Lightweight aluminum (Al) alloys have been widely used in frontier fields like aerospace and automotive industries, which attracts great interest in additive manufacturing (AM) to process high-value Al parts. As a mainstream AM technique, laser-directed energy deposition (LDED) shows good scalability to meet the requirements for large-format component manufacturing and repair. However, LDED Al alloys are highly challenging due to their inherent poor printability (e.g. low laser absorption, high oxidation sensitivity and cracking tendency). To further promote the development of LDED high-performance Al alloys, this review offers a deep understanding of the challenges and strategies to improve printability in LDED Al alloys. The porosity, cracking, distortion, inclusions, element evaporation and resultant inferior mechanical properties (worse than laser powder bed fusion) are the key challenges in LDED Al alloys. Processing parameter optimizations, in-situ alloy design, reinforcing particle addition and field assistance are the efficient approaches to improving the printability and performance of LDED Al alloys. The underlying correlations between processes, alloy innovation, characteristic microstructures, and achievable performances in LDED Al alloys are discussed. The benchmark mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized. This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys. Future opportunities and perspectives in LDED high-performance Al alloys are also outlined.

The compliant mechanism (CM)-based fast-tool servo (FTS) is used in ultraprecision machining contexts to produce high value products for technically advanced applications. Far too often, the FTS’ machined products are expected to be geometrically complex with minimal form tolerance and surface roughness. Since the FTS’ enclosing CM is responsible for guiding the cutting motion, its design is of utmost importance in determining the quality of the machined product. The objective of this paper is therefore to review specifically the design and structural related aspects of CM-based FTS that affects its ultraprecision machining performance. After a brief introduction, the fundamentals for designing ultraprecision capable CMs such as flexure hinge modelling, actuator selection and isolation and CM designing are comprehensively explained. In the subsequent section, the various configurations of CM-based FTSs that exist so far and their functionalities are listed. The critical factors which impact the CM-based FTS’ ultraprecision machining performance are identified and mitigating measures are provided wherever possible. Before concluding, the research questions that should be investigated for raising the state of the art of CM-based FTSs are presented as food for thought. With this review article, not only can practitioners have a clearer picture of how better to design their CMs for their FTSs, but they can also improve upon existing FTS designs from leading researchers so that products of higher quality than before can be made for the future.

High fill factor for Fresnel lens arrays has been achieved with the aid of polygonal lenses. This has been done for both circular trimmed lenses and full polygonal lenses, both of which present some optical drawbacks. The composite polygonal Fresnel lens (CPFL) avoids these issues with its unique design – a radial symmetric Fresnel center filling into a polygon, avoiding any intersecting facets within the lens by introducing fillets. To manufacture the CPFL, diamond shaping is applied to not only meet the strict standards required for optical fabrication but also maneuver around the curvilinear features that cannot be fabricated using conventional turning techniques. As such, direct diamond shaping (DDS) was employed to generate an array of CPFLs on a PMMA substrate. Optical simulation was used to validate the performance of the CPFL before production of the lens array, followed by testing of the fabricated lenses, showing less overall noise with better focus compared to conventional polygonal lenses.

Control of residual stresses (RS), inherent to fusion-based additive manufacturing (AM), process is important for the satisfactory mechanical performance of components. Recent work has attempted to control the RS profiles in AM components by applying mechanical peening between built layers. During laser powder bed fusion (LPBF), it has been shown that subsequent layer building does not relieve all the peening-induced compressive stresses. In this work, a similar study has been performed on a directed energy deposition (DED) process. It is shown that owing to the vastly different thermal profile in DED compared to LPBF, the compressive RS induced by peening, is completely alleviated during subsequent layer deposition for 316L stainless steel. Irrespective of the magnitude and depth, the peening-induced compressive stresses were not present in the final part. Experimental and numerical analyses revealed that stress relief due to intrinsic heating was insufficient to explain stress relaxation. Rather, the localized heating and constrained expansion from surrounding cold material was the mechanism responsible for strain redistribution and hence stress relaxation.