High Design Flexibility Research Articles

Recycled PET Fibers with Dopamine Surface Modification for Enhanced Interlayer Adhesion in 3D Printed Concrete.

Three-dimensional printed concrete (3DPC) is increasingly recognized in the construction industry for its high design flexibility and the elimination of conventional formwork. However, weak interlayer adhesion remains a significant challenge. The potential of recycled polyethylene terephthalate (PET) fibers for reinforcing 3DPC is being explored, driven by their environmental sustainability and economic advantages. However, there is an inadequate interfacial adhesion between these recycled fibers and the 3DPC matrix. This study investigated the use of dopamine modification to address this issue and enhance the interlayer adhesion of fiber-reinforced 3DPC. Recycled PET fibers were surface-modified using dopamine treatment, forming a polydopamine (PDA) film that improved surface roughness and hydrophilicity. Both unmodified and modified fibers were incorporated into 3DPC at various volume fractions (0.1%, 0.3%, 0.5%). The effects on interlayer adhesion strength, compressive strength, and flexural strength were systematically evaluated and compared. The results showed that the inclusion of 0.3 vol% dopamine-modified fibers resulted in a 22.5% increase in interlayer adhesion strength compared to the control group, and a 14.8% improvement over unmodified fibers at the same content. Additionally, the compressive strength and flexural strength of 3DPC with 0.3 vol% MPET fibers increased by 22.5% and 27.6%, respectively, compared to the control group. Microstructural analysis using SEM and XRD revealed that the dopamine modification significantly improved the interfacial adhesion between fibers and the concrete matrix, explaining the superior performance of modified fibers. This study demonstrates that recycled PET fibers modified with dopamine can effectively enhance the interlayer adhesion of 3DPC. The findings affirm that surface modification techniques can significantly elevate the utility of recycled PET fibers in 3DPC, contributing to the sustainable advancement of construction materials.

Reliable fabrication of 3D freestanding nanostructures via all dry stacking of incompatible photoresist

Three-dimensional (3D) free-standing nanostructures based on electron-beam lithography (EBL) have potential applications in many fields with extremely high patterning resolution and design flexibility with direct writing. In numerous EBL processes designed for the creation of 3D structures, the multilayer resist system is pivotal due to its adaptability in design. Nevertheless, the compatibility of solvents between different layers of resists often restricts the variety of feasible multilayer combinations. This paper introduces an innovative approach to address the bottleneck issue by presenting a novel concept of multilayer resist dry stacking, which is facilitated by a near-zero adhesion strategy. The poly(methyl methacrylate) (PMMA) film is stacked onto the hydrogen silsesquioxane (HSQ) resist using a dry peel and release technique, effectively circumventing the issue of HSQ solubilization by PMMA solvents typically encountered during conventional spin-coating procedures. Simultaneously, a dry lift-off technique can be implemented by eschewing the use of organic solvents during the wet process. This pioneering method enables the fabrication of high-resolution 3D free-standing plasmonic nanostructures and intricate 3D free-standing nanostructures. Finally, this study presents a compelling proof of concept, showcasing the integration of 3D free-standing nanostructures, fabricated via the described technique, into the realm of Fabry-Perot cavity resonators, thereby highlighting their potential for practical applications. This approach is a promising candidate for arbitrary 3D free-standing nanostructure fabrication, which has potential applications in nanoplasmonics, nanoelectronics, and nanophotonics.

Scanless Spectral Imaging of Terahertz Vortex Beams Generated by High‐Resolution 3D‐Printed Spiral Phase Plates

Terahertz technology has experienced significant advances in the past years, leading to new applications in the fields of spectroscopy, imaging, and communications. This progress requires the development of dedicated optics to effectively direct, control and manipulate terahertz radiation. In this regard, 3D printing technologies have shown great potential, offering fast prototyping, high design flexibility, and good reproducibility. While traditional 3D printing techniques allow for the preparation of terahertz optical components operating at relatively low frequencies (<0.4 THz) due to their limited resolution, two‐photon polymerization lithography (TPL) exhibits high detail resolution and low surface roughness and can thus potentially enable the fabrication of high‐frequency terahertz devices. Here, as a proof of principle, spiral phase plates operating at 1 THz are designed and fabricated by means of TPL. Moreover, these samples are characterized via a rapid and scanless terahertz imaging technique customized to obtain a coherent hyperspectral analysis of the generated vortex beams at varying distances along propagation. Numerical simulations are also conducted for comparison with experiments, revealing a good agreement. Current limitations of the technique are found to be mainly related with terahertz loss in TPL polymers, and possible solutions are discussed.

Design and Analysis of Ridge and Sub-Wavelength Grating Waveguide Based Micro Ring-Resonator Sensor

The subwavelength grating microring resonator based filter shows great promise in optical sensing and communication. However, it spectrum nature makes it unsuitable for tracking or extracting a single wavelength from a broadband light source. In this paper, we used side-mode suppression, based on an angular grating- subwavelength microring resonator which offer high flexibility in wavelength design within the silicon-on-insulator (SOI) waveguide. By periodically arranging silicon waveguide pieces in three different widths, we can set the effective index along the inner sidewall of subwavelength microring resonator. thereby can achieve the precise wavelength selection. We examine the effects of various key parameters on the center wavelength, side-mode suppressed ratio, and quality factor of this filter.The proposed structure's isalso analysed for coupling strength between the bus and subwavelength grating ring resonator. The wavelength selection, compact size, compatibility with other similar nature waveguide-based devices and design flexibility highlight its significant potential in compact optical sensing and optical communication

Study on the influence of geometric characteristics of micro-periodic structures with slits on sound absorption properties

In recent years, there has been considerable interest in acoustic metamaterial technology that leverages sub-wavelength scale microperiodic structures to control the behavior of sound waves for sound absorption material development. This technology offers high design flexibility in unit shapes and holds promise for the development of sound absorption materials with diverse characteristics. However, the field remains in its foundational exploration phase, with the detailed relationship between geometric shapes and sound absorption properties yet to be fully elucidated. To address this gap, we conducted a thorough investigation focusing on their relationship by examining the transport parameters of the Johnson-Champoux-Allard-Lafarge-Pride (JCALP) model, which are closely associated with sound absorption properties. We designed a cubic lattice with slits on the incident surface of the unit shape as a microperiodic structure and examined the normal incident sound absorption characteristics using the finite element method. Our results indicate that manipulation of slit partition numbers and slit widths allows for control of transport parameters, suggesting the potential to achieve various sound absorption properties.

Intelligent design of multi-layered variable stiffness composite structure based on transfer learning

Variable stiffness composite structures offer more flexible design space than thin-walled metal structures and have greater potential for vibration-resistant design. When faced with multiple new types of design problems, the complex modelling and analysis procedures frequently prove to be both time-consuming and costly in terms of optimization. In this study, an innovative multi-layered variable stiffness (MVS) composite structure with high design flexibility is proposed, with images representation for curvilinearly stiffened paths, non-uniform layouts, and fiber and layup angles. Moreover, an intelligent optimization method based on transfer learning is proposed for addressing a variety of factors affecting dynamic design, including boundary types, structural features, and dynamic responses. The objective of the transfer learning model is to facilitate the inheritance and sharing of variable stiffness features, thereby enabling the efficient design of new problems with limited datasets. The validation of different examples shows that the transfer learning can effectively acquire the structural features from the existing source domain datasets, thereby significantly reducing the data for some new target domains by approximately 50%. In comparison to the initial constant stiffness (CS) structures, the different optimized configurations indicate that the MVS composite structures are capable of effectively enhancing the dynamic responses by 10%∼146% for natural frequency and dynamic compliance. Furthermore, the MVS optimized configuration displays superior dynamic responses in some problems, when compared to the CS optimized configuration.

Algorithm for Designing Waveforms Similar to Linear Frequency Modulation Using Polyphase-Coded Frequency Modulation

Linear frequency modulation (LFM) waveforms have been widely adopted due to their excellent performance characteristics, such as good Doppler tolerance and ease of physical implementation. However, LFM waveforms suffer from high autocorrelation sidelobes (ACSLs) and limited design flexibility. Phase-coded frequency modulation (PCFM) waveforms can be used to design waveforms similar to LFM, offering greater design flexibility to optimize ACSLs. However, it has been found that the initial PCFM waveform experiences spectral expansion during the ACSL optimization process, which reduces its similarity to LFM. Therefore, this article jointly optimizes the ACSLs and spectrum of the initial PCFM waveform, establishes an optimized mathematical model, and then solves it using the heavy-ball gradient descent algorithm. Numerical experiments indicate that the proposed method effectively addresses the problem of waveform similarity degradation caused by spectral expansion while reducing waveform ACSLs. At the same time, a balance between reducing waveform ACSLs and preserving waveform similarity can be achieved by adjusting the parameters.

Effect of forming strategies on the microstructure and mechanical properties of thin-walled CuCrZr alloy fabricated by selective laser melting

Thin-walled structures are widely used in industrial fields such as radiators and critical aerospace components due to their advantages in lightweight design. However, traditional manufacturing techniques struggle to meet the high-precision requirements for complex components. Selective Laser Melting (SLM) technology, characterized by high design flexibility and high geometric production freedom, is a promising alternative. This study employs SLM technology to fabricate CuCrZr alloy thin walls and systematically investigates the effects of interlayer rotation angles and placement strategies on the forming quality and mechanical properties of the thin walls produced by SLM. The results indicate that different interlayer rotation angles and placement strategies lead to variations in defect types and shapes. When the interlayer rotation angle is 0° and the specimens are placed perpendicular to the recoater blade, numerous lack-of-fusion (LOF) defects are observed on the specimens. These lack-of-fusion defects are caused by factors such as low scanning line flatness and uneven energy distribution when the interlayer rotation angle is 0°. In contrast to the 0° interlayer rotation angle, the specimens with a 67° rotation angle exhibit significantly more curved columnar grains in the growth direction. The thin-walled specimens with a 67° interlayer rotation angle and placed parallel to the recoater blade show the best mechanical performance, with a maximum tensile strength of 254.19 MPa and an elongation of 48.81 %.

Prediction method for re-damage behavior of the repaired CFRP bolted joint

Composite materials are widely used in various aircraft due to their high specific strength, stiffness, corrosion resistance, and robust design flexibility. However, when subjected to complex loading conditions, composite structures are susceptible to damage, necessitating prompt repair upon aircraft return. Analyzing the re-damage process of repaired structures is crucial for assessing aircraft structural reliability, lifespan, and determining whether a repeat flight is warranted. In this study, a prediction method was proposed for re-damage behavior through meso-modeling and energy analysis of the repaired composite bolted joint. First, this article established a meso-mechanical model for composite laminates, analyzed force transfer characteristics at the fiber − matrix interface, and derived equations for stress field. Additionally, a strain energy distribution model was developed for composite bolted repaired joint near fibers and repaired area, proposing a damage prediction method based on the strain energy criterion. This method could anticipate the location, type, sequence, and magnitude of damage. Finally, simulation calculations yielded mechanical characteristics of the repaired area under typical load conditions, while loading tests verified the feasibility of the prediction method. This study offered an effective means of predicting performance degradation in composite structures and provided a vital direction for optimal spacecraft structure repairing methods and parameters.

Bio-Inspired Curved-Elliptical Lattice Structures for Enhanced Mechanical Performance and Deformation Stability.

Lattice structures, characterized by their lightweight nature, high specific mechanical properties, and high design flexibility, have found widespread applications in fields such as aerospace and automotive engineering. However, the lightweight design of lattice structures often presents a trade-off between strength and stiffness. To tackle this issue, a bio-inspired curved-elliptical (BCE) lattice is proposed to enhance the mechanical performance and deformation stability of three-dimensional lattice structures. BCE lattice specimens with different parameters were fabricated using selective laser melting (SLM) technology, followed by quasi-static compression tests. Finite element (FE) numerical simulations were also carried out for validation. The results demonstrate that the proposed BCE lattice structures exhibit stronger mechanical performance and more stable deformation modes that can be adjusted through parameter tuning. Specifically, by adjusting the design parameters, the BCE lattice structure can exhibit a bending-dominated delocalized deformation mode, avoiding catastrophic collapse during deformation. The specific energy absorption (SEA) can reach 24.6 J/g at a relative density of only 8%, with enhancements of 48.5% and 297.6% compared with the traditional energy-absorbing lattices Octet and body-center cubic (BCC), respectively. Moreover, the crushing force efficiency (CFE) of the BCE lattice structure surpasses those of Octet and BCC by 34.9% and 15.8%, respectively. Through a parametric study of the influence of the number of peaks N and the curve amplitude A on the compression performance of the BCE lattice structure, the compression deformation mechanism is further analyzed. The results indicate that the curve amplitude A and the number of peaks N have significant impacts on the deformation mode of the BCE lattice. By adjusting the parameters N and A, a structure with a combination of high energy absorption, high stiffness, and strong fracture resistance can be obtained, integrating the advantages of tensile-dominated and bending-dominated lattice structures.

Developing Terpyridine-Based Metal Complexes for Non-Aqueous Redox Flow Batteries

Redox flow batteries (RFBs) that utilize dissolved electroactive materials have shown great potential in storing intermittent solar and wind energy. The unique technological advantages of decoupled energy and power lead to high flexibility and scalability in RFB design, making it possible to satisfy a wide range of energy and power applications.[1,2] In traditional RFBs, inorganic transition-metal salts like all-vanadium, iron-chromium, and zinc-bromine RFBs are commonly used.[3,4] However, the narrow electrochemical stability window of water limits the attainable cell voltages in these aqueous systems. [5,6] To overcome these limitations, recent research has shifted towards non-aqueous RFBs (NARFBs) that use non-aqueous solvents, which can offer a wider electrochemical window up to 5 V.[7,8] Here, we introduce our research efforts on the design and synthesis of a series of terpyridine-based complexes of the first-row transition metals Cr, Mn, Fe, and Co for non-aqueous redox flow batteries (NARFBs). Electrochemical studies reveal that these complexes can undergo multi-electron transfer redox reactions. Notably, the Mn and Fe-based complexes exhibit both low negative redox potentials and high positive redox potential, enabling them to serve as a bipolar electrolyte for symmetric RFBs with a cell voltage of over 2 V. The assembled iron-based symmetric NARFB demonstrates a high cell voltage of 2.3 V, columbic efficiency of 97%, energy efficiency as high as 88%, and stable charge-discharge capacity retention of 60% after 160 cycles, corresponding to 99.75 % capacity retention per cycle. Figure 1

3D printing of customized Li-S microbatteries

Microbatteries serve as essential energy supply components in microelectronic, wearable and implantable devices. Despite recent efforts, developing lithium metal microbatteries with high energy densities and mechanical flexibility in structural design is still challenging, because of the poor interfacial stability and poor processability of lithium foil. Herein, we developed lithium-sulfur (Li-S) microbatteries with customized configurations using 3D printing techniques, which consist of a printable Li anode hosted within a graphene aerogel framework and a printable S cathode based on a carbon nanocages framework, featuring abundant porous structures and large specific surface areas. Consequently, the 3D-printed Li anode achieves over 900 hours of cycling with low overpotentials at an ultrahigh current density of 10 mA cm−2, and the 3D-printed S cathode delivers an ultrahigh capacity of 21.9 mAh cm−2 at the high thickness of 2.3 mm. Furthermore, the 3D-printed Li-S cell delivers an ultrahigh areal energy density of 48.4 mWh cm−2 at a high power density of 3.5 mW cm−2. The application potential of the 3D-printed customized Li-S microbatteries with arbitrary form factors is demonstrated by LED lighting and powering wearable sensor integration system, paving the way for their applications in miniaturized devices.

Nonlinear thermal flutter of variable angle tow composite laminates in supersonic airflow

Compared with traditional composite materials, variable stiffness composite materials with curvilinear fiber paths have higher design flexibility and the potential to improve structural efficiency. In view of this, the nonlinear flutter characteristics of Variable Angle Tow (VAT) composite laminates with thermal effect in supersonic airflow are investigated in this paper. The proposed panel flutter model is developed based on the von Kármán large deformation plate theory. The thermal stress is approximated according to the quasi-steady thermal stress theory, whilst the aerodynamic pressure is calculated based on the first-order piston theory. The aerothermoelastic equations of motion are first established using Hamilton’s variational principle, and the Rayleigh-Ritz method is then applied to solve the governing equations in the space domain. The time-domain nonlinear equations are solved through the fourth-order Runge-Kutta method. The accuracy and convergence of the proposed method are verified through the comparisons with the results available in the literature. The effects of several parameters such as fiber orientation angle, thermal load, and aerodynamic pressure on the nonlinear flutter responses of VAT laminates are comprehensively discussed. Several dynamic behaviors of VAT laminates, including stable flat, buckled, Limit Cycle Oscillation (LCO), multi-periodic motion, quasi-periodic motion, and chaotic motion, are revealed by using the time history, phase portrait, Poincaré map, and bifurcation diagram. The results presented herein may be beneficial for the design of VAT laminates in supersonic airflow.

On the low-velocity impact properties of CFRP/HAFRP interlayer hybrid fibre composite laminates

Hybrid fibre-reinforced polymer composites have been increasingly utilised in key engineering fields, such as the manufacture of aerospace structures, due to their high specific strength, stiffness, and design flexibility. This paper attempts to investigate the low-velocity impact performance and residual strength after impact of hybrid composites consisting of carbon fibre-reinforced polymer (CFRP) and heterocyclic aramid fibre-reinforced polymer (HAFRP). Since carbon fibres are brittle and vulnerable to impact loading despite their ultra-high strength, the aim of this study was to enhance the impact resistance of CFRP by hybridising it with high-toughness heterocyclic aramid fibres. The influence of hybrid layup configuration on the performance of both low-velocity impact and compression after impact (CAI) was explored. Four types of specimens, including pure CFRP and hybrid CFRP/HAFRP laminates with different layups, were manufactured and tested. Drop-weight impact tests were conducted on the specimens under impact energies of 25 J, 30 J and 40 J to measure the impact response, such as force-displacement and energy absorption curves. The internal impact damage was then assessed by ultrasonic C-scan method. The compressive strengths of specimens were measured both before and after low-velocity impact. The results indicated that hybrid laminates had better impact resistance than pure CFRP specimens, and the reduction in the compressive strength after impact for pure CFRP specimens was 2–4 times that of hybrid specimens. Therefore, hybridisation of heterocyclic aramid fibre with carbon fibre in composite laminates can retain high strength of carbon fibre while benefiting from the excellent fracture toughness of heterocyclic aramid fibre.

Advances in 4D printing of biodegradable photopolymers

AbstractOver the past decade, 4D printing has revolutionized the field of advanced manufacturing by fabricating structures that dynamically respond to environmental stimuli. During this process, shape‐memory polymers (SMPs) stand out, enabling transformations triggered by temperature, light, or other environmental factors, and show great potential for applications in biomedicine and beyond. Notably, biodegradable SMPs offer a compelling advantage in medical devices due to their ability to adapt within the body's temperature range and to be absorbed by tissues, reducing the risks associated with permanent implants. While extrusion techniques have laid the groundwork for 4D printing in biomedicine, vat photopolymerization methods like stereolithography and digital light processing are now at the forefront, favored for their high printing resolution and flexibility in material design. However, the search for suitable biodegradable materials for these advanced techniques continues, with current research focusing on developing systems that meet both the mechanical demands and degradation profiles required for medical applications. This review aims to critically analyze the advancements in biodegradable 4D photopolymers, particularly biodegradable elastomers, and discuss the challenges that lie ahead for their clinical translation.

Chaos generation of superconducting quantum bits coupled with LC resonant circuits

The dynamics of chaos have been widely used in nonlinear science, such as neural networks, extreme event statistics, and the biophysics of chaos self-organization. Superconducting qubits are artificial atoms based on the Josephson junction structure of nonlinear superconducting devices, offering high design flexibility and ease of coupling and control. In this paper, the generation of chaos through the coupling between superconducting qubits and LC resonant circuits is investigated. By varying the ratio of Josephson energy to charge energy, the coupling coefficient, and the energy of the external driving field, the generation and control of chaos within the system are numerically analyzed. This study provides theoretical support for parameter selection ensuring the confidentiality and fidelity of quantum information transmission based on the chaotic dynamics of superconducting qubits.

Magnetic cobalt metal organic framework for photocatalytic water splitting hydrogen evolution

Using water as a renewable and safe energy source for hydrogen generation has reduced the need to use toxic fossil fuels. Photocatalytic approaches provide a worthy solution to avoid the high expenditure on complicated electrochemical pathways to promote Hydrogen Evolution Reactions. However, several types of photocatalysts including noble metal-based catalysts have already been in use for this purpose, which are generally considered high-cost as well. The present study aims to use the benefits of metal–organic frameworks (MOFs) with semiconductor-like characteristics, highly porous structures and high design flexibility. These properties of MOFs allow more efficient and effective mass transport as well as exposure to light.in this paper, using MOF technology and benefiting from the characteristics of Fe3O4 nanoparticles as catalyst support for more efficient separation of catalyst, we have synthesized a novel composite. Our proposed photocatalyst demonstrates efficient harvest of light in all wavelengths from UV to visible to generate electron/hole pairs suitable for water splitting with a turnover frequency of 0.222 h−1 at ambient conditions without requiring any additives.Graphical abstract

The Investigations of Novel Circuits Printing on Substrates by Aerosol Jet Printing

Aerosol jet printing (AJP) is a straightforward write–fabrication technique with high resolution, design flexibility, and integration capabilities [...]

A universal strategy towards the fabrication of ultra-high temperature ceramic matrix composites with outstanding mechanical properties and ablation resistance

Materials with both excellent mechanical properties and good ablation resistance are urgently needed for the applications of thermal protection system in extreme high temperature oxidizing environments. However, owing to the lack of efficient fabrication processes, the existing materials suffer from either insufficient mechanical properties or poor ablation resistance. Herein, we report a novel solid–liquid combination fabrication strategy that successfully achieves the efficient incorporation of ultra-high temperature ceramics into 3D continuous carbon fiber performs as well as rapid densification. The relative density of the green body approaches the cubic close packing of spherical particles. Using Cf/ZrB2–SiC as an example, the as-prepared composite exhibits outstanding mechanical properties with a flexural strength surpasses 600 MPa and an unprecedented work of fracture of 11,851 ± 838 J/m2, which is two orders of magnitude higher than that of the currently reported monolithic ultra-high temperature ceramics. Moreover, the high ZrB2 content endows the composites with excellent ablation resistance and is thus capable of maintaining long-term non-ablative conditions at 2500 °C. The strategy possesses remarkable universality and high design flexibility, providing a time-saving and cost-effective universal strategy for the on-demand design and fabrication of high-performance ceramic, carbon, metal, and polymer matrix composites.

Structured mesh material with gradient surface wettability for high-power-density proton exchange membrane fuel cells

ABSTRACT A compact cell structure is highly desirable for next-generation high-power-density proton exchange membrane (PEM) fuel cell (>9.0 kW L−1). A novel integrated bipolar plate (BP) – gas diffusion layer (GDL) structure utilizing porous material is a promising configuration, which not only improves output power due to the reduced transport resistance but also reduces cell thickness. Herein, we propose a structured mesh material with gradient surface wettability for this cell structure, which is characterized by an ordered skeleton in the three-dimensional (3D) space with high structure design flexibility. It is experimentally found that the structured mesh material shows higher performance than serpentine and parallel flow fields. Meanwhile, 3D modeling work on an automobile fuel cell (cell area: 245.76 cm2) with the distribution zones of dot matrix structure for hydrogen, air and coolant flow, is conducted, and it is found that the structured mesh material effectively decreases the concentration and electric ohmic losses in comparison with the traditional “BP/flow field + GDL” structure, improving power density with uniform distribution characteristics. Moreover, the gradient wettability on the mesh surface helps promote the water detach the GDL and hold the residual liquid water in the top region, optimizing the water management.