This article reports on work at the Center for Thermal Spray Research over the past 25 years to develop and commercialize a new technology for digital printing of mesoscale circuits directly from a CAD file onto plates, cylinders, and complex 3D components and structures. With the evolution of cold spray technology and new powder materials, as well as advancements in control and robotics, innovative thermal spray applications are on the horizon.

Advances in additive manufacturing have enabled functional grading and multi-material deposition to produce “4D printed” parts that are net or near net shape; creating highly complex features that are difficult to produce with conventional manufacturing processes. This article addresses the fundamental challenge of how to ensure that the design, manufacturing, and functional intent for 4D printed parts can be accurately and unambiguously communicated across the design, manufacturing, inspection, and supply value chain. The use case of a generic mini-gripper sheds light on the benefits that a new standard could bring to the engineering and design of shape memory materials.

This article discusses the capabilities of two software tools, one optimized for design the other for FEA, and explains how they work together to optimize airframe structures incorporating metallic and composite components.