The rapid growth of the machining market and advancements in additive manufacturing (AM) present new opportunities for innovative tool designs. This preliminary study proposes a design for additive manufacturing (DfAM) approach to redesign a milling cutter head in 17-4 PH stainless steel by integrating topology optimization (TO) and internal coolant channel optimization, enabled by laser powder bed fusion (LPBF). An industrial eight-insert milling cutting tool was reimagined with conformal cooling channels and a lightweight topology-optimized structure. The design process considered LPBF constraints and was iteratively refined using computational fluid dynamics (CFD) and finite element analysis (FEA) to validate fluid flow and structural performance. The optimized milling head achieved approximately 10% weight reduction while improving stiffness (reducing maximum deformation under load from 160 μm to 151 μm) and providing enhanced coolant distribution to the cutting inserts. The results demonstrate that combining TO with internal channel design can yield a high-performance and lightweight milling tool that leverages the freedom of additive manufacturing. As proof of concept, this integrated CFD–FEA validation approach under DfAM guidelines highlights a promising pathway toward superior cutting tool designs for industrial applications.

Controlling electrostatic potential landscapes at the mesoscale is essential for the advancement of adaptive electronic systems. In edge‐gated electrostatic geometries based on ferroionic Li _2.99 B _a0.005 OCl films, directional spillover fields and polaron pinning effects generate structured, air‐side electrostatic gradients across centimeter‐scale gaps. A combination of piezoresponse force microscopy (PFM), micrometer‐resolution scanning Kelvin probe (µm‐SKP) analysis, electrochemical impedance spectroscopy (EIS), and temperature‐dependent transport measurements, supported by numerical solutions of the Poisson–Nernst–Planck (PNP) equations, shows dynamic coupling between surface polarization and mobile charge carriers. Apparent surface mobilities in the range of 300–500 cm ² V ⁻¹ s ⁻¹ are observed under non‐equilibrium polarization conditions, accompanied by negative static resistance (NSR) and field‐induced carrier asymmetry. These results point to topologically guided conduction paths constrained by interface geometry and electrostatic boundary conditions. Such phenomena enable programmable capacitance zoning and field shaping, with implications for the design of solid‐state transistors and batteries, neuromorphic elements, energy harvesters, and high‐sensitivity sensing platforms.