Design and Optimization for Metal Additive Manufacturing

Dear Colleagues,

Metal additive manufacturing (AM) has emerged as a transformative technology that enables the production of complex, high-performance components with unprecedented geometric and material flexibility. As the technology matures, the focus is increasingly shifting from feasibility to optimization—optimizing not only the final part of geometry and performance, but also the design methods, process parameters, and multi-scale material architectures that define the AM workflow.

This Special Issue aims to highlight cutting-edge research in the design, optimization, and performance enhancement of metallic components fabricated via AM. Contributions that advance our understanding of how to fully leverage the design freedom and unique capabilities of metal AM are especially welcome. We are particularly interested in work that integrates computational design, simulation, and experimental validation to drive innovation across materials, processes, and applications.

We invite original research articles and comprehensive reviews that address emerging challenges and opportunities in this dynamic field. Topics of interest include, but are not limited to, the following:

• Design methodologies for metal AM: Function-driven design, generative design, topology optimization, and functionally graded structures tailored for metal AM processes to improve product performance.
• Process–structure–property relationships: Studies that link AM process parameters to material microstructure and mechanical performance.
• Simulation and digital twin approaches: Use of numerical modeling and predictive tools for process planning, defect mitigation, and performance prediction.
• AI- and data-driven optimization: Applications of machine learning and data analytics in accelerating design cycles and optimizing build strategies for metallic AM parts and processes.
• Support structure design and process planning: Innovations in minimizing support material, reducing residual stress, and improving print efficiency.
• Multi-material and multi-scale design: Design strategies for incorporating multiple materials, heterogeneous architectures, and hierarchical structures.
• Post-processing optimization for performance: Investigation of post-processing (e.g., heat treatment and surface finishing) in relation to obtaining a better performance.
• Sustainability and design for recyclability: Design strategies that account for material reuse, energy efficiency, and life cycle considerations in metal AM.

This Special Issue offers a platform for researchers and practitioners to share their latest insights and breakthroughs, fostering interdisciplinary collaboration and guiding the future of metal additive manufacturing through informed design and optimization.

Dr. Guoying Dong
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 100 words) can be sent to the Editorial Office for announcement on this website.

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. Metals 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 2600 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.

• metal additive manufacturing
• computational design
• topology optimization
• process–structure–property relationships
• machine learning
• digital twin
• design for AM
• multi-material design
• support structure optimization
• sustainability in AM