Purpose Using wire as feedstock has several advantages for additive manufacturing (AM) of metal components, which include high deposition rates, efficient material use and low material costs. While the feasibility of wire-feed AM has been demonstrated, the accuracy and surface finish of the produced parts is generally lower than those obtained using powder-bed/-feed AM. The purpose of this study was to develop and investigate the feasibility of a fine wire-based laser metal deposition (FW-LMD) process for producing high-precision metal components with improved resolution, dimensional accuracy and surface finish. Design/methodology/approach The proposed FW-LMD AM process uses a fine stainless steel wire with a diameter of 100 µm as the additive material and a pulsed Nd:YAG laser as the heat source. The pulsed laser beam generates a melt pool on the substrate into which the fine wire is fed, and upon moving the X–Y stage, a single-pass weld bead is created during solidification that can be laterally and vertically stacked to create a 3D metal component. Process parameters including laser power, pulse duration and stage speed were optimized for the single-pass weld bead. The effect of lateral overlap was studied to ensure low surface roughness of the first layer onto which subsequent layers can be deposited. Multi-layer deposition was also performed and the resulting cross-sectional morphology, microhardness, phase formation, grain growth and tensile strength have been investigated. Findings An optimized lateral overlap of about 60-70% results in an average surface roughness of 8-16 µm along all printed directions of the X–Y stage. The single-layer thickness and dimensional accuracy of the proposed FW-LMD process was about 40-80 µm and ±30 µm, respectively. A dense cross-sectional morphology was observed for the multilayer stacking without any visible voids, pores or defects present between the layers. X-ray diffraction confirmed a majority austenite phase with small ferrite phase formation that occurs at the junction of the vertically stacked beads, as confirmed by the electron backscatter diffraction (EBSD) analysis. Tensile tests were performed and an ultimate tensile strength of about 700-750 MPa was observed for all samples. Furthermore, multilayer printing of different shapes with improved surface finish and thin-walled and inclined metal structures with a minimum achievable resolution of about 500 µm was presented. Originality/value To the best of the authors’ knowledge, this is the first study to report a directed energy deposition process using a fine metal wire with a diameter of 100 µm and can be a possible solution to improving surface finish and reducing the “stair-stepping” effect that is generally observed for wires with a larger diameter. The AM process proposed in this study can be an attractive alternative for 3D printing of high-precision metal components and can find application for rapid prototyping in a range of industries such as medical and automotive, among others.

St. John’s wort (Hypericum perforatum L.) is a medicinal plant that alleviates depression and other disorders due to its abundance of active ingredients. Hyperforin, rutin, and melatonin are the main active, and important, ingredients in St. John’s wort that alleviate depression. In order to investigate the optimal conditions for accumulating these active ingredients, design of experiments and response surface methodology (RSM) was employed in this study. Two-month-old St John’s wort plants were cultivated in growth chambers at varying temperatures, light intensities, and nutrient solution concentrations before analysis by HPLC, for determining differences in hyperforin, rutin, and melatonin content. The results showed that hyperforin and rutin contents were significantly influenced by temperature (18–23 °C) and light intensity (49–147 μmol m−2 s−1 photosynthetic photon flux density (PPFD)), whereas Hoagland’s nutrient solution concentration (25–75%) had little effect. The accumulation of melatonin might not be influenced by cultivation conditions. Light intensity and temperature are easily controlled environmental factors in artificial cultivation, both of which are related to secondary metabolite production in the plant. Based on RSM, the optimal conditions for the accumulation of hyperforin and rutin were obtained. The maximum content of hyperforin was 5.6 mg/g, obtained at a temperature of 19 °C, a nutrient solution concentration of 45%, and a light intensity of 49 μmol m−2 s−1 PPFD. The maximum content of rutin was 3.8 mg/g obtained at a temperature of 18 °C, a nutrient solution concentration of 50%, and a light intensity of 147 μmol m−2 s−1 PPFD. This evaluation of suitable conditions for the accumulation of bioactive compounds in St. John’s wort can be applied to plant factories on a large scale.

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