Research Progress on Advanced Additive Manufacturing Technologies

A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D3: 3D Printing and Additive Manufacturing".

Deadline for manuscript submissions: 30 November 2026 | Viewed by 7049

Special Issue Editor


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Guest Editor
Department of Industrial and Engineering Technology, Southeastern Louisiana University, Hammond, LA, USA
Interests: additive manufacturing; architected materials; polymer characterization; sustainable manufacturing; smart materials

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM), a process fundamentally different from subtractive manufacturing in that it builds three-dimensional structures by forming material in a layer-by-layer manner, has been at the forefront of research and development during the past decade. The ability to manufacture previously difficult or impossible geometries, lightweight products, and high-performance functional parts, coupled with shorter lead times, makes AM technologies very attractive to a broad range of industries, from automotive, healthcare, and consumer products to aerospace, defense, and transportation.

Recent developments in AM technologies go beyond well-known methods such as binder jetting, directed energy deposition, material extrusion, material jetting, powder bed fusion, and vat polymerization, where novel approaches based on these methods lead to further advancements spanning across material and process developments that fundamentally address challenges faced by existing AM technologies and material systems. These efforts have led to the development of AM driven biomedical, energy storage, and electronic devices among others. Accordingly, this Special Issue seeks to disseminate original research and comprehensive review articles on advanced AM technologies, novel material systems, and fundamental methodological developments. Submissions are welcome across all aspects of the development and application of advanced AM technologies.

Dr. Mohammad Faisal Ahmed
Guest Editor

Manuscript Submission Information

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Keywords

  • additive manufacturing
  • advanced manufacturing
  • 3D printing
  • 4D printing
  • design and modelling
  • functional materials
  • smart materials
  • composites
  • cellular materials
  • shape memory

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Published Papers (3 papers)

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Research

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25 pages, 8823 KB  
Article
Additively Manufactured Density-Graded Dual-Material Auxetic Structures: Enhanced Energy Absorption and Shape Recovery
by Mohammad Faisal Ahmed and Kyle Primes
Micromachines 2026, 17(5), 570; https://doi.org/10.3390/mi17050570 - 3 May 2026
Viewed by 444
Abstract
The auxetic reentrant structure, one of the most widely studied negative Poisson’s ratio structures for its geometric simplicity, has long seen limited applications due to challenges emanating from its inherent design when built from a single rigid or flexible material. This paper aims [...] Read more.
The auxetic reentrant structure, one of the most widely studied negative Poisson’s ratio structures for its geometric simplicity, has long seen limited applications due to challenges emanating from its inherent design when built from a single rigid or flexible material. This paper aims to address these challenges by taking advantage of dual-material extrusion technology and density gradient design strategy. Two density gradient reentrant auxetic structures are proposed and fabricated using material extrusion additive manufacturing in single-material (flexible) and dual-material (rigid/flexible) modes, with the introduction of a novel dual-material interface design. In-plane compression tests are carried out to assess the energy absorption characteristics of the structures. The results show that dual-material structures exhibit higher yield stress, mean crushing force, peak crushing force, and maximum crushing force, as well as superior specific energy, energy dissipation, and energy release compared to single-material structures. Dual-material structures also demonstrate high lateral stiffness, minimizing elastic instability, a highly desirable feature for reusable energy-absorbing structures with high shape recovery capability. The results substantiate the significance of the synergy between the dual-material and density gradient designs proposed in this study. Overall, the key findings of the study may serve as a reliable reference for the design of future lightweight energy-absorbing structures. Full article
(This article belongs to the Special Issue Research Progress on Advanced Additive Manufacturing Technologies)
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24 pages, 3724 KB  
Article
Numerical Investigation of Non-Newtonian Fluid Rheology in a T-Shaped Microfluidics Channel Integrated with Complex Micropillar Structures Under Acoustic, Electric, and Magnetic Fields
by Muhammad Waqas, Arvydas Palevicius, Cengizhan Omer Senol and Giedrius Janusas
Micromachines 2025, 16(12), 1390; https://doi.org/10.3390/mi16121390 - 8 Dec 2025
Viewed by 1076
Abstract
Microfluidics is considered a revolutionary interdisciplinary technology with substantial interest in various biomedical applications. Many non-Newtonian fluids often used in microfluidics systems are notably influenced by the external active fields, such as acoustic, electric, and magnetic fields, leading to changes in rheological behavior. [...] Read more.
Microfluidics is considered a revolutionary interdisciplinary technology with substantial interest in various biomedical applications. Many non-Newtonian fluids often used in microfluidics systems are notably influenced by the external active fields, such as acoustic, electric, and magnetic fields, leading to changes in rheological behavior. In this study, a numerical investigation is carried out to explore the rheological behavior of non-Newtonian fluids in a T-shaped microfluidics channel integrated with complex micropillar structures under the influence of acoustic, electric, and magnetic fields. For this purpose, COMSOL Multiphysics with laminar flow, pressure acoustic, electric current, and magnetic field physics is used to examine rheological characteristics of non-Newtonian fluids. Three polymer solutions, such as 2000 ppm xanthan gum (XG), 1000 ppm polyethylene oxide (PEO), and 1500 ppm polyacrylamide (PAM), are used as a non-Newtonian fluids with the Carreau–Yasuda fluid model to characterize the shear-thinning behavior. Moreover, numerical simulations are carried out with different input parameters, such as Reynolds numbers (0.1, 1, 10, and 50), acoustic pressure (5 Mpa, 6.5 Mpa, and 8 Mpa), electric voltage (200 V, 250 V, and 300 V), and magnetic flux (0.5 T, 0.7 T, and 0.9 T). The findings reveal that the incorporation of active fields and micropillar structures noticeably impacts fluid rheology. The acoustic field induces higher shear-thinning behavior, decreasing dynamic viscosity from 0.51 Pa·s to 0.34 Pa·s. Similarly, the electric field induces higher shear rates, reducing dynamic viscosities from 0.63 Pa·s to 0.42 Pa·s, while the magnetic field drops the dynamic viscosity from 0.44 Pa·s to 0.29 Pa·s. Additionally, as the Reynolds number increases, the shear rate also rises in the case of electric and magnetic fields, leading to more chaotic flow, while the acoustic field advances more smooth flow patterns and uniform fluid motion within the microchannel. Moreover, a proposed experimental framework is designed to study non-Newtonian fluid mixing in a T-shaped microfluidics channel under external active fields. Initially, the microchannel was fabricated using a high-resolution SLA printer with clear photopolymer resin material. Post-processing involved analyzing particle distribution, mixing quality, fluid rheology, and particle aggregation. Overall, the findings emphasize the significance of considering the fluid rheology in designing and optimizing microfluidics systems under active fields, especially when dealing with complex fluids with non-Newtonian characteristics. Full article
(This article belongs to the Special Issue Research Progress on Advanced Additive Manufacturing Technologies)
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Review

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45 pages, 2668 KB  
Review
Advances in 3D Bioprinting: Materials, Processes, and Emerging Applications
by Subin Antony Jose, Antonia Evtimow and Pradeep L. Menezes
Micromachines 2026, 17(3), 282; https://doi.org/10.3390/mi17030282 - 25 Feb 2026
Cited by 4 | Viewed by 5120
Abstract
Three-dimensional (3D) bioprinting has rapidly emerged as a transformative technology at the interface of biomedical engineering and regenerative medicine. By enabling the spatially controlled deposition of living cells, biomaterials, and bioactive molecules, it offers an unprecedented potential to fabricate functional tissues and potentially [...] Read more.
Three-dimensional (3D) bioprinting has rapidly emerged as a transformative technology at the interface of biomedical engineering and regenerative medicine. By enabling the spatially controlled deposition of living cells, biomaterials, and bioactive molecules, it offers an unprecedented potential to fabricate functional tissues and potentially whole organs in the future. This review explores recent advances in bioprinting materials, processes, and applications, emphasizing the integration of bioinks, printing methods, and mechanical design principles that underpin tissue functionality. Natural and synthetic biomaterials such as hydrogels (e.g., collagen, alginate), polyethylene glycol (PEG), and polyesters like PLGA are evaluated in terms of biocompatibility, printability, and degradation behavior. Key bioprinting modalities, including extrusion, inkjet, and laser-assisted bioprinting, are compared based on printing resolution, cell viability, and scalability. Structural considerations such as scaffold architecture, mechanical stability, and biomimetic design are discussed in relation to native tissue mechanics and requirements. The review also surveys emerging applications in tissue engineering (e.g., bone, cartilage, skin replacements), organ-on-a-chip systems for drug testing, and patient-specific implants, while addressing persistent challenges such as standardization of biofabrication, regulatory and ethical considerations, and manufacturing scale-up. Finally, future trends, including the integration of artificial intelligence (AI) and robotic automation, multi-material and four-dimensional (4D) bioprinting, and the maturation of personalized bioprinting strategies, are highlighted as pathways toward more autonomous and clinically relevant bioprinting systems. Collectively, these developments signify a paradigm shift in how biological constructs are designed and manufactured, bridging the gap between laboratory research and clinical translation. Full article
(This article belongs to the Special Issue Research Progress on Advanced Additive Manufacturing Technologies)
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