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Advances in Metal Additive Manufacturing: Processes, Materials, and Applications
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Advances in Metal Additive Manufacturing: Processes, Materials, and Applications

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

Deadline for manuscript submissions: 31 July 2026 | Viewed by 3327

Editor

Dr. Yang Du

E-Mail Website
Guest Editor
Department of Materials Science and Engineering, Iowa State University, Ames, IA 50011, USA
Interests: additive manufacturing; welding; machine learning; modeling; multi-laser manufacturing

Special Issue Information

Dear Colleagues,

Metal additive manufacturing (AM) has rapidly evolved from a prototyping tool into a transformative manufacturing technology that enables complex geometries, tailored microstructures, and unprecedented design freedom. Continued advances in process physics, materials development, in situ monitoring, and data-driven modeling are accelerating the adoption of metal AM in safety-critical and large-scale industrial applications.

We are pleased to invite you to contribute to a Special Issue of the Journal of Manufacturing and Materials Processing entitled “Advances in Metal Additive Manufacturing: Processes, Materials, and Applications.” This Special Issue aims to provide a timely platform for sharing cutting-edge research that advances both the fundamental understanding and practical implementation of metal additive manufacturing technologies. Topics of interest include, but are not limited to, metal AM processes, process–structure–property relationships, novel alloy design, defect formation and mitigation, multi-physics modeling, in situ sensing and control, artificial intelligence and machine learning, post-processing strategies, and emerging applications.

We warmly encourage researchers from academia, national laboratories, and industry to submit original research articles, reviews, and perspectives. We look forward to your valuable contributions and to showcasing the latest advances in metal additive manufacturing.

Best regards,

Dr. Yang Du
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-anonymized 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–structure–property
  • laser-based additive manufacturing
  • in situ monitoring
  • modeling
  • machine learning and deep learning

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

Published Papers (3 papers)

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Research

38 pages, 2038 KB  
Article
Practical Multivariate Equivalency Testing for Additively Manufactured Parts: Comparing Independent and Dependent Cases
by Colin M. Lynch, Rene Villalobos, Brenda Leticia Valadez Mesta, Cesar Gomez Guillen, Jorge Mireles and Ryan B. Wicker
J. Manuf. Mater. Process. 2026, 10(7), 229; https://doi.org/10.3390/jmmp10070229 - 30 Jun 2026
Viewed by 239
Abstract
Additive manufacturing (AM) requalification and change-control workflows often require evidence that a candidate machine, parameter set, scanner subsystem, facility, or measurement workflow remains comparable to a stable reference process after a change, but fabrication and testing costs limit exhaustive multifeature studies. The aim [...] Read more.
Additive manufacturing (AM) requalification and change-control workflows often require evidence that a candidate machine, parameter set, scanner subsystem, facility, or measurement workflow remains comparable to a stable reference process after a change, but fabrication and testing costs limit exhaustive multifeature studies. The aim of this study was to address this engineering design problem by developing a practical multifeature equivalency screening framework for AM settings in which prior engineering evidence already suggests that the candidate process should be comparable to the reference process. Building on prior work focused on the univariate problem, the proposed framework uses reference-defined percentile bins, feature-wise distributional tests, and family-wise error-rate control to screen for evidence of non-equivalency across multiple measured attributes. A direct joint-binning approach was first shown to become sample-intensive as dimensionality increases, after which an independent feature-wise method and an exploratory dependent bivariate extension were developed. Simulation-based power analyses quantified the trade-offs among power, detectable effect size, distributional resolution, feature count, and the combined costs of fabrication and measurement. In a laser-based powder bed fusion validation study with 40 observations per process and three corner-deviation features, the expected-equivalent AconityMIDI+ candidate satisfied all feature-wise equivalency criteria (V˜=0.207–0.214<CI+=0.276), whereas the expected non-equivalent SLM280 HL candidate failed all three feature-wise tests (V˜=0.357–1.000>CI+=0.276). These results support multivariate equivalency as a requalification screening tool for AM process comparability and change control, while confirming that it should not be interpreted as proof of physical-process identity or as a replacement for first-time formal qualification. Core procedures are implemented in the open-source R package MultivariateEquivalency. Full article
(This article belongs to the Special Issue Advances in Metal Additive Manufacturing: Processes, Materials, and Applications)
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14 pages, 3444 KB  
Article
Scan-Strategy Dependent Microstructural Modulation in L-PBF Ti-6Al-4V Components Through Selective Rescanning
by Kalyan Nandigama, Bharath Bhushan Ravichander, Yash Parikh and Golden Kumar
J. Manuf. Mater. Process. 2026, 10(3), 88; https://doi.org/10.3390/jmmp10030088 - 2 Mar 2026
Viewed by 1074
Abstract
Laser Powder Bed Fusion (L-PBF) can enable in situ microstructural tailoring of metallic components by precisely controlling the layer-wise processing parameters. Layer rescanning is one such strategy used to induce localized microstructural modification. In this study, we investigated the effect of a lattice-based [...] Read more.
Laser Powder Bed Fusion (L-PBF) can enable in situ microstructural tailoring of metallic components by precisely controlling the layer-wise processing parameters. Layer rescanning is one such strategy used to induce localized microstructural modification. In this study, we investigated the effect of a lattice-based selective rescanning approach applied to different base scan strategies for Ti-6Al-4V samples. The lattice regions were selectively rescanned at 50% reduced laser power relative to the initial scan along the same laser path. Relative density, porosity, martensitic α′ morphology, phase fraction, and Vickers microhardness were compared with those of non-rescanned reference counterparts. Different scan strategies, including unidirectional, stripes, and chess, exhibited distinct responses to selective rescanning, resulting in localized variations in martensitic phase formation and hardness values. The extent of localized microstructural modification and hardness enhancement was strongly governed by the underlying scan strategy. Selective rescanning using the stripes strategy yielded the largest contrast between non-rescanned and rescanned regions. The unidirectional strategy showed strong effects of rescanning, but the heat-affected zones extended to the non-rescanned regions. In contrast, the chess strategy exhibited comparatively moderate changes owing to its inherent thermal-management characteristics. These findings demonstrate that selective rescanning can provide an effective, localized approach for tailoring microstructure and hardness enhancement in L-PBF Ti-6Al-4V, with its effectiveness strongly dependent on the underlying scan strategy. Full article
(This article belongs to the Special Issue Advances in Metal Additive Manufacturing: Processes, Materials, and Applications)
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13 pages, 2794 KB  
Article
Exploring Metal Additive Manufacturing in Martian Atmospheric Environments
by Zane Mebruer and Wan Shou
J. Manuf. Mater. Process. 2026, 10(2), 67; https://doi.org/10.3390/jmmp10020067 - 17 Feb 2026
Viewed by 1398
Abstract
In-space manufacturing is essential for achieving long-term planetary colonization, particularly on Mars, where material transport from Earth is both costly and logistically restrictive. Traditional subtractive manufacturing methods are highly equipment-, energy-, and material-intensive, making additive manufacturing (AM) a more practical and sustainable alternative [...] Read more.
In-space manufacturing is essential for achieving long-term planetary colonization, particularly on Mars, where material transport from Earth is both costly and logistically restrictive. Traditional subtractive manufacturing methods are highly equipment-, energy-, and material-intensive, making additive manufacturing (AM) a more practical and sustainable alternative for extraterrestrial production. Among various AM technologies, laser beam powder bed fusion (PBF-LB) stands out due to its exceptional versatility, precision, and capability to produce dense metallic parts with complex geometries. However, conventional PBF-LB processes rely heavily on inert argon environments to prevent oxidation and ensure high-quality part formation—conditions that are difficult to reproduce on Mars. CO2 makes up over 95% of the Martian atmosphere, meaning printing in a majority-CO2 environment is of great interest for in situ manufacturing in a Martian colonization effort. This study investigates the feasibility of using pure carbon dioxide (CO2) as a potential substitute for argon in PBF-LB manufacturing. Single-track and two-dimensional 316L stainless steel specimens were fabricated under argon, CO2, and ambient air environments with a wide range of laser parameters to evaluate the influence of atmospheric composition on surface morphology, microstructural cohesion, and oxidation behavior. The results reveal that no single parameter controls the overall part quality; rather, a balance of parameters is essential to maintain thermal equilibrium during fabrication. Although parts produced in CO2 exhibited slightly inferior surface finish, cohesion, and oxidation resistance compared to argon, they performed significantly better than those fabricated in ambient air in terms of balling effects and overall cohesion. These findings suggest that CO2-assisted PBF-LB could enable sustainable in situ manufacturing on Mars and may also serve as a cost-effective alternative shielding gas for terrestrial applications. Full article
(This article belongs to the Special Issue Advances in Metal Additive Manufacturing: Processes, Materials, and Applications)
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