Manufacturing Demands Research Articles

Optimizing energy modeling in PBF-LB/M metal additive manufacturing: a detailed analysis of resource and energy demand based on standard tensile test specimen

Additive manufacturing is an essential tool in modern production processes. Competitive quality and the increasing importance of local manufacturing have allowed companies to maintain their production despite supply chains disrupted by the pandemic. However, the rising awareness of society towards environmental and climate protection, the increasing demand for resource-efficient products, and recent developments in energy costs are leading to a rethink in manufacturing processes. Additive manufacturing offers great potential for resource saving components. This study uses standard tensile test specimens to analyze AM processes regarding energy and material flows. The results show a high dependence of energy demand on process time and are transformed into a data-based energy model. Compared to previous energy models, the accuracy can be significantly improved using model data in combination with specific and system-oriented approaches. In addition to system-related saving potentials, design-related optimization potentials can be identified. Innovative and highly resource-saving components can be designed with a design methodology adapted to the extended degrees of freedom of AM. Further saving and recycling potentials can be identified along the material flows. A long-term goal is optimizing and predicting of resource demand in additive manufacturing with a view to the entire product lifecycle.

A comparative study on cryogenic formability and paint baking property of AA7075 alloy sheets tempered at fast retrogressed and pre-aged conditions

Forming at cryogenic temperatures provides a new approach to the formability improvement of 7000-series high-strength aluminum alloys. However, the cryogenic forming process based on solution-treated (W) or peak artificial aged (T6) alloys cannot meet the demands of autobody manufacturing for good formability, high post-formed strength and high efficiency simultaneously. The fast retrogression (FR) treatment of AA7075-T6 and pre-aging (PA) treatment of AA7075-W are elaborately designed to tailor a pre-hardened AA7075 alloy, which has good cryogenic formability and relatively high initial strength, and can be further strengthened by paint baking in high efficiency. The results show the optimum fast retrogression temperature for AA7075-FR is 400 °C, at which the sample can acquire a cryogenic elongation of 29.2% and obtain 90% of initial T6 sheet tensile strength by the combined effect of cryogenic pre-deformation and subsequent paint baking treatment. The optimum pre-aging temperature for AA7075-PA is 120 °C, at which the sample can acquire a cryogenic elongation of 31.0% and exceed 96% of tensile strength of AA7075-T6 after paint baking treatment. The comparative study demonstrates that the supersaturated solid solution matrix with an appropriate proportion of GP zones and η′ phases, but few Cr-containing dispersoids and precipitate free zones, is an ideal pre-hardened microstructure to get a good combination of cryogenic formability and final strength. The precipitation of GP zones and η′ phases is prior to the formation of precipitate free zones during pre-aging of AA7075-W, making the pre-aged hardening cryogenic forming process more suitable for automobile industry.

Responding to consumer environmental awareness: A variational inequality approach to green manufacturing optimization

In response to increasing consumer environmental awareness, our study introduces a sustainable supply chain optimization model that stimulates competition among multiple green manufacturers within an uncertain market context. Each manufacturer crafts a selection of products showcasing various degrees of greenness, purposefully designed to meet the expanding demand of environmentally conscious consumers. This strategic model emphasizes profit maximization for green manufacturers, necessitating the definition of ideal greenness levels and production quantities for an array of product types. By employing variational inequality theory, we transmute the preliminary optimization model into an interconnected variational inequality problem. We propose an improved Euler algorithm, a proficient tool for attaining equilibrium solutions. Empirical scenarios inspired by the electric vehicle industry lend credibility to our model, indicating that the surge in consumer environmental awareness compels manufacturers to diversify their offerings and accentuate their products’ greenness levels. Intriguingly, the research suggests that escalating competition can incentivize manufacturers to elevate their products’ greenness levels, strategically countering potential profit erosion. In addition, the study reveals that intensifying consumers’ green utility sensitivity doesn’t invariably augment demand for manufacturers, even with significant improvements in product greenness. This paradox highlights the necessity for manufacturers to strategically adjust their production approaches in light of varying consumer preferences. Moreover, when the level of consumer environmental awareness achieves a certain level, the fierce competition might not always be harmful to some manufacturers and the industry if they can adopt effective strategies to improve green utility sensitivity.

Accuracy enhancement and joint calibration method of multi-station triangulation network based on absolute ranging

Precision measurement methods and technologies for large-scale three-dimensional coordinates are in high demand in advanced equipment manufacturing. The multi-station triangulation network represented by the rotary-laser scanning measurement system has the advantages of having high precision, having multitask parallel measurement capability, and having a high degree of automation. It is widely used in the docking of large components, quality control of key points, and collaborative positioning of production equipment. Nevertheless, due to the limitations in the measurement principle, the positioning accuracy along the depth direction is notably lower when compared to other directions. This difference becomes more pronounced with increasing distance. This paper proposes a method to address this issue by integrating a distance measurement station into the network. A novel, to the best of our knowledge, cooperative target, coupled with a high-dynamic beam guidance mechanism, is designed to achieve fast absolute distance measurement to the target. The weighted fusion of the distance and angle observations effectively enhances the measurement accuracy while preserving the advantages of highly automated measurement. Additionally, we introduce a joint calibration method for extrinsic parameters of multi-type stations. High-precision absolute distances are utilized to establish optical scale bars, complemented by the incorporation of physical scale bars, thereby obviating the necessity for using external reference instruments such as laser trackers. Finally, a series of experimental verifications demonstrate the effectiveness of calibration and measurement methods. The root mean square error of all measured points drop to 42.6% of that the triangulation method measures.

Influence of boriding on the tribological behavior of AISI D2 tool steel for dry deep drawing of stainless steel and aluminum

Deep drawing of stainless steel and aluminum is a widely adopted method for manufacturing various industrial goods. However, the wear damage produced to die tools is a recurring problem in these processes. While lubricants are often employed to lubricate and reduce die wear, dry deep drawing is the current best alternative for meeting green manufacturing demands. Hence, enhanced solid lubricants or surface treatments for dies are highly required. This study aims to evaluate and compare the tribological behavior of a heat-treated AISI D2 steel and a boriding AISI D2 tool steel against stainless steel (AISI 304) and aluminum alloy (AA 6061 T6) in the absence of lubricant. The boride coating was formed on the AISI D2 steel by the closed-pack boriding technique, resulting in a tooth-saw morphology with an overall thickness of 33.6 μm. X-ray diffraction analysis confirmed the presence of FeB, Fe2B, and Cr2B3 phases on the surface of the borided AISI D2 tool steel. Notably, the boriding treatment led to a significant increase in the surface hardness of the tool steel, reaching a value of 20.7 GPa. The coefficient of friction (CoF) behavior and wear were evaluated by pin-on-disk tests, simulating conditions similar to those found in cold deep drawing operations. The wear surfaces were analyzed by optical profilometry and scanning electron microscopy (SEM). The results suggest boriding as a suitable treatment to reduce wear damage on the surface of deep drawing dies used for stainless steel and aluminum forming processes in the absence of lubricant. Two-body abrasion and adhesion were identified as the main wear mechanisms in AISI D2 steel against stainless steel and aluminum, with a significant amount of oxidation observed when aluminum was tested. Additionally, a reduction of approximately 20 % in the CoF was observed when employing borided tool steel against stainless steel. However, there was an observed increase of around 75 % in the CoF when the borided tool steel was tested against aluminum.

A novel F-shaped linear guiding mechanism based compliant positioning stage with restricted parasitic motion

Positioning stages are significant in precision technologies under higher demands of operation and manufacturing. The performance of the selected guiding mechanisms is a decisive factor affecting the positioning accuracy of the stage. To restrict the parasitic motions along the degrees of constraint during motion transmission, a piezo-actuated compliant positioning stage with novel F-shaped linear guiding mechanisms (FLGM) is developed in this paper to enable a precision motion. With a simple and compact structure, a single FLGM can generate an approximate straight-line motion and enhance the transverse stiffness. Four FLGMs are arranged symmetrically in parallel to theoretically eliminate the parasitic motions, bringing in the merits of a low coupling rate and a wide bandwidth in the working direction. A stack piezoelectric actuator embedded in a forward bridge-type displacement amplifier is utilized to drive the guided stage. Analytical modeling of its kinematic, static, and dynamic characteristics is mathematically established by utilizing the pseudo-rigid-body method, compliance matrix method, and Lagrange’s equation. Finite element analysis is conducted and a fabricated prototype is experimentally tested, validating the veracity of the analytical models. Experimental results show that the parasitic motion is constrained by the guiding mechanism effectively with a coupling rate below 0.95%, and a high natural frequency of 856.9 Hz is achieved simultaneously.

The process‐structure–property relationship of 3D printed G‐Polymer using fused filament fabrication technique

AbstractThe ever‐increasing demand for additive manufacturing (AM) is driven by the technology's rapid prototyping and flexible manufacturing benefits. Among the various AM techniques, fused filament fabrication (FFF) is one of the most commonly used techniques, in which thermoplastic polymer filaments are deposited layer by layer to create the final part. This technique has been used extensively in various sectors. However, new materials have yet to be developed for use in FFF. This research aims to introduce a new biodegradable highly amorphous polyvinyl alcohol (HAVOH), commercially known as G‐Polymer (GP), into the scope of FFF, to propose a process window for the fabrication of parts with enhanced mechanical properties and to discover the process‐structure–property relationship for this material. This study investigates the effect of five key parameters in GP FFF, including raster angle, number of contours, nozzle temperature, build platform temperature, and print speed. The results of the chemical, thermal, and thermo‐mechanical analysis of the filaments before and after hot extrusion of the 3D printer nozzle showed a significant increase in the mechanical properties of the hot‐extruded filaments. In addition, the mechanical characterization of 3D printed parts showed that increasing the number of contours can improve the mechanical properties of parts, while the raster angle can have a complex effect. The mechanical properties of the parts are also improved by reducing the temperature of the nozzle and the build platform. Printing speed, as an essential parameter in AM, was related to the previously mentioned parameters, and the results showed that increasing the printing speed could improve the UTS and Young's modulus of the 3D printed part.Highlights A novel biodegradable polymer (HAVOH) was introduced into the scope of FFF. The hot extruded G‐Polymer filament from the nozzle showed improved mechanical properties. 180°C nozzle and room temperature platform resulted in improved mechanical properties. 3D printed parts with +45°/−45° raster angle show improved mechanical properties 110 mm/s print speed results in higher mechanical strength than 70 mm/s print speed.

Sputtering-Deposited Ultra-Thin Ag-Cu Films on Non-Woven Fabrics for Face Masks with Antimicrobial Function and Breath NOx Response.

The multifunctional development in the field of face masks and the growing demand for scalable manufacturing have become increasingly prominent. In this study, we utilized high-vacuum magnetron sputtering technology to deposit a 5 nm ultra-thin Ag-Cu film on non-woven fabric and fabricated ultra-thin Ag-Cu film face masks. The antibacterial rates against Escherichia coli and Staphylococcus aureus were 99.996% and 99.978%, respectively, while the antiviral activity against influenza A virus H1N1 was 99.02%. Furthermore, the mask's ability to monitor respiratory system diseases was achieved through color change (from brownish-yellow to grey-white). The low cost and scalability potential of ultra-thin silver-copper film masks offer new possibilities for practical applications of multifunctional masks.

Raziskave o trajnostni proizvodnji tekstila: brezvodno barvanje poliestrskih in recikliranih poliestrskih tkanin

Due to water limitations and the growing global demand for raw materials, manufacturers and consumers are seeking more environmentally friendly alternatives. Polyester, a non-biodegradable fibre derived from petroleum, can be replaced with recycled polyester (r-PET), a sustainable alternative that reduces environmental impacts through the reuse of materials. The textile finishing industry, known for its high water and energy consumption, is calling for the development of low-water-consumption technologies. One innovative approach involves waterless dyeing procedures using a supercritical carbon dioxide (scCO2) medium that is particularly suitable for dyeing synthetic fibres. To assess its effectiveness, a study compared traditional water dyeing with scCO2 medium dyeing on woven fabrics made from both polyester (PET) and recycled polyester (r-PET) fibres with varying weights. After conducting tests on the dyed fabrics, the data revealed that r-PET fabrics dyed using a supercritical carbon dioxide (scCO2) medium appeared darker than fabrics dyed using traditional water dyeing techniques. Moreover, r-PET fabrics demonstrated better colour fastness. Notably, the K/Ssum values (measurement of colour intensity) of r-PET fabrics were at least as good as those of PET-based fabrics in all cases of dyeing, while the fastness values were similar for both PET and r-PET fabrics.

Making Room for Silicon: Including SiOx in a Graphite-Based Anode Formulation and Harmonization in 1 Ah Cells

Transitioning to more ambitious electrode formulations facilitates developing high-energy density cells, potentially fulfilling the demands of electric car manufacturers. In this context, the partial replacement of the prevailing anode active material in lithium-ion cells, graphite, with silicon-based materials enhances its capacity. Nevertheless, this requires adapting the rest of the components and harmonizing the electrode integration in the cell to enhance the performance of the resulting high-capacity anodes. Herein, starting from a replacement in the standard graphite anode recipe with 22% silicon suboxide at laboratory scale, the weight fraction of the electrochemically inactive materials was optimized to 2% carbon black/1% dispersant/3% binder combination before deriving an advantage from including single-wall carbon nanotubes in the formulation. In the second part, the recipe was upscaled to a semi-industrial electrode coating and cell assembly line. Then, 1 Ah lithium-ion pouch cells were filled and tested with different commercial electrolytes, aiming at studying the dependency of the Si-based electrodes on the additives included in the composition. Among all the electrolytes employed, the EL2 excelled in terms of capacity retention, obtaining a 48% increase in the number of cycles compared to the baseline electrolyte formulation above the threshold capacity retention value (80% state of health).

Low demand solution for (sub)urban personal transport by a direct hybrid (fuel cell-supercapacitors) source

For urban or suburban transport, the power demand of a personal car does not exceed 30 kW/ton, far below the power offered by regular cars designed for any ride. Moreover, it was formerly shown that the above power could be attained by a 10 kW fuel cell directly hybridized to a supercapacitor string able to deliver a 20 kW power peak. This theoretical fact, corresponding to low resource demand in the car manufacturing, was validated up to ½ scale on the bench. Within a research project in University of Lorraine, the target is to validate the low-resource demanding concept in a real hydrogen electric vehicle (fuel cell range extender Renault Kangoo) and to examine related aspects by combining engineering sciences to social and human sciences and economics. After reminding the former validation on a bench, the paper describes current work on how the electrical power is managed in the Renault H2 ZE Kangoo, by characterization of the fuel cell and thorough analysis of the transients of electrical and non-electrical variables available in the vehicle in various rides. Besides, risks and life cycle analysis of a one-ton hybrid vehicle have been evaluated in comparison with other 30 kW vehicles powered by either a fuel cell, or batteries or an internal combustion engine. Finally, social acceptability of the fuel cell cars by regular citizens is presented, revealing a positive opinion at fuel cells and hydrogen, however with a moderate readiness to its acquisition.

THE ROLE OF PRECISION METROLOGY IN ENHANCING MANUFACTURING QUALITY: A COMPREHENSIVE REVIEW

Precision metrology plays a pivotal role in modern manufacturing processes by ensuring the attainment of high-quality standards and the optimization of production efficiency. This comprehensive review delves into the significance of precision metrology in enhancing manufacturing quality across diverse industries. The review encompasses an examination of advanced metrological techniques, their applications, challenges, and future prospects. The review begins by elucidating the fundamental principles of precision metrology, emphasizing its critical role in quantifying dimensional accuracy, surface finish, and other crucial parameters in manufacturing. It explores the evolution of metrology from conventional methods to state-of-the-art technologies such as coordinate measuring machines (CMMs), optical metrology, and 3D scanning systems. The integration of these techniques into modern manufacturing environments has revolutionized quality control processes, enabling real-time monitoring and rapid feedback mechanisms. Furthermore, the review highlights the multifaceted applications of precision metrology across various industries, including automotive, aerospace, electronics, and medical devices. It elucidates how metrological advancements have facilitated the production of intricate components with tight tolerances, thereby enhancing product performance, reliability, and safety. Additionally, the review examines the role of metrology in ensuring compliance with regulatory standards and certifications, crucial for industries with stringent quality requirements. Despite its numerous benefits, precision metrology also poses challenges, such as measurement uncertainties, calibration complexities, and data interpretation issues. The review discusses these challenges in detail and explores emerging strategies and technologies aimed at mitigating them. Furthermore, it addresses the need for standardized metrological practices and international collaboration to foster interoperability and harmonization in global manufacturing ecosystems. Looking ahead, the review outlines future directions and opportunities in precision metrology, including advancements in artificial intelligence, machine learning, and Internet of Things (IoT) integration for predictive maintenance and autonomous quality control systems. It underscores the importance of continued research and innovation in metrology to address evolving manufacturing demands and ensure sustained improvements in product quality and competitiveness. In conclusion, this comprehensive review underscores the indispensable role of precision metrology in enhancing manufacturing quality, driving innovation, and shaping the future of modern industry.
 Keywords: Precision, Metrology, Manufacturing, Quality, Review.

Robotic compliant assembly for complex-shaped composite aircraft frame based on Gaussian process considering uncertainties

Robots are finding increasing application in aircraft composite structure assembly due to their flexibility and the growing demand of aircraft manufacturers for high production rates. The contact force of the composite frame in a robotic assembly of the aircraft composite fuselage panel can hardly be controlled due to the multi-surface variable contact stiffness caused by compliance and complex shape with multiple mating surfaces. The paper proposes a robotic assembly system for the aircraft composite fuselage frame with a compliant contact force control strategy using the Gaussian process surrogate model. First, a robotic assembly system is introduced, and the global coordinate system transformation model is built. Then, a compliant force control architecture is designed to generate the desired output force. Subsequently, a Gaussian process surrogate model with uncertainties is utilized to model the complicated relationship between the robot’s output force and the normal contact force acting on the mating surface of the composite frame. Furthermore, an optimal contact force control strategy is implemented to improve the contact quality. Finally, an experiment demonstrates that the proposed methodology can ensure that the contact force on each surface is within the limit of the engineering specification and uniformly distributed, improving the quality compared to the traditional assembly process.

Yield strength evaluation of 3D-printed Ti–6Al–4V components based on non-contact eddy-current measurement

The demand for metal additive manufacturing (AM), also known as three-dimensional (3D) printing, is increasing owing to its ability to produce components with complex shapes, heterogeneous material properties, low material waste, etc. However, for broader acceptance of metal AM, quality assurance of mechanical properties, such as elastic (Young's) modulus, Poisson's ratio, and ductility, is becoming critical in additively manufactured components. This study proposes a non-contact, non-destructive and automated eddy-current technique for yield strength estimation of additively manufactured Ti–6Al–4V components with the potential for online operation during metal AM. After conducting the eddy-current measurement at a specific inspection point within the Ti–6Al–4V component, the relationship between the eddy-current phase value and electrical conductivity is established. Subsequently, the yield strength of the Ti–6Al–4V component is estimated by utilizing the analytical relationship between yield strength and electrical conductivity, which is based on Andrew's research and the Hall–Petch relationship. For experimental validation, Ti–6Al–4V test specimens with different electrical conductivities (yield strengths) were fabricated by adjusting the cooling rate during metal direct energy deposition AM. Then, the yield strengths estimated using the proposed technique were compared with those obtained using conventional destructive tensile tests. The results show that the proposed technique can estimate the yield strength with an error rate of less than 8%. The uniqueness of this study lies in (1) the theoretical derivation of the relationship between the eddy-current phase value and yield strength, (2) non-destructive, non-contact, and automated estimation of the yield strength using eddy-current measurements, and (3) performance evaluation using additively manufactured Ti–6Al–4V specimens with different yield strengths.

Viscoelastic Water-Based Lubricants with Nopal Cactus Mucilage as Green Metalworking Fluids

Recent green manufacturing demands have boosted the development of new biodegradable lubricants to replace petroleum-based lubricants. In this regard, water-based lubricants have been at the vanguard of recent research for a wide range of industrial applications, including metalworking fluids (MWFs). In this work, we present an experimental investigation on the performance of novel green MWFs based on aqueous nopal mucilage solutions. For this, fully biodegradable solutions with different mucilage concentrations (2.29, 4.58, and 6.85 mg/mL) were evaluated in terms of rheological, tribological, thermal stability, and turning (minimum quantity lubrication) performance and compared to a commercial semisynthetic oil-based MWF (Cimstar 60). Mucilage solutions exhibited viscoelastic shear-thinning behavior, which was enhanced along with mucilage concentration. The solution with the highest mucilage content studied resulted in the lowest wear, friction, and temperature in comparison to the other solutions and neat water in extreme pressure four-ball tests and a similar level of lubricity as compared to the commercial MWF in cutting tests. This performance is associated with the enhanced viscosity and elasticity of the solution, as well as the contents of lipids with fatty acids in the mucilage. Overall, the present results reveal the relevance of the viscoelastic behavior of the lubricant, elasticity in particular, in lubrication processes and point to nopal mucilage as an effective green additive to produce innocuous MWFs.

Research Progress in Modifications, Bioactivities, and Applications of Medicine and Food Homologous Plant Starch.

Starchy foods are an essential part of people's daily diet. Starch is the primary substance used by plants to store carbohydrates, and it is the primary source of energy for humans and animals. In China, a variety of plants, including edible medicinal plants, such as Pueraria root, yam tuber and coix seed, are rich in starch. However, limited by their inherent properties, kudzu starch and other starches are not suitable for the modern food industry. Natural starch is frequently altered by physical, chemical, or biological means to give it superior qualities to natural starch as it frequently cannot satisfy the demands of industrial manufacturing. Therefore, the deep processing market of modified starch and its products has a great potential. This paper reviews the modification methods which can provide excellent functional, rheological, and processing characteristics for these starches that can be used to improve the physical and chemical properties, texture properties, and edible qualities. This will provide a comprehensive reference for the modification and application of starch from medicinal and edible plants.

Cross-border dual-channel supply chain decision-making under random demand and tariff conditions.

Given the cross-border e-commerce import tariff and random demands, this study establishes a pricing decision model for cross-border e-commerce dual-channel supply chain, which is composed of domestic manufacturers and overseas retailers, so as to analyze the effects of import tariff and random demand on the pricing, demand and profit of cross-border e-commerce. According to the research, import tariffs have a positive correlation with retailers' retail prices and a negative correlation with manufacturers' direct prices, wholesale prices, demand and profit from direct channels, and profit from retail channels. The export tax rebate policy will lessen the negative effects of import tariffs and maximize the best choices made by manufacturers and retailers.

ANALYSING THE PERFORMANCE OF A MANUFACTURING FIRM USING HIERARCHICAL APPROACH

There is a growing demand for manufacturers from within and outside the company to embrace stakeholder-satisfying production techniques. As a result, companies undertake a wide range of assessments as part of their strategic planning and performance monitoring processes. The Strengths, Weaknesses, Opportunities, and Threats (SWOT) analysis is used in strategic planning that helps businesses evaluate their current standing. In addition, through the Analytic Hierarchy Process (AHP), a pairwise comparison may be made between elements or criteria to prioritise them, making the SWOT analysis and multicriteria decision making method more effective. The purpose of the combined approach is to raise the effectiveness of strategic planning inside a business. This paper does a SWOT analysis of a small Kerala manufacturing company, outlining its strengths, weaknesses, opportunities, and threats. First, the company's strengths, weaknesses, opportunities, and threats (SWOT) are determined via an internal poll. Then, the AHP (analytic hierarchy process) compares alternatives by contrasting them head-to-head. The results of the company-wide poll of experts landed on seventeen distinct elements. With this information, the manufacturing firm can decide how best to boost its operations.

Students' Level of Awareness on the Waste Contribution of the Fast Fashion with Their Clothing Consumption Behavior

The accessibility and convenience of purchasing fashion items have increased due to continuous manufacturing and high demand. The fast fashion industry has capitalized on the latest trends by offering cheap, affordable, yet disposable items, contributing to global pollution through solid waste and wastewater. This study aims to assess (a) students' level of awareness regarding the waste contribution of the fast fashion industry, (b) their clothing consumption behavior concerning purchases and utilization, (c) their waste disposal practices, and (d) the relationship between clothing consumption behavior and their level of awareness. The study employs systematic random sampling to determine an appropriate sample size from the student population, resulting in 104 student respondents for the adapted survey. Goodman and Kruskal's Gamma analysis assesses the association between clothing consumption and awareness. The results indicate that the students know about the industry's wastewater and solid waste contribution. However, the study also reveals a negligible to moderate relationship between clothing consumption, including the frequency of purchases and utilization, and their overall awareness. This suggests that despite being highly aware of the environmental issues associated with the fast fashion industry, students continue to support and purchase products from this sector.

In situ hydrothermal growth of Zeolite-A membrane on polysulfone hollow fibers

Zeolite-A hollow-fiber membranes with a high surface area are explored to address the present demands of high-productivity bioethanol manufacturing. Herein, we prepared Zeolite-A membranes on polymeric hollow-fiber support via double hydrothermal crystallization. The first hydrothermal crystallization from the solution yielded zeolite A crystals anchored on the polysulfone support. This transformation of the hollow fiber's skin layer into an organic-inorganic interface layer, as observed through SEM-EDX elemental analysis. This interface layer with penetrated Zeolite-A provides nucleation sites for further Zeolite-A membrane formation during the second hydrothermal crystallization and simultaneously enhanced interphase adhesion of Zeolite-A with the polymer support. The duration of the first and second cycles of hydrothermal crystallization was systematically studied to obtain continuous, crack-free, and pure Zeolite-A membranes on polysulfone hollow-fiber support. The membrane exhibited fluxes of 3.8 and 9.75 kg m−2 h−1 at 25 °C and 75 °C, respectively, with >99.9 wt% water separated through pervaporation of the 90/10 wt % ethanol/water mixture.