Fabrication Cost Research Articles

Switchable liquid crystal lenticular microlens arrays based on photopolymerization-induced phase separation for 2D/3D autostereoscopic displays.

Conventionally, the fabrication of liquid crystal lenticular microlens arrays (LCLMLAs) is complicated and costly. Here, we demonstrate a one-step fabrication technique for LCLMLAs, which is prepared through the photopolymerization-induced phase separation in the LC/polymer composite. The LCLMLAs possess both polarization-dependent and electrically tunable focusing properties. Furthermore, we construct a 14-view 2D/3D switchable autostereoscopic display prototype based on a 2D LCD panel and the prepared LCLMLA, which has a viewing angle of 14° and a crosstalk of 46.2% at the optimal viewing zone. The proposed LCLMLAs have the merits of simple fabrication, large-scale production, and low cost.

Temperature-insensitive high-sensitivity refractive index sensor based on a thinned helical fiber grating with an intermediate period.

A temperature-insensitive high-sensitivity refractive index sensor is proposed and experimentally demonstrated, which is based on utilization of a thinned helical fiber grating but with an intermediate period (THFGIP). Attributed to the reduced diameter and an intermediate period of the grating, the proposed sensor has a high surrounding refractive-index (SRI) sensitivity and a low temperature sensitivity. The average SRI sensitivity of the proposed sensor is up to 829.9 nm/RIU in the range of 1.3410-1.4480 RIU. Moreover, unlike the traditional sensitivity-enhancement method by increasing the waveguide dispersion factor, here the waveguide dispersion factor at the resonant wavelength was decreased by reducing the diameter of the fiber grating and as a result, the crosstalk effect due to the temperature change can be further suppressed. The proposed temperature-insensitive SRI sensor has the superiorities of simple structure, ease fabrication, and low cost, which could be found more potential applications in the SRI sensing fields.

Grid composite meta-surface absorber with thermal isolation structure for terahertz detection.

This paper specifically focuses on the absorber, the critical component responsible for the detector's response performance. The meta-surface absorber combines two resonant structures and achieves over 80% absorptance around 210 GHz, resulting in a broad operating frequency range. FR-4 is selected as the dielectric layer to be compatible with standard printed circuit board (PCB) technology, which reduces the overall fabrication time and cost. The absorbing unit and array layout are symmetrically designed, providing stable absorptance performance even under incident waves of different polarization angles. The polarization-insensitive absorptance characteristic further enhances the compatibility between the absorber and the detector in the application scenario. Furthermore, the thermal insulation performance of the absorber is ensured by introducing thermal insulation gaps. After completing fabrication through PCB technology, testing revealed that the absorber maintained excellent absorptance performance within its primary operating frequency range. This performance consistency closely matched the simulation results.

Investigation of the Influence of Inner Geometries of the Receiver Tube of a Parabolic Trough Collector System Used for Water Heating

Solar collectors are devices that help to harvest solar thermal radiation and convert into other forms of energy. Because of its low fabrication cost and simple design, the Parabolic Trough Collector (PTC) is one of the finest alternatives for medium-temperature (i.e., in 80°𝐶𝐶-250°𝐶𝐶 range) needs among all types of concentrated solar collectors. The absorber tube or the receiver tube is one of the main critical components of a PTC. Thermal radiation of the sun falling onto a parabolic reflector is reflected to its focal line where the receiver tube is placed. Therefore, the performance of a PTC system significantly depends on Receiver Geometries (RGs). A locally developed PTC system with a new and accurate tracking system was designed and fabricated in the current study and steam generation inside the receiver was considered in the performance analysis. The experimental analysis was performed using seven different RGs. The experiments were carried out by measuring generated steam every 10 minutes for all the RGs, and simultaneously, solar insolation data was taken by a domestic solar Photovoltaic (PV) system with a capacity of 5 kW. The steam generation data was taken only when the power output of the reference solar PV system was ≥ 4kW. Having tested seven different RGs, the researchers were able to improve the steam generation to a maximum of 10.0% compared to the reference geometry using direct experimental data. This was 8.1% in accordance with the statistical approach via multiple linear regression model. A three-dimensional mathematical model for two-phase flow was formulated for a closed domain. Restricting this model into twodimensional geometry, the steam generation process was simulated as a TPF problem using ANSYS Fluent software. The volume fraction profiles clearly show the phase transition, which leads to evaporation and condensation inside the tube.

3D Printed Integrated Sensors: From Fabrication to Applications-A Review.

The integration of 3D printed sensors into hosting structures has become a growing area of research due to simplified assembly procedures, reduced system complexity, and lower fabrication cost. Embedding 3D printed sensors into structures or bonding the sensors on surfaces are the two techniques for the integration of sensors. This review extensively discusses the fabrication of sensors through different additive manufacturing techniques. Various additive manufacturing techniques dedicated to manufacture sensors as well as their integration techniques during the manufacturing process will be discussed. This review will also discuss the basic sensing mechanisms of integrated sensors and their applications. It has been proven that integrating 3D printed sensors into infrastructures can open new possibilities for research and development in additive manufacturing and sensor materials for smart goods and the Internet of Things.

Reuse of green parts for metal material extrusion: A recycling approach for improved sustainability

In the recent years, a novel variant of Material Extrusion technique has been developed. This proved additive technology has been combined with an innovative filament loaded with metallic powder dispersed into a polymeric matrix. The parts printed with this metal/polymer composite filament by means of the Material Extrusion process are called “green parts”. After debinding and sintering treatments, the green parts became completely made by metal. As a novel technology, Metal Material Extrusion is still not a fully optimized and, therefore, efficient process and this leads to the generation of a great number of scraps due to the wasted products and to still existing process inefficiencies, which also increase the total costs of fabrication and undermine its economic competitiveness.In this paper, a circular approach for this new additive process has been proposed with a focus on the reuse and the remanufacture of the wasted products. Particularly, the reuse of defective green parts of Metal Material Extrusion technique was investigated to assess a circular manufacture of metallic parts. A new filament was fabricated starting from wasted green parts as raw feedstock with a commercial extrusion system. A comparison between commercial and recycled filaments was conducted. The polymeric content was studied by means of macrographic and thermogravimetric analysis, while a particle size distribution analysis was proposed to evaluate any change in metal powder sizes. Sequentially, secondary green parts were produced and underwent a debinding and sintering process to obtain near fully dense metallic parts. Furthermore, preliminary structural and mechanical evaluations of the secondary metallic samples were proposed in terms of apparent density, microstructure, and Vickers hardness. The resulting properties were compared to those of the virgin de-bound and sintered samples to assess the feasibility of the suggested circular fabrication process.

Preliminary cost forecasting and optimization for the construction of steel pedestrian bridges in Egypt

PurposeThis research aims to create a methodology that integrates optimization techniques into preliminary cost estimates and predicts the impacts of design alternatives of steel pedestrian bridges (SPBs). The cost estimation process uses two main parameters, but the main goal is to create a cost estimation model.Design/methodology/approachThis study explores a flexible model design that uses computing capabilities for decision-making. Using cost optimization techniques, the model can select an optimal pedestrian bridge system based on multiple criteria that may change independently. This research focuses on four types of SPB systems prevalent in Egypt and worldwide. The study also suggests developing a computerized cost and weight optimization model that enables decision-makers to select the optimal system for SPBs in keeping up with the criteria established for that system.FindingsIn this paper, the authors developed an optimization model for cost estimates of SPBs. The model considers two main parameters: weight and cost. The main contribution of this study based on a parametric study is to propose an approach that enables structural engineers and designers to select the optimum system for SPBs.Practical implicationsThe implications of this research from a practical perspective are that the study outlines a feasible approach to develop a computerized model that utilizes the capabilities of computing for quick cost optimization that enables decision-makers to select the optimal system for four common SPBs based on multiple criteria that may change independently and in concert with cost optimization during the preliminary design stage.Social implicationsThe model can choose an optimal system for SPBs based on multiple criteria that may change independently and in concert with cost optimization. The resulting optimization model can forecast the optimum cost of the SPBs for different structural spans and road spans based on local unit costs of materials cost of steel structures, fabrication, erection and painting works.Originality/valueThe authors developed a computerized model that uses spreadsheet software's capabilities for cost optimization, enabling decision-makers to select the optimal system for SPBs meeting the criteria established for such a system. Based on structural characteristics and material unit costs, this study shows that using the optimization model for estimating the total direct cost of SPB systems, the project cost can be accurately predicted based on the conceptual design status, and positive prediction outcomes are achieved.

Analysing the prosumer opportunity. Prosumer products’ success or failure

Makerspaces and FabLabs have become prominent spaces in the prosumer and maker movements worldwide. Prosumers actively create products and services to meet their needs and wants. Availability of DIY manufacturing methods and digital fabrication tools are increasingly accessible; design and manufacturing knowledge, and reuse of parts and components, are also factors to consider. The prosumer system is influenced by economic factors and domestic fabrication costs. Emotional attachment and sustainability are also key components of the prosumer movement. Nevertheless, not everyone is inclined to become a prosumer for a variety of reasons. Prosumer design limitations need to be understood and evaluated, as do mechanisms and methods for identifying which concepts can be developed into successful products. A key objective of this work is to evaluate the transition from an idea to a fully functional product by identifying barriers and enabling factors, such as knowledge, resources and motivation. To assess the feasibility and success of prosumer-designed products, theoretical frameworks, metrics and evaluations are conducted.

Advancing understanding of structural, electronic, and magnetic properties in 3d-transition-metal TM-doped α-Ga2O3 (TM = V, Cr, Mn, and Fe): A first-principles and Monte Carlo study

In this paper, we investigated the properties of transition metal (TM)-doped α-Ga2O3 using first-principles calculations and Monte Carlo simulations. α-Ga2O3 is a wide-bandgap semiconductor material with enhanced performance and lower fabrication costs on sapphire substrates compared to β-Ga2O3. Doping with TMs can modify electrical transport, optical absorption, and magnetic properties, yet theoretical studies on this are scarce. Our study focused on V, Cr, Mn, and Fe impurities. We introduced a newly proposed scheme for efficiently determining the ground-state defect configuration during structural relaxation. We adopt a recent, novel image charge correction method to accurately calculate formation enthalpy and thermodynamic transition levels for spin-polarized transition metal ion doping, without employing the empirical dielectric constant. Results showed Cr ions tend to neutral substitutional Ga, while V, Mn, and Fe impurity ions tend to carry a negative charge in common n-type α-Ga2O3. Magnetic moments and spin-splitting impurity levels primarily arise from transition metal impurities and their d orbitals. We used the generalized four-state method to calculate exchange interaction constants between substitution lattice sites and identified (anti) ferromagnetic couplings at specific distances in a 120-atom supercell, which are negligible in total energy calculations. Monte Carlo simulations indicated a Curie temperature of 360 K in n-type α-Ga2O3: Mn system with 12.5% doping, suggesting intrinsic ferromagnetic ordering based on the Heisenberg model. Our study contributes to understanding TM-doped α-Ga2O3 electronic structure and magnetic properties through improved methodologies. The approach can be applied in research involving other TM-doped oxides or wide-bandgap semiconductors.

Optical fiber Fabry-Perot strain sensor based on metal welding

This paper presents a strain sensor based on Fabry-Perot (F-P) interference. The F-P strain sensor is composed of a single-mode fiber (SMF) and a silica capillary, which are encapsulated by metal welding. The relationship between the cavity length and sensitivity is analyzed theoretically, then the F-P strain sensor is calibrated and tested. The experiment results show that the strain sensitivity of the fabricated sensor reaches 4.4 pm/με when the length of the silica capillary is 12 mm and the F-P cavity length is 436 μm. In addition, the temperature sensitivity of the F-P sensor is 11.7 pm/°C. With the increase of the capillary, the strain sensitivity increases. When the capillary length is 20 mm and the cavity length is 341 μm, the sensitivity of the sensor reaches 9.11 pm/με. The sensor proposed fabricated by metal welding, has the advantages of high sensitivity, simple fabrication, simple structure, and low cost.

Acoustic absorption of3Dprinted glycol‐modified polyethylene terephthalate composites with organically modified montmorillonite and short carbon fibers: Experimentation andANNbased predictive strategy

AbstractIn this article, the acoustic properties of 3D printed glycol‐modified polyethylene terephthalate (PETG) reinforced with organically modified montmorillonite (OMMT) nanoclay/short carbon fiber (SCF) nanocomposites are experimentally investigated using ASTM E1050‐08 standard. To this end, the sound absorption coefficient (SAC) of different PETG composites was calculated with the aid of two microphone impedance tube, working in the frequency range of 50–6300 Hz. The effect of different weight percentages (wt%) of OMMT nanoclay, SCFs, and 3D printing infill density on the acoustic behavior of PETG nanocomposites is studied. The experimental results reveal that higher wt% of OMMT nanoclay and SCFs has a beneficial effect on sound absorption. Further, the trend of variation of SAC is justified with morphological studies. Also, an artificial neural network (ANN) based prediction methodology to predict SAC is developed using the datasets obtained from the experimentation. Levenberg–Marquardt backward propagation algorithm with 20 neurons trains the ANN model. Using the trained ANN model, the acoustic properties of PETG/OMMT/SCF nanocomposites with different operating frequencies, infill density and wt% of reinforcements are predicted with less than 5% average error. This can be beneficial in eliminating the fabrication and experimentation costs incurred while assessing the acoustic properties of the PETG composites.HighlightsPETG/OMMT nanoclay/SCF composite filaments are fabricated.Acoustic absorption of 3D printed PETG composites are experimentally studied.ANN based predictive tool is developed using experimental data.ANN tool predicts the sound absorption and reduces experimentation cost.Microstructural studies justify the trend of sound absorption.

Sulfur-Doped g-C3N4 Heterojunctions for Efficient Visible Light Degradation of Methylene Blue.

The discharge of synthetic dyes from different industrial sources has become a global issue of concern. Enormous amounts are released into wastewater each year, causing concerns due to the high toxic consequences. Photocatalytic semiconductors appear as a green and sustainable form of remediation. Among them, graphitic carbon nitride (g-C3N4) has been widely studied due to its low cost and ease of fabrication. In this work, the synthesis, characterization, and photocatalytic study over methylene blue of undoped, B/S-doped, and exfoliated heterojunctions of g-C3N4 are presented. The evaluation of the photocatalytic performance showed that exfoliated undoped/S-doped heterojunctions with 25, 50, and 75 mass % of S-doped (g-C3N4) present enhanced activity with an apparent reaction rate constant (kapp) of 1.92 × 10-2 min-1 for the 75% sample. These results are supported by photoluminescence (PL) experiments showing that this heterojunction presents the less probable electron-hole recombination. UV-vis diffuse reflectance and valence band-X-ray photoelectron spectroscopy (VB-XPS) allowed the calculation of the band-gap and the valence band positions, suggesting a band structure diagram describing a type I heterojunction. The photocatalytic activities calculated demonstrate that this property is related to the surface area and porosity of the samples, the semiconductor nature of the g-C3N4 structure, and, in this case, the heterojunction that modifies the band structure. These results are of great importance considering that scarce reports are found concerning exfoliated B/S-doped heterojunctions.

In Situ Etching of Multifunctional Three-Dimensional Interfacial Layers for the Construction of Porous Zn Anodes with Enhanced Surface Textures.

Aqueous Zn-ion batteries offer the advantages of greater security and lower fabrication costs over their lithium-ion counterparts. However, their further advancement and practical application are hindered by the drastic decay in their performance due to the uncontrollable dendrite growth on Zn anodes. In this study, we fabricated a versatile three-dimensional (3D) interfacial layer (3D PVDF-Zn(TFO)2 (PVDF: poly(vinylidene fluoride); TFO: trifluoromethanesulfonate), which simultaneously formed porous Zn-metal anodes (PZn) with an enhanced (002) texture, via a in situ etching scheme. The 3D PVDF-Zn(TFO)2@PZn symmetrical cells leverage the advantages of surface coating and 3D porous architectures to yield extra-long cyclic lifetimes of over 5300 h (0.1 mA cm-2). The fabricated anodes were found to be compatible with MnO2 cathodes, and the resulting full batteries delivered an outstanding capacity of 336 mAh g-1 at 0.1 A g-1 and exhibited impressive long-term reversibility with a capacity retention of 78.7% for 2000 cycles. The proposed coating strategy is viable for developing porous structures with cutting-edge designs and for textured surface engineering.

Equibiaxial flexural strength determination of UO2 using a ball-on-ring test

To increase nuclear fuel performance and reliability, their mechanical properties require an accurate and statistically relevant assessment. Biaxial flexural strength tests provide an alternative to bend bar techniques for assessing mechanical behavior; namely, the transverse rupture strength (TRS) of ceramic samples. Biaxial test samples require simple geometries and minimal surface preparation, reducing fabrication costs and handling hazards. This study investigated the TRS of polycrystalline UO2 fuel forms at room temperature using a ball-on-ring test fixture. Pellets were fabricated from UO2 powder using conventional powder processing and sintering techniques. The TRS and Weibull parameters were obtained through Weibull statistics on over 60 UO2 samples tested under equibiaxial flexure. The larger sample size in this study enabled a more robust Weibull statistical analysis than alternative test methods, which may not capture the stochastic failure of typical ceramics. Furthermore, two different loading ball diameters were employed to assess the impact of contact damage on fracture strength. While Hertzian contact damage was observed with the smaller loading ball, the fracture strength remained unaffected. A fracture analysis of the tested UO2 samples indicated a mixture of intergranular and transgranular fracture that transitions to transgranular fracture with increasing distance from the fracture origin. The characteristic strength of the combined data sets was determined to be 148 MPa, and the Weibull modulus was determined to be 9.1. The TRS values and Weibull parameters were close to values found in the literature for alternative testing techniques using samples with similar microstructure and density. The findings in this study validate the ball-on-ring method used to obtain the TRS of UO2 with a sample geometry more representative of nuclear fuels. Additionally, experimental TRS results from this study can be implemented in modeling codes to predict fuel performance, which is critical to fuel burnup extension and advanced nuclear fuel technologies.

Enhancing dye-sensitized solar cell performance by employing an innovative WSe2:Zn counter electrode for improved electrocatalytic activity

In this research, we introduced a novel counter electrode (CE) for dye-sensitized solar cells (DSSCs) based on crystalline WSe2 doped with Zn impurities. The crystalline nature of these CEs was confirmed through X-ray diffraction (XRD) analysis. Additionally, we demonstrated that Zn dopants significantly enhances the electrochemical and electrocatalytic properties of the CEs. These improvements were verified using electrochemical impedance spectroscopy (EIS), cyclic voltammetry (CV), and Tafel analysis with iodine-based electrolytes. Collectively, these enhancements resulted in a remarkable 42 % increase in DSSC efficiency, improving it from 5.78 % to 8.19 % under optimized conditions. Notably, this surpassed the performance of platinum-based CEs, which achieved 7.66 % efficiency. The proposed CE holds great promise for advancing DSSCs by elevating their efficiency and reducing fabrication costs.

A Manufacturability‐Driven Method for Designing Metamaterial Focusing Acoustical Lenses

Herein, a method for designing and fabricating acoustic metamaterial focusing lenses for imaging applications such as nondestructive testing is proposed. First, a refractive index distribution is designed using the time delay method for a target focal length. Second, unit cell structures that can achieve the required refractive indices are found using the effective property retrieval method. At this point, factors such as fabrication cost and manufacturing limitations are considered. Finally, the pressure field from the designed lens is calculated using finite element (FE) modelling and iterated until the required focusing performance is achieved. To increase manufacturability, the unit cells necessarily become larger than required for the homogeneous regime. As an example, a lens of focal length 200 ± 10 mm at a frequency of 40 kHz is designed using cross‐shaped unit cells and fabricated using three‐dimensional printing. The design methodology leads to 2.4 mm (wavelength/3.6) unit cells which operate near the cut‐off frequency of the first mode. The lens is experimentally tested, achieving a focal length of 208 mm and a focal width of 12 mm (1.4 × wavelength), and showing good agreement with an FE model. The focusing ability of the lens is demonstrated by measuring the size of various holes in thin plates.

Amorphization of MXenes: Boosting Electrocatalytic Hydrogen Evolution.

The emergence of amorphous 2D materials has opened up new avenue for materials science and nanotechnology in the recent years. Their unique disordered structure, excellent large-area uniformity, and low fabrication cost make them important for various industrial applications. However, there have no reports on the amorphous MXene materials. In this work, the amorphous Ti2C-MXene (a-Ti2C-MXene) model is built by ab initio molecular dynamics (AIMD) approach. This model is a unique amorphous model, which is totally different from continuous random network (CRN) model for silicate glass and amorphous model for amorphous 2D BN and graphene. The structure analysis shows that the a-Ti2C-MXene composited by [Ti5C] and [Ti6C] cluster, which are surrounded by the region of mixed cluster [TixC], [Ti-Ti] cluster, and [C-C] cluster. There is a high chemical activity for hydrogen evolution reaction (HER) in a-Ti2C-MXene with |ΔGH| 0.001eV, implying that they serve as the potential boosting HER performance. The work provides insights that can pave the way for future research on novel MXene materials, leading to their increased applications in various fields.

Graphene oxide coated fly ash for reinforcing dynamic tensile behaviours of cementitious composites

By virtue of its low cost, high workability, wide availability and suitability for large-volume fabrication, cement-based grouting is the most applied material in underground projects. However, due to the weak tensile strength and high-frequency impact dynamic load disturbance in underground engineering, cement-based grouting is vulnerable to tensile damage, seriously influencing the stability and safety of underground projects. Hence, in this work, the graphene oxide (GO) coated fly ash was adopted to reinforce the dynamic tensile behaviour of the cement-based matrixes to fabricate high-performance, cost-effective and environmentally friendly cementitious composites. The test results show that the GO-coated fly ash could significantly enhance the dynamic tensile performance of the cementitious composites. With only 0.08 wt% GO mixing, the dynamic tensile properties can be strengthened by 19.5–88.5%. After GO nanosheets accelerate the cement hydration process and improve the chemical composition of hydration products, GO nanosheets exhibit macroscopic nucleation and "crack-bridging" effects on the cement matrixes, and the cracks propagation of the hardened specimens would be suppressed under dynamic loading, thus enhancing the tensile resistance of the specimen. The fractal dimension calculation results prove that the GO-coated fly ash-modified cementitious composites have higher integrity after tensile impact, about 2.8–11.9% higher than plain cement-based slurry. Finally, the theoretical analysis reveals that GO nanosheets can enhance the tensile behaviours of the cement matrix by optimizing the dynamic load coefficient. Nevertheless, with the crack propagation, the reinforcing efficiency of GO would be gradually weakened. The findings of this study can promote an understanding of the enhancing mechanisms of GO on the dynamic tensile behaviour of cementitious composites and inspire the potential application of GO-coated fly ash to reduce cement usage in grouting engineering.

Tuning the Refractive Index Sensitivity of LSPR Transducers Based on Nanocomposite Thin Films Composed of Noble Metal Nanoparticles Dispersed in TiO2

This work reports on the development of nanoplasmonic thin films consisting of Au, Ag, or Au-Ag nanoparticles dispersed in a TiO2 matrix and the optimization of the deposition parameters to tune their optical response. The thin films were produced by reactive DC magnetron sputtering of a Ti target with Au and/or Ag pellets placed on the erosion zone. The thicknesses (50 and 100 nm) of the films, the current density (75 and 100 A/m2) applied to the target (titanium), and the number of pellets placed on its surface were the deposition conditions that were used to tailor the optical (LSPR) response. The total noble metal content varied between 13 and 28 at.% for Au/TiO2 films, between 22 and 30 at.% for Ag/TiO2 films, and 8 to 29 at% for the Au-Ag/TiO2 systems with 1:1, 1:1.5, and 1:2 Au:Ag atomic ratios. After thermal annealing at 400 and 600 °C, LSPR bands were found for all films concerning the Au-TiO2 and Au-Ag/TiO2, while for Ag/TiO2, only for thin films with 28 and 30 at.% of Ag concentration. Refractive index sensitivity (RIS) was evaluated for Au and Au-Ag/TiO2 thin films. It was found that for bimetallic nanoparticles, the sensitivity can increase up to five times when compared to a monometallic nanoplasmonic system. Using Au-Ag/TiO2 thin films can decrease the cost of fabrication of LSPR transducers while improving their sensitivity.

A facile and efficient preparation method for the doped light emitting layer in OLEDs: Blade-coated planar source evaporation

Although vacuum thermal evaporation (VTE) is a widely-used fabrication method in organic light-emitting diodes (OLED) industry, it has long been suffering from the sophisticated fabrication process, low material utilization, and high costs, which become much significant in the preparation of doped light emitting layer (EML). To overcome those intrinsic drawbacks of VTE, we propose a facile and efficient preparation method for the doped EML, i.e., blade-coated planar source evaporation (BCPSE), which combines the benefits of both solution-based blade-coating and combined planar source evaporation (BCPSE) techniques. BCPSE can simplify the fabrication process, increase the material utilization, and reduce the fabrication time, without degrading the device performance compared to that prepared by VTE. The film morphology and fabrication condition were carefully investigated and optimized, which show that BCPSE can increase the material utilization to 95 % and decrease the preparation time to several seconds, implying a great reduction in the fabrication cost. The validity of BCPSE was further demonstrated in a comparison study of a typical orange phosphorescent OLED, in which the mixed ternary EML comprising iridium-based dopant, n-type host, and p-type host was fabricated by using both VTE and BCPSE techniques. With the BCPSE technique, the device exhibited improved maximum external quantum efficiency (EQEmax) of 7.9 %, maximum current efficiency (CEmax) of 13.7 cd/A, and maximum power efficiency (PEmax) of 12.0 lm/W, which are comparable to the device employing VTE. In addition, both techniques gave the same electroluminescent spectra with the Commission International d'Eclairage (CIE) coordinates of (0.59, 0.38). The proposed method is not only helpful in reducing the fabrication costs while maintaining the device performance, but promising in advanced OLED applications, such as microOLEDs.