Ni–Ti shape memory alloys (SMAs) are popular in current research due to their usefulness and mechanical properties. At different temperatures, Ni–Ti alloys transition from austenite to martensite. To restore high-temperature memory in nickel-titanium SMAs, vanadium (V) is added as an alloying element. For Ni–Ti-based SMAs, the fiber laser is one of the best machining procedures for bio-implants, actuators, and aircraft engine parts. Using a Box–Behnken design to experiment with laser power, nozzle distance, cutting speed, and frequency, this study examines fiber laser micro-drilled Ni₅₀Ti₄₈V₂ SM alloy material removal and hole taper angle. By increasing power (P), frequency (F), and cutting speed (C _S ), Ni₅₀Ti₄₈V₂ alloy material removal rate (MRR) increased by 75.79%. The hole taper angle (H_TA) dropped 75.33% when cutting speed, laser power and frequency decreased. Lowering cutting speed and laser power increases micro-hole circularity and reduces H_TA. Upon surface topographical inspection, debris and molten materials were found on the drilled surface. The flow of nitrogen gas caused materials to diffuse on the Ni₅₀Ti₄₈V₂ alloy’s entry and exit surfaces, changing surface roughness. High parameters influence surface roughness, H_TA, and circularity due to nitrogen gas flow. The material’s DSC and XRD tests confirmed its suitability for biomedical microhole production.

Shape Memory Alloys (SMAs) are a class of metallic alloys that have the ability to return to their original shape after being deformed. NiTi (nickel–titanium) alloy a type of shape memory alloy that possesses unique properties such as remembering its shape, biocompatibility, and super-elasticity. These SMAs have the ability to deform when heated and regain their original shape when allowed to cool. The disadvantage of a fuse is that it can only be used once. By replacing a wire that melts with a NiTi shape memory alloy, we can turn it into a switch that opens when an excessive current (which leads to an increase in temperature of the wire) is applied. Magnets keep the circuit closed. When the wire heats up, the spring-shaped coil shrinks, which opens the circuit. The circuit can then be closed manually once the problems are rectified.

An integrated experimental–computational framework for predicting and optimizing the tensile strength of Fused Deposition Modeling (FDM)-printed High Impact Polystyrene (HIPS) is presented in this work. The novelty of the study lies in the synergistic integration of Response Surface Methodology based on Central Composite Design (RSM–CCD) with a Simulated Annealing (SA) metaheuristic algorithm to achieve global optimization of FDM process parameters. Nozzle temperature, print speed, and layer height were systematically investigated to establish their individual and interactive influences on tensile strength. The developed quadratic regression model exhibited high predictive capability with excellent agreement between experimental and predicted responses. To overcome the local-optimum limitations associated with standalone statistical models, the RSM-derived objective function was coupled with the SA algorithm. The hybrid RSM–SA framework identified an optimized parameter combination (250.36 °C, 43.33 mm/s, and 0.173 mm) yielding a maximum tensile strength of 27.95 MPa, exceeding all experimental DOE conditions. Tensile fractography further revealed a transition from brittle interlayer decohesion in the weakest specimen to pronounced ductile polymer fibrillation in the optimized sample, indicating enhanced interlayer diffusion and reduced defect-assisted failure. The proposed framework demonstrates a robust strategy for improving the mechanical reliability and structural integrity of polymer-based FDM components for engineering applications.