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1 f04Figure I.1 An overview of the basic components and materials used on the mos...Figure I.2 Classification of commercially available additive manufacturing m...

2 Chapter 1Figure 1.1 Overview of physical and digital links of an AM process chain.Figure 1.2 Schematic overview of functional AM components.Figure 1.3 Working schematic of the L‐PBF equipment, and functionally graded...Figure 1.4 Schematic of powder feedstock based Direct Energy Deposition (DED...Figure 1.5 Schematic of the UAM process. FBG's are high‐temperature optical ...Figure 1.6 Schematic of the hybrid metal AM process chain through sintering....

3 Chapter 2Figure 2.1 Evolution in number of research articles in materials 3D printing...Figure 2.2 Total market forecast for ceramics additive manufacturing for the...Figure 2.3 Additive manufacturing technologies as a function of the physical...Figure 2.4 Schematic representation of a LOM system.Figure 2.5 Schematic representation of extrusion‐based systems.Figure 2.6 Schematic representation of a photopolymerization‐based 3D printi...Figure 2.7 Schematic representation on a laser‐powder bed system.Figure 2.8 Schematic representation of a jetting‐powder bed system.

4 Chapter 3Figure 3.1 Schematic of a typical (a) thermal jet nozzle setup (b) FDM print...Figure 3.2 Schematic of the digital fabrication of composite strain sensors ...Figure 3.3 Schematic of the digital fabrication of CNT/SMP nanocomposites.Figure 3.4 (a) Optical images of CNT layers printed with 10, 20, 30, 40 cycl...Figure 3.5 (a) Resistance change–strain relationship of composite sensors wi...Figure 3.6 (a) Photographs of the rosette‐type strain sensor attached to tes...Figure 3.7 (a) Left: CNT/SMP composites that have (I) rectangular, (II) hemi...Figure 3.8 (a) Time‐dependent temperature of CS50 composites. (b) Steady‐sta...Figure 3.9 (a) Picture of “L”‐shaped CNT/SMP composites. (b) Snapshots of sh...Figure 3.10 Snapshots of shape recovery process and temperature distribution...

5 Chapter 4Figure 4.1 Topology optimization flowchart. FEA: Finite element analysis, MM...Figure 4.2 Sequence of design evolution of a bracket (selected snapshots). T...Figure 4.3 Overhang angle definition.Figure 4.4 Various overhang angle control approaches. (a) Limits the angle o...Figure 4.5 Overhang angle control approach based on inclusion of a simplifie...Figure 4.6 Conceptual sketches and TO results in case of three design scenar...Figure 4.7 Topology optimization of a pipe bend. (a) Design domain with inle...Figure 4.8 Topology optimization of a pipe bend. (a) Initial geometry. (b) P...Figure 4.9 Topology optimization of a pipe bend with an overhang filter. (a)...Figure 4.10 Topology optimization of a simple manifold. (a) Design domain wi...

6 Chapter 5Figure 5.1 Schematic diagram of EBM technology.Figure 5.2 Setup for fabrication of smart coupling using EPBF AM.Figure 5.3 Exploded (a) and assembled (b) schematic view of the “smart coupl...Figure 5.4 Machined alumina sensor housing used to prevent metallization of ...Figure 5.5 Smart coupling after fabrication of the metallic structure with e...Figure 5.6 Setup of compression–compression test of the smart coupling. An a...Figure 5.7 Schematic of temperature variation experiment on the smart coupli...Figure 5.8 Compression–compression cyclic testing results for three differen...Figure 5.9 Temperature values (a) occurring at the inlet of the smart coupli...Figure 5.10 Temperature comparison between the embedded sensor and the therm...Figure 5.11 XRD plots for the PZT sensor embedded in the smart‐part (darker)...

7 Chapter 6Figure 6.1 Schematic overview of the correlations between the used factors t...Figure 6.2 Deformation mechanism and SFE map of steel with 0.3 wt%C and at 2...Figure 6.3 Heat map of the investigated process parameter combinations with ...Figure 6.4 Color‐coded relative densities dependent on the different process...Figure 6.5 Actual resulting strut diameter depending on the track width comp...Figure 6.6 Block diagram showing the mean value of the grain area depending ...Figure 6.7 (a) HV 0.1 hardness map depending on the preheating temperature (...Figure 6.8 (a) Fracture surface of the tensile test samples are fracture of ...Figure 6.9 (a) Photo of the BASE and BASE+1Al at 40% compression during a la...

8 Chapter 7Figure 7.1 CAL volumetric fabrication. (a) Underlying concept: patterned ill...Figure 7.2 Performance of CAL. (a) Beer–Lambert model of light propagation t...

9 Chapter 8Figure 8.1 Schematic illustration [4] of 3D printed interdigitated microbatt...Figure 8.2 Schematic of battery preparation using a LiMn_0.21Fe_0.79PO₄‐based ...Figure 8.3 Schematics and SEM images of 3D‐printed hierarchical porous frame...Figure 8.4 Schematics and SEM images of four types of 3D‐printed hierarchica...Figure 8.5 Schematic illustration and optical images of 3D‐printed self‐supp...Figure 8.6 Schematic and SEM images of three types of 3D‐printed LFP electro...Figure 8.7 Schematic of the fabrication of 3D micro‐architected battery elec...Figure 8.8 Schematic illustration and SEM images of 3D‐printed Ni/r‐GO frame...Figure 8.9 Schematic of the 3D‐printed interdigitated LTO and LFP electrodes...Figure 8.10 SEM images of the annealed LFP/rGO electrodes.Figure 8.11 Optical images of a 3D‐printed interdigitated full cell battery ...Figure 8.12 Schematic of a process to 3D‐print solid electrolyte structures....Figure 8.13 Conceptual illustration and optical images of the 3D printing of...Figure 8.14 Three‐dimensional printed glasses with an electronic darkening L...

10 Chapter 9Figure 9.1 Charge/discharge profiles for ideal electrostatic capacitors, pse...Figure 9.2 Complete capacitor devices fabricated only by additive methods: (...Figure 9.3 Schematic overview of capacitor configurations in 2D and next‐gen...

11 Chapter 10Figure 10.1 (a) Schematic illustration of direct‐write assembly. (b) microgr...Figure 10.2 Inkjet printing. (a) Schematic illustration of the inkjet printi...Figure 10.3 The complete 14‐layer tandem stack (upper left) along with struc...Figure 10.4 Temperatures of DSC module without and with water cooling under ...Figure 10.5 (a) Schematic illustration of the external light trap. By concen...Figure 10.6 (a) A 3D‐printed compound parabolic concentrator (CPC) before an...Figure 10.7 (a) J–V characteristics of the bare solar cell (with the cage us...

12 Chapter 11Figure 11.1 (a) Scheme of a 5‐cells SOFC stack, (b) components of a SOFC sin...Figure 11.2 (a) Hybridization of SLA and robocasting technologies within the...Figure 11.3 Design of a fully 3D printed stack of Cell3Ditor project. From r...Figure 11.4 Schematics of a PEM fuel cell stack operation and components whe...Figure 11.5 Representation of the flow fields design for PEMFC inspired by t...Figure 11.6 A schematic of a microbial electrolysis cell (MEC) [114].

13 Chapter 12Figure 12.1 Characteristics of DED and LPBF processes [1].Figure 12.2 Exemplary process chains (top: repair of turbine blades, bottom:...Figure 12.3 Process chain A: defect areas (left, [6]) must be machined (midd...Figure 12.4 Defect areas are digitized by optical metrology (left). The resu...Figure 12.5 In parallel the original CAD data (left) have to be prepared (mi...Figure 12.6 With the stl file of captured data and master (left) best fit an...Figure 12.7 Volumes to be restored are deposited by using a coaxial powder n...Figure 12.8 Approaches of DED based hybrid AM [17].Figure 12.9 Position of the nozzle ring inside of the turbocharger and furth...Figure 12.10 Overview of components and additional hardware within the hybri...Figure 12.11 Influence of laser beam diameter on geometrical accuracy.Figure 12.12 Procedure of joining the top ring on top of the vanes.

14 Chapter 13Figure 13.1 (a) ZT for common TE materials as a function of working temperat...Figure 13.2 Figure 13.3 (a) Schematic illustration of fabrication of SLA 3D printed samp...Figure 13.4 (a) Schematic illustration of fabrication of 3D printed samples....

15 Chapter 14Figure 14.1 Flowsheet of a commercial CO₂ capture plant [4].Figure 14.2 Photograph of concrete absorber (left) at TCM [11].Figure 14.3 (a) Design of contactor surface [12]. (b) 3D printed sacrifi...