Over the past several decades, metal Additive Manufacturing (AM) has transitioned from a rapid prototyping method to a viable manufacturing tool. AM technologies can produce parts on-demand, repair damaged components, and provide an increased freedom of design not previously attainable by traditional manufacturing techniques. The increasing maturation of metal AM is attracting high-value industries to directly produce components for use in aerospace, automotive, biomedical, and energy fields. Two leading processes for metal part production are Powder Bed Fusion with laser beam (PBF-LB/M) and Directed Energy Deposition with laser beam (DED-LB/M). Despite the many advances made with these technologies, the highly dynamic nature of the process frequently results in the formation of defects. These technologies are also notoriously difficult to control, and the existing machines do not offer closed loop control. In the present work, the application of various Machine Learning (ML) approaches and in-situ monitoring technologies for the purpose of defect detection are reviewed. The potential of these methods for enabling process control implementation is discussed. We provide a critical review of trends in the usage of data structures and ML algorithms and compare the capabilities of different sensing technologies and their application to monitoring tasks in laser metal AM. The future direction of this field is then discussed, and recommendations for further research are provided. Graphical abstract

The need for new approaches to investigate ex vivo the causes and effects of tumor and to achieve improved cancer treatments and medical therapies is particularly urgent for malignant pathologies such as lymphomas and leukemias, whose tissue initiator cells interact with the stroma creating a three-dimensional (3D) protective environment that conventional mono- and bi-dimensional (2D) models are not able to simulate realistically. The solvent-casting particulate leaching (SCPL) technique, that is already a standard method to produce polymer-based scaffolds for bone tissue repair, is proposed here to fabricate innovative 3D porous structures to mimic the bone marrow niche in vitro. Two different polymers, namely a rigid polymethyl methacrylate (PMMA) and a flexible polyurethane (PU), were evaluated to the purpose, whereas NaCl, in the form of common salt table, resulted to be an efficient porogen. The adoption of an appropriate polymer-to-salt ratio, experimentally defined as 1:4 for both PMMA and PU, gave place to a rich and interconnected porosity, ranging between 82.1 vol% and 91.3 vol%, and the choice of admixing fine-grained or coarse-grained salt powders allowed to control the final pore size. The mechanical properties under compression load were affected both by the polymer matrix and by the scaffold's architecture, with values of the elastic modulus indicatively varying between 29 kPa and 1283 kPa. Preliminary tests performed with human stromal HS-5 cells co-cultured with leukemic cells allowed us to conclude that stromal cells grown associated to the supports keep their well-known protective and pro-survival effect on cancer cells, indicating that these devices can be very useful to mimic the bone marrow microenvironment and therefore to assess the efficacy of novel therapies in pre-clinical studies.

Bioactive glasses, discovered by Hench and co-workers at the end of the 1960s, are among the most promising biomaterials for bone repair and reconstruction, mainly thanks to their high bioactivity index. Unfortunately, due to their brittleness and relatively poor mechanical properties, their clinical applications are limited to non-load bearing implants. However, bioactive glasses can be successfully employed as coatings on bioinert metallic substrates, in order to combine high bioactivity with mechanical strength. After a brief introduction to the main properties of biomaterials and bioactive glasses, the present paper provides an overview of the different approaches and available techniques to realise bioactive glass coatings, with a particular emphasis on thermal spray, which is nowadays one of the most popular coating procedures.