Wearable strain sensors have drawn massive awareness in various studies and industrial fields.

In recent years, nanotechnology and materials science have evolved and matured, making it increasingly easier to design and fabricate next-generation 3D microelectronics.

Laser powder bed fusion (LPBF) is a promising additive manufacturing technique that allows layer-by-layer fabrication of metallic powders. Distinguished thermal dynamics result in the microstructure of intrinsic features. This review aims to provide a thorough insight into the solidification fundamentals and the microstructural tailoring during LPBF. It begins with the introduction of the LPBF and the challenges of its applications with aluminium alloys. The thermal dynamics and its influence on the microstructure in LPBF were thereafter discussed. The attempts to tailor microstructures by refinement in LPBF fabrication of various aluminium alloys were summarised. Finally, the review provides a conclusive remark on the microstructural controlling and an outlook on the remaining challenges and potential research topics in LPBF with Al alloys.

Nowadays, high-entropy alloys (HEAs) have become a hot research topic in the field of coating materials. However, HEAs have a large wide range of compositional systems, and the differences in their composition inevitably lead to the significant variations in the matching process parameters of laser cladding and post-treatment methods, which in turn give the coatings a broad range of microstructures and protective properties. Therefore, it is crucial to review and summarize the research progresses on laser cladding HEA coatings to provide a reference for obtaining high-performance HEA coatings and further expand the application of HEA coatings. This work describes the working mechanism of laser cladding and illustrates the advantages and drawbacks of laser cladding in detail. The effects of the addition of alloying elements, process parameters and post-treatment techniques on the microstructures and properties of the coatings are thoroughly reviewed and analyzed. In addition, the correlations between the chemical compositions of HEAs, process parameters of laser cladding, post-treatment techniques and the microstructure and protective properties of the coatings are investigated and summarized. On this basis, the future development direction of HEA coatings is outlined.