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Researchers Embed Working Strain Sensors In LPBF Titanium

Researchers at Argonne National Laboratory, UCL and the University of Sheffield have demonstrated a viable method to embed multilayer strain sensors directly into Ti‑6Al‑4V parts produced by laser powder‑bed fusion (LPBF). The approach combines direct‑ink‑writing of silver nanoparticle traces on a thermally tuned TPGDA polymer dielectric, protected by a one‑millimetre titanium powder shield during printing. Tested architectures showed that phenolic‑ and TPGDA‑backed gauges survived the melt‑pool cycle, retained electrical functionality, and maintained strain sensitivity after embedding. The workflow avoids post‑fit inserts, offering a scalable path toward smart, self‑monitoring metal components.