Among the several additive manufacturing techniques, fused filament fabrication (FFF) is a 3D printing technique that is fast, handy, and low cost, used to produce complex-shaped parts easily and quickly. FFF adds material layer by layer, saving energy, costs, raw material costs, and waste. Nevertheless, the mechanical properties of the thermoplastic materials involved are low compared to traditional engineering materials. This paper deals with the manufacturing of composite material laminates obtained by the Markforged continuous filament fabrication (CFF) technique, using an innovative matrix infilled by carbon nanofibre (Onyx), a high-strength thermoplastic material with an excellent surface finish and high resistance to chemical agents. Three macro-categories of samples were manufactured using Onyx and continuous carbon fibre to evaluate the effect of the fibre on mechanical features of the novel composites and their influence on surface finishes. SEM (Scanning Electron Microscopy) analysis and acquisition of roughness profile by a confocal lens were conducted. Tensile and compression tests, thermogravimetric analysis and calorimetric analysis using a DSC (differential scanning calorimeter) were carried out on all specimen types to evaluate the influence of the process parameters and layup configurations on the quality and mechanical behaviour of the 3D-printed samples.

Friction Stir Welding (FSW) and Friction Stir Processing (FSP) are solid-state joining and material processing techniques that have garnered considerable attention for their versatility and industrial applicability. In the present work, FSP was performed on AA 6056 T4, dealing with the issue of monitoring tool wear and assessing its impact on the process. The impact of tool wear on power requirements was analyzed, and it was expanded the understanding of tool behavior and its implications for the overall process performance. Specifically, variations in energy consumption, temperatures, and vibrations are observed with changing tool conditions. Further insights are provided by analyzing the microhardness and the pin volume ratio, which show distinct trends as the tool wears. Two tool maintenance ways are proposed, that are cleaning the tool with a sodium hydroxide solution and increasing the tool’s rotational speed. Both the strategies exhibit the potential to partially restore the tool’s initial characteristics. This study highlights the critical importance of assessing tool condition, energy consumption, and process sustainability, particularly in industrial settings where material processing requires efficiency and quality assurance.

Additive Manufacturing (AM) can be considered today as a real production technology, which allows to realize parts with a complexity degree that, in some cases, is not achievable otherwise. However, one of the most relevant weak spots is the high surface roughness, especially for metal parts, making necessary the adoption of post-process finishing treatments. This paper deals with the preliminary investigations on the Fluidised Bed Machining (FBM) technology, in which a sample is dipped into a fluidized bed, i.e. a two-phase system where an abrasive, kept in motion through a gas, behaves like a fluid performing a huge number of impacts on the considered surface. This peculiarity could guarantee a high degree of homogeneity of the treated surface morphology. The influence of the impact angle has been investigated by conducting experiments with AlSi10Mg plates made by Selective Laser Melting Technology (SLM), and the fluidized bed operated in bubbling fluidization regime. The treatment has been carried out by dipping the samples for a total time of 3 hours and monitoring the results with a step of 30 min for the first 2 hours. The treated surfaces have been characterized by means of Confocal Microscopy and Scanning Electron Microscopy (SEM). Weight loss measurements have been carried out as well for a preliminary evaluation of wear. Results suggest a poor decrease in surface roughness (S_a), as also demonstrated by the poor weight loss, both due to a low impact energy of the abrasives. However, variations of other surface texture parameters (S_z, S_sk, S_ku, R_dq), as well as SEM images, suggest that the main surface-abrasive flow interaction phenomena are micro-ploughing and micro-peening.

In recent years, the overall performances of inertial Micro-Electro Mechanical Sensors (MEMSs) exhibited substantial improvements to values very close or similar to so-called tactical-grade sensors. However, due to their high costs, numerous researchers are currently focusing on the performance enhancement of cheap consumer-grade MEMS inertial sensors for all those applications (as an example, small unmanned aerial vehicles, UAVs), where cost effectiveness is a relevant request; the use of redundancy proves to be a feasible method for this purpose. In this regard, the authors propose, hereinafter, a suitable strategy aimed at fusing raw measurements provided by multiple inertial sensors mounted on a 3D-printed structure. In particular, accelerations and angular rates measured by the sensors are averaged according to weights associated with the results of an Allan variance approach; the lower the noise figure of the sensors, the greater their weight on the final averaged values. On the other hand, possible effects on the measurements due to the use of a 3D structure in reinforced ONYX (a material capable of providing better mechanical specifications for avionic applications with respect to other solutions for additive manufacturing) were evaluated. The performance of a prototype implementing the considered strategy is compared with that of a tactical-grade inertial measurement unit in stationary conditions, exhibiting differences as low as 0.3 degrees in heading measurements. Moreover, the reinforced ONYX structure does not significantly affect the measured values in terms of both thermal and magnetic field while assuring better mechanical characteristics with respect to other 3D printing materials, thanks to a tensile strength of about 250 MPa and a specific stacking sequence of continuous fibers. Finally, a test conducted on an actual UAV highlights performance very close to that of a reference unit, with root-mean-square error in heading measurements as low as 0.3 degrees in observation intervals up to 140 s.