The one-step AM process is considered the goal many researchers seek in the field of Additive Manufacturing (AM) of high-technology ceramics. Among the several AM techniques, only Powder Bed Fusion (PBF) can directly print high-technology ceramics using one step. However, the PBF technique faces numerous challenges to efficiently be employed in the PBF of ceramics. These challenges include the formation of cracks, generated thermal stress, effective laser–powder interaction, and low acquired relative density. This study developed a new preheating mechanism for ceramic materials using two laser systems to surpass beyond these challenges and successfully print ceramics with a single-step AM method. One laser is used to preheat the powder particles before the second laser is utilised to complete the melting/sintering process. Both lasers travel along the same scanning path. There is a slight delay (0.0001 s) between the preheating laser and the melting/sintering laser to guarantee that the melting/sintering laser scans a properly preheated powder. To further facilitate testing of the preheating system, a numerical model has been developed to simulate the preheating and melting process and to acquire proper process parameters. The developed numerical model was shown to determine the correct process parameters without needing costly and time-consuming experiments. Alumina samples (10 × 10 × 6 mm3) were successfully printed using alumina powder as feedstock. The surface of the samples was nearly defect-free. The samples’ relative densities exceeded 80%, the highest reported relative density for alumina produced by a single-step AM method. This discovery can significantly accelerate the transition to a one-step AM process of ceramics.

Pressure-assisted single-point incremental forming (PA-SPIF) is one of the emerging forming techniques for sheet metals that have been the subject of rigorous research over the past two decades. Understanding of its forming mechanisms and capabilities is growing as a result. Open gaps are still present in material constitutive modelling for accurate numerical predictions and finite-element simulations as the characteristics of localised deformation behaviour in SPIF are different from those of conventional sheet metal forming. The current investigation focused on the comparison of three different material models for the finite-element analysis of PA-SPIF of cold-rolled, dual-phase steel DP600. Experimental trials using different fluid pressures showed good agreement with simulation results with discrepancies in deformed blank thickness and shape geometry predictions of 3–11% and 10–21%, respectively. Within the tested materials and range of parameters, the fracture-forming-limit diagram (FFLD) material model was identified to be of superior accord with experiments.