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Abstract Directed Energy Deposition (DED) is one of the main additive manufacturing (AM) families, enabling the fabrication of multi-material parts with high material addition rates. However, the incremental nature of DED fabrication makes it prone to local defect formation due to process condition fluctuations. Known for its rapid and precise 3D surface measurement capabilities, digital fringe projection (DFP) was previously demonstrated in process monitoring for powder bed AM. This study brings DFP to the DED process through development of a custom motor stage system and validates its effectiveness in assessing surface topography and build height measurement. Measurements were taken on both correctly deposited builds and builds with off-nominal deposition conditions, where the system was able to detect pitting as small as 0.425 mm in the lateral size and 0.154 mm in depth in the case of reduced laser energy. This work paves the way for future machine learning-enabled interlayer defect identification, classification, and healing via altering subsequent processing settings. 

Fiber-reinforced composites have provided tremendous opportunities in advanced engineering materials, but the fiber generation and spatial distribution are the most challenging aspects. This paper proposes a novel fabrication approach for fiber-reinforced composites with spatially resolved fiber distribution by combining immersion and near-field electrospinning. The new Immersed Electrohydrodynamic Direct-writing (I-EHD) process makes use of an electrostatic force to draw ultrafine fibers and allows the freestanding of electrospun fibers all inside a liquid matrix. This novel approach enables the dynamic control of fiber morphology and 3D spatial distribution inside the composites, which may lead to future scalable 3D printing of multifunctional composites. 

Electrochemical sensors have become a pivotal tool in ensuring the safety and security of the global food supply chain, which is crucial for public health, economic stability, and environmental sustainability. Modern food systems, with their complex global distribution and varied processing methods, require advanced solutions for detecting contaminants and maintaining food quality. This review delves into recent advancements in electrochemical food sensor technology, highlighting their operating principles, types, cutting-edge materials, and methods enhancing their effectiveness. These sensors are adept at identifying a broad range of foodborne pathogens, chemical contaminants, and adulterants while monitoring food freshness and quality. Innovations include using nanomaterials and conductive polymers and shifting towards miniaturized, portable devices for on-site and real-time analysis. The review also addresses challenges such as sensitivity, selectivity, and matrix effects, pointing out emerging trends and future research avenues to overcome these hurdles. Regulatory and standardization issues relevant to adopting these technologies in food safety protocols are also considered. Highlighting the last three years, this review emphasizes the indispensable role of electrochemical sensors in boosting food safety and security and the need for ongoing innovation and cross-disciplinary cooperation to advance this area.