High-performance Structures Research Articles

Deep learning-based topology optimization for multi-axis machining

This paper presents a novel framework that integrates topology optimization (TO) and deep learning (DL) to generate high-performance structures suitable for multi-axis machining. Within the proposed framework, DL is built on the pix2pix network, with the conditional channel used to determine the tool shape and feed direction in multi-axis machining. This DL model will be trained using our own generated dataset on TO for multi-axis machining. Then, users can customize tool dimensions and machining orientations of the multi-axis machining operation and specify the design boundary and loading conditions as input. The DL model will rapidly generate a near-optimized structure, which subsequently serves as the starting point for further optimization. Ultimately, a topology-optimized structure that meets the tailored requirements is apt for multi-axis machining and can be finalized with only a few iterations. 2D and 3D numerical examples for heat conduction problems are studied to prove the effectiveness of the proposed method, validating improved structural performance and optimization efficiency compared to conventional TO for multi-axis machining.

A semi-analytical model for predicting the shear buckling of laminated composite honeycomb cores in sandwich panels

Laminated composite honeycomb cellular core sandwich panels are widely utilized in various industries due to their exceptional stiffness-to-weight ratio and strength characteristics. Current analytical models often simplify honeycomb cores as homogenized continua, effectively predicting stiffness but falling short in capturing crucial failure modes, particularly shear buckling of honeycomb core walls. Existing theoretical studies on shear buckling are limited to isotropic materials and specific honeycomb geometries. While numerical models can simulate cell wall buckling, their computational demands render them impractical for large structures employing sandwich panels. This paper introduces a novel, simplified semi-analytical approach that accurately predicts the shear buckling load of laminated composite honeycomb cellular cores. The model accounts for bend-twist coupling effects and rotational restraints at laminate wall boundaries. To validate the proposed approach, predictions are compared with finite element analysis results for hexagonal honeycomb cores and cores of varying shapes, incorporating diverse fibre lay-up configurations. The findings demonstrate excellent agreement between the proposed approach and finite element analysis, indicating its reliability in predicting shear buckling. This research addresses the gap in existing methodologies by offering a practical and efficient tool for predicting shear buckling in laminated composite honeycomb cores, extending applicability beyond isotropic materials and specific honeycomb geometries. The proposed approach holds promise for optimizing the design and structural integrity of sandwich panels, impacting industries relying on these lightweight and high-performance structures.

Performance optimization of FASnI3 based perovskite solar cell through SCAPS-1D simulation

The article provides a detailed look at the fabrication of a high-performance structure for FASnI3-based perovskite solar cells (PSCs). The FTO/CeO2/FASnI3/CuI/Au structure is designed using the Solar Cell Capacitance Simulator in One Dimension (SCAPS-1D) to investigate the fabricated PSC's performance. This investigation's main objective is to improve PSCs performance by using non-traditional Hole transport layer (HTL) and Electron transport layer (ETL) materials, such as CeO2 and CuI, which have both been the subject of limited research. Moreover, the investigation seeks to determine the impact of several perovskite layer characteristics, including bandgap (Eg), electron affinity (χ), acceptor density (NA), thickness (t), and defect density (Nt). Additionally, this study also investigates the effect of various back contact work functions. Significant improvements in solar cell parameters, such as power conversion efficiency (PCE) from 22.06% to 24.87% and current density (Jsc) from 26.0274 to 30.675 mA/cm2, were observed by optimizing the device's parameters. In contrast, the fill factor (FF) and open circuit voltage (Voc) decreased their values from 86.13% to 87.10% and 0.9843 to 0.9308 V, respectively. These findings show that our designed solar cell structure performs better than those with conventionally used HTLs and ETLs. Consequently, this study highlights the potential benefits of lead-free PSCs and presents fresh opportunities for their development and use in various solar applications.

Bioinspired Composite Fabrics with Nanoneedle Structures for High Wicking-Evaporation performance

Achieving ultrafast antigravity water transport and evaporation in high-performance moisture-wicking fabrics remains a significant challenge in textile engineering. In this study, we introduce two novel asymmetric composite fabrics, NN-TS/PET/BS and NS-TS/PET/BS, developed through a straightforward one-step method. These fabrics incorporate different hydrophilic nanostructures—nanoneedles (NN) and nanosheets (NS) of cobalt carbonate—to enhance wicking-evaporation capabilities. The NN-TS/PET/BS fabric exhibited superior unidirectional water transport and evaporation performance, achieving a one-way transport value (R) of up to 330%, an outstanding overall moisture management capacity (OMMC) of 0.87, and a rapid water evaporation rate of 0.5 g h⁻¹, which is 2 and 2.3 times higher than that of NS-TS/PET/BS and Coolmax, respectively. Detailed analyses revealed that the curvature gradients in the nanoneedles significantly enhanced the wetting and evaporation stages, facilitating efficient antigravity water transport. Wear studies confirmed that the NN-TS/PET/BS fabric could swiftly remove sweat from the skin surface, enhancing comfort and performance. These findings offer new perspectives for developing high-performance unidirectional water transport fabrics with broad application potential, including smart textiles, fog harvesting, and wound dressings.

Confinement synthesis of few-layer MXene-cobalt@N-doped carbon and its application for electrochemical sensing

Herein, the few-layer Ti3C2Tx nanosheets loaded zeolitic imidazolate framework-67 nanoplates (Ti3C2Tx-ZIF-67) with a unique structure has been synthesized by surfactant control method, and then is employed as the core of precursor. A thin layer of polydopamine as the shell of precursor covered Ti3C2Tx-ZIF-67 forms a micro-nano reactor, leading to the confinement carbonization process. Consequently, a novel sensing material that few-layer Ti3C2Tx nanosheets loaded Co nanoparticles coated N-doped carbon (Ti3C2Tx-Co@NC) is obtained for the non-enzymatic determination of glucose. Owing to the impressive structure, the established glucose sensor based on Ti3C2Tx-Co@NC/glassy carbon electrode exhibits 0.5–100.0 μM of linear detection range and 66.8 nM of detection limit, which tends to detect low concentration of glucose. The synergistic few-layer Ti3C2Tx nanosheets, Co nanoparticles and NC are considered through a series of control experiments. First, few-layer Ti3C2Tx nanosheets provide a good transport channel for electron transfer, resulting in the lower steric hindrance. Second, Co nanoparticles provide active centers for the electrochemical detection. Third, N-doped carbon with conductivity and hydrophilia plays the role of stabilizing material structure to prevent the fragmentation of Ti3C2Tx and the agglomeration of Co nanoparticles. Such work proposes a confined strategy to develop MXene-ZIF-67-derived nanocomposite with high-performance structure.

Modelling of Bond Formation during Overprinting of PEEK Laminates.

The rapid technological progress of large-scale CNC (computer numerical control) systems for Screw Extrusion Additive Manufacturing (SEAM) has made the overprinting of composite laminates a much-discussed topic. It offers the potential to efficiently produce functionalised high-performance structures. However, bonding the 3D-printed structure to the laminate has proven to be a critical point. In particular, the bonding mechanisms must be precisely understood and controlled to ensure in situ bonding. This work investigates the applicability of healing models from 3D printing to the overprinting of thermoplastic laminates using semi-crystalline, high-performance material like PEEK (polyether ether ketone). For this purpose, a simulation methodology for predicting the bonding behaviour is developed and tested using experimental data from a previous study. The simulation consists of a transient heat analysis and a diffusion healing model. Using this model, a qualitative prediction of the bond strength could be made by considering the influence of wetting. It was shown that the thermal history of the interface and, in particular, the tolerance of the deposition of the first layer are decisive for in situ bonding. The results show basic requirements for future process and component developments and should further advance the maturation of overprinting.

Perturbation approaches to achieving diverse and competitive designs in topology optimisation

Utilising topology optimisation to generate diverse and competitive structures enables designers to create elegant and efficient designs according to their aesthetic intuition and functional needs. This study proposes load and support perturbation approaches based on the bi-directional evolutionary structural optimisation (BESO) method to achieve diverse designs. During the optimisation process, noise is introduced to the sensitivity calculations by randomly perturbing the load angles or material properties near the supports, leading to a variety of local optima. Numerical results demonstrate that the proposed approaches are capable of creating designs with similar stiffness but distinct geometries. In addition, the diversity of the obtained solutions can be controlled by utilising different perturbation functions. This work is of significant practical importance in both architecture and engineering, where multiple design options of high structural performance are in demand.

Improved mechanical properties of porous Si3N4 ceramics strengthened by β-Si3N4 seeds fabricated by vat photopolymerization

Porous Si3N4 ceramics are widely applied in aerospace and mechanical fields owing to their excellent properties. Furthermore, vat photopolymerization (VPP) technology can fabricate Si3N4 components with complicated structures and high precision, but its layer-by-layer printing method leads to poor mechanical properties of ceramics. In this study, porous Si3N4 ceramics with a porosity of 28.41 % strengthened by directional β-Si3N4 were fabricated by combining VPP technology and seeding method. Rheological behavior and curing properties of the slurry were explored, and the influence of β-Si3N4 content on the mechanical properties of printed Si3N4 ceramics was investigated systematically. With the increase of β-Si3N4 content, the orientation degree of β-Si3N4 grains increased gradually, while fracture toughness and flexural strength of the ceramics exhibited a trend of increased first and then decreased and Vickers hardness gradually decreased. As β-Si3N4 content increased to 5 wt%, the fracture toughness and flexural strength of porous Si3N4 ceramics were improved from 4.23 MPa m1/2 and 214.7 MPa–5.65 MPa m1/2 and 272.0 MPa, respectively. Therefore, this work indicates that vat photopolymerization combined with seeding method is a promising approach for the fabrication of porous Si3N4 ceramics with high performance and complex structures.

Optimizing self-compacting concrete: formulation approach enhanced by entropy method

This study investigates the optimization of self-compacting concrete (SCC), which is crucial for modern construction due to its ability to create durable and high-performance structures. The research delves into various weighting methods utilized in SCC formulation, underscoring their pivotal role in determining the ideal combination of components. It explores objective weighting techniques and their application in enhancing SCC performance by assigning weights to individual elements. Additionally, the effectiveness of additives such as superplasticizer, limestone filler, silica fume, and viscosity modifiers in enhancing SCC properties is assessed. Utilizing the Taguchi-TOPSIS method, the study proposes a systematic approach to tailor SCC formulations to specific criteria. The key findings demonstrate that the integration of the entropy method significantly enhances the optimization process, leading to improved flowability and stability of SCC. These insights provide a comprehensive framework for optimizing SCC, offering practical guidelines for the construction industry to achieve superior concrete performance.

One-step visible laser writing of Cu-doped graphene hybrid structure for in-plane supercapacitor assembly

High-quality copper-graphene holds great potential for applications in electronics, but fabricating these hybrid structures in a cost-effective route remains challenging. Herein, we propose a one-step writing process for manufacturing copper-doped graphene hybrid structure using low-cost visible laser. The ionic precursor coated on the surface of polymeric substrate not only acts as a copper source for doping, but also can promote near-surface graphenization of the polymer as proved in this study. The interaction between copper and graphene during this in-situ laser processing has been in-deep discussed to reveal the formation mechanism of the hybrid structure. The obtained hybrid structure shows excellent performance that can assemble high-performance devices, such as the in-plane supercapacitor we demonstrated. This study presents a low-cost, rapid, and efficient strategy for structuring the composites to meet the demands for high-performance structures in booming electronics.

Knit-Mycelium Hybrids: Textile Design Strategies for Biofabrication Systems Based on Mycocrete Injection in 3D Knitted Tubular Formworks

This paper investigates the design potential of monolithically grown Mycelium-based Composites (MBCs), focusing on integrating 3D knitted formworks within the fabrication process. Mycelium has gained attention as a sustainable, biodegradable construction material with insulating and self-healing capabilities. While there have been advancements in MBC, challenges remain regarding geometrical complexity and design potential at scale through in situ practices. Recent interest has emerged in digital fabrication methods and mould creation using textile logic and CNC knitting. However, fabricating mycelium within tubular soft moulds present a lack of stability and uneven growth distribution. The novel technique using injection filling of Mycocrete, a viscous mycelium paste, overcomes this structural disintegration. This method enables the creation of complex designs within a two-staged fabrication process while providing high structural performance. The paper presents three case studies demonstrating the impact of hanging, draping, and internal shape integration as fabrication steps as design tools for geometrical possibilities and diversity of expressions. It examines the relationship between knitted soft preform design and biofabrication parameters in relation to design expression, scale and mycelium growth. The paper concludes by emphasising the significance of 3D knitted formworks in scaling up MBCs in the built environment and its potential for implementing textile design parameters in MBC expressions and geometries. The fabrication steps provide newfound design opportunities, opening possibilities for aesthetical, material-saving and functionally graded design approaches. Further research in this area holds promise for advancing sustainable construction and textile design practices.

Terahertz absorption properties of different graphene layers based on the Salisbury effect

Terahertz (THz) absorbers based on the Salisbury screen have attracted significant attention for high absorption performance and simple structure. Graphene is suitable for high-performance THz absorbers due to its extraordinary electronic and optical properties. The study of graphene THz absorbers based on Salisbury screens has attracted great interest, where the number of graphene layers significantly affects the interface impedance matching and absorption efficiency. In this work, we proposed a sandwich-structured graphene/Polyimide (PI) /Au THz absorber based on the Salisbury screen. The results show that the absorption peak tended to increase and then decrease with the increase in the number of graphene layers. The simulation demonstrates that the real and imaginary parts of the relative impedance of the 3-5 layer graphene absorber were 1.02 and 0.01, which achieved a better impedance matching with the free space. Meanwhile, the measured sheet resistance value of 426 Ω/sq was closest to the free-space impedance value of 377 Ω, consistent with the simulation results. The corresponding absorption reached a maximum value of 98.7% at 0.82 THz (measured). In addition, the absorption peak decreased from 98.7% to 86.7% as the angle of incidence increased from 0° to 60°. This demonstrates the advantage of wide-angle absorption. The proposed device is suitable for applications in electromagnetic shielding and imaging, while the suggested method can be employed for the fabrication of other graphene-based devices.

Planar oscillation-enabled deterministic magnetorheological micro-polishing

Micro-optics are attracting ever-increasing attention in advanced optical systems owing to their merits of high optical performance and high structure compactness. Although deterministic polishing is crucial for obtaining optically qualified components, the decreased micro-optic feature size imposes significant challenges on the polishing process. To proceed the post-processing technique for micro-optics, we developed a novel magnetorheological micro-polishing (μMRP) method, which features a non-contact and deterministic removal of the workpiece materials. An electromagnetic polishing tool for stiffening the MR slurry was specially designed to tightly focus the high-gradient magnetic field within a small region around the tip, thereby enabling the material removal to occur at the micro-scale. The pulse-width modulation (PWM) control strategy for the excitation currents could continuously refresh the MR slurry in the polishing, as well as precisely control the material removal. Moreover, a planar dual-axial oscillation was employed to move the tool to generate relative motions between the abrasives and workpieces for removing the materials. In practice, smooth Gaussian-shape footprints with full width at half-maximum (FWHM) around hundreds of micrometers were achieved, and the influence of the working gap, oscillation frequency, and duty ratio on the material removal was further investigated. Finally, the deterministic material removal capability was demonstrated by generating a sinusoidal micro-grid surface with an amplitude of 80 nm and a spatial period of 600 μm. The surface roughness and form error were about Sa = 1.027 nm and 6.5 nm (RMS), demonstrating that the developed μMRP is promising for figuring micro-optics.

Feasibility study of friction stir joining of aluminium with carbon fibre reinforced thermoplastic composite

During the last decades, environmental concerns and limited resources have set focus of research on lightweight, mechanically high-performing structures for the transportation industry, in order to reduce fuel consumptions and CO2 emissions. Friction Stir Joining (FSJ), as a variant of the Friction Stir Welding (FSW), is an innovative friction-based joining technique for metal-composite hybrid structures. Joining in the plasticized state below the melting temperature of the metal leads to a comparatively small heat-affected zone, so that only minor metallurgical changes occur. Additionally, only a short processing time and no additional weight in form of fasteners is needed. The main objective of this study is to evaluate the feasibility of metal-composite structures via FSJ, intending to enable a macro-mechanical interlocking bonding mechanism. Main focus was given to the integration of an aluminium nub inserted in a carbon fiber-reinforced polyphenylene sulfide (CF-PPS) sheet, to ensure sufficient plasticization of the aluminium part and no degradation in the polymer part. Residual stress arising from the friction stir joining process was also characterised using the Contour method. In this study, aluminium alloy 6082-T6 and CF-PPS composite sheets were used to produce long lap joints. Results have shown that the joints were created at almost constant peak temperature slightly above the melting temperature of the PPS but no physical-chemical changes were detected in the PPS. In addition, the influence of a PPS film as interlayer between the sheets was investigated in order to explore a method for preventing galvanic corrosion. Preliminary results indicate that it is not possible to integrate a metal nub to the CF-PPS without interrupting the PPS film. However, it is possible to create a nub within the PPS film.

Highly Porous ZnO/CNT Hybrid Microclusters for Superior UV Photodetection.

The formation of nanoscale junctions among nanoparticles in self-assembled nanostructures is crucial for improving both interfacial conductivity and structural integrity. However, the inherent reliance on weak van der Waals forces to hold nanoparticles together poses challenges in developing commercially viable devices due to their inefficient carrier transport characteristics. This study presents the successful integration of carbon nanotubes (CNTs) into highly porous nanomicrocluster arrays of ZnO, resulting in the formation of cohesive and crack-free highly porous ZnO/CNT heterojunction films. This integration marks a significant improvement in UV photodetection performance, demonstrating a record-high photocurrent to dark current ratio of 3.3 × 106 and an exceptional responsivity of 18.5 A/W at a low bias of 0.5 V and under an ultra low light density of 25 μW/cm2. These findings underscore the efficacy of this high-performance structure as a versatile and scalable platform technology for the rapid, cost-effective fabrication of hybrid photodetectors in wearable and portable devices.

In-situ process monitoring and adaptive quality enhancement in laser additive manufacturing: A critical review

Laser Additive Manufacturing (LAM) presents unparalleled opportunities for fabricating complex, high-performance structures and components with unique material properties. Despite these advancements, achieving consistent part quality and process repeatability remains challenging. This paper provides a comprehensive review of various state-of-the-art in-situ process monitoring techniques, including optical-based monitoring, acoustic-based sensing, laser line scanning, and operando X-ray monitoring. These techniques are evaluated for their capabilities and limitations in detecting defects within Laser Powder Bed Fusion (LPBF) and Laser Directed Energy Deposition (LDED) processes. Furthermore, the review discusses emerging multisensor monitoring and machine learning (ML)-assisted defect detection methods, benchmarking ML models tailored for in-situ defect detection. The paper also discusses in-situ adaptive defect remediation strategies that advance LAM towards zero-defect autonomous operations, focusing on real-time closed-loop feedback control and defect correction methods. Research gaps such as the need for standardization, improved reliability and sensitivity, and decision-making strategies beyond early stopping are highlighted. Future directions are proposed, with an emphasis on multimodal sensor fusion for multiscale defect prediction and fault diagnosis, ultimately enabling self-adaptation in LAM processes. This paper aims to equip researchers and industry professionals with a holistic understanding of the current capabilities, limitations, and future directions in in-situ process monitoring and adaptive quality enhancement in LAM.

Finite Element Analysis of Stress Distribution in AL6061 Frame Structures Under Varying Applied Loads

The demand for lightweight and high-performance structures has driven the popularity of commercially available aluminum alloys such as AL6061, particularly in the transporterindustry. However, predicting stress distribution accurately within AL6061 frame structures under diverse loading conditions remains a significant challenge for clients due to the complex nature of their behavior. To address this challenge, a study has been conducted that utilizes the advanced 3D simulation software SolidWorks 2023 to model a custom dimension frame structure and evaluate their behavior under varied loads of up to 200% of the structure's weight, which is a significant departure from the standard loading conditions. The goal is to offer a thorough and accurate assessment of the frame structure's capabilities. This investigation analyzed the stress, strain, displacement, and safety factors of a specifically designed frame structure, ensuring that each value met or exceeded acceptable standards. This study also provides valuable insights into the structure's performance under various loading conditions, including the handling of heavy items and specimens that require the use of a transporter in industrial engineering applications. Additionally, a detailed assessment of the material properties of the aluminum alloy used in constructing the frame structure provides useful information for designing and optimizing high-performing structures in the industry. Based on the results, it appears that the critical von Mises stress, when exposed to maximum varying loads (76.54 MPa), remains below the structure's yield strength of 275 MPa. The equivalent strain reaches a maximum value of 0.5607E-03, and the structure's deformation at maximum loads is just 0.6705 mm. The safety factors of the structure, tested at three different varying loads, are above 3. These values conclusively demonstrate that the AL6061 frame structure is safe and reliable for industrial applications and can withstand loads up to 200% wt.

Sc3+ substituted Na3V2(PO4)3 on N-doped porous carbon skeleton boosting high structural stability and superior electrochemical performance for full sodium ion batteries

The poor structural stability and conductivity of Na3V2(PO4)3 (NVP) have been serious limitations to its development. In this paper, Sc3+ is selected to replace partial site of V3+ which can enhance its ability to bond with oxygen, forming the ScO6 octahedral unit, resulting in improved structural stability and better kinetic properties for the NVP system. Moreover, due to the larger ionic radius of Sc3+ compared to V3+, moderate Sc3+ substitution can support the crystal framework as pillar ions and expand the migration channels for de-intercalation of Na+, thus efficiently promoting ionic conductivity. The introduction of polyacrylonitrile (PAN) to provide an N-doped porous carbon substrate is another key aspect. The low-cost carbon resource of PAN can induce a beneficial nitrogen-doped carbon skeleton with defects, enhancing electronic conductivity at the interface to reduce the polarization phenomenon. The established pore structure can serve as a buffer for unit cell deformation caused by Na+ migration. Furthermore, the enlarged specific surface area provides more active sites for electrolyte infiltration, improving the material utilization rate. The after cycling X-ray Diffraction/scanning electron microscope (XRD/SEM) further confirms the stabilized porous carbon skeleton and improved crystal stability of Sc-3 material. Ex-situ XRD analysis shows that the crystal volume change in the Sc-3 cathode is relatively slight but reversible during the charge/discharge process, indicating that Sc3+ doping plays a crucial role in stabilizing the unit cell structure. The hybrid Sc/VO6 and PO4 units jointly build a strong bone structure to resist stress and weaken deformation. Accordingly, the optimized Sc-3 sample reveals an initial capacity of 115.9 mAh/g at 0.1C, with a capacity retention of 78.6 % after 2000 cycles at 30C. The Sc-3//CHC full battery can release a capacity of 191.3 mAh/g at 0.05C, accompanied by successful illumination, showcasing its promising practical applications.

On the fatigue behaviour of epoxy-based nanostructured composite materials

Epoxy composites and nanocomposites enable the creation of high-performance structures and innovative designs. However, there is limited research focused on their fatigue characterization. The purpose of this study is to analyze the fatigue resistance results of nanostructured composite materials made with an epoxy matrix of Diglycidyl Ether of Bisphenol F and 9,9-bis(3-chloro-4-aminophenyl) fluorine (DGEBF-CAF) reinforced with 5%wt of elastomeric nanoparticles with an average diameter of 200 nm. The tests are conducted at variable load and frequency using Rotating Bending (R-B) and Tensile-Tensile (T-T) tests, and the results are compared to those obtained with pure resin. The occurrence of thermal fatigue phenomena during the tests is monitored using a thermal camera. The results confirm that pure epoxy resin exhibits poor crack propagation resistance due to its low ductility and toughness, and the introduction of a second phase leads to an improvement of approximately 3 times in T-T tests and 5 times in R-B tests.

Evaluating consumer 3D printing nozzles as a low cost alternative for mesophase pitch-derived carbon fiber production

Synthetic fibers, such as Kevlar fibers, SiC fibers, and carbon fibers, are essential components for constructing high performance structures. Whether for engineering, sports, energy storage (batteries and supercapacitors), or aerospace applications, fiber microstructure plays a critical role in fiber properties and functionalities. However, studying fiber nozzle configurations and spinning parameters to achieve the desired microstructure remains challenging, costly, and time consuming. Here, mesophase pitch-derived fibers were used as an example to demonstrate that low cost, commercially available 3D printer nozzles can “print” fibers. Four different nozzles were used to “print” fibers and the effects of their features on fiber properties were observed and compared to other lab spun and commercial pitch-derived CF. A longer orifice length resulted in higher modulus fiber whereas a larger draw-down ratio yielded a stronger fiber. The findings provide a new opportunity for 3D printer hardware application and open opportunities for developing low-cost fibers.