Holistic Innovation in Additive Manufacturing
June 22-23, 2026 | Banff, AB, Canada
About the HI-AM Conference
HI-AM 2026
Location: Banff, AB, Canada
Venue: Banff Centre for Arts and Creativity - Kinnear Centre
Dates: June 22-23, 2026
Important Dates
| Abstract Submission Opens | September 1, 2025 |
| Abstract Submission Deadline | February 6, 2026 |
| Abstract Acceptance Notice | March 2, 2026 |
| Manuscript Submission Opens | March 2, 2026 |
| Manuscript Deadline | June 1, 2026 |
| Registration Deadline (Presenting Authors) | May 1, 2026 |
| Registration Deadline | To be announced |
| Proceedings Published | November 2026 |
Keynote Speakers
Christian Leinenbach
Christian Leinenbach
Presentation Title
Abstract
Fe-Mn-Si–based shape memory alloys (SMAs) have emerged as an attractive low-cost alternative to conventional NiTi systems, particularly for large-scale civil and structural engineering applications. Their good machinability, weldability and corrosion resistance, together with the ability to generate high recovery stresses, make them promising candidates for novel prestressing and actuation concepts. Over the past years, significant progress has been made in tailoring the composition and thermomechanical processing of these alloys, enabling their successful use in structural engineering. Recent advances in additive manufacturing now offer further opportunities to tune both the functional behaviour and the mechanical performance of Fe-Mn-Si SMAs. In this keynote, we discuss how laser powder bed fusion (L-PBF) can be used to deliberately modify microstructure and phase stability, thereby influencing the shape memory response. By adjusting process parameters and scanning strategies, local variations in chemical composition can be achieved, which can be exploited to produce graded microstructures with different phase fractions and varying mechanical and shape memory properties. These developments illustrate the strong potential of additive manufacturing as a tool for designing next-generation Fe-Mn-Si-based SMAs with improved functional properties. The presentation will highlight selected results that illustrate the links between processing, phase formation and functional behaviour, and outline where we see the most promising directions for future SMA design and application.
Biography
Dr. Christian Leinenbach earned his MSc in Materials Science and Engineering from the Universities of Saarbrücken (Germany) and Luleå (Sweden) in 2000, and a PhD from the University of Kaiserslautern (Germany) in 2004. Since 2005, he has been at Empa, the Swiss Federal Laboratories for Materials Science and Technology, where he is currently Head of the Advanced Processing and Additive Manufacturing of Metals Group Dübendorf/Zürich and Thun, Switzerland. He also serves as adjunct faculty in the Institute of Materials at École Polytechnique Fédérale de Lausanne (EPFL), teaching courses on advanced metallurgy, metal processing, and additive manufacturing. His research focuses on the development and characterization of high-performance structural alloys and metal-matrix (nano-)composites, with particular emphasis on additive manufacturing and laser processing. Recent work addresses Ni, Al, refractory high-entropy alloys, and oxide-dispersion-strengthened (ODS) alloys, as well as shape-memory alloys and TRIP steels. His approach combines computational materials design (high-throughput and machine-learning-assisted thermodynamic simulations, FEM/CFD) with advanced in situ and ex situ characterization, including synchrotron and neutron diffraction and imaging. He has authored over 200 peer-reviewed publications and is active in several national and international professional societies. He is regular keynote speaker at international conferences and is also co-initiator of the Alloys for Additive Manufacturing Symposium (AAMS), an annual international conference series dedicated to the materials science of metal additive manufacturing, which he co-organized in 2017 and again in 2025.
Christoph Leyens
Christoph Leyens
Presentation Title
Abstract
Metal additive manufacturing is making its way into industrial production. Slower than expected a few years ago, but nevertheless unstoppable, more and more additively manufactured products and components are coming onto the market. While on the scientific side, current research is still focusing on many issues such as targeted, spatially resolved property modification through microstructures or lattice structures, the expansion of the material palette, and the formation and avoidance of defects, the business case plays an important role in industrial applications. The presentation highlights current development work on beam shaping and grain refinement in DED and LPBF with the aim of increasing process stability and part quality. DED is also suitable for high-throughput screening of materials. At the same time, the optimal process parameters required for the production of a specific alloy are also being developed. Copper alloys are of great importance for a number of industries such as power generation, tool making and space, but they pose a particular challenge for production using AM. Large components can be manufactured using DED and – due to the increasing availability of LPBF machines with large build chambers - also in powder beds. Topology optimization and lattice structures are just two examples of the advantages of additive manufacturing. A reliable manufacturing process is particularly important for large components. This can significantly reduce the costs of component manufacturing and significantly increase their quality through 24/7 monitoring and a fully digitized process chain.
Biography
Prof. Dr.-Ing. Christoph Leyens studied physical metallurgy and materials technology at RWTH Aachen, Germany, where he earned his diploma in 1993 and his Ph.D. in 1997. He is currently a full professor for materials science and engineering at Dresden University of Technology, Germany, and the director of the Fraunhofer Institute for Material and Beam Technology, Dresden. Prof. Leyens has covered a wide range of research topics with a focus on high temperature and lightweight materials, surface technology and additive manufacturing. He has published more than 340 papers, 23 books and book chapters and holds 12 patents.
Bernhard Müller
Bernhard Müller
Presentation Title
Abstract
In times of global political and economical crisis and unmet industry expectations, additive manufacturing (AM) needs to find new answers to succeed on an industrial level. Beyond growing markets like space, medical and defence, another level of functionality, performance and sustainability needs to be reached by newly developed AM solutions, while accepting certain (physical) limits in size, productivity, cost and surface smoothness. The keynote highlights examples that aim to achieve this new level of functionality, performance and/or sustainability, from very different fields of application and a variety of AM technologies and materials. Next generation AM heat exchangers, like vapour chambers and pulsating heat pipes, reach multiplied performance levels when it comes to extremely fast dissipation of thermal loads and recovering waste heat for secondary use. To shorten the path to printable designs of complex internal structures like cooling channels, automatic design methods need to be developed and applied. To address more industrial use cases with AM, large format 3D printing is key for spare parts and molds, which will be demonstrated for a train front panel as exemplary use case scenario. Material innovation needs to go beyond qualifying just another alloy type – functional materials with unique properties are getting in focus. The keynote highlights developments of complex and filigree nickel-titanium structures with variable properties, that can by controlled by AM process parameters in laser powder bed fusion (LPBF). Other developments include successful LPBF processing and qualification for Invar, titanium aluminide and high performance aluminum alloys. When it comes to sustainability of AM, the utilization of renewable raw materials is gaining importance. The keynote highlights 3D Printing of stable, complex structures made of wood paste, including the adjustment of properties through mycelium growth. All the presented puzzle pieces contribute to shaping the bigger picture of next generation additive manufacturing solutions, reaching new levels of functionality, performance and sustainability.
Biography
Bernhard Mueller obtained his »Dr.-Ing.« (PhD) degree from TU Dresden (Germany), Faculty of Mechanical Engineering in 2001. He worked in German light metal foundry and automotive supply industry for 12 years, focussing on R&D as well as on management responsibilities, serving as a plant manager in his latest position, before joining Fraunhofer to establish »Additive Manufacturing Technologies« as a new field of research at Fraunhofer IWU in Dresden, Germany. In his education and previous positions, Bernhard has recurrently worked with additive manufacturing / 3D printing technologies for more than 30 years, working with very early AM systems at TU Dresden and BMW Munich (stereolithography and laser sintering) as well as SFM Dresden, California State University Long Beach and Helisys, Torrance, CA (laminated object manufacturing), focussing later on laser powder bed fusion (LPBF) technology for metals. Since 2014, Bernhard has been acting as the spokesperson for the »Fraunhofer Competence Field Additive Manufacturing«, which pools Fraunhofer’s competence in AM from 19 member institutes. He had also managed the German industrial »Beam Melting Network« for 15 years. He has been member of the board of directors at AGENT-3D e. V., Germany’s largest consortium for research, innovation and growth in 3D printing. He has been member in several technical committees, including »GPL FB1 FA105.2/.4 Additive Manufacturing« of the Association of German Engineers VDI and »FA13 Additive Manufacturing« of the German Research Association on Welding and Allied Processes of the DVS (German Welding Society). He has also been on the Advisory Council of rapid.tech 3D International Trade Show & Conference for Additive Manufacturing in Erfurt (Germany) as well as on the advisory board of the Springer Nature journal »Progress in Additive Manufacturing« (PIAM). Since 2016, Bernhard has been the conference chairman for the Fraunhofer Direct Digital Manufacturing Conference DDMC, one of the world’s most reputed international AM conferences for academia and industry, held bi-annually in Berlin, Germany. Bernhard has authored 140+ technical and scientific publications and presented 90+ technical papers at national and international conferences, symposia and workshops.
Sharon Nai
Sharon Nai
Presentation Title
Abstract
Over the years, Singapore has emerged as one of the global leaders in additive manufacturing (AM), transforming manufacturing through a coordinated national strategy that integrates research excellence, industry partnerships and talent development. This keynote will showcase Singapore’s AM ecosystem, highlighting NAMIC and A*STAR’s pivotal roles in advancing technologies from R&D to industrial scale deployment. It will explore trends shaping Singapore’s AM landscape including advanced materials, micro to large format printing, multi material 3D/4D printing and digitalization, illustrated through examples of cutting edge research translated into high value manufacturing solutions.
Biography
Dr. Sharon Nai is a Senior Principal Scientist at the A*STAR Singapore Institute of Manufacturing Technology (A*STAR SIMTech). She is also the Director of the Additive Innovation Centre (AIC) at A*STAR, a key translational hub supported by the National Additive Manufacturing Innovation Cluster (NAMIC). Dr. Nai holds a Ph.D. in Mechanical Engineering from the National University of Singapore. With expertise in additive and advanced manufacturing, Dr. Nai has led numerous collaborative R&D projects with both local and international industry partners, translating research into industrial applications and establishing joint labs with the industry. Dr. Nai has published over 150 peer-reviewed journal papers and filed two patents. Her contributions to the field have earned recognition, including the SG100 Women in Tech Award in 2021, the A*STAR Fellow in 2023 and the NUS Distinguished Alumni Award in 2025.
Martin Petrak
Martin Petrak
Presentation Title
Abstract
As global supply chains continue to evolve and foundational Industry 4.0 technologies mature, the transition toward AI-driven Industry 5.0 is accelerating the need for agile, intelligent, and resilient manufacturing platforms. Additive Manufacturing (AM) is a core enabler of this shift—supporting rapid innovation, compressing development timelines, and enabling scalable production for applications with increasingly demanding performance and certification requirements. Precision ADM, based in Winnipeg, Manitoba, has become one of Canada’s most highly certified additive manufacturing SMEs, achieving ISO 13485, AS9100, ISO 9001, US FDA Registration, and Controlled Goods certification. The company has established itself as a trusted supplier of advanced Medical, Aerospace, Defense, and Energy components, demonstrating how Canadian SMEs can drive global competitiveness by adopting AM technologies strategically. This presentation explores modern applications and materials across the medical, aerospace, and energy sectors, highlighting examples ranging from bespoke patient-specific solutions to validated serial production programs. In the medical device industry, Laser Powder Bed Fusion (LPBF) combined with Design for Additive Manufacturing (DfAM) enables next-generation metal orthopedic implants with enhanced biocompatibility, osseointegration, and patient-specific customization. Advances in Selective Laser Sintering (SLS) and Stereolithography (SLA) polymers further support flexible pathways to produce custom implant trials and surgical instrumentation to large-volume production of medical devices such as the nasopharyngeal swabs widely deployed during the COVID-19 pandemic. In aerospace and energy, modern nickel-based superalloy powders with excellent material properties are unlocking efficient LPBF production of high-value components that are increasingly costly and difficult to source. These materials enable rapid, economical, low-volume builds that support maintenance, repair, and overhaul (MRO) requirements across turbine and power-generation platforms. Above all, the critical role of DfAM and material science across all applications remains central to unlocking the full potential of AM and shaping the future landscape of advanced manufacturing in Canada.
Biography
Martin Petrak, M.Sc., P. Eng. Martin J. Petrak is a recognized Canadian leader in medical innovation and advanced manufacturing, with more than 22 years of experience in engineering, biotechnology, and high-performance additive manufacturing (AM) systems. Born in Winnipeg, Manitoba, he is a first-generation Canadian and holds two undergraduate degrees and a graduate degree in Engineering from the University of Manitoba. He also completed international studies at Charles University in Prague, Czech Republic. In 2015, Martin co-founded Precision ADM in Winnipeg, where he currently serves as President. Under his leadership, Precision ADM has become one of Canada’s most highly certified additive manufacturing companies—achieving ISO 13485, AS9100, ISO 9001, US FDA Registration, and Controlled Goods certification—and a trusted supplier of advanced Medical, Aerospace, Defense, and Energy components. Leveraging his biomedical engineering background, Martin helped develop both custom and serial manufacturing capabilities for complex medical implants, and he led the team that produced the world’s highest-volume 3D-printed nasopharyngeal swabs during the COVID-19 pandemic, manufacturing more than six million units. Prior to Precision ADM, Martin served as CEO of the Orthopaedic Innovation Centre in Winnipeg, where he championed translational biomedical engineering and commercialization. Today, he continues to expand Precision ADM’s capabilities in laser powder bed fusion AM of high-performance superalloys and extreme-environment components for aerospace, defense, and energy applications. Martin volunteers extensively in the Canadian advanced manufacturing ecosystem. He serves as a Director with the Manitoba Aerospace Association and its Economic Development Subcommittee, Canada Makes (Canada’s national additive manufacturing network), and volunteers with the Technology Access Centre for Aerospace, Manufacturing & Defence at Red River Polytechnique. He is currently advancing new additive manufacturing technologies to support Canada’s clean energy and next-generation power-generation initiatives.
Invited Speakers
Sami Arsan
Sami Arsan
Presentation Title
Abstract
Additive Manufacturing (AM) is increasingly strategic for the oil & gas sector as companies face long lead times, supply‑chain volatility, and aging infrastructure. AM enables on‑demand production, reduced inventory, and localized manufacturing, making it highly valuable for both OEMs and operators. For operators, AM improves uptime by reducing long-lead spare parts, enables component life extension, and lowers logistics costs in remote environments. For OEMs, it opens new service models—such as licensed digital parts—and supports faster design iterations, small‑batch production, and reduced inventory of seldom-used components. 1. Proven Benefits of AM for O&G How AM improves performance through design freedom, part consolidation, and high‑performance alloys. How AM reduces lead times, simplifies supply chains, and enables on‑demand manufacturing. Quantified sustainability gains through reduced material use and logistics. 2. Real‑World Case Studies & Measurable Results A downhole drilling components. A digital‑warehousing/reverse‑engineering success and a redesign success consolidating four legacy parts into a single AM component improved run life. 3. Standards, Certifications, and Quality Assurance DNV‑qualified manufacturer status and API 20S qualification work. 4. Technical Workflow and AM Process Chain End‑to‑end AM process: design, DFAM optimization, powder selection, simulation, printing, heat treatment, machining, and inspection. Reverse engineering workflows for legacy/obsolete parts and how these feed into digital warehousing. 5. Digital Warehousing & Digital Supply Chain Enablement How validated 3D files, digital passports, and controlled manufacturing parameters create a digital inventory that replaces physical stock. 6. Challenges and Lessons Learned Process qualification, NDE, regulatory requirements, and post‑processing complexities. 7. Path Forward for Industry Adoption Material innovation, standardization efforts, workforce development, and strategic partnerships across OEMs, suppliers, and operators.
Biography
Sami Arsan brings over 25 years of industry experience with leading tooling and equipment supply organizations; lately focus on AM applications in the Energy sector, roles in global sourcing, advance/disruptive manufacturing technologies and component engineering. He was a founding member of the voestalpine Additive Manufacturing Centers in North America. Sami holds a degree in mechanical engineering, is a Project Management Professional (PMP), a Professional Engineer (P.Eng) in the Province of Ontario and Certified in Additive Manufacturing by SME.
Changhong Cao
Changhong Cao
Presentation Title
Abstract
This talk presents two complementary platforms addressing persistent challenges in DIW 3D printing. 3D Necroprinting explores the use of biological structures—mosquito proboscises—as functional printing nozzles. The proboscis achieves ~20 micrometer printing resolution, approaching capabilities typically reserved for expensive specialized equipment. We characterize its mechanical performance, establish operational guidelines, and demonstrate feasibility for bioprinting applications with encouraging cell viability results. Binder Spraying Additive Manufacturing (BSAM) enables support-free printing of complex geometries through rapid interfacial polymerization. By combining controlled gelation with instantaneous in-situ polymer formation, we fabricate freestanding structures—overhangs, internal voids, and intricate lattices—without auxiliary supports. The platform accommodates diverse materials: organic, ceramic, and metal nanocomposites with tunable mechanical properties. Together, these approaches demonstrate how mechanics-informed design and chemistry can address practical manufacturing limitations.
Biography
Dr. Cao is an Assistant Professor, and Canada Research Chair (Tier 2) in small-scale materials and manufacturing, in the Department of Mechanical Engineering at McGill University. He earned his Ph.D. in Mechanical Engineering from the University of Toronto and was a postdoctoral fellow at MIT before joining McGill. His research interests include transfer printing technologies, experimental nanomechanics of advanced structures, and the development of new additive manufacturing mechanisms. As the lead author, his research has been published in journals, including Science Advances, Advanced Materials, Advanced Functional Materials, and ACS Nano. He has also been recognized with the Young Leaders Award and Young Leaders International Award from TMS, the Young Scientist Award from Springer Nature Microsystem and Nanoengineering, and Stony Brook University 40 under 40.
Lianyi Chen
Lianyi Chen
Presentation Title
Abstract
Laser powder bed fusion (LPBF) can manufacture metal components with complex geometries directly from digital models without the design constraints of traditional manufacturing routes, which has potential to revolutionize many industries. However, LPBF still faces challenges of (1) defects formation, (2) containing many uncertainties, (3) low fatigue life, and (4) lack of qualification and certification. This talk will present our research on overcoming these challenges to achieve predictable, consistent and reliable LPBF through revealing the transient dynamics and fundamental mechanisms of LPBF process by in-situ high-speed synchrotron x-ray imaging and diffraction, as well as designing novel alloys and processing strategies based on the newly discovered mechanisms. The dynamics and mechanisms of powder spreading, powder spattering, melt pool evolution, defect formation and evolution, and solidification will be discussed. Examples of developing processing approaches based on the revealed mechanisms that lead to orders of magnitude reduction of defects will be presented.
Biography
Dr. Lianyi Chen is the Kuo K. & Cindy F. Wang Associate Professor in the Department of Mechanical Engineering and Department of Materials Science and Engineering at University of Wisconsin-Madison. Dr. Chen received his Ph.D. degree in Materials Science and Engineering from Zhejiang University in 2009. His research activities and interests are at the intersection of materials science, manufacturing, and in-situ characterization. His research goal is to drive performance and manufacturing of metals to a new height by integrating materials design and manufacturing. His research program includes four highly interrelated research areas: metal additive manufacturing, autonomous metals design and manufacturing, metals design based on nanoelements, and in-situ/operando characterization. Dr. Chen has published more than 100 peer-reviewed journal papers. He is an inventor with 12 patents (2 licensed). His research results are highlighted, featured and reported by hundreds of news outlets all over the world.
Yuze Huang
Yuze Huang
Presentation Title
Abstract
Laser additive manufacturing (LAM) plays a pivotal role in achieving low-carbon manufacturing across modern industry, owing to its high material utilisation, localised heat input, design freedom, and strong compatibility with digital technologies. Yet, achieving stable, energy-efficient, and defect-controlled LAM processing across different materials and build scales remains challenging. Integrating physics-based modelling, process innovation and optimisation, and advanced monitoring might offer a pathway toward more sustainable and intelligent laser additive manufacturing. This presentation will share findings from our studies on laser–material interactions, with a focus on melt-pool behaviour, keyhole dynamics, and the formation and mitigation of defects such as porosity. By combining physics-informed models with machine-learning-based optimisation, we develop strategies to enhance processing rate while balancing quality. Drawing on case studies in laser metal additive manufacturing (DED-LB/p, DED-LB/w, and L-PBF), this work aims to demonstrate how laser additive manufacturing can be steered toward higher efficiency and digitally enabled production.
Biography
Dr Huang is a Lecturer in Low-Carbon Manufacturing, specialising in Additive Manufacturing and Welding, in the Department of Mechanical and Aerospace Engineering at the University of Manchester. He obtained his PhD degree from the University of Waterloo, Canada, in the year of 2019. He has also held a postdoctoral position at the University College London (2019-2022). His principal research interests lie in the areas of metal additive manufacturing, laser materials processing, welding and magnetic levitation. He is a member of the EPSRC Peer Review College, the Institute of Materials, Minerals and Mining (IOM3), Canadian Society for Mechanical Engineering (CSME), and Association of Laser Users (AILU). He is a Youth editor for the Journal of Materials Science & Technology and has also served as a guest editor for Advanced Manufacturing.
Cho-Pei Jiang
Cho-Pei Jiang
Presentation Title
Abstract
This study investigates the process–structure–property relationships of ceramic-modified Inconel 718 fabricated using Laser Powder Bed Fusion (LPBF), focusing on two reinforcement strategies: zirconia for metal–matrix composite (MMC) strengthening and alumina for oxide-dispersion-type (ODS-like) enhancement. A comprehensive characterization workflow was employed, including SEM–EDS for morphology and elemental distribution, EBSD for crystallographic analysis, XRD for phase identification, VR-3D profilometry for surface topography, Vickers microhardness testing, tensile evaluation, and simultaneous TGA–DSC for thermal behavior. For zirconia-reinforced alloys (1–10 wt.%), microstructural evolution and mechanical responses were highly sensitive to particle concentration. Additions of 1–2 wt.% ZrO₂ promoted stable melt-pool dynamics, reduced porosity, and refined grain structures through uniform dispersion. These features improved hardness, tensile strength, and overall integrity via combined load-transfer and grain-refinement mechanisms. In contrast, higher zirconia levels (5–10 wt.%) led to particle agglomeration, melt-pool instability, increased surface roughness, and lack-of-fusion defects, ultimately degrading mechanical performance and revealing the upper processing limits for ZrO₂-based MMCs in LPBF. The alumina-modified system (0.5–1 wt.%) exhibited consistent ODS-like behavior. EBSD analysis showed enhanced subgrain development, an increased fraction of low-angle boundaries, and suppression of boundary migration. XRD confirmed that Al₂O₃ remained inert during LPBF without forming secondary phases. Mechanical improvements—including higher hardness, tensile strength, and toughness—were most significant at 1 wt.% Al₂O₃. TGA–DSC results further demonstrated reduced mass gain and suppressed thermal transitions, indicating superior oxidation resistance and improved matrix stability. Overall, this work defines optimal reinforcement windows for ZrO₂-MMC and Al₂O₃-ODS-like Inconel 718 systems and provides a mechanistic foundation for designing ceramic-modified nickel-based superalloys tailored for LPBF. The findings advance the development of compositionally engineered superalloys with enhanced structural reliability for high-temperature and high-performance applications.
Biography
Dr. Cho-Pei Jiang is a Distinguished Professor and Associate Dean in the Department of Mechanical Engineering at National Taipei University of Technology (Taipei Tech), Taiwan. He is widely recognized for pioneering work in multi-material additive manufacturing, advanced ceramic photopolymerization, and functionally graded lattice architectures. His research focuses on developing dual-slurry and multi-slurry DLP/VPP systems, multi-vat photopolymerization technologies, and hybrid additive–casting processes for high-performance ceramic and metal-ceramic components.
As the principal investigator and corresponding author of numerous international collaborations, Prof. Jiang leads research programs with partners in Australia, New Zealand, Europe, India, and East Asia. His work addresses high-temperature ceramics, ceramic-metal composites, digital dentistry manufacturing, and AI-assisted optimization for complex AM processes. Prof. Jiang is also deeply engaged in industrial translation. He serves as President of the Additive Manufacturing Society of Taiwan (AMST) and is the founder or co-founder of several AM-related companies, including Enlighten Materials Ltd., 3dcelain Ltd., and Dr. Smile Tech, advancing next-generation 3D printing systems and automated dental manufacturing platforms. With extensive SCI publications, global collaborations, and leadership roles—including Chair of Powder Metallurgy and Additive Manufacturing of Titanium (PMAMTi 2026)—Prof. Jiang continues to drive innovations in advanced manufacturing for aerospace, biomedical, and sustainable engineering applications.
Justin Morrow
Justin Morrow
Presentation Title
Abstract
In-situ monitoring has become an important tool for improving reliability in industrial additive manufacturing, but most existing systems focus on temperature, melt pool behavior, porosity, and part geometry, with far less attention given to direct monitoring of alloy chemistry and contamination. This talk reviews major published approaches to in-situ chemical monitoring, including optical emission spectroscopy, laser-induced breakdown spectroscopy, x-ray fluorescence, and electron-optical methods, and evaluates their practical strengths and limitations from both manufacturing and spectroscopy perspectives. The presentation also introduces recent work on in-situ energy-dispersive x-ray spectroscopy (EDS) integrated into an electron beam melting (EBM) system as a case study in developing deployable chemical monitoring tools. This work highlights how long-term adoption depends on how well an analysis technique is aligned with the manufacturing process in terms of underlying physics, system integration, data quality, and cost. It emphasizes the importance of jointly considering process conditions, machine design, and analytical hardware requirements when developing practical engineering solutions. Using a combination of simulation and experimental validation, the study assesses data quality during in-situ EBM-EDS and explains deviations from conventional laboratory-based SEM-EDS measurements. Results illustrate how advanced spectroscopy methods can enable layer-by-layer alloy monitoring and fine contaminant detection during fabrication. The presentation concludes by discussing remaining technical and practical challenges and how close collaboration between AM machine builders, analytical instrumentation developers, and end users can accelerate development and technology transfer.
Biography
Justin D. Morrow, Ph.D., is a Research Assistant Professor in Environmental and Industrial Hygiene at the University of Cincinnati College of Medicine, where he conducts research at the intersection of additive manufacturing, spectroscopy, and occupational health. His work focuses on developing in-situ and near–real-time methods for characterizing chemical and particulate emissions from industrial and consumer-scale 3D printing systems. He has authored peer-reviewed publications in manufacturing science and materials characterization and is an inventor on multiple patents related to advanced analytical instrumentation. Prior to joining academia, he spent six years at Thermo Fisher Scientific developing microscopy and spectroscopy technologies, including in-situ sensors for additive manufacturing. His current work emphasizes technology transfer and close collaboration with industrial partners to translate measurement innovations into deployable monitoring and process-control solutions.
Bernard Rolfe
Bernard Rolfe
Presentation Title
Abstract
In 2025, Australia established a national industry–government–university consortium, the Additive Manufacturing Cooperative Research Centre (AMCRC), to accelerate innovation and industrial adoption of additive manufacturing (AM). The AMCRC has four strategic research themes: sustainable manufacturing; applications and materials development; technology and process innovation; and surface engineering and post-processing. This presentation introduces the AMCRC framework and outlines opportunities for collaboration, with particular emphasis on engagement with Canadian research institutions and industry. The presentation further highlights recent research at Deakin University on controlling microstructural evolution in titanium alloys produced by metal AM. Among metal AM technologies, laser powder bed fusion (L-PBF) and electron beam powder bed fusion (PBF-EB/M) are the most widely implemented processes for Ti-6Al-4V components in aerospace and biomedical applications. These processes generate different thermal histories, producing distinct microstructures, build qualities, and mechanical responses. Establishing scientific links between microstructural control in L-PBF and PBF-EB/M therefore represents a critical research challenge. L-PBF processing is characterised by rapid solidification and steep thermal gradients that promote metastable α′ martensite within columnar prior-β grains, yielding high strength but limited ductility and fracture toughness. Quantitative post-mortem characterisation combined with controlled cyclic and isothermal dilatometric heat treatments establishes transformation pathways leading to equilibrium α+β lamellae, α-globularisation, and equiaxed prior-β grain formation, enabling balanced strength–ductility performance. Conversely, PBF-EB/M operates at elevated build temperatures (~700 °C), producing lower cooling rates and α+β microstructures but introducing challenges including surface roughness, thermal-gradient-driven inhomogeneity, and continuous grain-boundary α. Systematic experimental design, microstructural analysis, and multi-scale mechanical testing reveal process–structure–property relationships and enable both inter-build and intra-build microstructural control. Collectively, this work establishes a comparative framework linking thermal history, phase transformation, and mechanical performance across L-PBF and PBF-EB/M, supporting the development of functionality-graded, microstructure-engineered AM components for high-reliability structural applications.
Biography
Professor Bernard Rolfe is a professor of advanced manufacturing in the School of Engineering at Deakin University. From 2022 to 2025, he served as the Associate Dean, Research (ADR) for the Faculty of Science, Engineering and Built Environment (SEBE). SEBE comprises four schools: Architecture and Built Environment, Information Technology, Engineering, and Life and Environmental Sciences. It also includes two institutes: Frontier Materials and Intelligent Systems Research Innovation. The faculty possesses over 500 continuing academic staff, 940 PhD students, and more than AUD $72 million per annum in external research income. The ADR role is strategic, aimed at improving research outcomes for the faculty while overseeing research policy and procedures. Bernard is an innovator in materials and manufacturing and an influencer in mobility engineering. He serves as a Director on the Board of the Society of Automotive Engineers – Australasia (2020-2027) and is a member of the Australian Research Council’s College of Experts (2022-2026). His current research focuses on the design and forming of lightweight structures, the investigation and simulation of metal additive manufacturing, and the design and analysis of 4D printing. Bernard has received five Vice Chancellor awards and has been part of over fifteen successful nationally competitive large research grants, totalling over AUD $35 million in awarded funds. He has published over 230 refereed research articles.
Sravya Tekumalla
Sravya Tekumalla
Presentation Title
Abstract
Fusion-based additive manufacturing (AM) creates complex, customizable metallic parts, making it ideal for biomedical use. Metal AM techniques such as laser powder bed fusion (LPBF) offer the potential to produce patient-specific implants using beta titanium (β-Ti) alloys, which are valued for their low density, excellent biocompatibility and mechanical strength. However, LPBF introduces unique microstructural features—such as melt pool boundaries, grain orientations, and dislocation networks—resulting from rapid solidification under steep thermal gradients. These characteristics impart a hierarchical structure that differs significantly from conventionally manufactured materials. In this work, we compare β-Ti alloys fabricated via LPBF with those produced through traditional arc melting to understand the influence of processing on microstructure and bio-mechanical properties. Detailed microstructural characterization is conducted to trace the thermal history and solidification dynamics unique to AM. We then correlate these findings with bio-mechanical behavior. These findings advance insights into AM Ti alloys for biomedical applications.
Chor Yen Yap
Chor Yen Yap
Presentation Title
Abstract
Singapore’s national approach to additive manufacturing (AM) demonstrates how a small, resource-constrained economy can build industrial scale through orchestration rather than volume. This presentation shares the role played by the National Additive Manufacturing Innovation Cluster (NAMIC) as a national platform hosted by A*STAR, integrating strategy, funding, research translation, and industry partnership to accelerate AM adoption. Operating through a distributed network of technology translational hubs embedded in the local Institutes of Higher Learning and A*STAR, NAMIC provides funding for translation of innovations, from feasibility assessment, proof-of-concept and validation through to standards and commercialisation. Anchoring the research-to-enterprise pipeline are these technology translational hubs, which taps on the advances in materials, process control, in-situ monitoring, and qualification science and engineering. Industrial case studies illustrate how research is translated into value: wire-arc additive manufactured propellers and certification frameworks for maritime, certified aircraft parts repair and production for aerospace, patient-specific medical devices and bioresorbable implants in healthcare, and 3D concrete printing for sustainable construction. These implementations highlight how AM is enabling digitally driven manufacturing models that reduce lead times, material waste, and inventory overheads while improving customization. Looking forward, intelligent AM systems. AI-accelerated design, computational materials discovery, closed-loop process control, and data-driven certification are emerging as foundational capabilities. When combined with digital inventory and distributed manufacturing networks, these technologies enable resilient supply chains and scalable industrialisation. National competitiveness in manufacturing can be augmented by AM through systematic integration, aligning business goals, technology roadmaps, standards, talent, and data into a cohesive innovation engine.
Biography
Dr. YAP Chor Yen received his doctorate from Nanyang Technological University, Singapore in 2016. From 2016 to 2021, he joined an AM startup, Divergent Technologies, in Los Angeles where he was responsible for the development of AM processes, materials and equipment. From 2021 to 2024, he was the Assistant Director Research Engineer at COMAC BATRI. Dr. Yap has more than a decade of experience in laser powder bed fusion. Currently, he works at the National Additive Manufacturing Innovation Cluster (NAMIC), hosted by the Agency for Science, Technology and Research of Singapore (A*STAR), promoting collaboration between enterprises and research institutes on translational AM research, lowering barrier of entry on AM adoption for local industries, and enhancing Singapore’s industrial competitiveness.
