and simulation. The ring hoop tensile test (RHTT) prov...

  • Article
  • Open Access
446 Views
22 Pages

Induction-Heated, Unrestricted-Rotation Rectangular-Slot Hot End for FFF

  • Miguel Rodríguez,
  • David Blanco,
  • Juan Antonio Martín,
  • Pedro José Villegas,
  • Alejandro Fernández and
  • Pablo Zapico

This work presents a fused-filament fabrication (FFF) hot end that combines an unrestricted-rotation C-axis with a rectangular-slot nozzle and an induction-heated melt sleeve. The architecture replaces the popular resistive cartridge and heater block...

  • Article
  • Open Access
400 Views
20 Pages

Novel Development of FDM-Based Wrist Hybrid Splint Using Numerical Computation Enhanced with Material and Damage Model

  • Loucas Papadakis,
  • Stelios Avraam,
  • Muhammad Zulhilmi Mohd Izhar,
  • Keval Priapratama Prajadhiana,
  • Yupiter H. P. Manurung and
  • Demetris Photiou

Additive manufacturing has increasingly become a transformative approach in the design and fabrication of personalized medical devices, offering improved adaptability, reduced production time, and enhanced patient-specific functionality. Within this...

  • Review
  • Open Access
915 Views
33 Pages

Artificial Intelligence in Biomedical 3D Printing: Mapping the Evidence

  • Maria Tănase,
  • Cristina Veres and
  • Dan-Alexandru Szabo

This study provides an integrated synthesis of Artificial Intelligence (AI) applications in Biomedical 3D Printing, mapping the conceptual and structural evolution of this rapidly emerging field. The bibliometric analysis, based on 229 publications i...

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J. Manuf. Mater. Process. - ISSN 2504-4494