Tech
Advanced sensors peer inside the ‘black box’ of metal 3D printing

With the ability to print metal structures with complex shapes and unique mechanical properties, metal additive manufacturing (AM) could be revolutionary. However, without a better understanding of how metal AM structures behave as they are 3D printed, the technology remains too unreliable for widespread adoption in manufacturing and part quality remains a challenge.
Researchers in Lawrence Livermore National Laboratory (LLNL)’s nondestructive evaluation (NDE) group are tackling this challenge by developing first-of-their-kind approaches to look at how materials and structures evolve inside a metal AM structure during printing. These NDE techniques can become enabling technologies for metal AM, giving manufacturers the data they need to develop better simulations, processing parameters and predictive controls to ensure part quality and consistency.
“If you want people to use metal AM components out in the world, you need NDE,” said David Stobbe, group leader for NDE ultrasonics and sensors in the Materials Engineering Division (MED). “If we can prove that AM-produced parts behave as designed, it will allow them to proliferate, be used in safety-critical components in aerospace, energy and other sectors and hopefully open a new paradigm in manufacturing.”
Measuring in the middle
NDE techniques involve sending signals like X-rays, ultrasound or electrical currents through objects and observing signal changes to infer information or reconstruct an image of what’s inside. NDE is important for quality control in all manufactured parts, but for metal AM, it can also help catch printing problems before it’s too late.
Most metal AM techniques use heat to bind material together, and since metals are extremely sensitive to heat, structures can change a lot during printing. Heat diffuses from the print surface into the already-printed structure, which can affect how well the material binds, create failure-inducing defects and lead to inconsistent products.
“Evolving processes in the subsurface need to be measured and characterized if you want to have a consistent print quality,” said Saptarshi Mukherjee, a research scientist in the Lab’s Atmospheric, Earth and Energy Division (AEED). “This is very challenging because most of the current NDE technologies cannot see through heat, and even infrared cameras and antennas only detect heat at the surfaces.”
Mukherjee is part of a project to monitor internal temperature during laser powder-bed fusion (LPBF) metal AM using eddy currents, swirling loops of electrical current induced by applying magnetic fields. Eddy currents are sensitive to electrical conductivity, and since conductivity is a function of temperature, eddy current sensors provide real-time localized temperature information from inside structures.
Simulations from collaborators at Michigan State University suggested the approach was viable, and the group validated it with a simple experiment, resulting in a recent paper published in Scientific Reports.
“To our knowledge, this is the first time that eddy current sensors have been used to look at these very rapid non-equilibrium thermal processes, which are suggestive of the sort of thermal processes you would see in a metal AM process,” said MED postdoc Ethan Rosenberg.
Rosenberg is now leading the experimental testing for a follow-up study using closer to real-world conditions such as non-uniform heating and faster timescales.
Trailblazers
NDE group leader Joe Tringe launched the first Laboratory-Directed Research and Development (LDRD) project in the area in 2018 and ever since, the group has been treading new ground to keep pace with metal AM.
In their first project, the group showed that millimeter wave signatures could efficiently characterize the shape of individual droplets of liquid metal used to create structures in liquid metal jetting. They eventually collected enough data to train a machine learning algorithm to predict droplet shape.
“If we can combine that feedback with system modeling, we may be able to learn whether the print parameters are working or if they need to be changed, in real time, so that we end up with what we want when we’re done,” said Stobbe.
Follow-up projects expanded to electrical resistance tomography—which measures changes in a current’s voltage and electrical potential—X-ray computed tomography, ultrasound and neutron detection, with an emphasis on lattice structures and other complicated geometries.
The group also uses NDE to inspect processing parameters like sonication—using ultrasonic waves to create vibrations and improve homogenization—in laser-based metal AM.
In a recent study published in Communications Materials, the group and collaborators at Pennsylvania State University and Argonne National Laboratory proved they could use high-speed synchrotron X-ray imaging for these measurements. The technique is the first step toward understanding sonication’s impact on printing, which will help manufacturers optimize the process to improve part quality.
“A lot of things happen in these AM processes that affect the part, but without using NDE techniques, it’s kind of a black box,” said Rosenberg. “With ingenuity and good physical understanding, you can open that box to see what’s happening inside, and that will hopefully help you control the process.”
Enabling the future
The group plans to continue evolving, improving and generalizing a variety of NDE techniques for metal AM, since different techniques are better at measuring different types of information. They also hope to train machine learning algorithms for real-time monitoring and error correction during the print to improve success.
The information they collect along the way will be crucial to enabling widespread adoption of metal AM, and they hope that their work will also help raise awareness of the opportunities for NDE in the emerging field.
“There’s a real gold rush aspect to it,” said Stobbe. “You’re out there doing or measuring things that you know no one has ever done or measured before because this is a new technology, and that’s certainly exciting.”
Other contributors to the work include MED’s Rosa Morales, Jordan Lum, Edward Benavidez and collaborators at the University of Colorado, Boulder.
More information:
Lei Peng et al, In-situ 3D temperature field modeling and characterization using eddy current for metal additive manufacturing process monitoring, Scientific Reports (2025). DOI: 10.1038/s41598-025-94553-6
Citation:
Advanced sensors peer inside the ‘black box’ of metal 3D printing (2025, September 23)
retrieved 23 September 2025
from https://techxplore.com/news/2025-09-advanced-sensors-peer-black-metal.html
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part may be reproduced without the written permission. The content is provided for information purposes only.
Tech
OpenAI Teams Up With Oracle and SoftBank to Build 5 New Stargate Data Centers

OpenAI is planning to build five new data centers in the United States as part of the Stargate initiative, the company announced on Tuesday. The sites, which are being developed in partnership with Oracle and SoftBank, bring Stargate’s current planned capacity to nearly 7 gigawatts—roughly the same amount of power as seven large-scale nuclear reactors.
“AI is different from the internet in a lot of ways, but one of them is just how much infrastructure it takes,” OpenAI CEO Sam Altman said during a press briefing in Abilene, Texas on Tuesday. He argued that the US “cannot fall behind on this” and the “innovative spirit” of Texas provides a model for how to scale “bigger, faster, cheaper, better.”
Three of the new sites, in Shackelford County, Texas, Doña Ana County, New Mexico, and a yet-to-be disclosed location in the Midwest, are being developed in partnership with Oracle. The move follows an agreement Oracle and OpenAI announced in July to develop up to 4.5 gigawatts of US data center capacity on top of what the two companies are already building at the first Stargate facility in Abilene.
OpenAI claims the new data centers, along with a planned 600 megawatt expansion of the Abilene site, will create more than 25,000 onsite jobs, though the number of workers required to build data centers typically dwarfs the amount needed to maintain them afterwards.
The two remaining sites are being helmed by OpenAI and SB Energy, a SoftBank subsidiary that develops solar and battery projects. These are located in Lordstown, Ohio and Milam County, Texas.
Stargate is one of several major US technology infrastructure projects that have been announced since President Donald Trump took office at the start of the year. OpenAI said in January that the $500 billion, 10 gigawatt commitment between the ChatGPT maker, SoftBank, Oracle and MGX would “secure American leadership in AI” and “create hundreds of thousands of American jobs.”
Trump touted the mammoth initiative just two days after he returned to the White House, promising that it would accelerate American progress in artificial intelligence and help the US compete against China and other nations. In July, Trump announced an AI action plan that called for speedy infrastructure development and limited red tape as the US tries to beat other countries in the quest for advanced AI. “We believe we’re in an AI race,” White House AI czar David Sacks said at the time. “We want the United States to win that race.”
OpenAI initially framed Stargate as a “new company” that would be chaired by Softbank CEO Masayoshi Son. Now, however, executives close to the project say it’s an umbrella brand name used to refer to all of OpenAI’s data center projects—except those developed in partnership with Microsoft.
The flagship site in Abilene is primarily owned and operated by Oracle, with OpenAI acting as the primary tenant, according to executives close to the project. The buildout, which is being managed by the data center startup Crusoe, is on track to be completed by mid 2026, sources close to the project say. It is already running on Oracle Cloud Infrastructure and supporting OpenAI training and inference workloads, those sources add.
Tech
Trump’s Tylenol Directive Could Actually Increase Autism Rates, Researchers Warn

For decades, the discussion around autism has been a hotbed of misinformation, misinterpretation, and bad science, ranging from the long-discredited link between the neurodevelopmental condition and vaccines, to newer claims that going gluten-free and avoiding ultra-processed foods can reverse autistic traits.
On Monday night, this specter arose again in the Oval Office, as President Donald Trump announced his administration’s new push to study the causes of autism with claims that the common painkiller Tylenol, otherwise known as acetaminophen, can cause the condition. The FDA subsequently announced that the drug would be slapped with a warning label citing a “possible association.”
David Amaral, professor and director of research at the UC Davis MIND Institute, was among those watching in dismay as the president launched into a diatribe about Tylenol, repeatedly warning pregnant women not to take it, even to treat fevers.
“We heard the president say that women should tough it out,” says Amaral. “I was really taken aback by that, because we do know that prolonged fever, in particular, is a risk factor for autism. So I worry that this admonition to not take Tylenol is going to do the reverse of what they’re hoping.”
The speculation surrounding Tylenol stems from correlations drawn by some studies that have touted an association between use of the painkiller and neurodevelopmental disorders. One such analysis was published last month. The problem, says Renee Gardner, an epidemiologist at the Karolinska Institute in Sweden, is that these studies often reach this conclusion because they don’t sufficiently account for what statisticians describe as “confounding factors”—additional variables related to those being studied that might influence the relationship between them.
In particular, Gardner points out that pregnant women needing to take Tylenol are more likely to have pain, fevers, and prenatal infections, which are themselves risk factors for autism. More importantly, given the heritability of autism, many of the genetic variants that make women more likely to have impaired immunity and greater pain perception, and hence use painkillers like acetaminophen, are also linked to autism. The painkiller use, she says, is a red herring.
Last year, Gardner and other scientists published what is widely regarded within the scientific field as the most conclusive investigation so far on the subject, one which did account for confounding factors. Using health records from nearly 2.5 million children in Sweden, they reached the opposite conclusion to the president: Tylenol has no link to autism. Another major study of more than 200,000 children in Japan, published earlier this month, also found no link.
Doctors are worried that Trump’s claims will have adverse consequences. Michael Absoud, a paediatric neurodisability consultant and a researcher in pediatric neurosciences at King’s College London, says he fears that pregnant women will start using other painkillers with a less well-proven safety profile.
Gardner is concerned that it will also lead to self-blaming among parents, a flashback to the 1950s and 60s, a time when autism was wrongly attributed to emotionally cold “refrigerator mothers.” “It’s making parents of children with neurodevelopmental conditions feel responsible,” she says. “It harks back to the early dark days of psychiatry.”
Tech
How a SIM farm like the one found near the UN threatens telecom networks

The U.S. Secret Service has found and is quietly dismantling a massive network of “SIM farms” across the New York area just as world leaders gather for meetings at the United Nations.
Matt McCool, the special agent in charge of the Secret Service’s New York field office, said agents found multiple sites filled with servers and stacked SIM cards, of which more than 100,000 cards were already active. Though the investigation is ongoing and no arrests have been made, he described it as a well-funded, highly organized enterprise and possibly run by nation-state actors—perpetrators from particular countries.
Officials also warned of the havoc the network could have caused if left intact. McCool compared the potential impact to the cellular blackouts that followed the Sept. 11 attacks and the Boston Marathon bombing, when networks collapsed under strain.
So what are these SIM farms and what are they capable of?
What the tech does
SIM farms are hardware devices that can hold numerous SIM cards from different mobile operators. These devices then exploit voice over internet protocol (VoIP) technology to send and receive bulk messages or calls.
While initially developed for legitimate purposes, such as low cost international calling, the technology has become a cornerstone of organized fraud targeting mass audiences—phishing texts and scam calls.

“Scams have become so sophisticated now. Phishing emails, texts, spoofing caller ID, all of this technology gives scammers that edge,” said Eva Velasquez, president and CEO of the Identity Theft Resource Center.
In this case, the devices were concentrated within 35 miles of the U.N. building. The investigation is ongoing, but McCool said forensic analysis currently believe the system could have been used to send encrypted messages to organized crime groups, cartels and terrorist organizations.
How these farms pose a threat to telecom networks
Anthony J. Ferrante, the global head of the cybersecurity practice at FTI, an international consulting firm, said the photos show a very sophisticated and established SIM farm that could be used for any number of nefarious activities, including the potential to overwhelm cellular networks with millions of calls in just a few minutes.
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This photo provided by the U.S. Secret Service, in New York, Monday, Sept. 22, 2025, shows SIM card packaging that was seized by the agency. Credit: U.S. Secret Service via AP
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This photo provided by the U.S. Secret Service, in New York, Monday, Sept. 22, 2025, shows part of a wall of SIM boxes that were seized by the agency. Credit: U.S. Secret Service via AP
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This photo provided by the U.S. Secret Service, in New York, Monday, Sept. 22, 2025, shows servers on desks at the location where they were seized by the agency. Credit: U.S. Secret Service via AP
“So if you can imagine that type of magnitude on cellular networks, it would just overwhelm them and cause them to shut down,” Ferrante said in an interview. He also notes that it’s possible the system could be used for surveillance operations, given its proximity to the United Nations, “potentially that equipment could be used to either intercept communications, eavesdrop on communications, or actually, clone devices, as well.”
Ferrante, who previously served in key security positions at the White House and the FBI, says he’s awaiting the results of the investigation before drawing any conclusions about the nature of the setup, but he emphasizes that the scale of the operation shows how simple tools can pose real risks to critical infrastructure.
“The masterminds could have set this up a long time ago and be operating from thousands of miles away,” he said. “It’s a stark reminder of how deeply interconnected our world has become, where local vulnerabilities can be exploited globally.”
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How a SIM farm like the one found near the UN threatens telecom networks (2025, September 23)
retrieved 23 September 2025
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