2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026): Defense Manufacturing II
Program Organizers: David Leigh, University of Texas at Austin
Wednesday 8:00 AM
August 5, 2026
Room: Zlotnick Ballroom 1
Location: AT&T Center
8:00 AM
AI-Driven Robotic Forming of Sheet Metals: A Smart Manufacturing Approach for Defense Applications: Kenneth Duran1; MD Tusher Ahmed1; Ahmed Bendaouia1; Jianzhi Li1; 1University of Texas Rio Grande Valley
Modern day defense applications demand lightweight, rapidly manufacturable, and highly customizable structures; however, conventional forming methods for thin metallic components remain slow, tooling-intensive, and highly dependent on trial-and-error process optimization. One of the greatest challenges in sheet metal forming is Springback, the elastic recovery of the material after unloading, which causes the final geometry to deviate significantly from the intended shape. Springback remains difficult to predict analytically. This project presents a simulation and machine learning driven robotic forming framework for intelligent sheet metal shaping aimed at next-generation drone manufacturing. A high-throughput computational pipeline based on PyMAPDL, a platform to efficiently automate ANSYS Mechanical finite element simulation (FEA), will be developed to automate large-scale three-point bending simulations across a wide parametric design space. By combining physics-based finite element simulations with data-driven intelligence, this work seeks to accelerate agile defense manufacturing and advance autonomous forming technologies for aerospace applications.
8:20 AM
Laser Powder Bed Fusion Additive Manufacturing of AlSi7Mg/MoB Metal Matrix Composite: Abdalla Elmaghraby1; AMM Nazmul Ahsan1; Jianzhi Li1; 1University of Texas Rio Grande Valley
Aluminum alloys are widely used owing to their high strength-to-weight ratio, high thermal and electrical conductivity, and inherent ductility derived from their face-centered cubic crystal structure. However, their performance under harsh operating conditions remains limited. This study investigates the effect of MoB ceramic particles on the laser powder bed fusion (LPBF) additive manufacturing of AlSi7Mg alloy metal matrix composites (MMCs). MoB ceramic particles with a size of 1-5 μm were mixed with pre-alloyed AlSi7Mg powder using a tumbler mixer. Both pure AlSi7Mg and AlSi7Mg/MoB MMC specimens were fabricated with LPBF. The as-printed AlSi7Mg/MoB exhibited superior mechanical properties and wear resistance compared to the as-printed pure AlSi7Mg. These findings highlight the potential of MoB-reinforced MMCs processed via LPBF to advance the performance of aluminum alloy components in defense, aerospace, and automotive applications.
8:40 AM
Feedstock-Based Tungsten Modification of LPBF IN718 for High-Temperature Manufacturing Applications: Santosh Rauniyar1; Mathew Farias1; Ben Xu1; 1University of Houston
Laser powder bed fusion (LPBF) enables rapid production of high-performance Ni-based superalloy components for defense manufacturing applications requiring elevated-temperature strength, material adaptability, and accelerated alloy development. This study investigates tungsten (W) feedstock modification of IN718 powders prepared through powder mixing and mechanical alloying routes to expand the compositional design space of LPBF superalloys. W-modified IN718 powders with varying W contents were processed under selected LPBF parameters, and fabricated specimens were evaluated for processability, surface characteristics, melt pool stability, microstructural evolution, and tensile performance at room temperature and approximately 600°C. Results show that both W content and feedstock preparation route influence LPBF response, surface condition, and microstructural features, producing measurable effects on elevated-temperature mechanical behavior. This work demonstrates refractory-element feedstock modification as a practical strategy for tailoring established superalloy powders for defense-relevant propulsion, structural, and thermal-management applications operating in demanding high-temperature environments.
9:00 AM
Rapid Changeover in Metal Additive Manufacturing:
A Case for Applying SMED Methodology to Laser Powder Bed Fusion: Chetan Shukla1; F. Frank Chen1; 1University of Texas at San Antonio
Laser Powder Bed Fusion (LPBF) is an established metal additive manufacturing process that enables the production of complex, high-value components. As adoption scales from prototyping to production, attention is shifting toward operational optimization. Current LPBF workflow contains a substantial volume of non-productive time embedded in pre-build preparation, inter-build transitions, material handling, inert atmosphere purging, build platform exchange, and post-process handoffs. Single Minute Exchange of Dies (SMED), or Rapid Changeover, foundational to the Toyota Production System, provides a systematic methodology for dramatically reducing changeover and setup time. SMED implementations across conventional manufacturing consistently achieve 50–90% reductions in setup time, enabling smaller batch sizes, higher machine availability, and greater scheduling flexibility. A systematic review of literature reveals no published study that explicitly applies SMED or rapid changeover methodology to LPBF or any powder bed fusion process. Our presentation will focus on findings from our assessment of opportunities and potential solutions.
9:20 AM
Thermal Simulation of WAAM Inconel 718 for Heat Accumulation and Process Stability: Anamol Thapa1; Mathew Farias1; Ben Xu1; 1University of Houston
Wire arc additive manufacturing (WAAM) is useful for producing large metallic components, but repeated heating and cooling can lead to heat accumulation, uneven thermal history, residual stress, and distortion. This study develops a three-dimensional finite element thermal model for WAAM of Inconel 718 (IN718). A moving heat source and temperature-dependent material properties are used to simulate multilayer deposition. The effects of travel speed, heat input, and interlayer dwell time are evaluated through peak temperature, interpass temperature, cooling rate, and thermal gradient. These thermal responses are discussed in relation to process stability and distortion risk. The study provides a practical simulation framework for understanding how WAAM parameters influence thermal history during IN718 deposition and can support improved parameter selection for more stable WAAM fabrication.
9:40 AM Break
10:00 AM
Case Studies on Information Encoding and Decoding Via Additive Manufacturing and Nondestructive Evaluation: Audrey DeKoninck1; Jessie Skidmore1; Andrea Best1; Partha Pandit1; Jitesh Panchal1; Luz Sotelo1; 1Purdue University
Information embedding techniques address security, counterfeiting, and intellectual property concerns by storing secure information inside of parts, but they require reliable information retrieval methods. This research proposes and discusses the feasibility of information embedding schemes that implement nondestructive evaluation methods to decode the information via two case studies. In both cases, binary geometries are encoded by varying printing parameters in fused filament fabrication (FFF) polylactic acid (PLA) samples. One case study emphasizes geometric precision, while the other focuses on sensitivity to print parameter variations. The information is retrieved with both X-ray computed tomography (CT) and ultrasonic imaging, highlighting the capabilities of each modality, their tradeoffs, and their combined use potential. The results demonstrate the viability of these information embedding and retrieval methods and lay the groundwork for their further development.
10:30 AM
ChainAM: A Distributed Trust Framework for Secure Additive Manufacturing File Exchange: Laraib Khan1; Frank Liou1; Todd Sparks2; 1Missouri University of Science and Technology; 2Product Innovation and Engineering (PINE) LLC
Additive manufacturing (AM) systems increasingly depend on distributed digital workflows where CAD models, process parameters, and manufacturing instructions are exchanged among designers, suppliers, and production facilities. However, the transmission of AM files across distributed networks introduces cybersecurity and data management challenges, including unauthorized changes to files, intellectual property (IP) theft, data tampering, lack of traceability, and insecure access controls. To address these challenges, this paper proposes a blockchain-enabled secure file-sharing framework combining Git, IPFS, and Hyperledger Fabric (HLF). Git manages file versioning and commit metadata, while IPFS provides decentralized content-addressed storage for AM files via unique content identifiers (CIDs). Hyperledger Fabric creates a permissioned blockchain layer for immutable logging, identity verification, and access control using Fabric CA/MSP and chaincodes. The proposed framework enables secure file registration, controlled data sharing, integrity verification, and traceable relationships among distributed manufacturing organizations, thereby improving cybersecurity, transparency, and data integrity in AM environments.
10:50 AM
Convergent Hammer AM: Forrest Orozco1; Jianzhi Li1; 1UTRGV
Mechanical properties of Additive Manufactured (AM) printed metal parts can have issues affecting their structural integrity and porosity. A separate forging process is needed. With the complexities of some AM parts applications, it is difficult to forge the small or intertwined components of a print without damaging or having it split into multiple parts. A solution is to add a hardening process that works in sync with a Laser Direct Energy (LDED)AM. A process that will be able to harden a part or select areas to user preference. This will occur when a “hammering” effect will be done on a printed part which will decrease the porosity, decrease the height of the print bands, and could potentially work harden the material. The effects of the hits per second, force/pressure applied to the material, and other factors will be explored with the testing of the Impact Crank Hammer (ICH).
11:10 AM
Study of Screw-Based Printing Using ABS Carbon Fiber on Planar and Non-Planer Surfaces: Daniel Ramos1; 1University of Texas Rio Grande Valley
Additive manufacturing continues to evolve through the development of screw-based extrusion systems capable of processing pellet based refined thermoplastic material with improved deposition control and material throughput. Among these materials, acrylonitrile butadiene styrene reinforced with carbon fiber (ABS-CF) has gained attention due to its enhanced mechanical strength, thermal resistance, and lightweight properties. However, limited research exists regarding the behavior of screw-based printing systems when depositing ABS-CF on non-planar or angled printing surfaces. The objective of this study is to investigate the print quality, material flow behavior, and dimensional consistency of screw-based extrusion printing using ABS-CF on both planar and angled surfaces. The research evaluates how surface orientation affects layer adhesion, extrusion stability, and geometric accuracy during the printing process. Experimental testing is conducted using a screw-driven extrusion additive manufacturing setup with controlled print parameters including nozzle temperature, extrusion rate, and print angle
11:30 AM Panel Discussion