The interest in additive manufacturing (AM) processes is constantly increasing due to the many advantages they offer. To this end, a variety of modelling techniques for the plethora of the AM mechanisms has been proposed. However, the process modelling complexity, a term that can be used in order to define the level of detail of the simulations, has not been clearly addressed so far. In particular, one important aspect that is common in all the AM processes is the movement of the head, which directly affects part quality and build time. The knowledge of the entire progression of the phenomenon is a key aspect for the optimization of the path as well as the speed evolution in time of the head. In this study, a metamodeling framework for AM is presented, aiming to increase the practicality of simulations that investigate the effect of the movement of the head on part quality. The existing AM process groups have been classified based on three parameters/axes: temperature of the process, complexity, and part size, where the complexity has been modelled using a dedicated heuristic metric, based on entropy. To achieve this, a discretized version of the processes implicated variables has been developed, introducing three types of variable: process parameters, key modeling variables and performance indicators. This can lead to an enhanced roadmap for the significance of the variables and the interpretation and use of the various models. The utilized spectrum of AM processes is discussed with respect to the modelling types, namely theoretical/computational and experimental/empirical.

Even though Additive Manufacturing (AM) has become a critical enabler of manufacturing in various industries, its full potential in terms of process quality and productivity has not been achieved yet. The recent developments in Artificial Intelligence (AI) can help toward this goal, especially through Human–AI Collaboration (HAIC). However, existing approaches are focused on certain aspects of the problem, without comprehensively tackling the issue. This study proposes a holistic and AM-specific HAIC framework that combines the different components of human expertise, explainable AI, simulation-based forecasting, and variable-based process control into an integrated decision-making structure. The key findings include the identification of the most important variables that should be utilized, including their classification through the input of experts in terms of importance (utilizing the presented M-S metric), controllability, and the most suitable agent (human, AI, both) to effectively control each variable. Finally, the concept of the framework for effective HAIC in AM is analyzed, including the operational sequence of sensing, AI analysis, human evaluation, decision implementation, and feedback loops. Two complementary case studies are presented; the first provides a conceptual example, and the second one develops a quantitative scenario that allows the comparison of three decision pathways—AI-only, Human-only, and HAIC.

This study investigates the effect of Interlayer Dwell Time (IDT) on the thermal behavior of the Wire-Laser Directed Energy Deposition (WLDED) process. A two-dimensional transient thermal model was developed in MATLAB, incorporating temperature-dependent material properties, a moving Gaussian heat source, and melting–solidification phase change to simulate sequential layer deposition. The model was calibrated for thin-walled geometries, numerically validated using ANSYS, and experimentally validated with literature data. Using the validated model, twenty-seven cases were simulated to examine the combined influence of IDT, part length, and layer thickness on melt-pool dimensions and layer-wise temperature distribution. The results show that increasing IDT reduces melt-pool depth and length by limiting heat accumulation, with the magnitude of this effect depending strongly on part length and layer thickness. Shorter parts and thicker layers exhibit the highest sensitivity to IDT variations. Additionally, the Thermal Stability Factor (TSF) is introduced, a dimensionless index that effectively identifies heat-accumulation phenomena and indicates thermal instabilities. Overall, the findings enhance the understanding of the impact of IDT in the thermal profile of WLDED and demonstrate that optimized IDT selection can stabilize melt-pool geometry and reduce thermal buildup, supporting future adaptive IDT strategies in wire-based metal additive manufacturing.

The increasing demand for energy, rising electricity costs, and the growing need to reduce carbon emissions have driven industries toward the adoption of Renewable Energy Sources (RES) and Energy Storage Systems (ESS). However, selecting the most suitable ESS for industrial peak-shaving applications remains a complex decision involving technical, economic, and operational considerations. This paper proposes a practical and structured methodology for ESS selection that integrates conventional performance criteria with Industry 5.0 (I5.0) requirements, emphasizing sustainability, resilience, and human-centric industrial operation. Unlike existing multi-criteria decision-making approaches, the proposed framework reduces reliance on expert-based weighting, improving transparency and reproducibility. The methodology is implemented in two stages: initial KPI-based shortlisting of technologies, followed by detailed comparative performance analysis. A case study conducted in a European tire manufacturing plant compares lithium-ion batteries and flywheel energy storage systems under different peak-shaving strategies. Lithium-ion batteries demonstrated superior performance, covering approximately 80% of demand peaks compared with the 73% achieved by the flywheel system, confirming the effectiveness of the proposed methodology for practical industrial ESS selection.