Enhancing Performance of High-Value Components Through Additive Manufacturing: Applications in Marine, Air, and Land Transportation

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: 31 January 2026 | Viewed by 337

Special Issue Editor


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Guest Editor
Mechanical Engineering, University of Notre Dame, Notre Dame, IN 46556, USA
Interests: AI-assisted additive manufacturing; multi-material multi-scale additive manufacturing; stretchable and conformal electronics

Special Issue Information

Dear Colleagues,

Additive manufacturing has emerged as one of the most transformative and rapidly growing fields of research, providing unparalleled capabilities regarding the production of parts with complex geometries and the integration of advanced materials. These capabilities enable the creation of parts with smart mechanical designs and material properties that surpass those achievable via the application of traditional manufacturing methods. Such advancements are critical for enhancing the performance of high-value components in transportation systems, including engines, turbines, sensors, and structural elements. By utilizing digitally optimized part design, innovative additive manufacturing techniques, and novel material development, transportation equipment can attain enhanced efficiency, enhanced mechanical and thermal properties, reduced weight, and the seamless integration of sensors with structural components.

This Special Issue aims to provide an overview of recent advances in the performance enhancement of high-value components in transportation machinery via the use of additive manufacturing. Contributions may include both review articles and original research papers. The scope of this Special Issue includes, but is not limited to, the following topics:

  • Part design optimization and generative design;
  • Part performance analysis and validation;
  • Part repair and maintenance;
  • Process–property relationship modeling and optimization;
  • Post-processing techniques;
  • Part quality control and real-time quality monitoring;
  • Hybrid additive manufacturing and multi-material, multi-scale manufacturing;
  • Performance enhancements through novel materials;
  • Functional graded materials and metamaterials;
  • Additive manufacturing-enabled sensor integration;
  • Case studies in marine, air, and land transportation applications;
  • Advanced simulation and modeling of additive manufacturing processes.

Dr. Yipu Du
Guest Editor

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Keywords

  • additive manufacturing
  • mechanical designs
  • material properties

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Published Papers (1 paper)

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Research

21 pages, 1890 KiB  
Article
Retrofitting of a High-Performance Aerospace Component via Topology Optimization and Additive Manufacturing
by Jorge Crespo-Sánchez, Claudia Solek, Sergio Fuentes del Toro, Ana M. Camacho and Alvaro Rodríguez-Prieto
Machines 2025, 13(8), 700; https://doi.org/10.3390/machines13080700 - 8 Aug 2025
Viewed by 80
Abstract
This research presents a novel methodology for lightweighting and cost reduction of components with high structural demands by integrating advanced design and manufacturing techniques. Specifically, it combines topology optimization (TO) with additive manufacturing (AM), also known as 3D printing. Unlike conventional approaches, the [...] Read more.
This research presents a novel methodology for lightweighting and cost reduction of components with high structural demands by integrating advanced design and manufacturing techniques. Specifically, it combines topology optimization (TO) with additive manufacturing (AM), also known as 3D printing. Unlike conventional approaches, the proposed method first determines the optimal geometry using an artificially stiff material, and only then evaluates real materials for structural and manufacturing feasibility. This design-first, material-second strategy enables broader material screening and maximizes weight reduction without compromising performance. The proposed workflow is applied to the design of a turbofan air intake—an aeronautical component operating under supersonic conditions—addressing both structural integrity and manufacturing feasibility. Three materials from distinct classes are assessed: two metallic alloys (aluminum alloy 6061 and titanium alloy, Ti6Al4V) and a high-performance polymer (polyetheretherketone, PEEK). This last option is preliminarily discarded after being analyzed for this specific application. Finite element (FE) simulations are used to evaluate the mechanical behavior of the optimized geometries, including bird-strike conditions. Among the evaluated manufacturing techniques, Selective Laser Melting (SLM) is identified as the most suitable for the metallic materials selected, providing an effective balance between performance, manufacturability, and aerospace compliance. This study illustrates the potential of TO–AM synergy as a sustainable and efficient design approach for next-generation aerospace components. Simulation results demonstrate a weight reduction of up to 71% while preserving critical functional regions and maintaining structural integrity in Al 6061 and Ti6Al4V cases, under the diverse loading conditions typical of real flight scenarios, while PEEK remains an attractive option for uses where mechanical demands are less stringent. Full article
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