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Our research at LaMPS IITH focuses on advanced manufacturing and materials processing, addressing both fundamental questions and technological implications. It integrates both theoretical insights with practical applications, tackling scientifically significant problems while emphasizing interdisciplinary perspectives and collaborative efforts.
Below is a brief overview of the key themes, scope, and objectives of our research areas:
1. Metal additive manufacturing: data-enabled smart AM system, active process monitoring & control, energy-efficient alternate powders
Commercial additive manufacturing (AM) systems currently provide limited flexibility for customizing instrumentation, which restricts comprehensive in-process monitoring. A more significant challenge is their rigid system architecture, which is often constrained to a narrow range of expensive or commercially available powder materials.
In this context, developing routes for producing powders of specific or emerging alloys beyond conventional methods and evaluating their processability in AM using modular systems could offer a more versatile and scalable solution.
Our research has enabled the development of alternative, cost-effective, and versatile routes for producing metal and ceramic powders based on solid-state abrasion[1][2]. These findings demonstrate strong potential for more efficient powder synthesis, largely independent of material systems. They also address the “powder bottleneck” challenge in the global additive manufacturing (AM) industry, particularly for emerging materials such as refractory-based superalloys, high-entropy alloys (HEAs), and electrode materials relevant to the rapidly growing electric vehicle sector. In addition, the development of a state-of-the-art AM system with a flexible, modular architecture could provide a sustainable pathway for broader adoption of AM in medium- and small-scale manufacturing industries. Further, integration with IoT-enabled and AI/ML-based process monitoring and decision-making can contribute to Industry 4.0 objectives by improving overall process efficiency and effectiveness.
2. Solidification dynamics: microstructure evolution during non-equilibrium cooling and growth of metals in confined geometries
Liquid metal solidification and growth exhibit a wide range of intriguing morphologies. Owing to their fundamental relevance in manufacturing processes such as metal additive manufacturing, casting, and powder metallurgy, understanding their evolution under rapid solidification conditions remains an active area of research. Recently, growing interest in electric vehicle batteries has further intensified efforts to investigate these solidification phenomena and their underlying mechanisms.
Our work on phenomenological modeling of solidification in confined geometries, such as spheres under homogeneous conditions using metal-analog organic materials offers an innovative approach. This framework has broad implications, ranging from in situ observation of microstructural evolution in metal additive manufacturing to understanding morphological development in battery electrodes [3] [4]. It represents a compelling multiphysics problem that can be investigated through the combined application of thermodynamics, heat transfer, and fluid mechanics, alongside experimental and numerical methodologies.
3. Surface mechanics in materials processing: leveraging chemo-mechanics, emergence of surface roughness
Materials with high strain-rate coefficient- such as Al, Fe, Ni, Nb, Ta, and related systems can be challenging to process despite their intrinsic softness, due to their unstable deformation behavior. This often leads to residual surface strains, crack-like defects, and increased surface roughness. Given their structural significance, it is important and intellectually compelling to investigate the underlying mechanisms and develop strategies to mitigate these processing issues.
Our ongoing research has demonstrated the possibility of tailoring surface properties by leveraging mechanochemical effects during deformation. Preliminary results have motivated in situ investigations of crack dynamics during bending in the presence of surface-adsorbed monolayers. This approach has potential applications in the semiconductor and MEMS industries.
More broadly, this concept can be extended to understand and control surface roughness evolution across a wide range of material processing techniques, from single-event additive processes such as additive manufacturing to multi-event subtractive processes such as grinding and milling [5] .
4. Mechanics of architected materials: materials for targeted and extreme applications
Geometrically and microstructurally engineered materials- such as metamaterials, cellular structures, and topologically architected materials are in high demand across aerospace, energy, construction, and biomedical sectors due to their ability to deliver tailored and multifunctional properties.
Our preliminary work has demonstrated the feasibility of fabricating structures with targeted properties and evaluating their performance under extreme conditions [6] . Building on this, we aim to explore this potential further by leveraging data-driven computational design tools and manufacturing architected structures with tailored mechanical, electrical, and magnetic properties using additive manufacturing. Such materials find applications in aerospace structures, damage-tolerant and shielding systems, and microelectromechanical systems (MEMS) devices. This research is also relevant to the design of efficient battery electrodes, addressing the growing demand in the electric vehicle sector.
5. Recycling, remanufacturing, and sustainability: processing metal matrix composites (MMCs), natural materials for social good
Metallic and machining byproducts have emerged as a significant environmental concern in recent years, driven by rapid industrialization and growing consumer demand. Exploring alternative recycling approaches can play a crucial role in addressing solid waste management through innovative solutions, while also contributing to broader carbon-neutrality goals.
In addition, processing biodegradable natural materials for applications such as water purification and desalination presents another promising research direction with strong potential for social and environmental impact.
Our work on the preparation and processing of metal matrix composites (MMCs) using machining and grinding-derived metal chips, via laser and conventional sintering as well as injection molding routes, offers a promising pathway to address sustainability and circularity challenges in manufacturing [7] . This approach enables the valorization of metallic waste streams into useful products for low-end applications, particularly when combined with suitable reinforcements [8]. In parallel, our work on bio-fiber-based composites has demonstrated potential for water filtration applications, providing a sustainable alternative that can also help reduce the burden of non-degradable plastic waste.
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