Additive friction stir deposition (AFSD) is a solid-state AM method that feeds, plasticizes, and deposits solid bars using frictional heat. Although the AFSD is a promising method, its limited technology readiness level precludes its wider use. The use of optimum process parameters is critical for achieving successful results, and closed-loop control of process parameters can improve quality even further by reacting to and resolving any unanticipated issues that arise during the process. This article investigates the utilization of a process monitoring setup including various sensors to examine temperatures, forces, vibrations, and sound during the AFSD of the Al6061 aluminum alloy. Furthermore, it benchmarks the outcomes of the same process’ parameter set with or without utilizing a proportional–integral–derivative (PID). Large thermal gradients were observed at various locations of the deposit. Significant fluctuations in temperature and force were demonstrated for the initial layers until stability was reached as the height of the deposit increased. It has been shown that the change in the process parameters may lead to undesired results and can alter the deposit shape. Finally, residual stresses were investigated using the contour measurement technique, which revealed compressive stresses at the core of the part and tensile stresses in the outer regions.

Neural mechanisms behind stereopsis, which requires simultaneous disparity inputs from two eyes, have remained mysterious. Here we show how ultrafast mirror-symmetric photomechanical contractions in the frontal forward-facing left and right eye photoreceptors give Drosophila super-resolution 3D-vision. By interlinking multiscale in vivo assays with multiscale simulations, we reveal how these photoreceptor microsaccades - by verging, diverging and narrowing the eyes’ overlapping receptive fields - channel depth information, as phasic binocular image motion disparity signals in time. We further show how peripherally, outside stereopsis, microsaccadic sampling tracks a flying fly’s optic flow field to better resolve the world in motion. These results change our understanding of how insect compound eyes work and suggest a general dynamic stereo-information sampling strategy for animals, robots and sensors. Significance statement: To move efficiently, animals must continuously work out their x,y,z-positions in respect to real-world objects, and many animals have a pair of eyes to achieve this. How photoreceptors actively sample the eyes’ optical image disparity is not understood because this fundamental information-limiting step has not been investigated in vivo over the eyes’ whole sampling matrix. This integrative multiscale study will advance our current understanding of stereopsis from static image disparity comparison to a new morphodynamic active sampling theory. It shows how photomechanical photoreceptor microsaccades enable Drosophila super-resolution 3D-vision and proposes neural computations for accurately predicting these flies’ depth-perception dynamics, limits, and visual behaviors.