Manufacturing and Advanced Machining Technologies–Design, Processing, and Validation

Dear Colleagues,

Additive manufacturing (AM) and advanced machining technologies are transforming the production landscape by enabling the fabrication of highly complex, lightweight and functionally optimized components. These technologies are being adopted at an accelerating rate across sectors such as aerospace, automotive, biomedical, energy and tooling, where precision, performance and customization are critical. As these technologies evolve, new challenges and opportunities arise in areas such as material development, process control and product validation.

The performance and reliability of AM parts are governed by the intricate interplay of alloy composition, microstructure, process parameters and post-processing. Defects such as porosity, residual stresses and surface irregularities are still a major concern and require robust strategies for in situ monitoring, defect prediction and process optimization. Artificial intelligence and machine learning are increasingly being used to improve decision-making processes and speed up development. Furthermore, integrating topology optimization, lattice structures and novel design strategies has paved the way for the creation of lightweight yet mechanically robust parts.

Meanwhile, modern machining and subtractive processes are continuing to evolve thanks to innovations in tool design, automation, CAM systems and hybrid manufacturing approaches. Post-processing of AM parts, high-precision machining and advanced metrology are all vital for meeting the exacting standards required by industrial applications. The convergence of digital technologies, such as digital twins, real-time diagnostics and simulation-driven design, further supports the transition towards intelligent, sustainable manufacturing ecosystems.

The aim of this Special Issue is to highlight recent advances in additive and advanced machining technologies, with a particular focus on integrated approaches spanning design and simulation, material processing and characterization and industrial validation. We particularly welcome contributions focusing on experimental research, computational modeling, process innovation and case studies with industrial relevance.

Topics of interest include, but are not limited to, the following:

• Additive manufacturing processes and their optimization;
• Defect formation, microstructure evolution and mechanical performance;
• AI and data-driven approaches in process control and monitoring;
• In situ sensing, adaptive control and closed-loop manufacturing;
• Post-processing techniques and hybrid process chains;
• Fracture behavior, fatigue performance and structural integrity;
• Topology optimization and architectured (lattice/porous) structures;
• Validation, certification and quality assurance frameworks;
• Sustainability, life cycle assessment and environmental impact;
• Laser-based and non-conventional machining techniques;
• Innovations in cutting tools, fixtures and machining strategies;
• CAM and NC programming trends in smart manufacturing;
• Surface modification and advanced finishing methods;
• Metrology, diagnostics and digital twin applications;
• Modeling, simulation and multiscale optimization of processes.

This Special Issue offers researchers, engineers and industry professionals a platform to share high-impact findings that contribute to advancing next-generation manufacturing technologies. We welcome original research articles, comprehensive reviews and case studies offering novel insights into designing, processing and validating components produced using additive and advanced machining technologies.

Prof. Dr. Miroslav Zetek
Dr. Miroslav Gombár
Dr. Alena Vagaská
Guest Editors

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