AccScience Publishing / MSAM / Online First / DOI: 10.36922/MSAM026180036
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ORIGINAL RESEARCH ARTICLE

Numerical and experimental assessment of non-monolithic fabrication effects on sound transmission and absorption in additively manufactured metamaterials

Ali Bin Naveed1 Aamir Mubashar1* Muhammad Khizer A. Khan2 Kamran A. Khan2,3*
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1 Department of Mechanical Engineering, School of Mechanical and Manufacturing Engineering, National University of Science and Technology, Islamabad, Pakistan
2 Department of Aerospace Engineering, Khalifa University of Science and Technology, Abu Dhabi, United Arab Emirates
3 Advanced Research and Innovation Center, Khalifa University of Science and Technology, Abu Dhabi, United Arab Emirates
Received: 29 April 2026 | Revised: 13 July 2026 | Accepted: 15 July 2026 | Published online: 20 August 2026
© 2026 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
Abstract

Additive manufacturing (AM) has enabled the realization of complex, high-performance acoustic metamaterials. However, bridging the gap between idealized numerical performance and physical reality remains an ongoing engineering challenge. This research investigates the effects of four AM technologies (fused deposition modeling [FDM], stereolithography, digital light processing [DLP], selective laser sintering [SLS]) on the acoustic performance of a specialized acoustic metamaterial (AMM). While numerical models in COMSOL Multiphysics provide idealized benchmarks for sound absorption coefficient (SAC) and sound transmission loss (STL), this study demonstrates that the physical manufacturing process introduces critical deviations. Experimental results reveal that for SAC, DLP provided the highest fidelity due to its superior surface finish and sharp geometric definition. In contrast, FDM samples showed significant SAC deviations, where inherent process limitations increased thermoviscous losses, leading to higher-than-predicted absorption. However, an inverse trend was observed for STL. The ability of FDM to produce a monolithic structure resulted in STL values that closely aligned with numerical predictions. Conversely, the high-precision DLP and SLS methods required subassembly joining, where microscopic interstitial leakages caused a sharp degradation in STL performance. The findings indicate that these leakages often appear as absorption in SAC measurements, hiding structural failures that only become evident during STL characterization. This study concludes that for industrial noise mitigation applications, the necessity of monolithic construction and the elimination of acoustic leaks outweigh the benefits of high-resolution surface finishes. These results provide a vital framework for selecting AM processes based on the specific acoustic requirements of the design.

Graphical abstract
Keywords
Sound absorption coefficient
Sound transmission loss
Selective laser sintering
Digital light processing
Stereolithography
Fused deposition modeling
Acoustics
Additive manufacturing
Funding
The authors declare that no financial support was received for the research, authorship, or publication of this work.
Conflict of interest
Kamran A. Khan is an Editorial Board Member of this journal, but was not in any way involved in the editorial and peer-review process conducted for this paper, directly or indirectly. The authors declare they have no competing interests.
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Materials Science in Additive Manufacturing, Electronic ISSN: 2810-9635 Published by AccScience Publishing