As one of the most important additive manufacturing (AM) techniques, laser metal deposition (LMD) has been extensively studied specially during the last few years. Similar to other AM techniques, the quality of LMD parts is highly dependent on the processing parameters that need to be optimized so as to obtain geometrically accurate parts as well as favorable microstructures and, thus, mechanical properties. The present review paper therefore aims to present a critical analysis and overview of the relationship between processing parameters, microstructure, and mechanical properties of LMD components made from the Ti–6Al–4V alloy. Moreover, we discuss the applications of LMD parts in the aerospace and biomedical industries as well as the potential of LMD techniques for fabrication of more complex parts such as cellular structures. The paper concludes with a summary of the most important findings and suggestions for future research.

The emergence of advanced 3D printing techniques and the recent interest in architected materials have sparked a surge of interest in mechanical metamaterials whose unusual properties are defined by their highly ordered microarchitectures. Mechanical metamaterials with disordered microarchitectures have, however, not received as much attention despite their inherent advantages, such as robustness against the precise arrangement and design parameters of individual unit cells. Here, we computationally studied the elastic properties of two general types of disordered networks, namely, lattice-restricted and unrestricted networks that were made of beamlike elements and possessed mean connectivity values, Z, ranging between 2.5 and 7. We also additively manufactured a number of representative networks using selective laser sintering and showed that their deformations are consistent with our computational predictions. Unrestricted networks exhibited several advantages over the lattice-restricted ones including a broader range of achievable elastic modulus-Poisson's ratio duos as well as a higher probability of exhibiting auxetic and double-auxetic (i.e., auxetic behavior in both orthogonal directions) behaviors. Most interestingly, we could find unrestricted auxetic networks for high connectivity levels of up to 4.5, while no lattice-restricted auxetic networks were found for any connectivity level beyond 3.5. Given the fact that, according to Maxwell's criterion, 3.5 is the highest Z for which both of our lattice-restricted and unrestricted networks are bending-dominated, we concluded that unrestricted networks exhibit auxetic behavior well into their stretch-dominated domain. This is a promising observation that underlines the potential of unrestricted networks for the challenging task of designing stiff auxetic metamaterials in the stretch-dominated domain (i.e., Z = 4-4.5).

Buckling, which was once considered the epitome of design failure, has been harnessed during the last few years to develop mechanical metamaterials with advanced functionalities. Soft robotics in general and soft actuators in particular could greatly benefit from such designer materials. Unlocking the great potential of buckling-driven materials is, however, contingent on resolving the main limitation of the designs presented to date, namely the limited range of their programmability. Here, we present multi-material buckling-driven metamaterials with high levels of programmability. We combined rational design approaches based on predictive computational models with advanced multi-material additive manufacturing techniques to 3D print cellular materials with arbitrary distributions of flexible and stiff materials in the central and corner parts of their unit cells. Using the geometry and spatial distribution of material properties as the main design parameters, we developed soft mechanical metamaterials behaving as mechanisms whose actuation force and actuation amplitude could be adjusted both independently and concomitantly within wide ranges. Our designs also resulted in the emergence of a new lowest instability mode, i.e. double-side buckling, in addition to the already known modes of side-buckling and symmetric compaction. Finally, we proposed a general approach to pre-dispose our soft mechanical metamaterials such that they can reliably actuate their higher instability modes without any need for additional boundary conditions or fixtures. To demonstrate this approach, we created a cellular mechanism with a rotational buckling pattern that clones the functionality of mechanical machines. The potential of the presented designs in robotics is then demonstrated by applying them as a force switch, kinematic controllers, and a pick and place end-effector.

Mechanical metamaterials are a sub-category of designer materials where the geometry of the material at the small-scale is rationally designed to give rise to unusual properties and functionalities. Here, we propose the concept of "action-at-a-distance" metamaterials where a specific pattern of local deformation is programmed into the fabric of (cellular) materials. The desired pattern of local actuation could then be achieved simply through the application of one single global and far-field force. We proposed graded designs of auxetic and conventional unit cells with changing Poisson's ratios as a way of making "action-at-a-distance" metamaterials. We explored five types of graded designs including linear, two types of radial gradients, checkered, and striped. Specimens were fabricated with indirect additive manufacturing and tested under compression, tension, and shear. Full-field strain maps measured with digital image correlation confirmed different patterns of local actuation under similar far-field strains. These materials have potential applications in soft (wearable) robotics and exosuits.

Nanopillar arrays that are bactericidal but not cytotoxic against the host cells could be used in implantable medical devices to prevent implant-associated infections. It is, however, unclear what heights, widths, interspacing, and shape should be used for the nanopillars to achieve the desired antibacterial effects while not hampering the integration of the device in the body. Here, we present an in-silico approach based on finite element modeling of the interactions between Staphylococcus aureus and nanopatterns on the one hand and osteoblasts and nanopatterns on the other hand to find the best design parameters. We found that while the height of the nanopillars seems to have little impact on the bactericidal behavior, shorter widths and larger interspacings substantially increase the bactericidal effects. The same combination of parameters could, however, also cause cytotoxicity. Our results suggest that a specific combination of height (120 nm), width (50 nm), and interspacing (300 nm) offers the bactericidal effects without cytotoxicity.

Up until recently, the rational design of mechanical metamaterials has usually involved devising geometrical arrangements of micro-architectures that deliver unusual properties on the macro-scale. A less explored route to rational design is spatially distributing materials with different properties within lattice structures to achieve the desired mechanical properties. Here, we used computational models and advanced multi-material 3D printing techniques to rationally design and additively manufacture multi-material cellular solids for which the elastic modulus and Poisson's ratio could be independently tailored in different (anisotropic) directions. The random assignment of a hard phase to originally soft cellular structures with an auxetic, zero Poisson's ratio, and conventional designs allowed us to cover broad regions of the elastic modulus-Poisson's ratio plane. Patterned designs of the hard phase were also used and were found to be effective in the independent tuning of the elastic properties. Close inspection of the strain distributions associated with the different types of material distributions suggests that locally deflected patterns of deformation flow and strain localizations are the main underlying mechanisms driving the above-mentioned adjustments in the mechanical properties.

Architectured materials with rationally designed geometries could be used to create mechanical metamaterials with unprecedented or rare properties and functionalities. Here, we introduce "shape-matching" metamaterials where the geometry of cellular structures comprising auxetic and conventional unit cells is designed so as to achieve a pre-defined shape upon deformation. We used computational models to forward-map the space of planar shapes to the space of geometrical designs. The validity of the underlying computational models was first demonstrated by comparing their predictions with experimental observations on specimens fabricated with indirect additive manufacturing. The forward-maps were then used to devise the geometry of cellular structures that approximate the arbitrary shapes described by random Fourier's series. Finally, we show that the presented metamaterials could match the contours of three real objects including a scapula model, a pumpkin, and a Delft Blue pottery piece. Shape-matching materials have potential applications in soft robotics and wearable (medical) devices.

Biomimetic composites are usually made by combining hard and soft phases using, for example, multi-material additive manufacturing (AM). Like other fabrication methods, AM techniques are limited by the resolution of the device, hence, setting a minimum length scale. The effects of this length scale on the performance of hard-soft composites are not well understood. Here, we studied how this length scale affects the fracture toughness behavior of single-edge notched specimens made using random, semi-random, and ordered arrangements of the hard and soft phases with five different ratios of hard to soft phases. Increase in the length scale (40 to 960 μm) was found to cause a four-fold drop in the fracture toughness. The effects of the length scale were also modulated by the arrangement and volumetric ratio of both phases. A decreased size of the crack tip plastic zone, a crack path going through the soft phase, and highly strained areas far from the crack tip were the main mechanisms explaining the drop of the fracture toughness with the length scale.

Bone’s resistance to fracture depends on several factors, such as bone mass, microarchitecture, and tissue material properties. The clinical assessment of bone strength is generally performed by Dual-X Ray Photon Absorptiometry (DXA), measuring bone mineral density (BMD) and trabecular bone score (TBS). Although it is considered the major predictor of bone strength, BMD only accounts for about 70% of fragility fractures, while the remaining 30% could be described by bone “quality” impairment parameters, mainly related to tissue microarchitecture. The assessment of bone microarchitecture generally requires more invasive techniques, which are not applicable in routine clinical practice, or X-Ray based imaging techniques, requiring a longer post-processing. Another important aspect is the presence of local damage in the bony tissue that may also affect the prediction of bone strength and fracture risk. To provide a more comprehensive analysis of bone quality and quantity, and to assess the effect of damage, here we adopt a framework that includes clinical, morphological, and mechanical analyses, carried out by means of DXA, μCT and mechanical compressive testing, respectively. This study has been carried out on trabecular bones, taken from porcine trabecular vertebrae, for the similarity with human lumbar spine. This study confirms that no single method can provide a complete characterization of bone tissue, and the combination of complementary characterization techniques is required for an accurate and exhaustive description of bone status. BMD and TBS have shown to be complementary parameters to assess bone strength, the former assessing the bone quantity and resistance to damage, and the latter the bone quality and the presence of damage accumulation without being able to predict the risk of fracture.

The elastic properties of mechanical metamaterials are direct functions of their topological designs. Rational design approaches based on computational models could, therefore, be used to devise topological designs that result in the desired properties. It is of particular importance to independently tailor the elastic modulus and Poisson's ratio of metamaterials. Here, we present patterned randomness as a strategy for independent tailoring of both properties. Soft mechanical metamaterials incorporating various types of patterned randomness were fabricated using an indirect additive manufacturing technique and mechanically tested. Computational models were also developed to predict the topology-property relationship in a wide range of proposed topologies. The results of this study show that patterned randomness allows for independent tailoring of the elastic properties and covering a broad area of the elastic modulus-Poisson's ratio plane. The uniform and homogenous topologies constitute the boundaries of the covered area, while topological designs with patterned randomness fill the enclosed area.

Crumpled-based materials are relatively easy to fabricate and show robust mechanical properties for practical applications, including meta-biomaterials design aimed for improved tissue regeneration. For such requests, however, the structure needs to be porous. We introduce a crumpled holey thin sheet as a robust bio-metamaterial and measure the mechanical response of a crumpled holey thin Mylar sheet as a function of the hole size and hole area fraction. We also study the formation of patterns of crease lines and ridges. The area fraction largely dominated the crumpling mechanism. We also show, the crumpling exponents slightly increases with increasing the hole area fraction and the total perimeter of the holes. Finally, hole edges were found to limit and guide the propagation of crease lines and ridges.