The present paper shows an experimental study on additive manufacturing for obtaining samples of polylactic acid (PLA). The process used for manufacturing these samples was fused deposition modeling (FDM). Little attention to the surface quality obtained in additive manufacturing processes has been paid by the research community. So, this paper aims at filling this gap. The goal of the study is the recognition of critical factors in FDM processes for reducing surface roughness. Two different types of experiments were carried out to analyze five printing parameters. The results were analyzed by means of Analysis of Variance, graphical methods, and non-parametric tests using Spearman’s ρ and Kendall’s τ correlation coefficients. The results showed how layer height and wall thickness are the most important factors for controlling surface roughness, while printing path, printing speed, and temperature showed no clear influence on surface roughness.

Today’s society is becoming aware that a new economic model of production and consumption must take into account its environmental and social impact. Industries are under increasing pressure from stakeholders to be transparent in reporting the environmental and social impacts of their operations. In this context, sustainable manufacturing must minimize negative environmental impacts and consumption of energy and natural resources, while also being socially responsible and economically viable. That is why the sustainable manufacturing concept is gaining increasing attention both in the research community and in organizations, especially in the industrial sector. However, even today, there is a great diversity of interpretations and ideas associated with this term. Accordingly, this article first presents an overview of the main concepts related to sustainable manufacturing, and metrics to evaluate organizations’ sustainability performance, and then an outlook of current trends. Our work highlights the consistencies and inconsistencies in the research community related to the interpretations of sustainable manufacturing and Industry 4.0, as well as the lack of consensus about the true social impact of Industry 4.0. However, the positive ecological and economic impacts of sustainable manufacturing seem fairly widespread. In this way, sustainable manufacturing practices seem to be reinforced by initiatives within the fourth stage of industrialization – the so-called Industry 4.0 – which offers great opportunities for sustainable manufacturing, thanks to digital transformation.

In the current paper, a methodology for the evaluation of fatigue crack shielding using 2D digital image correlation (DIC) is proposed. The crack tip shielding has been evaluated from the analysis of the displacements field observed at the vicinity of a growing fatigue crack. The proposed methodology is based on the evaluation of the stress intensity factors calculated from displacement fields measured around the crack tip using DIC. A comparative study employing four different mathematical models describing the crack tip displacements field (namely Westergaard, Williams and Muskhelishvili equations and Christopher, James and Patterson model) has been performed. For this purpose, a set of fatigue tests on aluminium 2024‐T3 compact tension specimens have been conducted at different R‐ratios. Results obtained from DIC technique have been compared with those obtained using compliance‐based methods. Results show a very good level of agreement illustrating the potential of the DIC technique for the analysis of crack shielding during fatigue crack growth.

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Incremental sheet forming (ISF) is gaining attention as a low cost prototyping and small batch production solution to obtain 3D components. In ISF, the forming force is key to define an adequate setup, avoiding damage and reducing wear, as well as to determine the energy consumption and the final shape of the part. Although there are several analytical, experimental and numerical approaches to estimate the axial forming force for metal sheets, further efforts must be done to extend the study to polymers. This work presents two procedures for predicting axial force in Single Point Incremental Forming (SPIF) of polymer sheets. Particularly, a numerical model based on the Finite Element Model (FEM), which considers a hyperelastic-plastic constitutive equation, and a simple semi-analytical model that extends the known specific energy concept used in machining. A set of experimental tests was used to validate the numerical model, and to determine the specific energy for two polymer sheets of polycarbonate (PC) and polyvinyl chloride (PVC). The approaches provide results in good agreement with additional real examples. Moreover, the numerical model is useful for accurately predicting temperature and thickness.