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High-Performance Metal Additive Manufacturing, 2nd Edition
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High-Performance Metal Additive Manufacturing, 2nd Edition

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

Deadline for manuscript submissions: closed (31 March 2026) | Viewed by 12066

Special Issue Editor

Dr. Hamed Asgari

E-Mail Website
Guest Editor
Department of Mechanical Engineering, University of New Brunswick, Fredericton, NB, Canada
Interests: metal additive manufacturing; texture and anisotropy; dynamic mechanical behaviour; materials characterization; light alloys
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metal additive manufacturing (AM), also known as 3D printing (3DP), has emerged as a transformative technology that revolutionizes traditional manufacturing processes. By enabling the direct fabrication of complex metal parts from digital designs, additive manufacturing offers unprecedented freedom in design and manufacturing flexibility. In this Special Issue, we seek to present a comprehensive collection of research articles, reviews, and case studies that highlight the state-of-the-art techniques, novel materials, in/ex situ material characterization, process optimization, modelling and simulation, and applications in metal AM, with a specific focus on achieving high-performance outcomes for strategic sectors, including the aerospace, marine, automotive, and energy industries. We encourage submissions that cover a wide range of topics, including, but not limited to, the following:

  • Design methodologies for high-performance metal parts using AM techniques.
  • Advanced metal powders and alloys tailored for AM, specifically metal matrix composites and smart alloys.
  • Process optimization and control strategies to enhance mechanical, chemical, and physical properties, as well as the surface finish of additively manufactured parts.
  • Novel post-processing techniques for improving the performance of additively manufactured metal components, particularly in extreme environments.
  • Real-world applications of high-performance metal AM in diverse sectors.

By assembling this collection of contributions, we aim to foster collaboration, knowledge exchange, and advancements in metal additive manufacturing. I invite researchers from academia and industry to share their expertise, innovative ideas, and developments in this exciting field. Together, we can push the boundaries of high-performance metal additive manufacturing and pave the way for its widespread adoption.

Dr. Hamed Asgari
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 250 words) can be sent to the Editorial Office for assessment.

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

  • metal additive manufacturing
  • process optimization
  • quality control
  • materials characterization
  • powder processing
  • design for additive manufacturing

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (5 papers)

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Research

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21 pages, 5215 KB  
Article
Finite Element Simulation-Driven Geometric Compensation for an LPBF-Fabricated Winged Annular Funnel Structure
by Yunpeng Zhang, Junfeng He, Xin Liao, Shilong Che, Xin Lin and Xufei Lu
J. Manuf. Mater. Process. 2026, 10(5), 178; https://doi.org/10.3390/jmmp10050178 - 19 May 2026
Viewed by 149
Abstract
Geometric distortion remains a major obstacle to achieving high dimensional accuracy in laser powder bed fusion (LPBF), especially for complex thin-walled components with heterogeneous structural constraint. In this study, a finite element simulation-driven geometric compensation strategy was applied and validated for an LPBF-fabricated [...] Read more.
Geometric distortion remains a major obstacle to achieving high dimensional accuracy in laser powder bed fusion (LPBF), especially for complex thin-walled components with heterogeneous structural constraint. In this study, a finite element simulation-driven geometric compensation strategy was applied and validated for an LPBF-fabricated winged annular funnel structure (WAFS). A transient thermo-mechanically coupled finite element model was established to predict the distortion behavior during fabrication and validated by 3D scanning measurements, showing good agreement in both global deformation trend and local distribution characteristics. The simulation results indicated that the distortion of the WAFS was dominated by the combined constraint effect of the wing-like features and the baseplate, resulting in a non-uniform and symmetric deformation pattern. Based on the validated displacement field, an inverse-mapping method was used to construct a compensated geometry for re-fabrication. The compensated WAFS exhibited a substantially reduced deformation level, and the overall geometric distortion was reduced by more than 85% after a single compensation iteration. The present results demonstrate that finite element simulation-driven geometric compensation provides an efficient and practical route for improving the dimensional accuracy of the investigated WAFS, while reducing dependence on repeated trial-and-error optimization. Full article
(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing, 2nd Edition)
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35 pages, 13241 KB  
Article
Effect of Process Co-Factors on Repeatable Process Capability for Subscale Feature Dimensions in PBF-LB/M Additive Manufacturing of TI6Al4V
by Utkarsh Thakre, Venkatavaradan Sunderarajan, Seneca Stevans and Suman Das
J. Manuf. Mater. Process. 2026, 10(5), 171; https://doi.org/10.3390/jmmp10050171 - 14 May 2026
Viewed by 160
Abstract
This article addresses the lack of repeatability and reproducibility that has inhibited the widespread adoption of Laser Powder Bed Fusion Additive Manufacturing (PBF-LB/M) for service-critical part fabrication in production. A rigorous analysis of critical dimensional variations at a statistically significant scale is essential [...] Read more.
This article addresses the lack of repeatability and reproducibility that has inhibited the widespread adoption of Laser Powder Bed Fusion Additive Manufacturing (PBF-LB/M) for service-critical part fabrication in production. A rigorous analysis of critical dimensional variations at a statistically significant scale is essential to understand the influence of process co-factors in PBF-LB/M, serving as a vital step toward process control. Structured white-light profilometry provides an effective balance of capability and features for performing such analysis, including advanced focus variation-based feature extraction. In this work, two types of samples were fabricated, each having either thin gaps or thin walls of varying widths ranging from 200 to 1000 µm. Samples containing these features were designed with and without a constraining base geometry and built along different orientations across various locations on the build plate in two layer thicknesses: 30 µm and 60 µm. Co-factors such as base geometry, specimen orientation, layer thickness, and location on the build plate were investigated for their impact on measurement variations in the as-built condition. The achievable resolution and repeatability was found to be 500 μm, and thus did not conform to the machine manufacturer’s stated minimum of 150 μm. The presence of a base geometry effectively reduced the variations preferentially for features larger than this limit. Features smaller than 500 µm exhibited a variation of approximately 1.5–3 times the D50 size of the powder feedstock, regardless of the co-factors. The tightest control over the variations was observed to occur at the center of the build plate. This study aims to quantify the combined effect of multiple process co-factors on the repeatable dimensional process capability of sub-millimeter PBF-LB/M features in Ti6Al4V. Full article
(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing, 2nd Edition)
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25 pages, 7000 KB  
Article
Small- to Large-Scale Electron Beam Powder Bed Fusion of Functionally Graded Steels
by Carlos Botero, William Sjöström, Emilio Jimenez-Pique, Andrey Koptyug and Lars-Erik Rännar
J. Manuf. Mater. Process. 2025, 9(1), 7; https://doi.org/10.3390/jmmp9010007 - 29 Dec 2024
Cited by 4 | Viewed by 2633
Abstract
The ability to control process parameters over time and build space in electron beam powder bed fusion (PBF-EB) opens up unprecedented opportunities to tailor the process and use materials of a different nature in the same build. The present investigation explored the various [...] Read more.
The ability to control process parameters over time and build space in electron beam powder bed fusion (PBF-EB) opens up unprecedented opportunities to tailor the process and use materials of a different nature in the same build. The present investigation explored the various methods used to adapt the PBF-EB process for the production of functionally graded materials (FGMs). In this way, two pre-alloyed powders—a stainless steel (SS) powder and a highly alloyed cold work tool steel (TS) powder—were combined during processing in an S20 Arcam machine. Feasibility experiments were first carried out in a downscaled build setup, in which a single powder container was installed on top of the rake system. In the container, one powder was placed on top of the other (SS/TS) so that the gradient materials were produced as the powders were spread and intermixed during the build. The process was later scaled up to an industrial machine setup, where a similar approach was implemented using two configurations of powder disposal: SS/SS + TS/TS and TS/TS + SS/SS. Each configuration had an intermediate layer of powder blend. The FGMs obtained were characterized in terms of their microstructure and local and macromechanical properties. For the microstructural analysis, optical microscopy, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDX) were performed on the polished cross-sections. This provided evidence of gradual microstructural and compositional transitions in the samples, with a shift from SS to TS and vice versa. Nanoindentation experiments confirmed that there was a consequent gradient in the hardness, stiffness, and wear ratio from the softer and ductile SS to the harder and stiff TS. Scratch experiments revealed gradual evolution in the sliding wear behavior of the printed materials. A “progressive spring” and a “hardness-tailored punching tool” were fabricated as demonstrators. The results obtained demonstrate the great potential to gradually tailor the composition, microstructure, mechanical properties, and wear resistance by combining different powders, and they suggest that any PBF-EB system can be repurposed to build gradient materials without hardware modification. Potential applications include the tooling industry, where hard and wear-resistant materials are needed for the surfaces of tools, with tougher and more ductile materials used in the cores of tools. Full article
(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing, 2nd Edition)
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Review

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24 pages, 374 KB  
Review
Recycled Stainless Steel as a Sustainable Feedstock for Direct Metal Laser Sintering: Challenges and Opportunities
by Shubham Chaudhry and Amy Hsiao
J. Manuf. Mater. Process. 2026, 10(2), 51; https://doi.org/10.3390/jmmp10020051 - 31 Jan 2026
Viewed by 1103
Abstract
Direct metal laser sintering (DMLS) is an advanced powder bed fusion (PBF) technology widely utilized in the medical device and aerospace sectors for the production of intricate and high-value components. The powdered metal materials used in the DMLS process can be expensive, and [...] Read more.
Direct metal laser sintering (DMLS) is an advanced powder bed fusion (PBF) technology widely utilized in the medical device and aerospace sectors for the production of intricate and high-value components. The powdered metal materials used in the DMLS process can be expensive, and it is uncommon for a single build to exhaust an entire batch of powder. As a result, the un-melted powder characterized by differences in particle size and morphology compared to fresh virgin powder is recommended to be recycled for use in subsequent builds. This comprehensive review delves into the essential role that powder quality plays in the realm of DMLS with a particular focus on effective and sustainable powder recycling strategies. In this study, the effects of recycling stainless steel powder, specifically used in the DMLS process, are rigorously investigated in relation to the quality of the finished components. This paper monitors critical powder material characteristics, including particle size, particle morphology, and the overall bulk chemical composition throughout the recycling workflow. Furthermore, this review brings to light significant challenges associated with the recycling of stainless steel powders, such as the need to maintain consistency in particle size and shape, manage contamination risks, and mitigate the degradation effects that can arise from repeated usage, including wear, fragmentation, and oxidation of the particles. In addition, this paper explores a variety of recycling techniques aimed at rejuvenating powder quality. These techniques, including sieving, blending, and plasma spheroidization, are emphasized for their vital role in restoring the integrity of recycled powders and facilitating their reuse in innovative and efficient manufacturing processes. Full article
(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing, 2nd Edition)
52 pages, 5052 KB  
Review
A Comprehensive Review of Sustainable and Green Additive Manufacturing: Technologies, Practices, and Future Directions
by Sudip Dey Dipta, Md. Mahbubur Rahman, Md. Jonaet Ansari and Md. Nizam Uddin
J. Manuf. Mater. Process. 2025, 9(8), 269; https://doi.org/10.3390/jmmp9080269 - 9 Aug 2025
Cited by 12 | Viewed by 7032
Abstract
Additive manufacturing (AM), commonly known as 3D printing, has emerged as a transformative technology across various industries due to its potential for design flexibility, material efficiency, and reduced production lead times. As global attention increasingly shifts toward environmental sustainability, there is a growing [...] Read more.
Additive manufacturing (AM), commonly known as 3D printing, has emerged as a transformative technology across various industries due to its potential for design flexibility, material efficiency, and reduced production lead times. As global attention increasingly shifts toward environmental sustainability, there is a growing need to evaluate the ecological implications and opportunities associated with AM. This comprehensive review explores the current state of sustainable and green additive manufacturing (SGAM) technologies and practices, highlighting innovations that reduce energy consumption, minimize material waste, and incorporate renewable or recyclable materials. This study focuses on the utilization of recyclable thermoplastics combined with biodegradable polymers, exploring sustainable source materials, cold fabrication techniques, and cyclic lifecycle strategies integrated with renewable energy systems. Despite its potential, SGAM faces key challenges such as material compatibility, scalability of manufacturing processes, mechanical property optimization, and the need for standardized production protocols. Nevertheless, this work finds that SGAM devices are effective in minimizing environmental impact across the entire manufacturing process, aligning with predominant research trends that emphasize strategic predictive models to guide future developments in AM system implementation. The review concludes with future directions and research opportunities to enhance the environmental performance of AM technologies, ultimately contributing to a more sustainable manufacturing landscape. Full article
(This article belongs to the Special Issue High-Performance Metal Additive Manufacturing, 2nd Edition)
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