Embedded multilayer strain architectures create self-sensing multifunctional titanium in additive manufacturing

Year: 2026

Type: article

Abstract: Multifunctional structural metals capable of monitoring their internal mechanical state are increasingly important for aerospace, biomedical, and intelligent manufacturing applications, yet integrating thermally sensitive sensing architectures into high-temperature metal additive manufacturing remains challenging. Here we show that multilayer strain sensing architectures can be embedded directly within Ti-6Al-4V during laser powder bed fusion by combining high-resolution printing of polymer–metal gauges with powder mediated thermal protection. We evaluate four sensor architectures, including commercial foil gauges and directly printed gauges with different dielectric layers, and identify material stacks that survive embedding while retaining electrical functionality. The embedded sensors preserve strain sensing performance under mechanical loading, maintain structural integrity, and exhibit cytocompatibility. These results establish a route to multifunctional titanium with internal sensing capability and provide a materials integration framework for embedding functional devices within additively manufactured metals.

Source: Communications Materials

DOI: 10.1038/s43246-026-01346-z

Authors: Alisha Bhatt, Wenqing Chen, Zheng Wu, Prasenjit Kabi, Paul Brennan, Samy Hocine, Elena Ruckh, Hazel Assender, Rob Snell, Ian Todd, Peter D. Lee, Manish K. Tiwari

Institutions: Research Complex at Harwell, University College London, University of Oxford, University of Sheffield

Language: English

Topic: Additive Manufacturing Materials and Processes

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $3,690

Funders: UK Research and Innovation, Henry Royce Institute, Royal Academy of Engineering, University of Manchester, Wellcome / EPSRC Centre for Interventional and Surgical Sciences, Engineering and Physical Sciences Research Council

OpenAlex ID: W7212056345