New machine learning framework enhances precision and efficiency in metal 3D printing, advancing sustainable manufacturing

Research led by University of Toronto Professor Yu Zou aims to produce higher quality and more reliable metal parts for aerospace, automotive, energy and health-care applications

Peer-Reviewed Publication

University of Toronto Faculty of Applied Science & Engineering

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Students in the the Laboratory for Extreme Mechanics & Additive Manufacturing. (photo by Safa Jinje / University of Toronto Engineering)

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Credit: photo by Safa Jinje / University of Toronto Engineering

Researchers at University of Toronto Engineering, led by Professor Yu Zou, are leveraging machine learning to improve additive manufacturing, also commonly known as 3D printing.  

In a new paper, published in the journal of Additive Manufacturing, the team introduces a new framework they’ve dubbed the Accurate Inverse process optimization framework in laser Directed Energy Deposition (AIDED). 

The new AIDED framework optimizes laser 3D printing to enhance the accuracy and robustness of the finished product. This advancement aims to produce higher quality metal parts for industries, such as aerospace, automotive, nuclear and health care, by predicting how the metal will melt and solidify to find optimal printing conditions.  

“The wider adoption of directed energy deposition — a major metal 3D printing technology — is currently hindered by the high cost of finding optimal process parameters through trial and error,” says Xiao Shang, PhD candidate and first author of the new study. 

“Our framework quickly identifies the optimal process parameters for various applications based on industry needs.” 

Metal additive manufacturing uses a high-powered laser to selectively fuse fine metallic powder, building parts layer by layer from a precise 3D digital model. 

Unlike traditional methods, which involve cutting, casting or machining materials, metal additive manufacturing directly creates complex, highly customized components with minimal material waste. 

“One major challenge of 3D metal printing is the speed and precision of the manufacturing process,” says Zou. “Variations in printing conditions can lead to inconsistencies in the quality of the final product, making it difficult to meet industry standards for reliability and safety. 

“Another major challenge is determining the optimal settings for printing different materials and parts. Each material — whether it’s titanium for aerospace and medical applications or stainless steel for the nuclear reactors — has unique properties that require specific laser power, scanning speed and temperature conditions. Finding the right combination of these parameters across a vast range of process parameters is a complex and time-consuming task.” 

These challenges inspired Zou and his lab group to develop their new framework. AIDED operates in a closed-loop system where a genetic algorithm — a method that mimics natural selection to find optimal solutions — first suggests process parameters combinations, which machine learning models then evaluate for printing quality. 

The genetic algorithm checks these predictions for optimality, repeating the process until the best parameters are found. 

“We have demonstrated that our framework can identify optimal process parameters from customizable objectives in as little as one hour, and it accurately predicts geometries from process parameters,” says Shang. “It is also versatile and can be used with various materials.”

To develop the framework, the researchers conducted numerous experiments to collect their vast datasets. This essential but time-consuming challenge ensured that the datasets covered a wide range of process parameters.  

Looking ahead, the team is working to develop an enhanced autonomous, or self-driving, additive manufacturing system that operates with minimal human intervention, similar to how autonomous vehicles drive themselves, says Zou. 

“By combining cutting-edge additive manufacturing methods with artificial intelligence, we aim to create a novel closed loop controlled self-driving laser system,” he says.  

“This system will be capable of sensing potential defects in real-time, predicting issues before they occur, and automatically adjusting processing parameters to ensure high-quality production. It will be versatile enough to work with different materials and part geometries, making it a game-changer for manufacturing industries.”  

In the meantime, the researchers hope AIDED will transform process optimization in industries that use metal 3D printing.  

“Industries such as aerospace, biomedical, automotive, nuclear and more would welcome such a low-cost yet accurate solution to facilitate their transition from traditional manufacturing to 3D printing,” says Shang.   

“By the year 2030, additive manufacturing is expected to reshape manufacturing across multiple high-precision industries,” adds Zou. “The ability to adaptively correct defects and optimize parameters will accelerate its adoption.”

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Journal

Additive Manufacturing

DOI

10.1016/j.addma.2025.104736 

A less toxic way to manufacture daily goods

University of California - San Diego

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Diisocyanates are used in the preparation of all polyurethanes, ranging from the foams used in shoe soles to the thermoplastics used in cell phone cases. Aromatic diisocyanates, which give polyurethane foams their structure, are commonly prepared on the megaton scale in highly secure facilities due to the use of phosgene, a highly reactive and toxic chemical reagent. Michael Burkart’s lab at UC San Diego recently reported the preparation of fully bio-based aromatic diisocyanates from a simple monosaccharide, D-galactose. This new route avoids the use of transition metals, gaseous reagents or any high-pressure/temperature reactions. As an application, the team demonstrates the synthesis of a thermoplastic polyurethane (TPU) using these renewable diisocyanates, which show excellent material properties equivalent to petroleum-based TPUs. These materials can serve as drop-in replacements for existing polyurethanes, which can now be sourced from 100% bio-based materials. Next, the team is developing scale-up procedures to prepare them on kilogram quantities for prototype applications.

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Journal

Angewandte Chemie

DOI

10.1002/anie.202421540 

Article Title

Renewable Terephthalates and Aromatic Diisocyanates from Galactose

Article Publication Date

17-Feb-2025

COI Statement

Michael D. Burkart is founder and holds an equity position in Algenesis Materials.

 

Cool mission: ONR aids deployment of data buoys across Arctic Ocean

Office of Naval Research

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Alaska Air National Guard Senior Master Sgt. Cecil Dickerson, left, observes as Master Sgt. Tony Johnson, center, and Master Sgt. John Massi, all C-17 Globemaster III loadmasters assigned to the Alaska Air National Guard’s 144th Airlift Squadron at JBER, deploy Ice Ball and CryOS buoys during an airdrop mission over the Arctic Ocean, Jan. 30, 2025. The Office of Naval Research partnered with the 144th AS to deploy data-gathering buoys over hundreds of nautical miles of the Arctic Ocean.
 

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Credit: (Alaska Air National Guard photo by Staff Sgt. Daniel Bellerive)

ARLINGTON, Va.—In January 2025, the Office of Naval Research (ONR) partnered with the 144th Airlift Squadron of the Alaska Air National Guard, the U.S. Interagency Arctic Buoy Program (USIABP) and the International Cooperative Engagement Program for Polar Research (ICE-PPR) to deploy meteorological and oceanographic buoys across more than 5,000 nautical miles of the Arctic Ocean.

The mission marked the eighth successful buoy-drop collaboration by the partners since 2023, with approximately 126 buoys deployed so far. Such deployments are critical for maintaining the Arctic Observing Network (AON), which provides critical observations for weather and ice forecasting and related research.

USIABP’s objective is to establish and maintain a network of data buoys across the entire Arctic Ocean to provide meteorological, sea ice and oceanographic data for real-time operational requirements and research purposes. Such data is especially valuable for informing U.S. naval operations and enhancing warfighting readiness in the Arctic — a region that is becoming more accessible to both allies and competitors, thanks to diminishing sea ice in the summer months. 

ONR is an executive member of ICE-PPR and a major supporter of USIABP, contributing significantly to the acquisition and deployment of buoys in the Arctic.

“Understanding ocean and weather conditions in the Arctic region is crucial to ensuring safe, effective naval operations in this arduous part of the world,” said Chief of Naval Research Rear Adm. Kurt Rothenhaus. “Exercises like this buoy drop demonstrate the value of strong partnerships between military, government and academia, enabling the exchange of knowledge, resources and insights benefiting the Sailors and Marines we have the privilege of serving.”

During the January 2025 deployment, two flights dropped approximately 35 buoys along a flight path from Barrow, Alaska, over the Arctic Ocean and its peripheral East Siberian, Laptev, Chukchi and Beaufort seas. The buoys track air pressure, temperature, ice drift and ocean currents.

The 144th Airlift Squadron (known as the “Arctic Wolves”) conducted the buoy drops, each of which lasted 10-14 hours, on a C-17 Globemaster III aircraft. In addition to squadron personnel, participants included professors and scientists from several universities and ONR reservists.

Flying over such a large area provided a great opportunity for visual surveys and documentation of the ice. Five types of buoys — Ice Trackers, Ice Balls, ICEXAIR, Air Expendable Ice Beacons (AXIBs) and experimental buoys — were deployed from the C-17. The Ice Trackers, Ice Balls, ICEXAIRs and experimental buoys were deployed directly onto the ice, while the AXIBs landed in cracks between the sea ice. The buoys have unique design features to help them survive the harsh environment.

Both air drops provided a worthwhile training objective for the 144th Airlift Squadron and served as an excellent method for deploying buoys across the austere, remote region. The squadron also used the mission as training for Arctic rescue air drops. 

Data collected from the buoys will enhance weather and ice forecasting and environmental models by organizations such as the National Weather Service, Naval Ice Center and National Oceanic and Atmospheric Administration — reducing the risk to naval assets operating in the Arctic.

In addition, as the annual cycles of freezing and thawing occur, buoys may be crushed by the sea ice, drift out of the Arctic Ocean or reach the end of their service lives. The AON, and the buoys comprising it, must be replenished periodically to provide continuous environmental data.

The buoy air drop effort emphasizes the great scientific and operational capabilities achieved through collaboration between U.S. Department of Defense research professionals, academic professors and researchers, Navy Reserve and Air National Guard units, and contractors.

Such partnerships have many benefits, such as standardization, equipment sharing and eliminating unnecessary duplication of work. The cooperation also facilitates efficient and cost-effective polar research, development, test and evaluation projects.

 

Obesity Action Coalition & The Obesity Society send letter to FDA on behalf of more than 20 leading organizations & providers urging enforcement of compounding regulations

The Obesity Society

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March 19, 2025 — Today, the Obesity Action Coalition (OAC) and The Obesity Society (TOS) sent a letter to the U.S. Food & Drug Administration (FDA), along with more than 20 leading organizations and providers across the healthcare continuum, urging the agency to enforce federal regulations around compounding following the recent resolution of GLP-1 medicine shortages. Among the signatories include: the Alliance for Women’s Health & Prevention, the Association of Black Cardiologists, the National Hispanic Medical Association and the National Consumers League. 

The letter follows recent announcements from the FDA that Eli Lilly’s tirzepatide, marketed as Zepbound for weight loss and Novo Nordisk’s semaglutide, marketed as Ozempic for diabetes and Wegovy for weight loss, are no longer in shortage. In addition, a federal court in Texas recently declined to issue an injunction blocking the FDA’s tirzepatide decision – underscoring the “ceasing” of all copycats by compounders.   

Following the recent resolution of GLP-1 shortages, we applaud the FDA’s clarification issued last week for GLP-1 compounders which indicates that outsourcing facilities making versions of tirzepatide have until March 19 to cease operations. Pharmacies must stop compounding semaglutide by April 22 while larger outsourcing facilities have until May 22, or until the district court rules on a pending injunction in the district court case – what comes first will take precedence.  

The letter also acknowledges that U.S. regulations permit some compounding pharmacies to produce versions of brand-name medications under limited circumstances, including when they are in short supply or where necessary to meet the individualized needs of a specific patient.  However, continued mass-production compounding of GLP-1s, in the absence of a shortage, undermines the regulatory framework designed to protect patients from potential risks associated with unapproved and unregulated drug formulations.  

To address this issue, the signatories urge FDA to take the following action:  

1. Enforce Existing Regulations: Ensure that compounding pharmacies adhere to federal regulations by discontinuing the production of GLP-1 medications now that the shortage has been resolved.  

2. Monitor Compliance: Implement measures to monitor and enforce compliance during and after the grace period to prevent unauthorized compounding of these medications.  

3. Educate Stakeholders: Provide clear guidance to healthcare providers, pharmacists, and patients about the transition back to FDA-approved medications and the importance of obtaining treatments through appropriate channels.   

4. Enforce Existing Rules Against Misleading Information: Ensure that companies promoting misleading information about compounded GLP-1s are held accountable under existing regulatory authority of the FDA. 

“GLP-1 medications have made a transformative impact in the obesity care space. As these medicines continue to grow in popularity, regulatory action and enforcement is critically needed at the state and federal level to ensure that patients have access to safe, FDA-approved treatments,” said Joseph Nadglowski, President and CEO of the Obesity Action Coalition.  

“Now that the GLP-1 shortage is resolved, FDA faces a critical juncture in upholding its commitment to patient safety,” said Anthony Comuzzie, PhD, FTOS, CEO of TOS. “Our message is simple – FDA, the time is now to take decisive action by enforcing the existing regulatory framework around compounding.” 

The letter was signed by the following organizations & physicians: 

• Aimed Alliance  

• Alliance for Women’s Health & Prevention  

• Association of Black Cardiologists 

• Bone Health & Osteoporosis Foundation 

• Chronic Care Policy Alliance 

• Color of Gastrointestinal Illnesses 

• Diabetes Patient Advocacy Coalition   

• Global Liver Institute 

• HealthyWomen 

• Mended Hearts 

• Minority Health Institute  

• National Alliance for Caregiving  

• National Black Nurses Association 

• National Consumers League 

• National Hispanic Health Foundation 

• National Hispanic Medical Association  

• Obesity Action Coalition  

• The Obesity Society 

• WomenHeart 

• Lyn Behnke, DNP, MSN 

• Lisa Larkin, MD 

• Spence Nadolsky, MD 

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About OAC: 
The Obesity Action Coalition (OAC), a more than 85,000 member-strong national nonprofit organization dedicated to improving the lives of individuals affected by the disease of obesity through education, advocacy and support. The OAC is the first and only organization of its kind and the nation’s leading voice representing those impacted by obesity. To learn more about our work, please visit  www.ObesityAction.org. 

About TOS:
Founded in 1982, The Obesity Society (TOS) is the leading professional society focused on obesity science, treatment and prevention. 

The mission of The Obesity Society (TOS) is to advocate and promote the highest quality in research, clinical care, education, and policy development to address the needs of people living with obesity. In addition, we offer our members a community to facilitate professional networking with peers in all fields related to obesity. To learn more about The Obesity Society, please visit www.obesity.org.

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Disclaimer: AAAS and EurekAlert! are n

 Origin of life: How microbes laid the foundation for complex cells

ETH Zurich

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An artist’s depiction of an Asgard archaeon, based on cryo-electron tomography data: the cell body and appendages feature thread-like skeletal structures, similar to those found in complex cells with nuclei.

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Credit: Graphic: Margot Riggi, Max Planck Institute of Biochemistry

Ten years ago, nobody knew that Asgard archaea even existed. In 2015, however, researchers examining deep-sea sediments discovered gene fragments that indicated a new and previously undiscovered form of microbes.

With computer assistance, the researchers assembled these fragments like puzzle pieces to compile the entire genome. It was only then that they realised they were dealing with a previously unknown group of archaea.

Like bacteria, archaea are single-celled organisms. Genetically, however, there are significant differences between the two domains, especially regarding their cell envelopes and metabolic processes.

After a further search, microbiologists identified the corresponding organisms, described them and classified them as a separate archaeal sub-group: Asgard archaea. Their name, taken from the heavenly realm in Norse mythology, references their initial discovery close to Loki’s Castle – a black smoker on the mid-Atlantic ridge between Norway and Svalbard.

In fact, Asgard archaea appeared almost heaven-sent for research: they turned out to be a missing link between archaea and eukaryotes – that is, between archaea and organisms whose cells contain a nucleus, such as plants and animals.

Tree of life with one branch fewer

In recent years, researchers have found growing indications of close links between Asgard archaea and eukaryotes, and that the latter may have evolved from the former. The division of all living organisms into the three domains of bacteria, archaea and eukaryotes did not hold up to this surprising discovery.

Some researchers have since proposed regarding eukaryotes as a group within Asgard archaea. This would reduce the number of domains of life from three to two: archaea, including eukaryotes, and bacteria.

At ETH Zurich, Professor Martin Pilhofer and his team are fascinated by Asgard archaea and have examined the mysterious microbes for several years.

In an article published in Nature two years ago, the ETH researchers explored details of the cellular structure and architecture of Lokiarchaeum ossiferum. Originating in the sediments of a brackish water channel in Slovenia, this Asgard archaeon was isolated by researchers in Christa Schleper’s laboratory at the University of Vienna.

In that study, Pilhofer and his postdoctoral researchers Jingwei Xu and Florian Wollweber demonstrated that Lokiarchaeum ossiferum possesses certain structures also typical of eukaryotes. “We found an actin protein in that species that appears very similar to the protein found in eukaryotes – and occurs in almost all Asgard archaea discovered to date,” says Pilhofer.

In the first study, the researchers combined different microscopy techniques to demonstrate that this protein – called Lokiactin – forms filamentous structures, especially  in the microbes’ numerous tentacle-like protrusions. “They appear to form the skeleton for the complex cell architecture of Asgard archaea,” adds Florian Wollweber.

In addition to actin filaments, eukaryotes also possess microtubules. These tube-shaped structures are the second key component of the cytoskeleton and are comprised of numerous tubulin proteins. These tiny tubes are important for transport processes within a cell and the segregation of chromosomes during cell division

The origin of these microtubules has been unclear – until now. In a newly published article in Cell , the ETH researchers discovered related structures in Asgard archaea and describe their structure. These experiments show that Asgard tubulins form very similar microtubules, albeit smaller than those in their eukaryotic relatives.

However, only a few Lokiarchaeum cells form these microtubules. And, unlike actin, these tubulin proteins only appear in very few species of Asgard archaea.

Scientists do not yet understand why tubulins appear so rarely in Lokiarchaea, or why they are needed by cells. In eukaryotes, microtubuless are responsible for transport processes within the cell. In some cases, motor proteins “walk along” these tubes. The ETH researchers have not yet observed such motor proteins in Asgard archaea.

“We have shown, however, that the tubes formed from these tubulins grow at one end. We therefore suspect that they perform similar transport  functions as the microtubules in eukaryotes,” says Jingwei Xu, the co-first author of the Cell study. He produced the tubulins in a cell culture with insect cells and examined their structure.

Researchers from the fields of microbiology, biochemistry, cell biology and structural biology collaborated closely on the study. “We would never have progressed so far without this interdisciplinary approach,” emphasises Pilhofer with a degree of pride.

Was the cytoskeleton essential for the development of complex life? While some questions remain unanswered, the researchers are confident that the cytoskeleton was an important step in the evolution of eukaryotes.

This step could have occurred aeons ago, when an Asgard archaeon entwined a bacterium with its appendages. In the course of evolution, this bacterium developed into a mitochondrion, which serves as the powerhouse of modern cells. Over time, the nucleus and other compartments evolved – and the eukaryotic cell was born.

“This remarkable cytoskeleton was probably at the beginning of this development. It could have enabled Asgard archaea to form appendages, thereby allowing them to interact with, and then seize and engulf a bacterium,” says Pilhofer.

Fishing for Asgard archaea

Pilhofer and his colleagues now plan to turn their attention to the function of actin filaments and archaeal tubulin along with the resulting microtubules.

They also aim to identify the proteins that researchers have discovered on the surface of these microbes. Pilhofer hopes his team will be able to develop antibodies precisely tailored to these proteins. This would enable researchers to “fish” specifically for Asgard archaea in mixed microbe cultures.

“We still have a lot of unanswered questions about Asgard archaea, especially regarding their relation to eukaryotes and their unusual cell biology,” says Pilhofer. “Tracking down the secrets of these microbes is fascinating.”

Reference

Wollweber F, Xu J, et al. Microtubules in Asgard archaea, Cell, published online March 21 2025, DOI 10.1016/j.cell.2025.02.027

 

 

 

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Journal

Cell

DOI

10.1016/j.cell.2025.02.027 

Article Title

Microtubules in Asgard archaea

Article Publication Date

21-Mar-2025

New Microbiology Society policy briefing on Antimicrobial Resistance (AMR) in wastewater

Microbiology Society

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AMR occurs when disease-causing bacteria, viruses, fungi and parasites (pathogens) are no longer affected by the medicines that have been developed to target them. Drug-resistant pathogens can cause infections that are difficult or impossible to treat; they increase the risk of disease spread and can lead to severe illness, disability and death.

Wastewater is commonly contaminated with antimicrobial resistant micro-organisms and antimicrobial compounds. Upon entering our environment, such as rivers and seas, contaminated wastewater therefore serves as a pathway for, and major contributor to, the spread of AMR in the UK and worldwide. There are various interventions to tackle AMR in wastewater, including strengthening monitoring and surveillance, improving stakeholder engagement and enhancing treatment technologies and practices.

In recognition of World Water Day (22 March) and the global threat of AMR, the Microbiology Society has published a new policy briefing outlining the current state of AMR in wastewater.  The new briefing aims to promote the understanding of AMR in wastewater, as well as highlight key interventions for stakeholders to tackle the spread of AMR in the environment.

Visit the policy hub on our website to read the new briefing.

This briefing is part of the Microbiology Society’s Knocking Out AMR project, an ambitious, bold and extensive scheme of work aiming to promote feasible and effective solutions to AMR. Find out more here. 

About the Microbiology Society

The Microbiology Society is a membership charity for scientists interested in microbes, their effects and their practical uses. It has a worldwide membership based in universities, industry, hospitals, research institutes, schools, and other organisations. Find out more at microbiologysociety.org.

For further information please contact press@microbiologysociety.org