Researchers at Johns Hopkins University have established a simulation-driven process framework guided by thermal information to stabilize thin-walled aluminum alloy structures in metal extrusion additive manufacturing (MEAM). This work addresses two types of thermal failure modes that previously limited the reliability of this process for high-melting-point metals. The team identified underheating and overheating as the two dominant failure modes: underheating occurs when heat dissipation from deposited layers causes premature solidification and nozzle clogging, while overheating happens when the extrusion speed exceeds the cooling capacity of deposited layers, leading to remelting and structural collapse. By adopting a layer-by-layer strategy to regulate the bed temperature, the researchers introduced a time-based interlayer cooling criterion—while maintaining constant nozzle temperature and print speed—to ensure each layer cools to the solidus before further deposition. Using ER4043 aluminum welding wire (approximately 5% silicon, 95% aluminum), they successfully printed thin-walled structures with consistent surface roughness and repeatable geometry.