Experienced engineering leader with a strong foundation in industrial operations and academic research, specializing in advanced manufacturing, metal additive manufacturing, and innovation strategy. With over 15 years of experience managing high-impact projects, deploying cutting-edge technologies, and leading multicultural teams in matrix environments, I consistently drive operational efficiency and sustainable transformation.
As a Ph.D. researcher, I bridge academia and industry by translating complex insights into scalable, high-value solutions. Passionate about aligning innovation with technical excellence and business objectives to enable competitive advantage and long-term growth through advanced manufacturing technologies.
EDUCATION
PhD Metallurgical and Materials Engineering
RESEARCH, TEACHING, or OTHER INTERESTS
Materials Science, Metals and Alloys
20
Scopus Publications
200
Scholar Citations
8
Scholar h-index
6
Scholar i10-index
Scopus Publications
From Technology to Strategy: A Gated Decision Framework for Integrating Metal Additive Manufacturing into Sustainable Industrial Systems Jose Manuel Costa Metals, 2026 Metal additive manufacturing (AM) has progressed from prototyping toward industrial deployment, yet adoption remains uneven because many initiatives are still driven by isolated process demonstrations rather than system-level manufacturing strategy. This framework review proposes a gated decision workflow for integrating metal AM into industrial systems by coupling process-family selection and route definition, Design for Additive Manufacturing (DfAM) and sustainability considerations. The paper consolidates a comparative matrix of six metal AM process families for early down-selection, introduces a minimal evidence checklist linking each decision gate to required artifacts, and contextualizes the workflow through representative part archetypes. The framework is further supported by practical guidance on process-specific DfAM constraints, including support strategy, residual stress, and surface integrity in powder bed fusion; shrinkage-driven design in sinter-based routes; and machining allowances in repair and hybrid manufacturing. Rather than positioning metal AM as a universal substitute for conventional manufacturing, this work defines it as a complementary, strategy-dependent enabler whose sustainability benefits depend on system-level integration and application context.
Development of a Workflow for Topological Optimization of Cutting Tool Milling Bodies Bruno Rafael Cunha, Bruno Miguel Guimarães, Daniel Figueiredo, Manuel Fernando Vieira, José Manuel Costa Metals, 2026 This study establishes a systematic and reproducible workflow for topology optimization (TO) of indexable face milling cutter bodies with integrated internal coolant channels, designed for Additive Manufacturing (AM) of metallic parts. Grounded in Design for Additive Manufacturing (DfAM) principles, the workflow combines displacement-based TO and computational fluid dynamics analysis to generate simulation-driven tool geometries tailored to the constraints of AM. By leveraging iterative design knowledge, the proposed methodology enhances the scalability and repeatability of the design process, reducing development time and supporting rapid adaptation across various tool geometries. AM is explicitly exploited to integrate support-free internal coolant channels directed toward the insert cutting edge, thereby achieving a 20% mass reduction relative to the initial milling tool designs, and improving material usage efficiency at the design stage. The workflow yields numerically optimized geometries that maintain simulated global stiffness under the considered loading conditions and exhibit coolant flow distributions that effectively target the exposed cutting edges. These simulation results demonstrate the feasibility of an AM oriented, workflow-based approach for the numerical design of milling tools with internal cooling, mass reduction and provide a focused basis for subsequent experimental validation and comparison with conventionally manufactured counterparts.
Robust All-Solid-State Batteries with Sodium Ion Electrolyte, Aluminum and Additive Manufacturing Inconel 625 Electrodes Manuela C. Baptista, Antonio B. Vale, Jose M. Costa, Maria Helena Braga Molecules, 2025 This study investigates all-solid-state batteries employing multifunctional metallic current collectors/electrodes that remain electrochemically inert toward an alkali-based Na ion solid electrolyte. Inconel 625 was evaluated as the positive current collector in combination with aluminum as the negative electrode and the ferroelectric electrolyte Na2.99Ba0.005OCl. The inertness of both electrodes enabled the construction of a robust device architecture that behaved as a true battery, exhibiting a two-phase equilibrium discharge plateau at ~1.1 V despite the absence of traditional Faradaic reactions. After a one-month rest period, the cell was sequentially discharged through external resistors and retained full functionality for one year. Cyclic voltammetry confirmed a stable electrochemical response over repeated cycling. The final long-term discharge under a 9.47 kΩ load produced a steady ~0.92 V plateau and delivered a total capacity of 35 mAh (~2.3 mAh·cm−2). Post-mortem analyses revealed excellent chemical and mechanical stability of Inconel 625 after extended operation, while aluminum showed superficial surface degradation attributed to residual moisture, with X-ray diffraction indicating the formation of aluminum hydroxide. Scanning Kelvin probe measurements guided electrode selection and provided insight into interfacial energetics, whereas scanning electron microscopy confirmed interface integrity. Complementary density functional theory simulations optimized the crystalline bulk and surfaces of Inconel, demonstrating interfacial stability at the atomic scale. Overall, this work elucidates the fundamental driving forces underlying traditional battery operation by studying a “capacity-less” system, highlighting the central role of interfacial electrostatics in sustaining battery-like discharge behavior in the absence of redox-active electrodes.
Topology Optimization of a Milling Cutter Head for Additive Manufacturing Ilídio Brito Costa, Bruno Rafael Cunha, João Marouvo, Daniel Figueiredo, Bruno Miguel Guimarães, et al. Metals, 2025 The rapid growth of the machining market and advancements in additive manufacturing (AM) present new opportunities for innovative tool designs. This preliminary study proposes a design for additive manufacturing (DfAM) approach to redesign a milling cutter head in 17-4 PH stainless steel by integrating topology optimization (TO) and internal coolant channel optimization, enabled by laser powder bed fusion (LPBF). An industrial eight-insert milling cutting tool was reimagined with conformal cooling channels and a lightweight topology-optimized structure. The design process considered LPBF constraints and was iteratively refined using computational fluid dynamics (CFD) and finite element analysis (FEA) to validate fluid flow and structural performance. The optimized milling head achieved approximately 10% weight reduction while improving stiffness (reducing maximum deformation under load from 160 μm to 151 μm) and providing enhanced coolant distribution to the cutting inserts. The results demonstrate that combining TO with internal channel design can yield a high-performance and lightweight milling tool that leverages the freedom of additive manufacturing. As proof of concept, this integrated CFD–FEA validation approach under DfAM guidelines highlights a promising pathway toward superior cutting tool designs for industrial applications.
Topology optimization of an aluminum bicycle pedal crank using laser powder bed fusion Jose Manuel Costa, Mariana Cerqueira Maia, Adriana Pinho Fernandes, Elsa Costa Oliveira, Manuel Fernando Vieira, et al. Materials Science in Additive Manufacturing, 2025 This study investigates the application of topology optimization (TO) in combination with laser powder bed fusion (LPBF) to design a lightweight, high-performance bicycle pedal crank using AlSi10Mg alloy. The optimization process was carried out using Fusion 360 and nTopology, resulting in a 20% mass reduction while ensuring compliance with the ISO 14781 standards for pedal cranks. The component was characterized in terms of microstructure, surface roughness, dimensional accuracy, powder distribution, and Vickers hardness. The microstructure exhibited the characteristic melt pool patterns associated with LPBF, indicative of the manufacturing process. Surface roughness measurements showed a mean value of 23.4 μm, with dimensional analysis revealing a mean deviation of 7% from nominal dimensions. The powder distribution analysis indicated a narrow particle size distribution, contributing to consistent print quality. The component’s hardness was measured at 134 HV0.3, highlighting its promising mechanical properties. This work demonstrates the potential of TO and LPBF to produce structurally optimized, lightweight components with enhanced performance, providing valuable insights into the application of Design for Additive Manufacturing for metallic materials.
Characterization of 316L Stainless Steel Powders: Correlating Microstructural and Mechanical Properties in LPBF Components Elsa Sequeiros, Ana Figueiredo, Regina Coelho, Rui Ribeiro, Jose Costa Euro Powder Metallurgy 2025 Congress and Exhibition Euro Pm 2025, 2025 This study aimed to characterize a 316L stainless steel powder and a component produced from the same powder batch using the Laser Powder Bed Fusion (LPBF) process. SEM and EDS analyses, apparent density, tapped density, and pycnometric tests were conducted, alongside DSC and XRD analyses. The powders exhibited predominantly spherical morphology, with some variation in particle size and surface oxidation due to recycling and improper storage. Particle size distribution analysis using a Mastersizer 3000 revealed a fine powder fraction, with a median particle size (Dv50) of approximately 2?µm, significantly below the typical LPBF range. The crystalline structure of the powder was predominantly austenitic, with minor peaks that could correspond to ferrite or martensite. The component exhibited hardness values between 230 and 260 HV0.1, with a homogeneous distribution along both build and transverse directions. These results highlight the critical importance of powder condition monitoring for maintaining LPBF component quality.
Characterization Of Inconel 718 Powder And Specimens Produced By L-PBF In Different Orientations Ilidio Costa, Diogo Mota, Mariana Maia, Afonso Nogueira, Jose M. Costa, et al. Euro Powder Metallurgy 2025 Congress and Exhibition Euro Pm 2025, 2025 This study investigates the comprehensive characterization of Inconel 718 powder and specimens produced by Laser Powder Bed Fusion (L-PBF). The powder exhibited spherical morphology with a D50 of 23 µm, demonstrating good flowability with a Hausner ratio of 1.10 ±0.01 and Hall flow of 21.8 ±0.5 s|50g. As-built specimens showed dendritic microstructure with Laves phase, while heat-treated samples developed wrought microstructure with d phase precipitates. Heat treatment significantly enhanced mechanical properties, increasing yield strength from 566 MPa to 1135 MPa and ultimate strength from 858 MPa to 1286 MPa, though elongation decreased from 36.8% to 19.4%. Microhardness improved from 285 HV0.2 to 492 HV0.2 in the building direction, with anisotropy increasing from 3.6% to 5.4% post-treatment. The builds showed minimal defects and high density (>8.20 g|cm³), demonstrating the effectiveness of the L-PBF process for producing high-quality Inconel 718 components.
Characterisation of Ti6Al4V Powder for Laser Powder Bed Fusion Jose Costa, Bernardo Tavares, Gonçalo Cruz, Ines Silva, Jose Silva, et al. Euro Powder Metallurgy 2025 Congress and Exhibition Euro Pm 2025, 2025 The performance of Laser Powder Bed Fusion (LPBF) is highly dependent on the quality of the metallic powder feedstock. This study characterizes a gas-atomized Ti6Al4V (Grade 5) powder, analyzing morphology, particle size distribution, flowability, true density, chemical composition, phase constitution, and thermal stability. Optical and SEM imaging revealed predominantly spherical particles with some irregular shapes and satellites. Particle size analysis showed that only 46.49% of the volume fell within the specified 5–22?µm range, contributing to poor flowability (Hausner Ratio 1.86; Carr Index 46%). True density (4.35 g|cm³) closely matched the theoretical value, indicating low internal porosity. SEM|EDS confirmed the alloy composition but detected elevated oxygen levels. X-ray diffraction revealed an a-phase structure, while thermogravimetric analysis showed thermal stability up to 400?°C, followed by gradual oxidation. The results emphasize the critical influence of powder characteristics on LPBF processability and highlight the importance of stringent powder quality control to ensure reliable outcomes.
Benchmarking L-PBF Systems for Die Production: Powder, Dimensional, Surface, Microstructural and Mechanical Characterisation Jose Manuel Costa, Elsa Wellenkamp Sequeiros, Ruben Filipe Santos, Manuel Fernando Vieira Metals, 2024 While conventional die manufacturing techniques often lead to limitations in production speed and design intricacy due to labour-intensive procedures like machining and casting, Additive Manufacturing (AM) emerges as a key player offering substantial potential for cost reduction and process improvement in mass production. This study benchmarks four leading Laser Powder Bed Fusion (L-PBF) systems for producing maraging steel (EN 1.2709) dies. Despite the shared material and technology, variations in dimensional accuracy, surface finish, and microstructure were observed among the maraging steel parts. SEM/EDS, EBSD, hardness testing, and dimensional analysis revealed system-specific performance differences. Additionally, select parts underwent heat treatment and tensile testing, demonstrating the impact of post-processing on mechanical properties. These results offer valuable guidance for industrial stakeholders considering AM, highlighting the importance of supplier selection and process optimisation for achieving consistent part quality and unlocking the full potential of AM technologies.
Topology Optimization of a Robot Gripper with nTopology Beatriz Monteiro, Francisca Rocha, Jose Costa U Porto Journal of Engineering, 2024 The robot gripper works analogously to the human hand, being the end effector of a robotic mechanism and acting as a bridge between the robot and the environment. A topology optimized gripper can be fully functional while allowing weight reduction. In this paper, the topology optimization of a 316L-SS four-clamp gripper capable of withstanding a 2 N load was conducted using the nTopology software. Fusion360 static stress analysis showed a reduction of 43% in weight, keeping the safety factor above 3, and leading to a displacement of 0,0067 mm. Finally, the maximum induced stress was shown not to cause permanent deformation of the clamp since it was observed to be inferior to the yield strength of 316L-SS.
Development of a Workflow for Topological Optimization of Cutting Tool Milling Bodies BR Cunha, BM Guimarães, D Figueiredo, MF Vieira, JM Costa Metals 16 (1), 116 , 2026 2026 Citations: 2
Robust All-Solid-State Batteries with Sodium Ion Electrolyte, Aluminum and Additive Manufacturing Inconel 625 Electrodes MC Baptista, AB Vale, JM Costa, MH Braga Molecules 30 (22), 4465 , 2025 2025 Citations: 2
Exploring the Potential and the Disruptiveness of Additive Manufacturing for Metallic Materials JM Costa University of Porto - Faculty of Engineering | https://hdl.handle.net/10216 … , 2025 2025 Citations: 1
Topology Optimization of a Milling Cutter Head for Additive Manufacturing IB Costa, BR Cunha, J Marouvo, D Figueiredo, BM Guimarães, MF Vieira, ... Metals 15 (7), 729 , 2025 2025 Citations: 8
Topology optimization of an aluminum bicycle pedal crank using laser powder bed fusion JM Costa, MC Maia, AP Fernandes, EC Oliveira, MF Vieira, EW Sequeiros Materials Science in Additive Manufacturing 4 (1) , 2025 2025 Citations: 3
Characterization of Ti6Al4V Powder for Laser Powder Bed Fusion JM Costa, B Tavares, G Cruz, I Silva, J Silva, PR Rodriguez, ... Euro PM2025 Congress Proceedings, https://doi.org/10.59499/EP256768096 , 2025 2025
Characterization of Inconel 718 Powder and Specimens Produced by LPBF in Different Orientations IB Costa, D Mota, M Maia, A Nogueira, JM Costa, EW Sequeiros Euro PM2025 Congress Proceedings, https://doi.org/10.59499/EP256768283 , 2025 2025
Characterization of 316L Stainless Steel Powders: Correlating Microstructural and Mechanical Properties in LPBF Components EW Sequeiros, AC Figueiredo, RA Coelho, RP Ribeiro, JM Costa Euro PM2025 Congress Proceedings, https://doi.org/10.59499/EP256768115 , 2025 2025
Optimizing Metal AM Potential through DfAM: Design, Performance, and Industrial Impact JM Costa, EW Sequeiros, D Figueiredo, AR Reis, MF Vieira IntechOpen , 2024 2024 Citations: 8
Teaching Design for AM to Science Materials Engineering Graduate Students: Hand-on Approach JM Costa, MF Vieira Modern Concepts in Material Science 6 (3), 10.33552/MCMS.2024.06.000640 , 2024 2024 Citations: 1
The heat treatment effects on the microstructure, hardness, and sigma phase content of L-PBF SAE 316L stainless steel JM Costa, BS Monteiro, FA Rocha, MS Cunha, MF Vieira, EW Sequeiros Academia Materials Science , 2024 2024 Citations: 2
Topology optimization applied to additive-manufactured hydrofoil wing components M Mata, E Bencatel, RIcardo, Sequeiros, M Vieira, J Costa Academia Materials Science 1, https://doi.org/10.20935/AcadMatSci6213 , 2024 2024 Citations: 6
Benchmarking L-PBF Systems for Die Production: Powder, Dimensional, Surface, Microstructural and Mechanical Characterisation JM Costa, EW Sequeiros, RF Santos, MF Vieira Metals 14 (5), 520 , 2024 2024 Citations: 11
Effect of Aging Heat Treatment in an Al-4008 Produced by Liquid Metal Printing CM Ladeiro, FL Nunes, M Trindade, JM Costa U. Porto Journal of Engineering 10 (1), 45-58 , 2024 2024 Citations: 5
Design and Optimization of a Gripper Clamp MS Cunha, ES Alves, JM Costa U. Porto Journal of Engineering 10 (1), 34-44 , 2024 2024 Citations: 6
Production and nTopology optimization of an additive manufactured support for smart glasses F Nunes, M Trindade, J Costa U. Porto Journal of Engineering 10 (1), 20-33 , 2024 2024 Citations: 4
Topology Optimization of a Robot Gripper with nTopology B Monteiro, F Rocha, J Costa U. Porto Journal of Engineering 10 (1), 11-19 , 2024 2024 Citations: 10
Fused Filament Fabrication for Metallic Materials: A Brief Review JM Costa, EW Sequeiros, MF Vieira Materials 16 (24), 7505 , 2023 2023 Citations: 52
O Fabrico Aditivo de Materiais Metálicos JM Costa, A Nogueira, EW Sequeiros, MF Vieira Ciência & Tecnologia dos Materiais 2022, 49-54 , 2023 2023
Characterization of D2 Tool Steel fabricated thru Fused Filament Fabrication Process J Johnsson, T Tufvesson, J Costa U. Porto Journal of Engineering 9 (3), 181-193 , 2023 2023 Citations: 3
MOST CITED SCHOLAR PUBLICATIONS
Fused Filament Fabrication for Metallic Materials: A Brief Review JM Costa, EW Sequeiros, MF Vieira Materials 16 (24), 7505 , 2023 2023 Citations: 52
Additive manufacturing: Material extrusion of metallic parts J Costa, E Sequeiros, MT Vieira, M Vieira U. Porto Journal of Engineering 7 (3), 53-69 , 2021 2021 Citations: 38
Production of an Office Stapler by Material Extrusion Process, using DfAM as Optimization Strategy C Oliveira, M Maia, J Costa U. Porto Journal of Engineering 9 (1), 28-41 , 2023 2023 Citations: 14
Topological Optimization of a Metal Extruded Doorhandle using nTopology M Mata, M Pinto, J Costa U. Porto Journal of Engineering 9 (1), 42-54 , 2023 2023 Citations: 14
Benchmarking L-PBF Systems for Die Production: Powder, Dimensional, Surface, Microstructural and Mechanical Characterisation JM Costa, EW Sequeiros, RF Santos, MF Vieira Metals 14 (5), 520 , 2024 2024 Citations: 11
Topology Optimization of a Robot Gripper with nTopology B Monteiro, F Rocha, J Costa U. Porto Journal of Engineering 10 (1), 11-19 , 2024 2024 Citations: 10
Topology Optimization of a Milling Cutter Head for Additive Manufacturing IB Costa, BR Cunha, J Marouvo, D Figueiredo, BM Guimarães, MF Vieira, ... Metals 15 (7), 729 , 2025 2025 Citations: 8
Optimizing Metal AM Potential through DfAM: Design, Performance, and Industrial Impact JM Costa, EW Sequeiros, D Figueiredo, AR Reis, MF Vieira IntechOpen , 2024 2024 Citations: 8
Topology optimization applied to additive-manufactured hydrofoil wing components M Mata, E Bencatel, RIcardo, Sequeiros, M Vieira, J Costa Academia Materials Science 1, https://doi.org/10.20935/AcadMatSci6213 , 2024 2024 Citations: 6
Design and Optimization of a Gripper Clamp MS Cunha, ES Alves, JM Costa U. Porto Journal of Engineering 10 (1), 34-44 , 2024 2024 Citations: 6
Effect of Aging Heat Treatment in an Al-4008 Produced by Liquid Metal Printing CM Ladeiro, FL Nunes, M Trindade, JM Costa U. Porto Journal of Engineering 10 (1), 45-58 , 2024 2024 Citations: 5
Production and nTopology optimization of an additive manufactured support for smart glasses F Nunes, M Trindade, J Costa U. Porto Journal of Engineering 10 (1), 20-33 , 2024 2024 Citations: 4
Topology optimization of an aluminum bicycle pedal crank using laser powder bed fusion JM Costa, MC Maia, AP Fernandes, EC Oliveira, MF Vieira, EW Sequeiros Materials Science in Additive Manufacturing 4 (1) , 2025 2025 Citations: 3
Characterization of D2 Tool Steel fabricated thru Fused Filament Fabrication Process J Johnsson, T Tufvesson, J Costa U. Porto Journal of Engineering 9 (3), 181-193 , 2023 2023 Citations: 3
Recycling Potential of Onyx Composite for Additive Manufacturing M Mergulhão, S Magalhães, JM Costa U. Porto Journal of Engineering 9 (3), 91-101 , 2023 2023 Citations: 3
Infiltration of aluminum in 3D‐printed metallic inserts H Nunes, O Emadinia, J Costa, R Madureira, R Soares, J Silva, I Frada, ... Applied Research 2 (1), e202200062 , 2023 2023 Citations: 3
Development of a Workflow for Topological Optimization of Cutting Tool Milling Bodies BR Cunha, BM Guimarães, D Figueiredo, MF Vieira, JM Costa Metals 16 (1), 116 , 2026 2026 Citations: 2
Robust All-Solid-State Batteries with Sodium Ion Electrolyte, Aluminum and Additive Manufacturing Inconel 625 Electrodes MC Baptista, AB Vale, JM Costa, MH Braga Molecules 30 (22), 4465 , 2025 2025 Citations: 2
The heat treatment effects on the microstructure, hardness, and sigma phase content of L-PBF SAE 316L stainless steel JM Costa, BS Monteiro, FA Rocha, MS Cunha, MF Vieira, EW Sequeiros Academia Materials Science , 2024 2024 Citations: 2
Additively Manufactured Ti-6Al-4V: Effects of Heat-Treatment H Nunes, JM Costa, F Viana, MF Vieira Materials Proceedings 8 (1), 111 , 2022 2022 Citations: 2