In a variety of industries, Additive Manufacturing has revolutionized the whole design–fabrication cycle. Traditional 3D printing is typically employed to produce static components, which are not able to fulfill dynamic structural requirements and are inappropriate for applications such as soft grippers, self-assembly systems, and smart actuators. To address this limitation, an innovative technology has emerged, known as “4D printing”. It processes smart materials by using 3D printing for fabricating smart structures that can be reconfigured by applying different inputs, such as heat, humidity, magnetism, electricity, light, etc. At present, 4D printing is still a growing technology, and it presents numerous challenges regarding materials, design, simulation, fabrication processes, applied strategies, and reversibility. In this work a critical review of 4D printing technologies, materials, and applications is provided.

Lightweight structures with an internal lattice infill and a closed shell have received a lot of attention in the last 20 years for satellites, due to their improved stiffness, buckling strength, multifunctional design, and energy absorption. The geometrical freedom typical of Additive Manufacturing allows lighter, stiffer, and more effective structures to be designed for aerospace applications. The Laser Powder Bed Fusion technology, in particular, enables the fabrication of metal parts with complex geometries, altering the way the mechanical components are designed and manufactured. This study proposed a method to re-design the original satellite structures consisting of walls and ribs with an enclosed lattice design. The proposed new structures must comply with restricted requirements in terms of mechanical properties, dimensional accuracy, and weight. The most challenging is the first frequency request which the original satellite design, based on traditional fabrication, does not satisfy. To overcome this problem a particular framework was developed for locally thickening the critical zones of the lattice. The use of the new design permitted complying with the dynamic behavior and to obtain a weight saving maintaining the mechanical properties. The Additive Manufacturing fabrication of this primary structure demonstrated the feasibility of this new technology to satisfy challenging requests in the aerospace field.

Due to the nature of Selective Laser Melting process, the built parts suffer from high chances of defects formation. Powders quality have a significant impact on the final attributes of SLM-manufactured items. From a processing standpoint, it is critical to ensure proper powder distribution and compaction in each layer of the powder bed, which is impacted by particle size distribution, packing density, flowability, and sphericity of the powder particles. Layer-by-layer study of the process can provide better understanding of the effect of powder bed on the final part quality. Image-based processing technique could be used to examine the quality of parts fabricated by Selective Laser Melting through layerwise monitoring and to evaluate the results achieved by other techniques. In this paper, a not supervised methodology based on Digital Image Processing through the build-in machine camera is proposed. Since the limitation of the optical system in terms of resolution, positioning, lighting, field-of-view, many efforts were paid to the calibration and to the data processing. Its capability to individuate possible defects on SLM parts was evaluated by a Computer Tomography results verification.

Despite the potential of additive manufacturing and specifically of selective laser melting, several considerable barriers exist to widespread utilization, especially in specific industries that produce high-value components. Quality control and mechanical characterization remain the most expensive challenge. The quality and mechanical properties of the manufactured parts are influenced by potential defects; the characteristics of these defects, such as size, shape, location, and distribution, have shown to play key roles in mechanical properties. This work proposes a methodology for providing the identification of powder bed anomalies and consequent part defects through a synchronized analysis of the powder layers via digital image processing. This method can be used to study the critical defects formation during the layerwise process, providing important information about their location without the use of expensive or destructive measurements.