Conventional Manufacturing Research Articles

Influence of hydrogen uptake on additive manufacturing and conventional austenitic stainless steels 316L

This study investigates the hydrogen embrittlement resistance of 316L stainless steels fabricated via conventional manufacturing (CM) and directed energy deposition (DED) additive manufacturing (AM). The hydrogen effect on the mechanical properties of these samples has been examined through a combination of microstructural investigation correlated with hydrogen solubility and trapping. Results show the CM sample has a lower solubility of hydrogen with a relatively low dislocation density. In the case of the as-built AM sample, the higher amount of hydrogen is linked with a deterioration in the mechanical behaviours of the steel (strength/elongation) and a higher hydrogen embrittlement sensitivity. This deterioration can be attributed to the higher misorientation density in AM material with a larger grain size. Conventionally, global hydrogen concentration is measured from thermal desorption spectroscopy (TDS), however this study presents a new measurement using glow discharge optical emission spectroscopy (GDOES). This method provides a new insightful understanding of hydrogen embrittlement with local hydrogen distribution and a comparison for existing standards.

Appraising sustainability and economic growth through Fintech, green finance and natural resource in Asian economies: A CS-ARDL study

Governments in Asian economies are under immense pressure from an ecological perspective and are trying to increase compliance with environmental policies by institutions and households, which have the objective of reducing environmental pollution. This is because the Asian region contributes two-thirds of the global growth. However, because of the conventional manufacturing facilities and infrastructure, the Asian region had to rely on the consumption of the Natural Resource (NTR) for their economic development; thus,the environment is being harshly affected, eventually affecting the quality of life of every dweller. Therefore, this research revisits the Asian economies due to their global significance in financial, environmental and sustainable development. Moreover, the present study evaluates the role of Fintech (FNT), Green Finance (GFN) and Natural Resource (NTR), in diluting the disparity betweeneconomic and ecological sustainability. The current study explores these relationships through the help of an advanced and recent estimation technique named “Cross-section augmented autoregressive distributed lags (CS-ARDL)”. Through the generated outcome from CS-ARDL, FNT, NTR, and GFN are found to support the Economic Growth (ECG). From the environmental perspective, the role of FNT and GFN was found to be satisfying as they lead to reduced environmental pollution. However, the role of NTR was found to destroy ecological health, which is the validation of the earlier studies but does require careful attention from the concerned authorities. In light of these findings, the Asian governments will be in a better position to identify, devise and select appropriate strategies and policies that will assist in alleviating environmental pollution and strengthening economic development.

Comparison of Tensile Bond Strength of Soft Denture Liner Material on Denture Base Resins

Aim: This study aims to evaluate the tensile bond strength (TBS) of a silicone-based soft denture liner material on denture bases produced via conventional, subtractive, and additive manufacturing techniques and examine the effect of aluminum oxide particle abrasion (APA) on TBS. Material and Methods: A total of 48 cylindrical denture base resin samples were manufactured using three different techniques: conventional, subtractive, and additive manufacturing. The samples were divided into two groups: control and APA. All samples were separated at the center, and the soft liner was applied to the corresponding surfaces. The specimens then underwent TBS testing. Data were analyzed using Two-way ANOVA and Bonferroni post hoc tests. Results: Two-way ANOVA results indicated a significant difference among the denture base resins, while no significant difference was found between the control and APA groups. The highest TBS was observed in the subtractive-manufactured APA group, while the lowest TBS was in the additive-manufactured APA group. Significant differences were found between the subtractive and additive-manufactured groups (p=0.022). Conclusion: This study demonstrates that TBS varies with the DB's manufacturing technique. While APA increased TBS in subtractive manufacturing, it had no statistically significant effect. Further research should explore different soft lining materials and consider in vivo conditions for more comprehensive insights.

Machine Learning Techniques for Cyber Security in Internet of Robotic Things

Robots are becoming common in domestic, medical, industrial, entertainment, and educational routine activities. The use of robots automates the work processes thus minimizes human labor. The Robots perform complex and repetitive tasks with efficiency and agility, therefore, the conventional industrial manufacturing process are being replaced by smart manufacturing. Robotics encompasses the design and development of robot-based automated systems. It integrates various emerging technologies i.e. operational technology (OT), cloud computing, and artificial intelligence (AI). The Internet of Robotic Things (IoRT) seamlessly combines robots and Internet of Things (IoT) devices, enabling connectivity through the Internet. IoRT enables simple robots to coordinate with each other to achieve well-defined goals by creating a multi-robot system. Cyber security is an inherent challenge for IoRTs because of the interconnected infrastructure and reliance on critical industrial operations on the internet. Any cyber-attack can affect the ongoing operations and compromise the safety of robots. The growing interest among governments, researchers, and industries in robotics and automation demands a dependable cyber-security solution. This paper explores machine learning (ML) based cyber security solutions to mitigate cyber vulnerabilities and threats to IoRT and its dependent systems.

OPTIMIZATION OF ANNEALING AND 3D PRINTING PROCESS PARAMETERS OF PLA PARTS

Fused Filament Fabrication (FFF) has gained significant popularity as the prevalent additive manufacturing technique due to its ability to reduce production time and expenses. However, the constraints of limited dimensional precision, poor surface quality, and relatively low Ultimate Tensile Strength (UTS) hinder compliance with the stringent regulatory norms of conventional manufacturing, necessitating post-processing for enhancement. In this investigation, the response surface method was used to optimize annealing and certain printing parameters in order to enhance the quality of PLA parts produced by FFF. The optimization technique aimed to enhance the UTS and match the CAD dimensions while also minimizing surface roughness. The RSM optimization analysis identified the optimal parameters as: layer height of 0.1 mm, build orientation at 0 degrees, annealing temperature of 110 degrees, and annealing time of 180 dk mm. The proposed models are substantiated by the consistent achievement of high levels of agreement between estimated and experimental response values. A composite desirability value of 0.80 was derived for the variables as a consequence of the optimization investigation.

Conventional Manufacturing by Pouring Versus Additive Manufacturing Technology of β-Tricalcium Phosphate Bone Substitute Implants.

The aim of the study was to compare conventional sintering with additive manufacturing techniques for β-TCP bioceramics, focusing on mechanical properties and biocompatibility. A "critical" bone defect requires surgical intervention beyond simple stabilization. Autologous bone grafting is the gold standard treatment for such defects, but it has its limitations. Alloplastic bone grafting with synthetic materials is becoming increasingly popular. The use of bone graft substitutes has increased significantly, and current research has focused on optimizing these substitutes, whereas this study compares two existing manufacturing techniques and the resulting β-TCP implants. The 3D printed β-TCP hybrid structure implant was fabricated from two components, a column structure and a freeze foam, which were sintered together. The conventionally fabricated ceramics were fabricated by casting. Both scaffolds were characterized for porosity, mechanical properties, and biocompatibility. The hybrid structure had an overall porosity of 74.4 ± 0.5%. The microporous β-TCP implants had a porosity of 43.5 ± 2.4%, while the macroporous β-TCP implants had a porosity of 61.81%. Mechanical testing revealed that the hybrid structure had a compressive strength of 10.4 ± 6 MPa, which was significantly lower than the microporous β-TCP implants with 32.9 ± 8.7 MPa. Biocompatibility evaluations showed a steady increase in cell proliferation over time for all the β-TCP implants, with minimal cytotoxicity. This study provides a valuable insight into the potential of additive manufacturing for β-TCP bioceramics in the treatment of bone defects.

Coordinate system setting for post-machining of impeller shape by wire arc DED and evaluation of processing efficiency

Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process that uses arc welding. It is a method of stacking beads made by melting metal wires with an arc heat source generated by a short-circuit current. Compared to other metal additive manufacturing methods, this process can be used to quickly produce large and complex-shaped metal parts. However, due to the multi-bead stacking method, the surface is highly curved and the dimensional errors are large; therefore, post-processing of the surface by cutting is required. Impellers, which are widely used in various industries, have complex shapes and high material consumption during cutting; therefore, the WAAM process can improve the manufacturing efficiency. In this study, a manufacturing process for an impeller with a diameter of 160 mm was developed by using the WAAM process. A 6-bladed fan-type impeller used for high-pressure fluid delivery was similarly modeled, and the product was additively manufactured using an Inconel 625 alloy wire. Manufacturing conditions that ensure productivity and quality or the product were determined through experimentation. Considering the post-processing of the WAAM-fabricated structure, the robot and tool paths of the impeller model were designed, and the error in the process coordinate system caused by attaching and detaching the workpiece between the two processes was reduced. Through the post-processing of the WAAM-fabricated structure, the production efficiency and process reliability were verified when the conventional manufacturing method and WAAM process were applied.

Insights into morphology and mechanical properties of architected interpenetrating aluminum-alumina composites

Additive manufacturing (AM) technologies are unleashing the restrictions imposed by conventional manufacturing, allowing the production of innovative designs tailored to improve properties or performance. AM techniques in ceramic production allow the application of novel designs to ceramic parts, opening new opportunities for combining technologies aiming to obtain architected interpenetrating phase composites (IPCs). In this study, alumina structures with different architectures and Computer Aided Design (CAD) structure porosity oriented unidirectionally or bidirectionally, were fabricated by vat photopolymerization technique, namely Digital Light Processing. Afterwards, these structures were infiltrated with an aluminum alloy through investment casting, thus obtaining aluminum-alumina IPCs. Under compression, the IPCs presented a ductile behavior, conversely to the fragile ceramic counterparts. The IPCs compressive strength and absorbed energy were expressively higher than their ceramic counterparts. Comparing the bidirectional IPCs with the unidirectional ones, a significant increase in compressive strength and absorbed energy was observed, from 36.2% to 42.3% and from 164.8% to 358.1%, respectively, due to the greater amount and interconnection of the metal inside the ceramic structure. This study demonstrates the feasibility of this manufacturing route, combining two distinctive technologies, for the fabrication of metal-ceramic architected IPCs, allowing to tailor their mechanical properties and energy absorption capacity for a given application.

Enhanced mechanical properties of sandwich panels via integrated 3D printing of continuous fiber face sheet and TPMS core

Sandwich panel structures have widespread applications in various components, owing to their excellent lightweight properties. However, conventional manufacturing methods involve multiple steps, which limits the exploration of innovative sandwich panel structure. In this study, an integrated 3D printing method for continuous fibers reinforced sandwich panel with Triply Periodic Minimal Surface (TPMS) core structure is proposed via Fused Deposition Modelling (FDM). A bridging layer and a continuous basalt fiber pre-impregnated by stiff thermoset epoxy resin are utilized to address the issue of overhanging printing for the upper face sheet. Two kinds of TPMS are employed as the core, as well as two kinds of honeycomb. Multi-step printed samples using a bonding process and counterpart samples without fiber were prepared for the comparison. 3-point bending tests were conducted and a finite element model which can represent the structure characteristic is proposed to investigate the mechanical properties. The results show that the integrated printed sample exhibits better performance in terms of printing quality, flexural modulus, strength and energy absorption (EA) compared with the multi-step printed sample. It has an excellent ability to avoid the catastrophic damage which is usually encountered in the multi-step printed sample due to the introduction of brittle epoxy resin, showing a notable 162.88 % augmentation in specific energy absorption (SEA). The significant improvement lies in that it uses the reinforcement of fiber and the energy absorption capacity of core to full advantage via the strong binding. In addition, as one kind of TPMS, Schwarz Primary structure exhibits the maximum flexural modulus, strength and energy absorption among the four cores. The proposed design and fabrication methodology pave the way for the creation of high-performance sandwich panels with different core structures.

Inkjet-Printed LSM-YSZ Thin Films for Enhanced Oxygen Electrodes in Solid Oxide Fuel Cells.

In the present work, symmetrical oxide ion conducting solid oxide single cells with inkjet-printed composite LSM-YSZ electrodes, onto commercially available YSZ dense substrates using GDC as buffer interlayer, were fabricated and characterized. Stable inkjet-printable LSM-YSZ nanoparticle inks were developed based on water solvent, after processing with high intensity ball milling. The deposition of LSM-YSZ electrodes was performed by inkjet printing, as well as a conventional additive manufacturing technique, screen printing, in order to compare the electrochemical performance of the produced cells for the reversible charge transfer reaction (O2 + 4 e- ↔ 2 O2-). The physicochemical properties of the LSM-YSZ nanoparticle ink was investigated to determine ink printability. The electrochemical performance of fabricated inkjet-printed and screen printed symmetrical cells (LSM-YSZ | GDC | YSZ | GDC | LSM-YSZ) exposed under a synthetic air atmosphere was evaluated in a single chamber cell reactor, employing the AC impedance spectroscopy and linear scan voltammetry techniques, at the temperature range of 700-850 °C. The inkjet-printed electrodes exhibited highly homogeneous and porous morphologies with the corresponding cell achieving current densities almost five times higher, up to 1 A/cm2 at 2 V cell potential and 850 °C, than those of the equivalent screen-printed one. To the best of our knowledge, this is the first successful implementation of water-based inks of LSM-YSZ electrodes in the fabrication of inkjet-printed solid oxide cells.

Cold spray - a solid-state additive manufacturing technology

Abstract Cold spray is a solid-state powder deposition technique and has evolved into an additive manufacturing process. Unlike conventional additive manufacturing technologies that rely on melting and solidification, cold spray additive manufacturing (CSAM) forms components at low temperatures at a relatively high build rate. This article introduces the technical principles, process parameters and typical microstructure of cold spray, as well as its applications in the fabrication of 3D components and damaged component repair. Current issues faced in cold spray research and future development directions in CSAM are also discussed.

Design of a Robotic 3D Printing System

Abstract Additive manufacturing enables the production of complex shapes with a large degree of freedom compared to conventional manufacturing techniques such as injection molding, thermoforming or pressing. In particular, the creation of moving parts, complex structures and large-scale printing remains underexplored and research is constantly expanding. Due to design limitations related to the construction of currently available printers, 3D printing technology is increasingly being combined with robotics. Using a robot to 3D print products eliminates the need to design complex printer structures, which ultimately should simplify the process of manufacturing large-scale products and shorten the time required for preparation and production. The paper deals with the description of the designed 3D printing system and the procedure of the steps of creating a robotic simulation model with the generation of a control program for the FDM 3D printing process by an industrial robot.

Characterisation of the Decoring Behaviour for Furan Resin Bonded Sands Using DEM Simulation

Sand cores and moulds form the inner and outer structures of casting parts with tolerances of up to a few tenths of a millimetre. These must fulfil two complementary characteristics. During casting, they must withstand the high thermal and mechanical loads and subsequently disintegrate without leaving any residue. The production of these mostly organically bonded cores and moulds is done with conventional manufacturing processes, such as core shooting, or what is becoming increasingly more important for foundries, using 3D printing. In order to better understand this complex disintegration behaviour of these different core types and thus minimise the enormous energy input for their removal, a suitable simulation model based on discrete element methods (DEM) is considered as a tool to describe and further analyse the prevailing complex interactions in more detail. This contribution discusses the characterisation of furan resin bonded sand cores/parts, presenting various test apparatuses designed for this purpose, and outlines the foundational setup and definition of bonded-particle models (BPM) to be used as breakable structures in respective DEM simulations.

On the feasibility to obtain CuCrZr alloys with outstanding thermal and mechanical properties by additive manufacturing

The CuCrZr alloy combines high thermal conductivity and mechanical strength with stability at high-medium temperatures, making it a promising heat sink material for the EU-DEMO divertor and limiters. Additive Manufacturing (AM) technologies have proven effective in developing complex-shaped components with almost no constraints on geometry and minimal machining and welding requirements. This makes them particularly suitable for the production of heat exchangers featuring complex cooling channels with intricate inner structures.This study demonstrates the feasibility to obtain dense CuCrZr via Electron Beam Powder Bed Fusion (EB-PBF) with high thermal conductivity and enhanced mechanical strength compared to conventional routes. Gas atomization was used to produce spherical powders with a composition close to ITER specifications. By optimising the EB-PBF process parameters, relative density values of 99.7 % were achieved after HIP treatment, that removes the eventual residual porosity. The results underscore the importance of meticulous powder manufacturing to mitigate oxidation and microstructural defects in the final components. Achieving high relative densities in the EB-PBF process requires a focus on adopting high-energy absorption rates in the powders. This strategy can be accomplished by reducing the scanning speed and consequently the building rate of the process. The microstructural characterization revealed a complex hierarchical microstructure composed of grains and grain boundaries, solidification-enabled cellular-like subgrains elongated along the building direction and an ultra-fine precipitate state (already present in the as-built condition) mainly consisting of Cr-rich nanoprecipitates, although Zr-rich precipitates were also found at the melt pool boundaries. The thermal conductivity, hardness, mechanical strength at room temperature and high-medium temperatures were measured and correlated with the EB-PBF process parameters and the microstructure obtained after HIP treatment. The results indicate that it is possible to obtain CuCrZr with improved mechanical behaviour compared to conventional manufacturing technologies, while maintaining the thermal conductivity requirements for EU-DEMO.

A new combined fabrication process to shape small flexure hinges

This paper presents a new combined fabrication method, named 3D-PLAST, aimed at overcoming inherent limitations of conventional additive manufacturing techniques when producing small flexure hinges in compliant mechanisms. Flexure hinges play a crucial role in various applications, offering advantages such as cost reduction, increased precision, and weight reduction. However, traditional additive manufacturing proves challenging in achieving satisfactory mechanical properties when manufacturing small-size hinges. To overcome these limitations, the 3D-PLAST process combines fused filament fabrication with compressive plastic deformation. This hybrid process exploits the advantages of both techniques, i.e., flexibility, low cost, and ease of use. This process enables the fabrication of small-size mechanisms with good dimensional accuracy. Finally, the paper reports experimental tests on two materials comparing flexure hinges manufactured by 3D-PLAST versus 3D printing methods to demonstrate the effectiveness of the proposed process.

Red and Green Laser Powder Bed Fusion of Pure Copper in Combination with Chemical Post-Processing for RF Cavity Fabrication

Linear particle accelerators (Linacs) are primarily composed of radio frequency cavities (cavities). Compared to traditional manufacturing, Laser Powder Bed Fusion (L-PBF) holds the potential to fabricate cavities in a single piece, enhancing Linac performance and significantly reducing investment costs. However, the question of whether red or green laser PBF yields superior results for pure copper remains a subject of ongoing debate. Eight 4.2 GHz single-cell cavities (SCs) were manufactured from pure copper using both red and green PBF (SCs R and SCs G). Subsequently, the surface roughness of the SCs was reduced through a chemical post-processing method (Hirtisation) and annealed at 460 °C to maximize their quality factor (Q0). The geometric accuracy of the printed SCs was evaluated using optical methods and resonant frequency (fR) measurements. Surface conductivity was determined by measuring the quality factor (Q0) of the SCs. Laser scanning microscopy was utilized for surface roughness characterization. The impact of annealing was quantified using Energy-Dispersive X-ray Spectroscopy and Electron Backscatter Diffraction to evaluate chemical surface properties and grain size. Both the SCs R and SCs G achieved the necessary geometric accuracy and thus fR precision. The SCs R achieved a 95% Q0 after a material removal of 40 µm. The SCs G achieved an approximately 80% Q0 after maximum material removal of 160 µm. Annealing increased the Q0 by an average of about 5%. The additive manufacturing process is at least equivalent to conventional manufacturing for producing cavities in the low-gradient range. The presented cavities justify the first high-gradient tests.

Parametric Optimization of Structural Frame Design for High Payload Hexacopter

For drones, the use of which has been increasing recently for load carrying, lightweight drone frame design is significant for increased flight time and payload capacity. Drones are produced in different configurations with three, four or six rotors, and in different sizes depending on the purpose of use. While agility is more important in three and four rotor drone applications, six-rotor and relatively large-bodied drones are preferred in cases such as load carrying. When the body structure has to be large, lightening the design becomes very critical. Lightweight designs can be achieved by two commonly used methods for structural optimization: topology optimization and parametric optimization. Topology optimization is an advanced method that can significantly reduce weight but is expensive and time-consuming. Parametric optimization is a more practical approach for conventional manufacturing methods and was used in this study. This study aims to first simplifying the hexacopter frame model and defining key geometric parameters for mass-decreasing optimization. Finite element analysis simulations were used to evaluate the strength and deformation of the frame under various design scenarios. The results showed that parametric optimization successfully reduced the weight of the hexacopter frame while maintaining structural integrity. The maximum Von Mises stress was found as approximately one quarter of the yield strength of the frame material. The maximum total deformation was achieved below 0.3 mm, and deformation under 1 mm is considered safe in the literature. As a result, the optimized design offers a lighter drone structure in line with conventional manufacturing methods, providing better flight time and payload capacity while maintaining cost effectiveness. In future studies, comparisons can be made based on this study by performing weight optimizations suitable for current methods such as topology optimization or generative design. the cost factor and the availability of existing production lines should be taken into consideration when comparing the mentioned methods with parametric optimization.

A Survey on Fused Filament Fabrication to Produce Functionally Gradient Materials.

Fused filament fabrication (FFF) is a key extrusion-based additive manufacturing (AM) process for fabricating components from polymers and their composites. Functionally gradient materials (FGMs) exhibit spatially varying properties by modulating chemical compositions, microstructures, and design attributes, offering enhanced performance over homogeneous materials and conventional composites. These materials are pivotal in aerospace, automotive, and medical applications, where the optimization of weight, cost, and functional properties is critical. Conventional FGM manufacturing techniques are hindered by complexity, high costs, and limited precision. AM, particularly FFF, presents a promising alternative for FGM production, though its application is predominantly confined to research settings. This paper conducts an in-depth review of current FFF techniques for FGMs, evaluates the limitations of traditional methods, and discusses the challenges, opportunities, and future research trajectories in this emerging field.

A Comparison Study on Detailed Strengthening mechanism analysis on micro structure and mechanical properties of 3 phases FGM Material with vibrational behavior analysis is fabricated using WAAM process and traditional method

Additive Manufacturing (AM) techniques implement the surface thickness accumulating through the support of CAD/CAM model for improving the 3D (three dimensional) products. Metal Additive Manufacturing provides design versatility as well as the freedom in fabricating the materials. The preparation technology of the metal composites integrates pressure leaching, agitation casting, powder metallurgy and friction stirring. The strengthening mechanism of the metal composites comprises of ceramic particle, short fiber and whisker etc. The two common strengthening mechanism to attain the high performing material composite are ceramic particulate reinforced composites (CPRCs) and precipitation hardening (PH). Thus, the current study evaluates the strengthening mechanism of fabricated material along with vibrational behavior using Wire Arc Additive Manufacturing (WAAM). The study fabricated three functionally graded material. The FGM materials are SS316L, SS316L+Inconel 625 + Ti6Al4V and SS316L+Inconel 625 + Inconel 718. The three phase FGM material is annealed at 700⁰C, 900⁰C and 1200⁰C for 60 min. Later, it have been air-cooled to the room temperature. The heating process strengthens the three phase FGM materials. The heating process of FGM material results in the precipitation which might not improve the mechanical properties. Nonetheless, the varied annealing temperature such as 900⁰C and 1200⁰C has enhanced the mechanical properties of the three phase FGM materials. As per the analysis, 60 % SS316L+20 % INCONEL 625+20 % Ti6Al4V material has been completely broken whereas 60 % SS316L+20 % INCONEL 625+20 % Inconel 718 has slight crack which show the increased strength of the material. The resonance frequency in conventional part is lower than the AM part. The resonance is oscillated with greater amplitude at certain frequencies. In damping, a higher resonance frequency is less vibrated in common frequencies. Thus, the study concludes that 60 % SS316L+20 % INCONEL 625+20 % Ti6Al4V and 60 % SS316L+20 % INCONEL 625+20 % Inconel 718 has significant strength compared to parent material SS316L. Moreover, AM has better vibration behavior compared to the conventional manufacturing.

Paclitaxel-loaded elastic liposomes synthesised by microfluidics technique for enhance transdermal delivery.

The inherent flexibility of elastic liposomes (EL) allows them to penetrate the small skin pores and reach the dermal region, making them an optimum candidate for topical drug delivery. Loading chemotherapy in ELs could improve chemotherapy's topical delivery and localise its effect on skin carcinogenic tissues. Chemotherapy-loaded EL can overcome the limitations of conventional administration of chemotherapies and control the distribution to specific areas of the skin. In the current studies, Paclitaxel was utilised to develop Paclitaxel-loaded EL. As an alternative to the conventional manufacturing methods of EL, this study is one of the novel investigations utilising microfluidic systems to examine the potential to enhance and optimise the quality of Els by the microfluidics method. The primary aim was to achieve EL with a size of < 200nm, high homogeneity, high encapsulation efficiency, and good stability. A phospholipid (DOPC) combined with neutral and anionic edge activators (Tween 80 and sodium taurocholate hydrate) at various lipid-to-edge activator ratios, was used for the manufacturing of the ELs. A preliminary study was performed to study the size, polydispersity (PDI), and stability to determine the optimum microfluidic parameters and lipid-to-edge activator for paclitaxel encapsulation. Furthermore, physiochemical characterisation was performed on the optimised Paclitaxel-loaded EL using a variety of methods, including Dynamic Light Scattering, Fourier Transform Infrared Spectroscopy, Atomic force microscopy, elasticity, encapsulation efficiency, and In vitro release. The results reveal the microfluidics' significant impact in enhancing the EL characteristics of EL, especially small and controllable size, Low PDI, and high encapsulation efficiency. Moreover, the edge activator type and concentration highly affect the EL characteristics. The Tween 80 formulations with optimised concentration provide the most suitable size and higher encapsulation efficiency. The release profile of the formulations showed more immediate release from the EL with higher edge activator concentration and a higher % of the released dug from the Tween 80 formulations.