The fabrication of polymer–metal hybrids in an additive process makes it possible to further improve the geometrical and material adaption in a multi-material design. In this work, PLA is fabricated through a fused filament fabrication process on AlSi10Mg structures manufactured by laser powder bed fusion. The mechanical connection is realised by form fit, for which different geometries are examined through tensile tests. Deep penetration of the PLA into the metallic structures is achieved by optimisation of the process parameters. The penetration depth is assessed through the use of micro-computed tomography. Finally, the interplay of mechanisms leading to a firm connection is discussed.

Besides the optimisation of process parameters such as laser power or scan speed, the choice of the scan path represents a possibility to optimise the laser powder bed fusion process even further. The usual hatching strategy creates a homogeneous microstructure but makes it necessary to switch the laser off and on after each scan vector, which can slow down the fabrication. Moreover, the end of each scan vector is a location susceptible to the creation of keyhole pores. In this work, these disadvantages were meant to be avoided by using scan strategies that consist of longer paths and thus less end of track points. To this end, an open-source tool to tailor the LPBF G-code to geometric part features and advanced path configurations was developed and embedded into a co-visualization platform. With this tool, specimens built with four different types of paths were fabricated and the effect of these alternative scan strategies on pore distributions and path neighbourhood was investigated using micro-computed tomography. In the examined example geometry, a spiral scan pattern reduced the distance the laser had to jump between scanning by 78%. However, with the alternative path patterns, the defect architecture was strongly dependant on the part geometry and increased the overall porosity to 0.42%. Respective alleviation approaches are therefore necessary and are discussed in the remainder of this work.

The coherent control of electron beams and ultrafast electron wave packet dynamics have attracted significant attention in electron microscopy as well as in atomic physics. In order to unify the conceptual pictures developed in both fields, we demonstrate the generation and manipulation of tailored electron orbital angular momentum (OAM) superposition states either by employing customized holographic diffraction masks in a transmission electron microscope or by atomic multiphoton ionization utilizing pulse-shaper generated carrier-envelope phase stable bichromatic ultrashort laser pulses. Both techniques follow similar physical mechanisms based on Fourier synthesis of quantum mechanical superposition states allowing the preparation of a broad set of electron states with uncommon symmetries. We describe both approaches in a unified picture based on an advanced spatial and spectral double slit and point out important analogies. In addition, we analyze the topological charge and discuss the control mechanisms of the free-electron OAM superposition states. Their generation and manipulation by phase tailoring in transmission electron microscopy and atomic multiphoton ionization is illustrated on a 7-fold rotationally symmetric electron density distribution.