Fused filament fabrication (FFF, often called FDM) is widely used in polymer additive manufacturing; however, it suffers from mechanical anisotropy and weak bonding in the Z direction. This work examines how the infill pattern influences the tensile response of PLA parts at fixed printing conditions. Dog-bone specimens (PLA, four patterns: grid, honeycomb, rectilinear, adaptive cubic) were printed and tested in tension (n = 3 per pattern). Grid yielded the highest ultimate tensile strength, whereas honeycomb produced the largest Young’s modulus; rectilinear was intermediate and adaptive cubic was trailed in both metrics. X-ray diffraction of printed PLA showed a broad halo at 16–20° (2θ) with weak α-form reflections, consistent with largely amorphous microstructure after FFF. Together, the results indicate that, at constant material and nominal infill, pattern selection alone can shift the strength–stiffness balance, with grid favoring strength and honeycomb favoring stiffness.

Additive manufacturing (AM) of stainless steel has been gaining industry attention in recent years due to the need to manufacture complex steel components. Many sectors stand to benefit from the design flexibility, customization, and rapid production capabilities of AM. However, the industry’s adoption of this technology remains limited due to concerns about the mechanical integrity and reliability of AM products. This experimental study examines the wear and tribological behavior of Wire Arc Additive Manufactured (WAAM) austenitic stainless steel 316L. Pin-on-disk tests were conducted using a 5 mm tungsten carbide ball under dry sliding conditions at normal loads of 1.5 and 2.5 N and sliding speeds between 0.03 and 0.229 m/s. The results showed that the coefficient of friction remained relatively stable at approximately 0.6, while wear volume generally decreased with increasing sliding speed. Lower normal loads resulted in lower wear volume, whereas the wear factor showed only limited sensitivity to the applied load. Optical microscopy revealed a ferrite–austenite microstructure with residual δ-ferrite that contributes to the observed wear behavior. These findings demonstrate the suitability of WAAM-produced 316L stainless steel for tribological applications requiring stable frictional performance.

Wire Arc Additive Manufacturing (WAAM) has emerged as a cost-effective and high-deposition-rate technique for fabricating large-scale metallic components; however, the complex thermal history inherent to the process leads to heterogeneous microstructures that can significantly influence tribological performance. In this study, the dry sliding wear behavior of WAAM-fabricated austenitic stainless steel 308L (SS308L) was systematically investigated using a pin-on-disk configuration. The influence of applied normal load (1.5–15 N) and sliding speed (0.03–0.229 m/s) on wear volume, specific wear rate, coefficient of friction (COF), and tangential force was evaluated. Optical microstructural observations indicated features consistent with a ferritic–austenitic solidification structure, including regions resembling polygonal ferrite, Widmanstätten ferrite, and austenitic dendritic morphologies. Wear results showed that wear volume and cross-sectional area increased monotonically with increasing load, while the effect of sliding speed was comparatively less significant. The specific wear rate remained on the order of 10⁻⁴ mm³/N·m with minor variations across test conditions. The COF decreased with increasing load up to 10 N, followed by a speed-dependent response at higher loads. The findings demonstrate that load is the dominant factor governing wear behavior in WAAM SS308L, while microstructural heterogeneity may contribute to frictional stability and wear resistance. This study provides valuable insight into the structure–tribology relationship of WAAM stainless steels and supports the optimization of process parameters for wear-critical applications.

High-temperature proton-exchange membrane fuel cells (HT-PEMFCs) generate useful thermal energy that can be recovered for additional power production. This study investigates an integrated HT-PEMFC–organic Rankine cycle (ORC) system by combining response surface methodology (RSM) with thermodynamic energy analysis. A 17-run response-surface design was used to quantify the effects of pressure, temperature, and current density on polarization voltage. Power density was derived directly from the RSM-predicted voltage using P_d = iE to preserve physical consistency. The electrochemical model was benchmarked against published phosphoric-acid-doped polybenzimidazole HT-PEMFC polarization data under comparable conditions. The constrained optimization identified an operating condition of 400 kPa, 443 K, and approximately 1.198 A cm⁻², giving a predicted voltage of 0.5395 V and a power density of approximately 0.6462 W cm⁻². This represents a 12.9% increase in power density relative to the adopted reference condition. Separately, the reference thermodynamic case produced 13.08 kW of gross HT-PEMFC stack electrical power and 15.45 kW of thermal output assumed available to the ORC. The available legacy R409A reference case was evaluated at an evaporator pressure of 2 MPa, yielding approximately 1.24 kW of ORC net power and a net thermal efficiency of about 8.02%. The resulting combined modeled electrical output was approximately 14.32 kW before unmodeled balance-of-plant auxiliary power consumption, with the ORC contribution corresponding to about 9.5% of the gross HT-PEMFC stack output. The results demonstrate the complementary potential of physically consistent HT-PEMFC operating-condition optimization and waste-heat recovery, while the ORC results remain specific to the retained R409A reference dataset.