Magnetic field-assisted control of magnetite location is a promising strategy for developing flexible, electrically conductive sensors with enhanced performance and adjustable properties. This study investigates the effect of static magnetic fields applied on thermoplastic elastomer (TPE) composites with magnetite and multi-walled carbon nanotubes (MWCNT). The composites were prepared by compression moulding and the magnetic field was applied on the mould cavity during processing. Composites were prepared with a range of concentrations of magnetite (1, 3, and 6 wt.%) and MWCNT (1 and 3 wt.%). The effect of particle concentration on composite viscosity was investigated. Rheological analysis showed that MWCNTs significantly increased the composite viscosity while magnetite had minimal impact, ensuring stable processing and facilitating particle orientation under a static magnetic field. Particle orientation and electrical conductivity were evaluated for the composites prepared with different particle concentrations under different processing temperatures. Magnetic field application at 190 °C enhanced magnetite/MWCNT interactions, substantially reducing electrical resistivity while preserving thermal stability. The composites showed no degradation at 220 °C and above, demonstrating suitability for high-temperature applications requiring thermal resilience. Furthermore, magnetite’s magnetic response facilitated precise sensor positioning and strong adhesion to polyimide substrates at 220 °C. These findings demonstrate a scalable and adaptable approach for enhancing sensor performance and positioning, with broad potential in flexible electronics.

Smart textiles provide a significant technological advancement, but their development must balance traditional textile properties with electronic features. To address this challenge, this study introduces a flexible, electrically conductive composite material that can be fabricated using a continuous bi-component extrusion process, making it ideal for sensor electrodes. The primary aim was to create a composite for the filament’s core, combining multi-walled carbon nanotubes (MWCNTs), polypropylene (PP), and thermoplastic elastomer (TPE), optimised for conductivity and flexibility. This blend, suitable for bi-component extrusion processes, exemplifies the role of advanced materials in combining electrical conductivity, mechanical flexibility, and processability, which are essential for wearable technology. The composite optimisation balanced MWCNT (2.5, 5, 7.5, and 10 wt.%) and TPE (0, 25, and 50 wt.%) in a PP matrix. There was a significant decrease in electrical resistivity between 2.5 and 5 wt.% MWCNT, with electrical resistivity ranging from (7.64 ± 4.03)104 to (1.15 ± 0.10)10−1 Ω·m. Combining the composite with 25 wt.% TPE improved the flexibility, while with 50 wt.% TPE decreased tensile strength and hindered the masterbatch pelletising process. The final stage involved laminating the composite filament electrodes, with a 5 wt.% MWCNT/PP/(25 wt.% TPE) core and a TPE sheath, into a textile triboelectric impact detection sensor. This sensor, responding to contact and separation, produced an output voltage of approximately 5 V peak-to-peak per filament and 15 V peak-to-peak with five filaments under a 100 N force over 78.54 cm2. This preliminary study demonstrates an innovative approach to enhance the flexibility of conductive materials for smart textile applications, enabling the development of triboelectric sensor electrodes with potential applications in impact detection, fall monitoring, and motion tracking.

This study investigates the development of hydrofoil components for an unmanned boat designed for control testing.Hydrofoils, characterized by their hydrodynamic shape, generate lift forces that elevate the boat above the water, enhancing its speed.Utilizing Fusion 360, a mechanism was designed to adjust the angle of attack of the hydrofoil wings.Subsequently, nTop and Eiger software were used to optimize and prepare these components for additive manufacturing (AM), with the primary objective being weight reduction.Material extrusion was selected as the preferred AM technology.The workflow within nTop was adapted for two materials: Onyx and carbon fiber-reinforced Onyx.Generative design techniques were applied, including field-driven design, lattice structures, and topology optimization (TO).Utilizing variable-thickness shells proved an efficient approach for reducing mass while preserving mechanical integrity.TO of the lever resulted in a significant reduction in mass.

This research aims to enhance the understanding of the interrelationships among the manufacturing process, microstructure, and mechanical properties in the Laser Powder Bed Fusion (L-PBF) of SAE 316L stainless steel (SS), which can lead to the appearance of undesirable phases, like sigma (σ). As part of this investigation, as-built samples underwent solubilization heat treatment (HT), primarily targeting the dissolution of the σ phase and microstructure homogenization, with a subsequent assessment of its impact on hardness. The study reveals the efficacy of HT in reducing σ phase content, particularly following treatments at 950°C and 1,050°C for 2 h. Notably, the dissolution of the process-induced microstructure becomes progressively significant within the temperature range of 800–950°C for 2 h. Furthermore, the study identifies a hardening effect associated with the process-induced microstructure on the samples. Remarkably, the sample exhibiting the highest hardness value featured a substantial σ phase content and maintained the process-induced structure after HT.

Design for Additive Manufacturing (DfAM) is a transformative approach designed explicitly to optimize designs using metal additive manufacturing (AM). Exploring core DfAM principles, the chapter highlights the advantages of geometric freedom, material selection, and aligning designs with the capabilities of specific metal AM processes. It examines advanced optimization techniques like topology optimization and lattice structures to achieve high performance on lightweight metallic components. The transformative impact of metal DfAM is shown through real-world applications encompassing aerospace, healthcare, and automotive domains. The chapter acknowledges challenges inherent in metal DfAM, such as geometric limitations, surface finish considerations, and cost implications. Finally, it emphasizes the critical role of sophisticated software tools in driving design efficiency and explores future trends in AM metallic materials, technologies, and research.

Direct Energy Deposition (DED) is a highly efficient technology for the manufacture and/or repair of different components for multiple industries, including aeronautical. However, a good understanding of the various process variables is essential for producing deposits with the desired properties and ensuring process efficiency. In this study, the optimisation of Inconel 718 single-track deposits was carried out by varying laser power, scanning speed, and powder feed rate to minimise dilution and maximise height, always ensuring the efficiency of the process. The influence of the DED process’ inputs (laser power, scanning speed, and feed rate) and outputs (deposit’s geometry and dilution) were evaluated in the construction of Response Surface Plots and regression analysis equations, allowing the selection of the most promising processing conditions that achieve high-quality single tracks, with predicted dilution percentage, and deposit height. Optimisation analysis selected process parameters, and a block with 300 × 50 × 3 mm3 was built. Mechanical and microstructural characterisation of the built block before and after heat treatment (homogenisation at 1080 °C, followed by solubilisation at 980 °C, and double ageing at 720 and 620 °C) was performed through Optical Microscopy, SEM/EDS analysis, Vickers hardness and tensile tests. It could be observed that the chosen process leads to the formation of a dendritic structure with considerable amounts of Laves phase. However, heat treatments make it possible to obtain a more homogeneous structure with higher amounts of hardening phases, such as γ’ and γ”, which promotes an increase in hardness and tensile strength, and partial elimination of the Laves phase. With proper optimisation of the DED process and understanding of the different parameters’ influence on the deposit’s microstructure, it is possible to manufacture or repair Inconel 718 components for several industries.

While conventional die manufacturing techniques often lead to limitations in production speed and design intricacy due to labour-intensive procedures like machining and casting, Additive Manufacturing (AM) emerges as a key player offering substantial potential for cost reduction and process improvement in mass production. This study benchmarks four leading Laser Powder Bed Fusion (L-PBF) systems for producing maraging steel (EN 1.2709) dies. Despite the shared material and technology, variations in dimensional accuracy, surface finish, and microstructure were observed among the maraging steel parts. SEM/EDS, EBSD, hardness testing, and dimensional analysis revealed system-specific performance differences. Additionally, select parts underwent heat treatment and tensile testing, demonstrating the impact of post-processing on mechanical properties. These results offer valuable guidance for industrial stakeholders considering AM, highlighting the importance of supplier selection and process optimisation for achieving consistent part quality and unlocking the full potential of AM technologies.

Refractory High-Entropy Alloys (RHEAs) have been presented as attractive materials for high-temperature applications, such as combustion engines for the aerospace sector, due to the possible service temperature increase, which can result in superior yield of the combustion itself. This work presents the combination of CALPHAD simulations with the in-situ alloying of the MoNbTaW system by Direct Energy Deposition (DED) for a high-throughput screening of RHEAs. CALPHAD simulations show that the addition of V and Ti allows a single-phase BCC structure to be kept. For the DED setup available, MoNbTaW single-track deposits were optimised through Response Surface Methodology. Afterwards, in-situ alloying with V was conducted. Microstructural characterisation was assessed at room temperature through SEM/EDS, and the mechanical characterisation was performed at room temperature (RT), 350 degrees C and 700 degrees C, through nanoindentation tests. The microstructural characterisation shows that alloying up to 40 at.% V to the base system allows to keep a single-phase structure; however, some segregations are observed. Mechanical characterisation revealed that V alloying of 22 % promotes a 93 % increase in hardness at RT and a 150 % increase at 700 degrees C. This study contributes to increasing the practical knowledge of RHEAs, thus accelerating the application of these alloys in aerospace applications.

Fused filament fabrication (FFF) is an extrusion-based additive manufacturing (AM) technology mostly used to produce thermoplastic parts. However, producing metallic or ceramic parts by FFF is also a sintered-based AM process. FFF for metallic parts can be divided into five steps: (1) raw material selection and feedstock mixture (including palletization), (2) filament production (extrusion), (3) production of AM components using the filament extrusion process, (4) debinding, and (5) sintering. These steps are interrelated, where the parameters interact with the others and have a key role in the integrity and quality of the final metallic parts. FFF can produce high-accuracy and complex metallic parts, potentially revolutionizing the manufacturing industry and taking AM components to a new level. In the FFF technology for metallic materials, material compatibility, production quality, and cost-effectiveness are the challenges to overcome to make it more competitive compared to other AM technologies, like the laser processes. This review provides a comprehensive overview of the recent developments in FFF for metallic materials, including the metals and binders used, the challenges faced, potential applications, and the impact of FFF on the manufacturing (prototyping and end parts), design freedom, customization, sustainability, supply chain, among others.

The fabrication of low-electrical-percolation-threshold polymer composites aims to reduce the weight fraction of the conductive nanomaterial necessary to achieve a given level of electrical resistivity of the composite. The present work aimed at preparing composites based on multiwalled carbon nanotubes (MWCNTs) and magnetite particles in a polyurethane (PU) matrix to study the effect on the electrical resistance of electrodes produced under magnetic fields. Composites with 1 wt.% of MWCNT, 1 wt.% of magnetite and combinations of both were prepared and analysed. The hybrid composites combined MWCNTs and magnetite at the weight ratios of 1:1; 1:1/6; 1:1/12; and 1:1/24. The results showed that MWCNTs were responsible for the electrical conductivity of the composites since the composites with 1 wt.% magnetite were non-conductive. Combining magnetite particles with MWCNTs reduces the electrical resistance of the composite. SQUID analysis showed that MWCNTs simultaneously exhibit ferromagnetism and diamagnetism, ferromagnetism being dominant at lower magnetic fields and diamagnetism being dominant at higher fields. Conversely, magnetite particles present a ferromagnetic response much stronger than MWCNTs. Finally, optical microscopy (OM) and X-ray micro computed tomography (micro CT) identified the interaction between particles and their location inside the composite. In conclusion, the combination of magnetite and MWCNTs in a polymer composite allows for the control of the location of these particles using an external magnetic field, decreasing the electrical resistance of the electrodes produced. By adding 1 wt.% of magnetite to 1 wt.% of MWCNT (1:1), the electric resistance of the composites decreased from 9 × 104 to 5 × 103 Ω. This approach significantly improved the reproducibility of the electrode's fabrication process, enabling the development of a triboelectric sensor using a polyurethane (PU) composite and silicone rubber (SR). Finally, the method's bearing was demonstrated by developing an automated robotic soft grip with tendon-driven actuation controlled by the triboelectric sensor. The results indicate that magnetic patterning is a versatile and low-cost approach to manufacturing sensors for soft robotics.

Soft robotics is an expanding area with multiple applications; however, building low-cost, soft, and flexible robots requires the development of sensors that can be directly integrated into the soft robotics fabrication process. Thus, the motivation for this work was the design of a low-cost fabrication process of flexible sensors that can detect touch and deformation. The fabrication process proposed uses a flexible polymer nanocomposite with permanent magnets strategically placed where the conductive electrodes should be. The nanocomposite is based on poly(dimethylsiloxane) (PDMS) and multi-walled carbon nanotubes (MWCNTs). The MWCNT contains ferromagnetic impurities remaining from the synthesis process, which can be used for magnetic manipulation. Several electrode geometries were successfully simulated and tested. The magnetic patterning was simulated, allowing the fabrication of conductive patterns within the composite. This fabrication process allowed the reduction of the electrical resistivity of the nanocomposites as compared to the composites with homogeneous MWCNT dispersion. It also allowed the fabrication of piezoresistive and triboelectric sensors at MWCNT concentration as low as 0.5 wt.%. The fabrication process proposed is flexible, allows the development of sensors for soft robotics, as well as monitoring large and unconventional areas, and may be adapted to different mould shapes and polymers at low cost.

Micro hot embossing is a well-established technology to produce polymer microdevices and parts. This technology on metal powder/binder feedstocks is an innovator challenge that fits into the sustainable circular economy, being excellent for small series production of precision metallic parts. The powder hot embossing technology is integrated into processes denominated SDS (shaping, debinding, and sintering). This study presents the feasibility of replicating the die features into metallic parts by comparing two binders (Lc and M1). A new binder involves optimising critical parameters during hot embossing to ensure the replication of microdetails and the quality of metallic parts. Comparing the two binders, Lc contributes to the best precision of geometric details, and M1 improves surface quality. The study shows that hot powder embossing is a promising process to manufacture metallic parts with high precision and high-quality geometrical features on a microscale.

The rising energetical needs of modern society have been increasingly pushing for the improvement in energy efficiency. Thin-film solar cell technology encompasses several types of devices whose purpose is to gather energy emitted from a luminous source and convert it into usable electrical energy for a variety of applications, particularly low-powered devices. Micro concentrator solar cells are promising devices to solve the materials availability problem and address the power conversion efficiency simultaneously. Since the energy conversion efficiency for this type of solar cell is not particularly high, it stands out to benefit greatly from using an optical concentrator element to increase the light intensity reaching the active surface. The micro-concentrator element is comprised of a micro-lens array, which can be manufactured by different technologies, such as polymer injection moulding, extrusion, or hot embossing. In this work, we explore how hot embossing can be used to inexpensively produce spherical lenses with Ø 1 mm in an array according to micro concentrator solar cell requirements. A simple compression system coupled with an infrared lamp heat chamber was used to emboss PMMA disks. Different mould insert manufacturing technologies were used and different hot embossing parameters were assessed. The process replicability of the micro-lens cavities was determined by infinite focus microscopy and optical microscopy. The most promising lens array was achieved with a mould insert produced by μ-EDM (with Ra and Rz values of 0.6 μm and 4.58 μm, respectively).

Additive manufacturing (AM) is one of the most trending technologies nowadays, and it has the potential to become one of the most disruptive technologies for manufacturing. Academia and industry pay attention to AM because it enables a wide range of new possibilities for design freedom, complex parts production, components, mass personalization, and process improvement. The material extrusion (ME) AM technology for metallic materials is becoming relevant and equivalent to other AM techniques, like laser powder bed fusion. Although ME cannot overpass some limitations, compared with other AM technologies, it enables smaller overall costs and initial investment, more straightforward equipment parametrization, and production flexibility.This study aims to evaluate components produced by ME, or Fused Filament Fabrication (FFF), with different materials: Inconel 625, H13 SAE, and 17-4PH. The microstructure and mechanical characteristics of manufactured parts were evaluated, confirming the process effectiveness and revealing that this is an alternative for metal-based AM.

Additive manufacturing (AM) is one of the most trending technologies nowadays, and it has the potential to become one of the most disruptive technologies for manufacturing. Academia and industry pay attention to AM because it enables a wide range of new possibilities for design freedom, complex parts production, components, mass personalization, and process improvement. The material extrusion (ME) AM technology for metallic materials is becoming relevant and equivalent to other AM techniques, like laser powder bed fusion. Although ME cannot overpass some limitations, compared with other AM technologies, it enables smaller overall costs and initial investment, more straightforward equipment parametrization, and production flexibility.This study aims to evaluate components produced by ME, or Fused Filament Fabrication (FFF), with different materials: Inconel 625, H13 SAE, and 17-4PH. The microstructure and mechanical characteristics of manufactured parts were evaluated, confirming the process effectiveness and revealing that this is an alternative for metal-based AM.

Hot embossing is a small-scale, low-cost processing technology that can deliver products to the market in a short time. This microreplication technology is well established to produce polymeric components and has applications in several industrial sectors. The use of micropowder hot embossing in the production of metal components is an emerging and challenging process that, when compared to other typical technologies, brings some economic advantages in a volatile market with an increasing tendency to manufacture customized products. The main objective of this review is to analyze the potential of powder hot embossing and its developments in the production of metallic microparts/components. This technology requires four distinct steps: (1) production feedstock (preparation of mixtures), (2) hot embossing (shape forming), (3) debinding and (4) sintering. These steps are interrelated and influence the characteristics of the final metallic microparts. This study summarizes the approaches implemented for the use of different metallic powders and polymeric binder systems for the preparation of the feedstock, the mold materials and the critical conditions tested in the embossing step to produce green parts, and the production of the final parts through the application of debinding and sintering. Powder hot embossing is a viable replication technology that allows the production of new metallic microcomponents, contributing to the global scientific effort of miniaturizing manufacturing process, equipment and products. The merit of powder hot embossing for industrialization needs further development to assert itself in the market and compete with other micromanufacturing techniques.

Microfabrication technologies not only possess a considerable market potential but are also regarded as promising technologies for today and for the near future, due to the growing demand for microengineering applications such as micromolds, micromechanical structures, sensors and micromedical devices [1]. Metal powder hot embossing is a new micro-manufacturing alternative to conventional powder metallurgy processes, providing dimensional precision and micro details in metallic components [2,3]. This new powder metallurgy approach requires four distinctive steps: (1) preparation of feedstocks (selection and characterization of powder and binder); (2) shapeforming of the component by hot embossing (green part); (3) debinding (brown part); and (4) sintering (final part). These steps are interrelated and the variables of each one affect the properties of final products.

The microfabrication technologies not only possess a considerable market potential but are also regarded as leading technologies of our days and key technologies for the future, due to the growing demand for microengineering applications such as micromoulds, micromechanical structures, sensors and micro-medical devices [1,2]. Metal powder hot embossing is an emerging replicative process that can provide dimensional precision and microdetails of metallic parts. Metal powder hot embossing requires four distinctive steps: (1) preparation of feedstocks (implying the selection and characterization of powder and binder); (2) shape-forming of the part by hot embossing (green part); (3) debinding (brown part); and (4) sintering (final part).

The use of replicative processes has become strategic and critical in industry to produce precise, microscopically detailed metallic parts and devices via low cost manufacturing routes. Metal powder hot embossing is an emerging process that brings some advantages associated with the reduction of production costs relative to powder injection moulding (PIM). The technology involves four distinct steps: preparation of the selected feedstock material (powder and binder); hot embossing; debinding; and sintering. The effect of continuous pressure during the hot embossing step as a means of replicating microdetails in 316L stainless steel parts is examined. Dimensional accuracy, microstructure and mechanical properties of the parts produced were evaluated. For the configuration tested, the most promising results were achieved when processing at 180°C for 30 min at a pressure of 14 MPa.

Intermetallics and superalloys brazing development is a current topic owing the extending use of these alloys in industrial applications. In this work a γ-TiAl alloy was joined to Inconel 718 by active metal brazing, using Incusil-ABA as filler. Joining was performed at 730 °C, 830 °C and 930 °C, with a 10 min dwelling time. The interfaces were characterized by Scanning Electron Microscopy (SEM), Energy Dispersive X-ray Spectroscopy (EDS) and Electron Backscatter Diffraction (EBSD). For all processing conditions, the reaction between the base materials and the braze alloy produced multilayered interfaces. For all processing temperatures tested (Ag), (Cu), AlNi2Ti and AlCu2Ti were identified at the interface. Raising the brazing temperature increased the thickness of the interface and coarsened its microstructure. The increase of the extension of the interface was essentially due to the growth of the reaction layers formed near each base material, which were found to be mainly composed of intermetallic compounds. The mechanical behavior of the joints, at room temperature, was assessed by microhardness and shear tests. For all processing conditions the hardness decreases from periphery towards the Ag-rich centre of the joints. Brazing at 730 °C for 10 min produced the joints with the highest average shear strength (228±83 MPa). SEM and EDS analysis of the fracture surfaces revealed that fracture of joints always occurred across the interface, preferentially through the hard layer, essentially composed of AlNi2Ti, resulting from the reaction between Inconel 718 and the braze alloy.