This paper provides a comprehensive analysis of recent advancements in additive manufacturing, a transformative approach to industrial production that allows for the layer-by-layer construction of complex parts directly from digital models. Focusing specifically on Directed Energy Deposition, it begins by clarifying the fundamental principles of metal additive manufacturing as defined by International Organization of Standardization and American Society for Testing and Materials standards, with an emphasis on laser- and powder-based methods that are pivotal to Directed Energy Deposition. It explores the critical process mechanisms that can lead to defect formation in the manufactured parts, offering in-depth insights into the factors that influence these outcomes. Additionally, the unique mechanisms of defect formation inherent to Directed Energy Deposition are examined in detail. The review also covers the current landscape of process evaluation and non-destructive testing methods essential for quality assurance, including both traditional and contemporary in situ monitoring techniques, with a particular focus given to advanced machine-vision-based methods for geometric analysis. Furthermore, the integration of process monitoring, multiphysics simulation models, and data analytics is discussed, charting a forward-looking roadmap for the development of Digital Twins in Laser–Powder-based Directed Energy Deposition. Finally, this review highlights critical research gaps and proposes directions for future research to enhance the accuracy and efficiency of Directed Energy Deposition systems.

Utilization of a heat source to regulate the shock wave–boundary layer interaction (SWBLI) of hypersonic inlets during throttling was computationally investigated. A plug was installed at the intake isolator’s exit, which caused throttling. The location of the heat source was established by analysing the interaction of the shockwave from the compression ramp and the contact spot of the shockwave with that of the inlet cowl. Shockwave interaction inside the isolator was investigated using steady and transient cases. The present computational work was validated using previous experimental work. The flow distortion (FD) and total pressure recovery (TPR) of the inflows were also studied. We found that varying the size and power of the heat source influenced the shockwaves that originated around it and affected the SWBLI within the isolator. This influenced most of the performance measures. As a result, the TPR increased and the FD decreased when the heat source was applied. Thus, the use of a heat source for flow control was found to influence the performance of hypersonic intakes.