TABLE OF CONTENTS
Proceedings of the 36th Annual International
SOLID FREEFORM FABRICATION SYMPOSIUM 2025
– An Additive Manufacturing Conference –
August 10-13, 2025
AT&T Hotel and Conference Center • Austin, Texas, USA
SFF Topics covered in the Symposium include:
AM of Composites Applications
Data, Economics, and Education Materials
Modeling Process Development
Special Sessions
Edited by: David K. Leigh Desiderio Kovar Michael Cullinan Zhenghui Sha Maryam Tilton Matthew Jones
TABLE OF CONTENTS
Proceedings of the 36th Annual International SOLID FREEFORM FABRICATION SYMPOSIUM 2025
– An Additive Manufacturing Conference –
Development of a PDMS Tissue Chip and Media Circulation System for Xiphophorus Biomedical Research
Using Additive Manufacturing 2
Md. Sakif Uddin Khan, Swarnali Deb Bristi, Pratik Paudel, Noah Richardson, Junior Segura-Ontiveros, Kira Smith, Yuan Lu, and Bahram Asiabanpour
Beyond the Solid Raft: Geometric Strategies to Prevent Build Plate Bowing in CuCrZr L-PBF 14
Andrei-Alexandru Popa, Andrew Seltzman, Sebastian Leon Lasowy, Erick Liang, and F. N. Depboylu
Design and Fabrication of a C-Shaped Oscillating Heat Pipe with Integrated Heat Sink via Laser Powder Bed Fusion 25
Ishfaqur Rahman and Scott Thompson
Design, Manufacture and Testing of Structural Trusses Using Additively Manufactured Polymer Composites 31
Tyler Godfrey, David Hardt, A.J. Perez, Kenan Sehnawi, and Arjun Chandar
Enhancing Juvenile Xiphophorus Fish Survival: Modular, Bio-Inspired Habitat Design Using MEX
Md. Sakif Uddin Khan, Swarnali Deb Bristi, S.M. Sirazam Sadekin, Pratik Paudel, and Bahram Asiabanpour
Route Your Ooze (RYO) Drive: A New Way to Route Flexible Filament in 3D Printing with Motion-Decoupled Rolling Joints 64
Ryo Takei, Brett Emery, Albert Lin, Jacob Miske, Jeffrey I. Lipton, and John P. Whitney
Slit Accuracy of Thin Walls in Laser Powder Bed Fusion 76
B. Johnstone, C. Saldana, and K. Saleeby
Applications: Lattices and Cellular
Additive Manufacturing of Bio-inspired Design Elements for Lightweighting 90
Shivani Pandit, Salil Bapat, and Ajay P. Malshe
Compression, Shear, and Flexural Durability of Viscous Thread Printed (VTP) Foams Produced from Thermoplastic Polyurethane for Consumer Goods 105
Jacob N. Miske, Brett A. Emery, Keith A. Brown, and Jeffrey I. Lipton
A. Prey, N. Giusti, Z. Okun, Y. Mistry, and D. Bhate
Evaluating the Performance of Novel Tpms-Based Acoustic Liner Designs Suitable for Additive Manufacturing 142
Alden Packer, C. Aaron Reimann, Julian Winkler, Kenji Homma, Jeffrey Mendoza, Eric Greenwood, Michael Manahan, and Nicholas Meisel
Identification of Stochastic Manufacturing Defects within Additively Manufactured Acoustic Liners 161
Joseph Windows, Alden Packer, Eric Nelson, Jeffrey Chowaniec, Jr., Jeffrey Mendoza, C. Aaron Reimann, Julian Winkler, Kenji Homma, and Nicholas Meisel
Machine-Learning-Based Inverse Design of Multi-Material Curved Lattice Structures 181
Xiaochen Yu and Ajit Panesar
Shape Optimization and Sensitivity Analysis for Triply Periodic Minimal Surface Lattice Structures Under Periodic Boundary Conditions 190
Chongyi Wei and Douglas E. Smith
Applications: Topology Optimization
Generative Adversarial Networks for Topology Optimization with Orientation 205
Nathan Hertlein and Joseph Kubalak
Mechanical Performance and Weight Reduction of Additively Manufactured Titanium Bolts Aimed for Supply Chain Resiliency of Critical Material 218
Henrik Neibig, Salil Bapat, and Ajay P. Malshe
Materials: Ceramics and Glasses
Laser Powder Bed Fusion of Reaction-Bonded Silicon Carbide: Process Advancements 233
W. Declercq, S. Meyers, J. Vleugels, and B. Van Hooreweder
Additive Manufacturing of Copolyamide-Modified Magnetic Composites for High-Temperature Bonded Magnets 252
Pratik U. Karkhanis , Oluwasola K. Arigbabowo, Everest Sweet, Andrew Luis Geise, Oleksandr Syzov, Lorenzo Williams, and Jitendra S. Tate
Microstructure-Driven Fracture Behavior and Thermo-Mechanical Analysis of Large Area Additive Manufactured Short Fiber Composites 273
Douglas E. Smith, Arief Yudhanto, and Neshat Sayah
Aywan Das and Chad E. Duty
Silicon Carbide Nanoparticle-Filled Nanocomposites Using SLA Resin for Low Thermal Expansions 303
Muhammad Sufian, Juan Rodriguez, Kam Brown, and Jitendra Tate
Additive Manufacturing of Multi-Material Parts Using PBF-LB-Enabling New Material Combinations 328
Constantin Jugert, Maja Lehmann, Georg Schlick, and Wolfram Volk
Assessing Cross-Equivalency in Terms of Part Structure on Different L-PBF Systems 346
Mikyle Paul, Erfan Maleki, Shuai Shao, Nima Shamsaei
Assessing the Reproducibility of IN718 Parts on Similar L-PBF Systems Through Mechanical Properties
Mikyle Paul, Indrajit Nandi, Shuai Shao, and Nima Shamsaei
Controlled Residual Stress Evolution in LPBF 316SS Through Interlayer Shot Peening 381
Claire Soller, Aidan Pierce, Adam Walker, Bella Barney, Jackson Emerson, Sivasubramanian Chandramouli, Rajeshree Varma, and Michael P. Sealy
by Dual-Laser Powder Bed Fusion 393
Ishfaqur Rahman and Scott Thompson
A1000-RAM10 Aluminum Alloy 401
Md. Faysal Khan, Reza Ghiaasiaan, Paul R. Gradl, Shuai Shao, and Nima Shamsaei
Effect of Part Geometry on the Temperature-Dependent Tensile Behavior of LP-DED A6061-RAM2 Aluminum Alloy 411
Md. Faysal Khan, Paul R. Gradl, Shuai Shao, and Nima Shamsaei
Effects of Process Induced Differences in Power Bed Feedstock Particle Size Distribution for Processability and Quality In PBF-LB/M 421
N.A. Pielczyk, J. Mireles, and R.B. Wicker
Effects of Machine-to-Machine Variability on the Tensile Behavior of L-PBF Ti-6Al-4V 435
Mikyle Paul, Shaikha Shohuda Tuktuk, Matthew T. Lowney, Shuai Shao, and Nima Shamsaei
Investigation of the Surface Roughness of Micromilled 316L Stainless Steel Fabricated by FDM/FFF Technology 449
Suleiman Obeidat, Jacob Nicholas, Jhoana Alfaro, Syed Faruqui, and Iftekhar Basith
Location-Based Structure-Property Relationships of Laser Powder Bed Fusion(L-PBF) Inconel 718 Parts 460
Prudhvi Raj Pola, Kaustubh Deshmukh, Prahalada Rao, and Ranji Vaidyanathan
Microstructure and Mechanical Properties of Bulk EB-PBF Fabricated Gamma-TiAl: Post-HIP and
S.T. Nabil, K.I. Watanabe, and F. Medina
Predicting LPBF Ti-6Al-4V Microstructure via Multi-Modal In-Situ Process Monitoring 489
Ankita Roy, Dana Drake, Rajiv Mishra, Yash Parikh
Role of Defect Interaction and Multi-Site Damage in Fatigue Life of Additively Manufactured Metals 497
Seyedmostafa Nasrollahpourshirvani and Aref Yadollahi
Room Temperature Mechanical Behavior of Monel K500 Alloy Fabricated via L-PBF and LP-DED 508
Indrajit Nandi, Paul R. Gradl, Colton Katsarelis, Shuai Shao, and Nima Shamsaei
Stress-Corrosion Behavior of Magnesium Alloy AZ91 Manufactured by Laser Powder Bed Fusion 517
Chelsea O’Donnell, Alejandro Avila, Bradley Kauffman, Adrian Passinger, Robert Stewart,
David Scott Fernander, Dina Khattab, Michael Titus, and Michael P. Sealy
Study of Fatigue Endurance on Artificially Aged Additive Manufactured AlSi10Mg After Stress Relived and Hot Isostatic Pressed + T6 529
L.A. Barrera, F. Medina, E. Arrieta. and L. Marquez
Understanding the Effect of Retained Austenite on Mechanical Properties of Additive Manufactured
1.2709 Grade Maraging Steel 546
Johny Varghese, Robert Brandt, Tim Robert Brocksieper, Jan T. Sehrt, Koteswararao V. Rajulapati, and K. Nandakishore
Vinay Kenny, Salil Bapat, and Ajay Malshe
Use of In-Situ Thermography to Study Scan Strategy for Laser Foil Printing of Metallic Glass 567
Hung-Chu Chiang, Sung-Heng Wu, Chia-Hung Hung, and Ming C. Leu
Effect of Filler Size on Porosity of Porous Parts Obtained via PBF-LB/P and Filler Dissolution 589
Koichi Fujii, Takashi Kigure, Ryuichi Kobayashi, and Yuki Yamauchi
Yuki Yamauchi, Koichi Fujii, Takashi Kigure, Yuki Asano
Estimating Radiative Properties in Porous Medium Using Micro-Scaled Additive Manufacturing and
Farhin Tabassum and Shima Hajimirza
Exploring the Functional Performance of a Commercial High-Temperature Photopolymer Resin for Vat
Photopolymerized Injection Molding Tools 623
Haley W. Jones, Andrew P. Rhodes, Anastasia Mullins, and Camden A. Chatham
Impact of Layer Orientation on Radio Frequency Dielectric Properties of Fused Filament Fabricated ULTEM 9085 635
Carson Rogers, Jutima Simsiriwong, Juan Aceros, and Daniel Santavicca
Innovative Gaseous Treatment and Foam Extrusion System for Large-Scale Additive Manufacturing Applications 649
A.L H.S. Detry, A.A. Perez, A.S. Chandar, P. Arroyo, A. Duncan, D.K. Keller, and S. Cotton
Mechanical Performance and Internal Porosity of 3D Printed PLA Across Varying Parameters 666
Roman Chavez, Nathan Nevarez, Fidel Baez Avila, and Borys Drach
Photoelastic Visualization of Residual Stresses in PLA After Interlayer Shot Peening During Fused
Christian Sosa, Lila Johnson, Melanie Charron, Noah Brinker, Noah Stenberg, Elena Parial, Langdon Feltner, Paul Mort, and Michael P. Sealy
A Parametric Workflow for Brazing-Ready, Self-Supporting Metal AM Components with Recoverable Features 698
Andrei-Alexandru Popa and Fatma Nur Depboylu
Characterisation of Geometric Fidelity as a Function of Attenuation in Tomographic Volumetric
N. Pellizzon and J. Spangenberg
Convolutional Neural Network Approach for Predicting Melt Pool Dimensions in Laser Powder Bed Fusion Process 717
Oluwapelumi O. Adejumo, Nayan Pundhir, K. Chandrashekhara, Heath Misak, and Cesar O. Rios
Effects of Hatch Distance and Spray Pattern on Film Morphology in Micro-Cold Spray 729
Ronnie F. P. Stone, Arun Ruhfus, Minh Le, Emmanuel Ekoi, Desiderio Kovar, and Zhenghui Sha
Nayan Pundhir, Oluwapelumi O. Adejumo, K. Chandrashekhara, and Joseph W. Newkirk
Topology and Toolpath Optimization-Inspired Toolpath Planning for Continuous Fiber Material Extrusion 759
Joseph R. Kubalak
Towards Parametric Design for Additive Manufacturing of Coral Structures Using a Digital Twin Approach 778
Z. Okun, Y. Mistry, and D. Bhate
A FE Based Global-Submodel Simulation Approach for Shape Compensation and Predicting Failure in Metal Parts Fabricated by Laser Powder Bed Fusion 790
Kaushik Das, Hongqing Sun, Geng Yun, Enqiang Lin, Reza Yavari, Anton Salem, Syed Zia Uddin, Nicholas Lajoie, Jack Jenny, and Joseph Petsinger
A Machine Learning Model to Predict Mechanical Property of Directed Energy Deposition Processed
Atiqur Rahman, Md. Hazrat Ali, Muhammad Arif Mahmood, Asad Waqar Malik, and Frank Liou
Application of Scientific Machine Learning Techniques to Metal Additive Manufacturing Simulation: A Comparison Between Physics-Informed Neural Networks and Extended Physics-Informed Neural Networks 823
Bohan Peng and Ajit Panesar
Computational Fluid Dynamics Modeling and Experimental Analysis of Rapid Curing in 3D Printing for Structural Applications 840
Daniel Helmuth Meile, Carl Emil Hansen Thor, Yohan Jacquet, Md. Tusher Mollah, Berin Šeta, and Jon Spangenberg
Computational Fluid Dynamics Modeling of Sequential Multi-Material Extrusion Additive Manufacturing 852
Daniel Helmuth Meile, Carl Emil Hansen Thor, Yohan Jacquet, Md. Tusher Mollah, Berin Šeta, and Jon Spangenberg
Conditional Variational Autoencoder Method Framework for Geometric-Constrained, Nonlinear Property-Driven Composite Microstructure Design 864
Jay O. Yen, Denis Molchanov, Zhangxian Yuan, and Lin Cheng
Effect of Build Parameters on Mechanical Properties and Residual Stresses of LP-DED Inconel 718
Angel F. Bravo, Kurtis Watanabe, Kevin Wheeler, Vasyl Haffychuk, Paul Gradl, Colton Katsarelis, Francisco Medina, and Edel Arrieta
Numerical Analysis of Pre- and Post-Heating Strategies for Reducing Residual Stresses in Laser-Based Directed Energy Deposition 888
Usman Tariq, Sung-Heng Wu, Muhammad Arif Mahmood, Frank Liou
Numerical Modeling of Thermal Predictions in Wire-Arc Additive Manufacturing for Online Implementations 909
Kathryn Kelly, Andrew Hill, Christopher Saldaña, and Kyle Saleeby
Predicting Microstructure Properties Using Transfer Learning for Microscale Selective Laser Sintering (μ-SLS) 922
Farzana Tasnim, Joshua Grose, Nathan F. Sheu, Remi Dingreville, and Michael Cullinan
Qualification of Laser-Based Powder Bed Fusion of Metals (PBF-LB/M) Using Scanner Data 943
Jesus Rivas, Jorge Mireles, and Francisco Medina
Ryan Delaney, Catherine B. Ashley, Andrew Killian, and Nicholas Meisel
Federated Learning for Defect Detection in Additive Manufacturing: Mitigating Label-Flipping Attacks in Distributed Factories 977
Md. Sazol Ahmmed , Sriram Praneeth Isanaka , Sung-Heng Wu , Atiqur Rahman , Muhammad Arif Mahmood , and Frank Liou
3D Printing of Small and Irregular 316l Powder Through a Novel Slurry-Based LPBF Technique 1001
M. Sinée, M. Sinico, S. Meyers, Y. Kinds, and B. Van Hooreweder
Powder Bed Fusion Systems 1014
D.D. Borup, C.J. Elkins, J. Mireles, H.H. Estrada, and R. Wicker
Accurate Alignment of Metal Binder Jetted Part Assemblies 1027
Jeremy Cook, David Hayes, Richard Vanfleet, Brian D. Jensen, Nathan B. Crane, and Robert C. Davis
Blockchain-Enabled Cybersecurity for Additive Manufacturing: A Framework for Data Integrity and Traceability 1035
Laraib Khan, Muhammad Arif Mahmood, Todd Sparks, and Frank Liou
Correlation of Process Parameters and Layer Characteristics in High-Speed Directed Energy Deposition using Optical Coherence Tomography 1047
H. Wexel, C. Krull, P. Gajek, S. Maffia, T. Stittgen, S. Koß, J. Schleifenbaum, and F. Zanger
Data-Driven Part Quality Analysis and Prediction in Cooperative 3D Printing 1061
Anuj Swaminathan and Zhenghui Sha
Development of a Novel ShL AM Process for Deployable and Metamaterial Devices 1092
H.H. Waites, C.P. Meyer, A.B. Wengreen, J.M. Hancey, T.R. Stevens, and N.B. Crane
Heterogeneity and Distortion in Shelled Binder Jet Geometries in Green and Sintered Parts 1105
Madi Lawrence and Nathan B. Crane
Hybrid Sensor in the Loop Approach for Generating Synthetic Event Imager Data of Melt Pool Dynamics 1123
Anthony Starleaf, Aidan Gribble, Nicholas Bruns, David Mascareñas, Mahtab Heydari, and Bruce Tai
Hybridization of Commercial Directed Energy Deposition System for In-Situ Repair of Parts 1139
Juan Pablo Garcia Chavira, Angel Bravo, Jason McCleary, Kurtis Watanabe, and Francisco Medina
Increased Spatial Resolution with a Single Nozzle in Fused Filament Fabrication Through Controlled Distributions and Volume Fractions of Soluble and Insoluble Materials Including Formation of Functionally Graded Lattices 1146
I.A. Rybak, J.W. McKee, and J.T. Green
Influence of Bead Width and Layer Time on the Interlayer Bonding of Large-Format Printed Polymer Composites 1162
Tyler Corum, Maximilian Heres, Jeff Foote, and Chad Duty
In-Situ Determination of Powder-Laser Focus Overlap in High-Speed DED Using Multispectral Emission Analysis 1170
Patrick Gajek, Helena Wexel, and Frederik Zanger
Rakin Ahmed, Tanvir Ahmed Shanto, Md. Mahmudur Rahman, Robert M Taylor, and Ankur Jain
T. Mertens, Y. Kinds, B. Vrancken, B. Van Hooreweder
Carl Sander Kruse, Nicole Pellizzon, Roozbeh Salajeghe, Jon Spangenberg, Frieder Lucklum, and Aminul Islam
Evaluation of FPGA-Based Track-Wise Process Quality Monitoring for Laser Powder Bed Fusion 1228
Chen-Wei Yang, Gisuk Hong, Yang Zhuo, Yan Lu, Shengyen Li, and Haw-Ching Yang
Rheology-Informed Mixture Engineering of Aggregates for Extrusion Additive Manufacturing 1245
S.U.M. Rabbi Hossain, Timothy Moore, and Philip King
Kaya J. Bayazitoglu, Joseph J. Beaman, James Ottaway, Joseph Dodd, Halley Harvey, Carrigan Braun, Chris Corey, and Arthur Paolella
Special Session: Big Data Analytics
Data-Efficient Design of Multistable, Robust Structures for Additive Manufacturing Using Bayesian Optimization 1277
Zihan Li, Moneef Mohamed Elobaid Musa, Andrea N. Camacho-Betancourt, Anna E. Jaeger, Krista L. Boaz, Han Liu, Simon Laflamme, Thomas W. Secord, Ayodele Iyanalu, Rob Whitehead, Iris V. Rivero, and Minhee Kim
Profiles in Solid Freeform Fabrication of Functionally Graded Materials Using Maxel (Material Voxel) Framework 1288
Bharat Dwivedi and Arihant Panwar
Machine Learning Based Evaluation of Surface Roughness of Additively-Manufactured Nylon 12 Surgical Guides 1296
A. Pressly, J. Simsiriwong, and G. May
Special Session: Defense Manufacturing
Additive Manufacturing of Embedded Passive Electronic Components 1323
Ariful Islam, Md. Shahriar Forhad, Jianzhi Li, and Farid Ahmed
Anomaly Detection in UR5 Robots Using Reinforcement Learning for Smart Manufacturing 1342
Messaoudi Salma, Kenneth Duran, Esequiel Garcia, Md. Shahriar Forhad, Ahmed Bendaouia, El Hassan Abdelwahed, and Jianzhi Li
Enhancing Deposition Rates in Additive Friction Stir Deposition: A Comprehensive Review 1359
Lewis Bediako Ansah, Ahmed Bendaouia, Monsuru Ramoni, and Jianzhi Li
Marcos Flores, Ahmed Bendaouia, Monsuru Ramoni, and Jianzhi Li
Review on Atomization of Metals 1389
Forrest Orozco, Noah McCoy, Jianzhi Li, Monsuru Ramoni, and Ahmed Bendaouia
Special Session: Feedforward and Feedback Control in AM
Control for Part Qualification 1411
Yash Parikh, Yasham Mundada, and Ankita Roy
Real Time Measurement System for Digital Glass Shaping Processes 1420
Matthew Morgan, Balark Tiwari, Cindy Huang, Nudrat Nawal, Nishan Khadka, Edward C. Kinzel, and Robert G. Landers
Real Time Vision-Based Morphology Tracking of Glass Additive Manufacturing Processes 1439
Cindy S. Huang, Balark Tiwari, Matthew D. Morgan, Edward C. Kinzel, and Robert G. Landers
Lucky Ekene Bernard, Kareem Chaar, Chukwuzubelu Okenwa Ufodike, and Gaius Chukwuka Nzebuka
Special Session: Metal Jetting and Droplet Deposition Processes
Dimensional Accuracy of 17-4 PH SS Geometric Features Fabricated Using L-PBF and MBJ Technologies 1483
Indrajit Nandi, Quentin Charron, Paul R. Gradl, Guillaume Mohara, Benoit Verquin, Shuai Shao, and Nima Shamsaei
Special Session: Multi-Axis and Robotic Enabled Additive Manufacturing
Bharat Dwivedi, Arun Skanda Rebbapragada, and Arka Rebbapragada
DamageEst: Accurate Estimation of Damage for Repair Using Additive Manufacturing
Patrick Gambill, Devesh K. Jha, Bala Krishnamoorthy, Arvind Raghunathan, and William S. Yerazunis
Special Session: Wire-Fed AM/Wire-Fed Directed Energy Deposition
Contour Toolpath Planning with Limits on Bead Width Constraints in WAAM 1528
Wei Sheng Lim, Siddharth Ganesh, and Gim Song Soh
Robotic Wire Arc DED (Directed Energy Deposition) of 316 l Stainless Steel Preform for Forging Preforms 1543
Stibitz Christin, Stevens Hill, Jared Seals, Hossein Taheri, and Bishal Silwal
Monitoring of Wire-Arc DED 1558
Charlotte Thompson, Reid Schaff, J. Logan Betts, and Matthew W. Priddy
The Effects of Gravity on Track Integrity During Collaborative Robot-Assisted Wire Arc Additive Manufacturing 1573
Mohammad Arjomandi, Quang Ngo, and Tuhin Mukherjee