All of the articles in this proceedings volume have been presented at the Global Symposium on Adaptive Manufacturing (GSAM 2026) on 7th Sepetmber 2026 in Ulster University Derry~Londonderry Campus, Northern Ireland, UK. These articles have been peer reviewed by the members of the Programme Committee...

The transient liquid phase (TLP) diffusion bonding is carried out using the Box Behnken design matrix, and the bonding parameters such as temperature, pressure and holding time have been optimized using the desirability function. The diffusion bonded joints are studied for their microstructure, intermetallic...

Directed Energy Deposition (DED) is increasingly adopted for the manufacture, repair, and reconditioning of high-value components; however, process variability remains a significant barrier to repeatable and adaptive production. This study presents an experimental foundation for adaptive manufacturing...

Wire Arc Additive Manufacturing (WAAM) enables the fabrication of large-scale metallic components with a high deposition rate (2-3 kg/hr) [1]. However, this additive process can be susceptible to thermal accumulation which can negatively affect geometrical and mechanical characteristics. This study investigates...

Directed Energy Deposition (DED) is fundamentally an additive manufacturing (AM) technique, capable for the fabrication of Fe-Si soft magnetic materials, which are important for transformers, motors and other energy structures. This study utilizes optical microscopy (OM), X-ray Diffraction (XRD), Electron...

Often times, cultural heritage artifacts and idols are damaged by aging, environmental conditions, accidents and natural disasters. Traditional methods for the restoration are time consuming and need skilled artisans. The proposed approach an Idol reconstruction framework based on an AI-assisted additive...

Accurate prediction of the substrate temperature during Wire Arc Directed Energy Deposition (Wire Arc DED) is critical for managing thermal gradients, avoiding residual deformation, and maintaining the dimensional correctness and mechanical performance of manufactured metallic components. The research...

In the current study, the sound absorption performance of 3D-printed PLA micro-perforated panels fabricated via fused deposition modelling was evaluated. During evaluation, thickness was kept constant at 1 mm while pore diameter was varied as 0.4 mm, 0.6 mm, 0.8 mm, and 1 mm. For experimentation, the...

The use of Polyetheretherketone (PEEK) is common in biomedical applications due to its excellent mechanical properties, chemical resistance and biocompatibility. However, the main limitation of PEEK for biomedical applications is its bioinert nature, resulting in a lack of bioactive response in-vivo....

This study investigates the influence of localised continuous fibre toolpaths on the structural behaviour of additive manufactured composite components containing geometric defects. Using a Markforged platform, 40-layer symmetrical specimens ( O n ...

Recent developments in adaptive manufacturing have enabled the design of smart knee implants by combining additive manufacturing, embedded sensing technologies, and artificial intelligence (AI). These implants facilitate continuous assessment of implant performance and patient biomechanics, while AI-based...

Wire Arc Additive Manufacturing (WAAM) is an efficient process for producing large metallic parts with high deposition rates and less cost. This study investigates the influence of different shielding gas mixtures (SG-1: 100%Ar, SG-2: 95%Ar+5%CO₂, SG-3: 90%Ar+10%CO₂, and SG-4: 80%Ar+20%CO₂) on CMT-WAAM...

Cycle-time root-cause analysis in wafer fabrication still relies on descriptive severity rankings, yet severity does not equate to causal impact, does not reveal how delays propagate, and cannot explain why a particular lot was slow. DMBSI-CARE closes these gaps by seeding a structural causal model with...

Adaptive manufacturing integrates computational simulation with advanced manufacturing to optimize orthopedic implant design. A Ti-6Al-4V tibial plate was analyzed using ANSYS Mechanical 2025 R2 where a compressive load of 2000 N was applied on the model while restraining the bottom surface of the implant....

Energy optimisation of multi-pump stations requires pump-specific energy, yet many installations measure only total station flow. This simulated feasibility study reconciles discharge pressures, pump electrical powers and station flow against a calibrated 1D hydraulic model to identify degradation. Controlled...

Fused filament fabrication of semi-crystalline polymers is influenced by complex thermal behaviour that contributes to residual stress and part distortion. This work presents the development of a two-dimensional thermo-mechanical finite element framework for modelling the multi-layer deposition of polypropylene...

During the fabrication of large components using Wire Arc Additive Manufacturing (WAAM), the process involves a unique thermal cycle that results in significant heat accumulation in the deposited layers. This research proposes a data-driven technique that combines finite element analysis (FEA) and Machine...

This study presents a Unity-based digital twin for robot arm monitoring and remote operation. Physical robot joint states were transmitted to Unity for real-time visualization, while operator-defined commands were sent from Unity to the physical robot. The two data flows were integrated through User...

Industrial settings often suffer from operational lags owing to the unforeseen depletion of cylinders and manual tracking of their inventory. In this paper, an IoT-based zero-intervention monitoring technique that uses a strain-gauge load cell, HX711 amplifier, and ESP32 microcontroller to measure the...

Industries need a maintenance strategy that not only predicts failure but also optimises machine operating conditions to maximise the lifespan. This work addresses this by introducing a new prescriptive maintenance strategy. This framework provides actionable recommendations to optimise the machine’s...

Accurate cutting-tool degradation prediction is essential for predictive maintenance in Industry 4.0. This paper presents an explainable ensemble framework for direct Remaining Useful Life (RUL) prediction using the NASA Milling Dataset. Wavelet Packet Decomposition (WPD), training-only feature selection...

A conventional UHMWPE tibial spacer and a spring-integrated spacer manufactured were evaluated under compressive loading using FEA in ANSYS Workbench at 3.085 MPa. The conventional design showed a maximum von Mises stress of 9.91 MPa and deformation of 0.312 mm, while the spring-integrated design exhibited...

Total Knee Arthroplasty (TKA) is a common procedure used in patients with severely affected knee joints due to trauma, osteoarthritis and severe knee degeneration. Traditional knee implants are, however, available in fixed sizes, which are often not suitable for all patients, depending on their anatomical...

The images captured using the Wire Arc Additive Manufacturing (WAAM) process may exhibit problems such as bright arc glare, sensor noise, and non-uniform illumination of the image which can hinder the analysis of bead geometry and heat-affected-zone (HAZ) features. In the proposed research to enhance...