This work investigates the feasibility of manufacturing a near net shape structural part directly on a subassembly for application in crane construction without post-machining. Single- and multi-pass welding experiments, using the Cold Metal Transfer process (CMT), were executed to identify and verify suitable process parameters. The obtained parameters were then used to manufacture a wall structure and an optical measurement of the resulting geometry was performed. Mechanical properties of the all-weld metal in the as-built condition in different directions were determined. The results for tensile testing showed similar values to the filler material specifications and fracture toughness matched literature values, but a decrease of impact toughness was obtained. Although mechanical testing showed no significant anisotropy, hardness measurements showed the influence of the local temperature profile. Finally, strategies to manufacture a complex structural part were investigated. It was possible to establish a stable process to manufacture a section of the specified geometry in a first attempt. However, results indicate that there is still further work necessary to optimize this process and to investigate the influences on the mechanical properties of the final component.

The nanocomposites were prepared by synthesizing (2,2,6,6-tetramethylpiperidin-1-yl)oxyl (TEMPO)-oxidized cellulose nanofibrils (TCNFs) or cellulose nanocrystals (CNCs) with hydroxyapatite (HA) in varying composition ratios in situ. These nanocomposites were first obtained from eggshell-derived calcium and phosphate of ammonium dihydrogen orthophosphate as precursors at a stoichiometric Ca/P ratio of 1.67 with ultrasonication and compressed further by a uniaxial high-pressure technique. Different spectroscopic, microscopic, and thermogravimetric analyses were used to evaluate their structural, crystalline, and morphological properties, while their mechanical properties were assessed by an indentation method. The contents of TCNF and CNC were shown to render the formation of the HA crystallites and thus influenced strongly on the composite nanostructure and further on the mechanical properties. In this sense, the TCNF-based composites with relatively higher contents (30 and 40 wt %) of semicrystalline and flexible TCNFs resulted in smoother and more uniformly distributed HA particles with good interconnectivity, a hardness range of 550–640 MPa, a compression strength range of 110–180 MPa, an elastic modulus of ~5 GPa, and a fracture toughness value of ~6 MPa^1/2 in the range of that of cortical bone. Furthermore, all the composites did not induce cytotoxicity to human bone-derived osteoblast cells but rather improved their viability, making them promising for bone tissue regeneration in load-bearing applications.