A novel, temperature‐controlled post‐consolidation unit is developed to test its potential to improve the melt impregnation process used to manufacture continuous fiber‐reinforced filaments for additive manufacturing of high‐performance thermoplastics. Preliminary laboratory characterizations have identified Hexcel HexTow AS7 and Arkema Kepstan 6004 as suitable dry carbon‐fiber roving and thermoplastic matrix material, respectively. Filaments are processed by melt impregnation with varying parameters (e.g., different temperatures), as well as with and without the post‐consolidation unit. A thermographic camera is used to monitor the process and observe the temperature distribution of the filament during post‐consolidation. The filament quality is determined by a 3‐axis measurement device (filament diameter), micrographs, and X‐ray microscopy. The test results show that the temperature of the filament drops below the glass transition temperature over a production length of less than 100 mm when cooled by air. Using the post‐consolidation unit keeps the filament above the glass transition temperature of the matrix (160 °C) for a production length of 550 mm, allowing compaction by the integrated grooved rollers. The test results show that post‐consolidation reduces defects, improves the roundness of the filament cross‐section, and minimizes diameter variation.

Thermomechanical Metamaterials The cold spray technique, primarily meant for component repair applications, preserves the original material properties owing to non-melting, producing dense, well-adhered coatings with minimal oxidation or thermal distortion. The image illustrates the powder metals being deposited on the substrate from a spray gun, with a magnified inset showing the jetting behavior of individual particle during high-energy impact. The orientation maps of the powders in-flight and after coating, highlights the microstructural evolution in each impacted particle viz-a viz the whole coating. More information can be found in the Research Article by Malar Vadani, Sabeur Msolli, Ayan Bhowmik, and co-workers (10.1002/adem.202501848).

Piezoresistive sensors are crucial for strain monitoring but often suffer from rigidity and susceptibility to failure under large deformations. Auxetic materials, characterized by a negative Poisson's ratio, offer a promising solution by enabling sensors with enhanced flexibility, sensitivity, and stretchability. This study investigates the effects of curvature on two auxetic structures: re‐entrant and s‐shape lattices. These structures are designed with varying curvature, simulated under uniaxial tension, and experimentally are tested using photoelasticity and image processing. Results indicate that curvature influences auxetic behavior, stress concentration, and overall stretchability. The re‐entrant s‐shape hybrid honeycomb (RSHH) and reduced curve re‐entrant hybrid honeycomb (RCRSHH) exhibit maximum stretchability (≈56 mm), outperforming conventional auxetic structures. While RCRSHH achieves 200% linear deformation and distributes stress more uniformly, it shows diminished auxeticity. Finite element analysis using Ogden hyperelastic modeling successfully captures experimental trends. This study bridges the gap in auxetic material research by exploring curvature‐driven enhancements in structural performance. The findings offer new insights into optimizing stretchable sensors, with potential applications in aerospace, medical devices, and flexible electronics, where materials must sustain extreme deformations while maintaining structural integrity.

This work presents a novel method for producing metal matrix nanocomposite powders using an in situ precipitation technique. As a proof‐of‐concept, TiN nanoparticles are synthesized directly on the surface of FeTi intermetallic powder particles (d 90 < 8.0 μm) through plasma‐assisted nitriding treatment. An equipment is specially designed to enable the movement of powder particles under a controlled 33%H 2 + 67%N 2 atmosphere in a rotating drum anode placed around a hollow‐cathode discharge producing the nitrogen reactive species. Plasma operating parameters are fixed at −650 V (cathode potential) and 1.5 Torr (gas pressure), and the treatments are carried out at 550 °C for 4 h. Treated particles’ surface analysis indicated the formation of TiN spherical nanoparticles distributed all over the particle. In addition to the TiN phase, the diffractograms showed the formation of the α‐Fe (ferrite). The presence of N in the samples, as well as the chemical bond between Ti and N, is measured by X‐ray photoelectron spectroscopy (XPS) analysis. The results demonstrated the feasibility of producing nitride‐reinforced nanocomposite powders through an in situ technique using a new plasma‐assisted nitriding process for metallic powders. This approach opens up a huge field for the development of other metallic matrix nanocomposites.

Ultra‐high molecular weight polyethylene (UHMWPE) possesses excellent wear resistance and low friction but suffers from poor metal adhesion due to its low surface energy and chemical inertness. Herein, a graphene‐mediated electroplating strategy is developed to enable dense and adherent Ni coatings on UHMWPE. The graphene interlayer enhances interfacial conductivity, promotes uniform Ni nucleation, and suppresses oxidation. Systematic optimization of NaCl concentration, current density, and plating time identifies current density as the dominant factor. Under optimal conditions, a compact 224 μm Ni layer yields a 37.9% reduction in friction coefficient. This work demonstrates an effective graphene‐assisted metallization route for inert polymers, offering a pathway toward robust, low‐friction engineering interfaces.

The rapid proliferation of smart electronics and 5G/6G wireless infrastructure has heightened environmental and operational concerns associated with electromagnetic wave (EMW) pollution. Extended EMW exposure is implicated in adverse health outcomes and induces electromagnetic interference (EMI) that undermines the reliability of advanced electronic and power distribution systems. To address these challenges, a solvent‐free, two‐step synthesis introduces a sustainable, wood‐derived EMI shielding material, “Magwood (MW).” This approach integrates vacuum‐assisted FeCl 2 impregnation (0–3 m ) with direct N 2 pyrolysis (400–1000 °C), eliminating the need for organic solvents, delignification, or any harsh chemical treatment to synthesize in situ metal crystals, thereby advancing green‐chemistry principles. This scalable method generates a hierarchically porous, magnetic, and electrically conductive structure that can be implemented for any wood species. Optimizing the precursor concentration (1 m ) and pyrolysis temperature (800 °C) yields a saturation magnetization of 25.2 emu g −1 , an electrical conductivity of 24.3 S cm −1 , and a total shielding effectiveness (SE T ) of 45.9 dB (>99.99% attenuation of X‐band). MW additionally exhibits intrinsic hydrophobicity (static contact angle ≈99°) and self‐extinguishing behavior, endorsing its use in lightweight, sustainable EMI gaskets, casings, and architectural interlayers.

Developing brake pad friction materials is critical to enhancing the automotive brake system's performance. Solid lubricants play a crucial role in reducing wear and maintaining friction under demanding conditions. While molybdenum disulfide (MoS 2 ) remains widely used, recent progress in 2D materials has opened new possibilities. Among these, titanium‐based MXenes (Ti 3 C 2 T x ) have emerged as promising candidates due to their mechanical strength, thermal resilience, and inherent self‐lubricating properties. This study presents the first comprehensive evaluation of Ti 3 C 2 T x and MoS 2 as a solid lubricant in automotive brake pad composites. A fixed matrix composition of steel fibers, barium sulfate, phenol‐formaldehyde resin, and iron oxide is maintained across three formulations: a MoS 2 ‐based, a Ti 3 C 2 T x ‐based, and a hybrid combining both additives. The samples are fabricated adopting powder metallurgical techniques. Samples evaluation is conducted to analyze their thermal, mechanical, physical, and tribological properties. Microstructural analyses are performed using scanning electron microscopy and energy‐dispersive X‐ray spectroscopy. Tribological performance is assessed through pin‐on‐disk against a gray cast iron disk. Results show that Ti 3 C 2 T x ‐containing composites excel in all aspects compared to MoS 2 . The hybrid formulation composite reduces specific wear rate by 16.5%, while the Ti 3 C 2 T x ‐only composite achieves a 48.5% reduction relative to the MoS 2 composite.

This study investigates the mechanical performance of three auxetic structures: re‐entrant, re‐entrant‐star hybrid, and S‐shape, to identify the most effective design for high‐impact applications. Among these, the re‐entrant‐star hybrid structure demonstrates superior specific energy absorption (SEA), achieving 0.92 ± 0.12 J g −1 , attributed to its combination of re‐entrant and star‐shaped elements, which enhances both energy dissipation and structural integrity. In contrast, the re‐entrant and S‐shaped structures recorded SEAs of 0.80 ± 0.02 and 0.19 ± 0.05 J g −1 , respectively. The hybrid structure also exhibits the highest crush force efficiency (CFE) and equivalent plateau stress (EPS), highlighting its ability to maintain consistent load‐bearing capacity and to sustain stress during compression. Flexural and impact tests further validate the hybrid structure's performance, with notable improvements in bending strength and impact resistance. To further enhance its performance, finite element analysis (FEA) simulations are conducted to optimize geometric parameters, specifically strut thickness and inclination angle, to maximize mechanical performance. Postoptimization, the SEA of the re‐entrant‐star structure increases by 449%, EPS by 3400%, and in‐plane flexural modulus by 514%. These results demonstrate the effectiveness of optimizing geometric parameters to maximize the mechanical performance of auxetic structures for applications requiring high‐energy absorption.

This study develops a novel melt foaming technique for fabricating aluminum foam‐filled tubes (FFTs) with in situ bonding. Through a high‐temperature foaming process within a dynamically rotating mold, the foam and tube of FFT are cofabricated. The microstructure of FFT is observed, and the compression performance of FFT is also explored. The results demonstrate that the plateau stress of FFT is 25.50 MPa. The energy absorption and specific energy absorption of FFT are 12.75 MJ m − 3 and 15.0 kJ kg −1 , respectively. Due to the in situ bonding, the energy absorption of FFT is increased by 87.2%. The stress remains stable in the axial compression process, and no macroscopic fracture occurs in FFT. Finite element models based on specimens are reconstructed by X‐ray tomography. The tensile test is applied to the tube of FFT to obtain the parameters of the finite element simulation. The results of the finite element simulation also show that the composite structure of FFT deforms cooperatively in axial compression. The purpose of this study is to provide a high‐efficiency strategy for achieving a composite structure aluminum foam with superior energy absorption and overcoming bonding failure during the deformation process.