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Advanced Design and Materials for Additive Manufacturing
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Advanced Design and Materials for Additive Manufacturing

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

Deadline for manuscript submissions: 31 December 2026 | Viewed by 1629

Special Issue Editors

Dr. Shuzhi Xu

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Graduate School of Engineering, The University of Osaka, Osaka 565-0871, Japan
Interests: topology optimization; additive manufacturing; design for manufacturing
Prof. Dr. Yun-Fei Fu

E-Mail Website
Guest Editor
College of Mechanical and Electronic Engineering, Shandong University of Science and Technology, Qingdao 266590, China
Interests: additive manufacturing; structural optimization; composite materials; design for manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) has emerged as a transformative fabrication technology, enabling the production of complex geometries, functionally graded structures and multi-material components with unprecedented design freedom. However, the intricate thermal–mechanical interactions, anisotropy and process-induced defects inherent to AM continue to pose challenges for achieving reliable, high-performance components.

To address these challenges, research efforts have increasingly focused on advanced design strategies, process–structure–property optimization and the development of AM-tailored materials. The integration of computational optimization, high-performance computing, machine learning and multiscale modeling has accelerated innovation in AM—from digital design to material development and process control. Moreover, emerging paradigms such as multi-material architectures, lightweight lattice and metamaterial systems and functional composites open new opportunities for achieving customized, high-efficiency and multifunctional structures.

This Special Issue aims to gather cutting-edge research on advanced design, material innovation and multiscale modeling for additive manufacturing, fostering a unified framework for high-performance, lightweight and application-driven AM materials and structures. The guest editors warmly welcome submissions of original research articles and reviews that contribute to advancing design and material innovations of additive manufacturing.

Dr. Shuzhi Xu
Prof. Dr. Yun-Fei Fu
Guest Editors

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

  • additive manufacturing
  • design for manufacturing
  • material design
  • integrated materials and structure design
  • computational optimization
  • topology optimization
  • data-driven
  • multiscale modeling
  • high-performance computing
  • process simulation

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Published Papers (2 papers)

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24 pages, 4939 KB  
Article
Modeling and Simulation of Multi-Layer WAAM Structures for Digital Twin Integration
by Berend Denkena, Volker Böß, Klaas Maximilian Heide, Andrii Skryhunets and Talash Malek
J. Manuf. Mater. Process. 2026, 10(3), 106; https://doi.org/10.3390/jmmp10030106 - 18 Mar 2026
Viewed by 628
Abstract
In modern production, Wire Arc Additive Manufacturing (WAAM) is becoming an essential technology for manufacturing complex components. However, the complexity of planning such processes constrains their widespread use in production cycles. Using various numerical simulation approaches allows for the investigation of resulting geometries [...] Read more.
In modern production, Wire Arc Additive Manufacturing (WAAM) is becoming an essential technology for manufacturing complex components. However, the complexity of planning such processes constrains their widespread use in production cycles. Using various numerical simulation approaches allows for the investigation of resulting geometries with respect to process parameters, reducing the need for experiment-based process planning. Similar to various subtractive processes, there is increased interest in integrating simulation approaches into digital twin applications for planning and optimization of WAAM processes. This requires dynamic geometry mapping and simulation time comparable to the process duration. In this paper, a numerical simulation employing a Dexel-based geometry representation and a model for single-bead geometry parameter prediction is investigated as a vital alternative to Finite Element Method (FEM)-based simulations. The focus lies on the accuracy of the simulated components with respect to the simulation settings, the time needed for it to complete, and the degree of compliance between the simulated and produced multi-layer structures. Using optimized simulation settings achieves an accuracy loss of under 7% due to geometry discretization, with a simulation time that is approximately 37% faster than the process duration. The simulated components closely correspond to the experimental ones in terms of width and height, with a volumetric similarity ranging from 63.3% to 88.8%. Full article
(This article belongs to the Special Issue Advanced Design and Materials for Additive Manufacturing)
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39 pages, 31180 KB  
Article
A Segmental Joining Method for Large-Scale Additive Components: Case Study on a Fan Blade
by Ronald Bastovansky, Matus Veres, Rudolf Madaj, Robert Kohar and Peter Weis
J. Manuf. Mater. Process. 2026, 10(3), 87; https://doi.org/10.3390/jmmp10030087 - 27 Feb 2026
Viewed by 610
Abstract
This study presents a case-specific joining method for modular, large-scale components manufactured using Selective Laser Sintering (SLS). A T-slot joint reinforced with a pultruded carbon fiber rod was developed to enable the segmental assembly of polymer fan blades that exceed the build volume [...] Read more.
This study presents a case-specific joining method for modular, large-scale components manufactured using Selective Laser Sintering (SLS). A T-slot joint reinforced with a pultruded carbon fiber rod was developed to enable the segmental assembly of polymer fan blades that exceed the build volume of common SLS printers. Through an iterative design process, five joint variations were investigated, focusing on the optimization of slot geometry (fillet radii and wall thickness) and the integration of carbon fiber reinforcements to create a high-strength hybrid connection. The experimental findings were validated using a non-linear finite element analysis (FEA) utilizing an iteratively calibrated Young’s modulus of 710 MPa, which accounts for the 50/50 virgin-to-reused PA2200 powder ratio employed in the study. The numerical model identified that the primary sites for crack initiation were the fillet radii of the female slot, where localized equivalent plastic strains reached critical levels of up to 84% in tension and 78% in bending. The final design achieved an average tensile strength of 27.6 MPa, exceeding the design threshold of 21.9 MPa with a safety factor of 2.5. While unreinforced joints showed a 73.4% reduction in bending strength compared to solid specimens, the addition of an 8 mm carbon rod increased performance by 238.7%, restoring over 90% of the monolithic material’s strength. Numerical results confirmed that the reinforcement assumed the primary load-bearing role, effectively mitigating stresses in the polymer matrix below the ultimate tensile strength. Failure analysis clarified that the observed audible failure originated from internal fiber breakage within the rod at stresses between 900–1050 MPa. This work demonstrates that a segmental, reinforcement-based joining method can effectively overcome size constraints in polymer additive manufacturing, providing a robust and repeatable solution for rotating components subject to complex loading conditions. Full article
(This article belongs to the Special Issue Advanced Design and Materials for Additive Manufacturing)
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