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research article

On design, analysis, and hybrid manufacturing of microstructured blade-like geometries

Antolin, Pablo  
•
Bartoň, Michael
•
Bonneau, Georges Pierre
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January 1, 2026
CAD Computer Aided Design

With the evolution of new manufacturing technologies such as multi-material 3D printing, one can think of new type of objects that consist of considerably less, yet heterogeneous, material, consequently being porous, lighter and cheaper, while having the very same functionality as the original object when manufactured from one single solid material. We aim at questioning five decades of traditional paradigms in geometric CAD and focus at new generation of CAD objects that are not solid, but contain heterogeneous free-form internal microstructures. We propose a unified manufacturing pipeline that involves all stages, namely design, optimization, manufacturing, and inspection of microstructured free-form geometries. We demonstrate our pipeline on an industrial test case of a blisk blade that sustains the desired pressure limits, yet requires significantly less material when compared to the solid counterpart.

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Type
research article
DOI
10.1016/j.cad.2025.103967
Scopus ID

2-s2.0-105016789469

Author(s)
Antolin, Pablo  

École Polytechnique Fédérale de Lausanne

Bartoň, Michael

Basque Center for Applied Mathematics (BCAM)

Bonneau, Georges Pierre

Université Grenoble Alpes

Buffa, Annalisa  

École Polytechnique Fédérale de Lausanne

Calleja-Ochoa, Amaia

Universidad del Pais Vasco

Elber, Gershon

Technion - Israel Institute of Technology

Elgeti, Stefanie

TU Wien

Gómez Escudero, Gaizka

Universidad del Pais Vasco

Gonzalez, Alicia

Innovalia Metrology

González Barrio, Haizea

Universidad del Pais Vasco

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Date Issued

2026-01-01

Published in
CAD Computer Aided Design
Volume

190

Article Number

103967

Subjects

5-axis CNC machining

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Finishing operations

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Heterogeneous microstructure

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Hybrid manufacturing

•

Isogeometric analysis

•

Laser bed power fusion

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Microstructured free-forms

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Shape optimization

Editorial or Peer reviewed

REVIEWED

Written at

EPFL

EPFL units
MNS  
FunderFunding(s)Grant NumberGrant URL

European Union’s Horizon 2020 program

862025

Available on Infoscience
October 3, 2025
Use this identifier to reference this record
https://infoscience.epfl.ch/handle/20.500.14299/254580
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