Additive manufacturing (AM), an enabler of Industry 4.0, recently opened limitless possibilities in various sectors covering personal, industrial, medical, aviation and even extra-terrestrial applications. Although significant research thrust is prevalent on this topic, a detailed review covering the impact, status, and prospects of artificial intelligence (AI) in the manufacturing sector has been ignored in the literature. Therefore, this review provides comprehensive information on smart mechanisms and systems emphasizing additive, subtractive and/or hybrid manufacturing processes in a collaborative, predictive, decisive, and intelligent environment. Relevant electronic databases were searched, and 248 articles were selected for qualitative synthesis. Our review suggests that significant improvements are required in connectivity, data sensing, and collection to enhance both subtractive and additive technologies, though the pervasive use of AI by machines and software helps to automate processes. An intelligent system is highly recommended in both conventional and non-conventional subtractive manufacturing (SM) methods to monitor and inspect the workpiece conditions for defect detection and to control the machining strategies in response to instantaneous output. Similarly, AM product quality can be improved through the online monitoring of melt pool and defect formation using suitable sensing devices followed by process control using machine learning (ML) algorithms. Challenges in implementing intelligent additive and subtractive manufacturing systems are also discussed in the article. The challenges comprise difficulty in self-optimizing CNC systems considering real-time material property and tool condition, defect detections by in-situ AM process monitoring, issues of overfitting and underfitting data in ML models and expensive and complicated set-ups in hybrid manufacturing processes.

In this paper, the investigation of chip formation of aluminum alloy in different machining strategies (i.e., micro and macro cutting) is performed to develop a holistic view of the chip formation phenomenon. The study of chip morphology is useful to understand the mechanics of surface generation in machining. Experiments were carried out to evaluate the feed rate response (FRR) in both ultra-precision micro and conventional macro machining processes. A comprehensive study was carried out to explore the material removal mechanics with both experimental findings and theoretical insights. The results of the variation of chip morphology showed the dependence on feed rate in orthogonal turning. The transformation of discontinuous to continuous chip production—a remarkable phenomenon in micro machining—has been identified for the conventional macro machining of Al alloy. This is validated by the surface crevice formation in the transition region. Variation of the surface morphology confirms the phenomenology (transformation mechanics) of chip formation.

This paper investigates the tensile properties of jute-reinforced composites fabricated using stereolithography (SLA) 3D printing. Tensile tests were conducted using dog-bone tensile specimens following ASTM D638 Type IV specifications. Additionally, the study explores the effect of layer thickness on the tensile properties of the 3D-printed composite material, examining four different layer thicknesses: 0.025 mm, 0.05 mm, 0.075 mm, and 0.1 mm. The findings revealed that the tensile strength of the 3D-printed jute-reinforced composites increased with the printing layer thickness, reaching its maximum at a layer thickness of 0.1 mm. This represents an enhancement of approximately 84% compared to pure resin. Examination of the fiber–matrix interface under an optical microscope revealed a wavy pattern, suggesting that the interface may act as a mechanical interlock under tensile loads, thereby significantly enhancing tensile strength. The strength of the 3D-printed jute-reinforced composites was found to be comparable to that of glass fiber mat epoxy composites. This demonstrates that 3D SLA-printed jute-reinforced composites offer a promising avenue for producing next-generation composites that are typically challenging to manufacture using traditional fabrication techniques.

In the present work, an investigation on the surface topography and geometry variation of bagasse fibers was correlated with their mechanical properties via image analysis. The fibers were tested under a universal tensile testing machine and the diameter of the fibers was calculated using images obtained in a digital microscope. Furthermore, surface characterization and quantification were also performed using images obtained via SEM. The results showed that the surface roughness of alkali-treated bagasse fiber increased compared to that of the untreated one. Moreover, it was observed that the diameter variation of bagasse fiber along its length and among different fibers is not only variable but also unpredictable. The tensile test results revealed that bagasse fibers showed lower stress at a rupture with considerable scatter. It can be inferred that the synergistic effect of thick bagasse fiber, bagasse fiber diameter variations along its length and among fibers, and the fiber fracture mechanism establishes a local condition for fracture and resulted in such variations in tensile properties. Finally, the results clearly showed that the two-parameter Weibull fit the experimental data fairly well ($R^2=0.97$). The Weibull modulus $\left(m\right)$ was found to be 1.7, indicating that the strength distribution is high.

The growing interest in sustainable and biodegradable materials has prompted significant attention towards natural fiber-reinforced composites (FRC) due to their lower environmental impacts. In a similar sustainable vein, this study fabricated composite materials utilizing bagasse fibers with the 3D SLA (Stereolithography) printing method. To start with, a novel fiber extraction process was adopted for extracting fiber from the bagasse stem in three distinct methods (Process-1, Process-2, and Process-3). The fiber extraction process includes washing, sun-drying, manual collection of rind fibers, immersion of rind fibers in NaOH at specific concentrations for specific durations, combing, and drying. In Process-1, the rind fibers were immersed in 5% NaOH for 15 h, while in Process-2 and Process-3, the rind fibers were immersed in 1% NaOH, but the soaking time varied: 25 h for Process-2 and 18 h for Process-3.for 25 h, and in Process-3, the rind fibers were immersed in 1% NaOH for 18 h. The resulting bagasse fibers underwent comprehensive property assessment with a focus on functional group analysis, diameter measurement, and tensile strength assessment. Subsequently, these fibers were used to fabricate composite materials via the 3D SLA printing technique after being treated in a NaOH solution. The Fourier Transform Infrared (FTIR) Spectroscopy results clearly showed that a fraction of hemicellulose and lignin was removed by NaOH, resulting in improved tensile strength of the bagasse fibers. Three-dimensional-printed composites reinforced with bagasse fibers extracted through the P1 method showed the highest improvement in tensile strength (approximately 70%) compared to specimens made from pure resin. The lack of pores in the composite and the observable fiber fracture phenomena clearly indicate that 3D printing technology effectively enhances the quality of the interface between the fiber and the matrix interfacial bonding, consequently resulting in improved tensile properties of the composites. The 3D-printed composites reinforced with bagasse fiber showcased impressive tensile properties and provided solutions to the limitations of traditional composite manufacturing methods. This sets the stage for developing innovative composite materials that combine natural fibers with cutting-edge fabrication techniques, offering a promising path to tackle present and future economic and ecological challenges.