Large-scale Manufacturing Research Articles

Chitosan-Based Electronics: The Importance of Acid Strength and Plasticizing Additives on Device Performance.

A rise in demand for disposable consumer electronics such as smart packaging, wearable electronics, and single-use point-of-source sensors requires the development of eco-friendly and compostable electronic materials. Chitosan is derived from crustacean waste and offers high dielectric constant values without requiring rigorous purification, making it sustainable for large-scale electronic device manufacturing. When processed in acidic media, the protonated backbone of chitosan pairs with counterions from the acid dissociation to form chitosan thin films with electrical double layers (EDLs) and tunable capacitive properties. We report the importance of the choice of acid when processing chitosan by surveying a series of halogenated and biosourced acids with varying pKa values and solutions with different pH values. Oxalic acid outperforms other acids, with a maximum areal capacitance of 161 nF·mm-2. Tartaric acid and citric acid, despite lower capacitance values, showed promising results with a stable EDL capacitance and high reproducibility, making them optimal for large-area manufacturing. The incorporation of sorbitol as a plasticizer boosts the EDL formation onset of all chitosan-acid combinations to 1 × 103-105 Hz and improves reproducibility. High-performing single-walled carbon nanotube thin film transistors were made using chitosan-based dielectrics treated with different acids with and without sorbitol, leading to transconductance as high as ≈5.2 μS and Ion/Ioff of 105. The capacitors and transistors remain functional after one year of storage in ambient conditions. Overall, this study demonstrates durable high-performance electronics based on chitosan and stresses the importance of processing acid and the use of plasticizing additives, such as sorbitol.

Fractals as Pre-Training Datasets for Anomaly Detection and Localization

Anomaly detection is crucial in large-scale industrial manufacturing as it helps to detect and localize defective parts. Pre-training feature extractors on large-scale datasets is a popular approach for this task. Stringent data security, privacy regulations, high costs, and long acquisition time hinder the development of large-scale datasets for training and benchmarking. Despite recent work focusing primarily on the development of new anomaly detection methods based on such extractors, not much attention has been paid to the importance of the data used for pre-training. This study compares representative models pre-trained with fractal images against those pre-trained with ImageNet, without subsequent task-specific fine-tuning. We evaluated the performance of eleven state-of-the-art methods on MVTecAD, MVTec LOCO AD, and VisA, well-known benchmark datasets inspired by real-world industrial inspection scenarios. Further, we propose a novel method to create a dataset by combining the dynamically generated fractal images creating a “Multi-Formula” dataset. Even though pre-training with ImageNet leads to better results, fractals can achieve close performance to ImageNet under proper parametrization. This opens up the possibility for a new research direction where feature extractors could be trained on synthetically generated abstract datasets mitigating the ever-increasing demand for data in machine learning while circumventing privacy and security concerns.

Enhancing activated carbon supercapacitor electrodes using sputtered Cu-doped BiFeO3 thin films.

This work describes the fabrication of a composite supercapacitor electrode made of Cu-doped BiFeO (Cu-BFO) films on an activated carbon (AC) electrode using radio-frequency (RF) magnetron sputtering. To prevent exfoliation of Cu-BFO and AC upon immersion in an electrolyte, the nickel foam sandwiching electrode technique was introduced. The Cu-BFO films significantly enhanced electrochemical properties, increasing specific capacitance by up to 151% compared to that of an AC electrode. This was attributed to Faradaic reactions and specific surface area in the Cu-BFO/AC electrode. The highest specific capacitance achieved was 169 F at 0.5 A , and cycling stability retention was 93.12% after 500 cycles. However, the remaining percentage of the specific capacitance decreased differently with increasing thickness, which is also discussed. Furthermore, an asymmetric supercapacitor using Cu-BFO/AC and AC electrodes demonstrated a high energy density of 4.71 Wh , power density of 2.66 kW , and over 90% retention after 1000 cycles, highlighting its durability. The uniform RF magnetron sputtering deposition is vital for mass production. Combined with impressive retention in asymmetric supercapacitors, this scalability suggests a promising pathway for large-scale manufacturing. Consequently, this work could pave the way for the large-scale production of supercapacitors.

Solution-Processed Fabrication of Ni3S2-Based Nanoheterostructure on Silicon Heterojunction Photocathode for Boosting Solar Hydrogen Generation.

Silicon heterojunction (SHJ) solar cell is an advanced and mature photovoltaic cell. Development of photoelectrochemical (PEC) water splitting devices for hydrogen fuel production using SHJ solar cells is considered as a promising approach to address energy crisis. To achieve this goal, it is necessary to deposit passivation layer and cocatalyst layer on the photoelectrode. However, the development of low-cost and scalable preparation methods for high-quality passivation and cocatalyst layer continues to be a significant challenge. Herein, an efficient passivation layer and hydrogen evolution reaction (HER) catalyst are successfully fabricated via solution processed methods. To improve the HER activity of Ni3S2, a Ni3S2-based nanoheterostructure of crystalline Ni3S2, Ni, and amorphous Y(OH)3 is constructed. The optimized photocathode exhibits excellent PEC-HER performance, which achieves a saturated photocurrent of -35.5mA cm-2 and an applied bias photon-to-current efficiency (ABPE) of 8.4 ±0.1% under simulated AM1.5G one-sun illumination and more than 120h of continuous water splitting. This study paves a way for the design and large-scale manufacturing of cost-efficient SHJ photocathode devices.

Bioengineered lubricin alters the lubrication modes of cartilage in a dose-dependent manner.

The low friction nature of articular cartilage has been attributed to the synergistic interaction between lubricin and hyaluronic acid in the synovial fluid (SF). Lubricin is a mucinous glycoprotein that lowers the boundary mode coefficient of friction of articular cartilage in a dose-dependent manner. While there have been multiple attempts to produce recombinant lubricin and lubricin mimetic cartilage lubricants over the last two decades, these materials have not found clinical use due to challenges associated with large scale production, manufacturing, and purification. Recently, a novel method using codon scrambling was developed to produce a stable, full-length bioengineered equine lubricin (eLub) in large reproducible quantities. While preliminary frictional analysis of eLub and other recombinantly produced forms revealed they can lubricate cartilage, a complete tribological characterization is lacking, with previous studies evaluating the friction coefficient only at a single dose or a single speed. The objective of this study was to analyze the dose-dependent tribological properties of eLub using the Stribeck framework of tribological analysis. Recombinantly produced eLub at doses greater than 1.5 mg/mL exhibits friction coefficients on par with healthy bovine SF, and a maximal 5 mg/mL dose exhibits a nearly 50% lower friction coefficient than healthy SF. eLub also modulates the shift in lubrication mode of the cartilage from the high friction boundary mode to the low friction minimum mode at high concentrations.

Identifying and optimizing critical process parameters for large-scale manufacturing of iPSC derived insulin-producing β-cells

BackgroundType 1 diabetes, an autoimmune disorder leading to the destruction of pancreatic β-cells, requires lifelong insulin therapy. Islet transplantation offers a promising solution but faces challenges such as limited availability and the need for immunosuppression. Induced pluripotent stem cells (iPSCs) provide a potential alternative source of functional β-cells and have the capability for large-scale production. However, current differentiation protocols, predominantly conducted in hybrid or 2D settings, lack scalability and optimal conditions for suspension culture.MethodsWe examined a range of bioreactor scaleup process parameters and quality target product profiles that might affect the differentiation process. This investigation was conducted using an optimized High Dimensional Design of Experiments (HD-DoE) protocol designed for scalability and implemented in 0.5L (PBS-0.5 Mini) vertical wheel bioreactors.ResultsA three stage suspension manufacturing process is developed, transitioning from adherent to suspension culture, with TB2 media supporting iPSC growth during scaling. Stage-wise optimization approaches and extended differentiation times are used to enhance marker expression and maturation of iPSC-derived islet-like clusters. Continuous bioreactor runs were used to study nutrient and growth limitations and impact on differentiation. The continuous bioreactors were compared to a Control media change bioreactor showing metabolic shifts and a more β-cell-like differentiation profile. Cryopreserved aggregates harvested from the runs were recovered and showed maintenance of viability and insulin secretion capacity post-recovery, indicating their potential for storage and future transplantation therapies.ConclusionThis study demonstrated that stage time increase and limited media replenishing with lactate accumulation can increase the differentiation capacity of insulin producing cells cultured in a large-scale suspension environment.

Nanomaterials in Solid-State Batteries: Enhancing Safety and Performance

Solid-state batteries (SSBs), utilizing solid electrolytes instead of liquid ones, represent a promising advancement in energy storage technology due to their higher energy density and enhanced safety. Despite their potential, SSBs face significant challenges such as high interfacial resistance, low ionic conductivity, and high production costs. Recent advancements in nanomaterial technology have offered innovative solutions to these issues. Nanomaterials with high specific surface areas and controllable morphologies optimize interfacial contact, reduce resistance, and enhance ionic conductivity through efficient ion transport channels. Additionally, surface modifications and doping improve the chemical and thermal stability of SSB components, extending battery life and preventing adverse reactions. Although initial preparation costs are high, advancements in production technology and large-scale manufacturing are expected to lower these costs, facilitating commercialization. Future research should focus on new nanostructure designs, nanocomposites, and interfacial engineering to further enhance battery performance and safety. Understanding the influence of nanomaterials on safety performance and improving thermal and mechanical shock resistance are crucial for the reliable implementation of solid-state batteries in practical applications.

Silk fibroin nanoparticles for locoregional cancer therapy: Preliminary biodistribution in a murine model and microfluidic GMP-like production

Silk fibroin nanoparticles (SFNs) have been widely investigated for drug delivery, but their clinical application still faces technical (large-scale and GMP-compliant manufacturing), economic (cost-effectiveness in comparison to other polymer-based nanoparticles), and biological (biodistribution assessments) challenges. To address biodistribution challenge, we provide a straightforward desolvation method (in acetone) to produce homogeneous SFNs incorporating increasing amounts of Fe2O3 (SFNs-Fe), detectable by Magnetic Resonance Imaging (MRI), and loaded with curcumin as a model lipophilic drug. SFNs-Fe were characterized by a homogeneous distribution of the combined materials and showed an actual Fe2O3 loading close to the theoretical one. The amount of Fe2O3 incorporated affected the physical-chemical properties of SFNs-Fe, such as polymer matrix compactness, mean diameter and drug release mechanism. All formulations were cytocompatible; curcumin encapsulation mitigated its cytotoxicity, and iron oxide incorporation did not impact cell metabolic activity but affected cellular uptake in vitro. SFNs-Fe proved optimal for biodistribution studies, as MRI showed significant nanoparticle retention at the administration site, supporting their potential for locoregional cancer therapy. Finally, technical and economic challenges in SFN production were overcome using a GMP-compliant microfluidic scalable technology, which optimized preparation to produce smaller particle sizes compared to manual methods and reduced acetone usage, thus offering environmental and economic benefits. Moreover, enabling large-scale production of GMP-like SFNs, this represents a considerable step forward for their application in the clinic.

A polysulfides adsorption strategy through cation-anion interactions for achieving high-safety lithium-sulfur batteries in multiple scenarios

The widespread application of lithium-sulfur batteries (LSBs) is hindered by challenges such as the shuttle effect of polysulfides (LiPSs), slow reaction kinetics, and fire safety concerns. In this study, surface-functionalized boron nitride nanosheets (ChBN) are prepared and employed as functional separator coatings, enabling multiple application scenarios of LSBs. Specifically, a creative strategy of cation-anion interactions is constructed through the strong chemisorption of N+ on the ChBN surface to Sn- in LiPSs. In addition, the boron nitride and N+ showed synergistic effects on adsorption-catalysis, further facilitating the rapid and sufficient deposition of Li2S. The prepared LSBs with ChBN + SP/PP separators exhibit excellent cycle stability (an ultralow capacity degradation of 0.034 % per cycle over 500 cycles at 2C). These LSBs are available over a wide temperature range of −20 to 60 °C, offering a capacity of 1208 mA h/g at 60 °C and 919 mA h/g at −20 °C. Furthermore, the presence of ChBN effectively improves the fire-safety of pouch batteries through the condensed-phase flame retardant mechanism. This simple fabrication process of ChBN is effective and favorable for large-scale manufacturing, which provides a feasible method for the development of high-safety LSBs.

Emerging trends and innovations in all-solid-state lithium batteries: A comprehensive review

All-solid-state lithium batteries, which utilize solid electrolytes, are regarded as the next generation of energy storage devices. Recent breakthroughs in this type of rechargeable battery have significantly accelerated their path towards becoming commercially viable. Nevertheless, the development of such devices is impeded by various obstacles, including limitations in ion transfer capability, interfacial hurdles, and chemical and electrochemical stability. This paper provides a comprehensive review of the latest advancements in all-solid-state lithium-based batteries. The main emphasis is on the fabrication techniques, novel solid electrolytes, and the application of advanced cathode and anode materials to expedite research and development in this field. Moreover, the feasibility of large-scale manufacturing of solid-state batteries has been evaluated. Finally, the most practical and effective approaches for the advancement of these batteries have been proposed and examined.

Efficient 7-Dehydrocholesterol Production by Multiple Metabolic Engineering of Diploid Saccharomyces cerevisiae.

7-Dehydrocholesterol (7-DHC), a direct precursor of vitamin D3, has attracted increasing attention in microbial fermentation recently. In this study, 7-DHC biosynthesis in diploid Saccharomyces cerevisiae with robust ergosterol production was achieved by heterologous 24-dehydrocholesterol reductase expression, generating 44.1 mg/L 7-DHC, whereas the titer of ergosterol decreased by 40.5%. The ergosterol biosynthetic pathway was completely blocked by knocking out ERG6 and ERG5, affording a 4.2-fold increase in the 7-DHC titer. Subsequently, the facilitation of the mevalonate and the postsqualene pathways accompanied by elimination of transcriptional repressors enhanced 7-DHC synthesis, and the 7-DHC titer reached 738.5 mg/L in a shake flask. Further validation in a 50 L fermenter demonstrated that the 7-DHC titer reached 3.80 g/L within just 24 h, with productivity reaching 158.3 mg/L/h, setting a new benchmark as the highest reported to date. This study paves the way toward a large-scale and cost-effective manufacture of 7-DHC.

The production study of Auger emitters in platinum group metal for radiotherapy

Targeted radioisotope therapy (TRT) is a type of internal radiotherapy that combines radiation therapy and targeted therapy to eliminate cancer cells without damaging healthy tissue. Radionuclides attached to targeting molecules travel to cancer cells and emit radiation in the form of beta-ray emitting nuclides and alpha nuclides. A third type of nuclide called Auger emitter can be used in a treatment called Auger therapy. Dr Tomoyuki Ohya, Department of Advanced Nuclear Medicine Sciences, Institute for Quantum Medical Sciences (iQMS), National Institutes for Quantum Science and Technology (QST), Japan, is interested in Auger therapy as a radiotherapy that only affects the tissues that require treatment. Challenges associated with this treatment are the short range of Auger electrons, meaning that they must be precisely targeted in order to be effective. With a view to overcoming this, Ohya is focusing on Pd-103 and Rh-103m as optimal nuclides for Auger therapy. He is working to develop a technology to facilitate high-quality, large-scale manufacturing that can be applied to the clinical use of Auger therapy, enhancing its efficiency and rendering its use on a wide scale possible. In one project, Ohya investigated the potential of developing an efficient and reliable method for producing Rh-103m. Due to its short half-life it needs to be produced by a generator for clinical use. As the anion-exchange resins used in previously developed generators are no longer commercially available, Ohya and the team prepared and tested generators using commercially available anion-exchange resins.

Cooperative augmented assembly (CAA): augmented reality for on-site cooperative robotic fabrication

Recent years have witnessed significant advances in computational design and robotic fabrication for large-scale manufacturing. Although these advances have enhanced the speed, precision, and reproducibility of digital fabrication processes, they often lack adaptability and fail to integrate manual actions in a digital model. Addressing this challenge, the present study introduces cooperative augmented assembly (CAA), a phone-based mobile Augmented Reality (AR) application that facilitates cooperative assembly of complex timber structures between humans and robots. CAA enables augmented manual assembly, intuitive robot control and supervision, and task sharing between humans and robots, creating an adaptive digital fabrication process. To allocate tasks to manual or robotic actions, the mobile AR application allows multiple users to access a shared digital workspace. This is achieved through a flexible communication system that allows numerous users and robots to cooperate seamlessly. By harnessing a cloud-based augmented reality system in combination with an adaptive digital model, CAA aims to better incorporate human actions in robotic fabrication setups, facilitating human–machine cooperation workflows and establishing a highly intuitive, adaptable digital fabrication process within the Architecture, Engineering, and Construction sector.

Research on the influence of cutter overhang length on robotic milling chatter stability

Serial industrial robots are widely in demand in the field of large-scale component processing and manufacturing. However, the structure characteristic of serial robots makes it easy to generate chatter during milling and the overhang length of milling cutter has an important influence on the stability of robotic milling. Milling cutter overhang length refers to the length from the tip of the cutter to the protrusion of the spindle, to study the influence of milling cutter overhang length on the stability behavior of robotic milling, the modal parameters of milling cutter under different overhang length were obtained by hammer experiment, and its dynamic characteristics were analyzed. The stability behavior for robotic milling under different cutter overhang lengths was analyzed by using the stability lobe diagrams, and the stability lobe diagrams were verified by robotic milling experiments. The results show that the rigidity and natural frequency of milling cutter decrease with the increase of overhang length. There is a big gap between the stability lobe diagrams and the actual machining state when the cutter overhang length is short, and the low frequency vibration is easy to occur in the robotic milling process when the spindle speed is low, which is most probably because that the absorbed vibration energy by the cutter has been transferred to the robot body before the milling cutter vibrates. When the cutter overhang is increased and the feed direction is along the y-axis of the robot global coordinate system, the stability lobe diagrams by considering the multi-mode coupling effect is more consistent with the actual milling state.

Scalable Production of Functional Fibers with Nanoscale Features for Smart Textiles.

Functional fibers, retaining nanoscale characteristics or nanomaterial properties, represent a significant advance in nanotechnology. Notably, the combination of scalable manufacturing with cutting-edge nanotechnology further expands their utility across numerous disciplines. Manufacturing kilometer-scale functional fibers with nanoscale properties are critical to the evolution of smart textiles, wearable electronics, and beyond. This review discusses their design principles, manufacturing technologies, and key advancements in the mass production of such fibers. In addition, it summarizes the current applications and state of progress in scalable fiber technologies and provides guidance for future advances in multifunctional smart textiles, by highlighting the upcoming impending demands for evolving nanotechnology. Challenges and directions requiring sustained effort are also discussed, including material selection, device design, large-scale manufacturing, and multifunctional integration. With advances in functional fibers and nanotechnology in large-scale production, wearable electronics, and smart textiles could potentially enhance human-machine interaction and healthcare applications.

Efficient mass manufacturing of high-density, ultra-low-loss Si3N4 photonic integrated circuits

Silicon nitride (Si3N4) photonic integrated circuits (PICs) offer significant advantages over traditional silicon photonics, including low loss and superior power handling at optical communication wavelength bands. To facilitate high-density integration and effective nonlinearity, the use of thick, stoichiometric Si3N4 films is crucial. However, when using low-pressure chemical vapor deposition (LPCVD) to achieve high optical material transparency, Si3N4 films exhibit large tensile stress on the order of GPa, leading to wafer cracking that challenges mass production. Methods for crack prevention are therefore essential. The photonic Damascene process has addressed this issue, attaining record low-loss Si3N4 PICs, but it lacks control of the waveguide height, leading to large random variations of waveguide dispersion and unpredictable spectrum responses of critical functional devices such as optical couplers. Conversely, subtractive processes achieve better dimension control but rely on techniques unsuitable for large-scale production. To date, an outstanding challenge is to attain both lithographic precision and ultra-low loss in high-confinement Si3N4 PICs that are compatible with large-scale foundry manufacturing. Here, we present a single-step deposited, DUV-based subtractive method for producing wafer-scale ultra-low-loss Si3N4 PICs that harmonize these necessities. By employing deep etching of densely distributed, interconnected trenches into the substrate, we effectively mitigate the tensile stress in the Si3N4 layer, enabling direct deposition of thick films without cracking and substantially prolonged storage duration. A secondary ion mass spectrometry (SIMS) analysis reveals that these deep trenches simultaneously serve as gettering centers for metal impurities, in particular copper, thereby reducing the absorption loss in Si3N4 waveguides. Lastly, we identify ultraviolet (UV)-radiation-induced damage that can be remedied through a rapid thermal annealing. Collectively, we develop ultra-low-loss Si3N4 microresonators and 0.5-m-long spiral waveguides with losses down to 1.4 dB/m at 1550 nm with high production yield. This work addresses the long-standing challenges toward scalable and cost-effective production of tightly confined, low-loss Si3N4 PICs as used for quantum photonics, large-scale linear and nonlinear photonics, photonic computing, and narrow-linewidth lasers.

Fabrication of Scalable Covalent Organic Framework Membrane-based Electrolytes for Solid-State Lithium Metal Batteries.

The conventional covalent organic framework (COF)-based electrolytes with tailored ionic conducting behaviors are typically fabricated in the powder morphology, requiring further compaction procedures to operate as solid electrolyte tablets, which hinders the large-scale manufacturing of COF materials. In this study, we present a feasible electrospinning strategy to prepare scalable, self-supporting COF membranes (COMs) that feature a rigid COF skeleton bonded with flexible, lithiophilic polyethylene glycol (PEG) chains, forming an ion conduction network for Li+ transport. The resulting PEG-COM electrolytes exhibit enhanced dendrite inhibition and high ionic conductivity of 0.153 mS cm-1 at 30 °C. The improved Li+ conduction in PEG-COM electrolytes stems from the loose ion pairing in the structure and the production of higher free Li+ content, as confirmed by solid-state 7Li NMR experiments. These changes in the local microenvironment of Li+ facilitate its directional movement within the COM pores. Consequently, solid-state symmetrical Li|Li, Li|LFP, and pouch cells demonstrate excellent electrochemical performance at 60 °C. This strategy offers a universal approach for constructing scalable COM-based electrolytes, thereby broadening the practical applications of COFs in solid-state lithium metal batteries.

A Comparative Analysis of Models for AAV-Mediated Gene Therapy for Inherited Retinal Diseases.

Inherited retinal diseases (IRDs) represent a diverse group of genetic disorders leading to progressive degeneration of the retina due to mutations in over 280 genes. This review focuses on the various methodologies for the preclinical characterization and evaluation of adeno-associated virus (AAV)-mediated gene therapy as a potential treatment option for IRDs, particularly focusing on gene therapies targeting mutations, such as those in the RPE65 and FAM161A genes. AAV vectors, such as AAV2 and AAV5, have been utilized to deliver therapeutic genes, showing promise in preserving vision and enhancing photoreceptor function in animal models. Despite their advantages-including high production efficiency, low pathogenicity, and minimal immunogenicity-AAV-mediated therapies face limitations such as immune responses beyond the retina, vector size constraints, and challenges in large-scale manufacturing. This review systematically compares different experimental models used to investigate AAV-mediated therapies, such as mouse models, human retinal explants (HREs), and induced pluripotent stem cell (iPSC)-derived retinal organoids. Mouse models are advantageous for genetic manipulation and detailed investigations of disease mechanisms; however, anatomical differences between mice and humans may limit the translational applicability of results. HREs offer valuable insights into human retinal pathophysiology but face challenges such as tissue degradation and lack of systemic physiological effects. Retinal organoids, on the other hand, provide a robust platform that closely mimics human retinal development, thereby enabling more comprehensive studies on disease mechanisms and therapeutic strategies, including AAV-based interventions. Specific outcomes targeted in these studies include vision preservation and functional improvements of retinas damaged by genetic mutations. This review highlights the strengths and weaknesses of each experimental model and advocates for their combined use in developing targeted gene therapies for IRDs. As research advances, optimizing AAV vector design and delivery methods will be critical for enhancing therapeutic efficacy and improving clinical outcomes for patients with IRDs.

Three-stage resilience enhancement via optimal dispatch and reconfiguration for a microgrid

Extreme weather causes an increase in power system failure. Previous studies on system resilience have often overlooked the user-side of a microgrid. This study proposes composite resilience indices (RI) based on the power supply of a large-scale manufacturing campus microgrid to quantify its ability to withstand extreme events. The proposed RI consider load priority, minimum supply load, total energy supplied, and the performance recovery-to-degradation slope ratio in an islanding microgrid. Accordingly, this study presents a three-stage resilience optimal dispatch and reconfiguration strategy, including energy-level scheduling, grid-level reconfiguration, and dynamic-level verification. A multi-objective optimization approach is used for energy scheduling, followed by system reconfiguration via DIgSILENT system modeling to meet the grid code and maximize load supply. Value at Risk methods are used to verify microgrid stability and load shedding requirements, supported by the virtual synchronous generator control of the energy storage system. The test results from a practical large-scale manufacturing campus microgrid validate the proposed approaches for enhancing system resilience considering load values.

Optimizing the Pore Structure of Lotus-Type Porous Copper Fabricated by Continuous Casting.

Lotus-type porous copper was fabricated using a continuous casting method in pressurized hydrogen and nitrogen gas atmospheres. This study evaluates the effects of process parameters, such as the hydrogen ratio, total pressure, and transference velocity, on the resulting pore structure. A continuous casting process was developed to facilitate the mass production of lotus-type porous copper. To achieve the desired porosity and pore diameter for large-scale manufacturing, a systematic evaluation of the influence of each process parameter was conducted. Lotus-type porous copper was produced within a hydrogen ratio range of 25-50%, a transference velocity range of 30-90 mm∙min-1, and a total pressure range of 0.2-0.4 MPa. As a result, the porosity ranged from 36% to 55% and the pore size varied from 300 to 1500 µm, demonstrating a wide range of porosities and pore sizes. Through process optimization, it is possible to control the porosity and pore size. The hydrogen ratio and total pressure were found to primarily affect porosity, whereas the hydrogen ratio, transference velocity, and total pressure significantly influenced pore diameter. When considering these parameters together, porosity was most influenced by the hydrogen ratio, whereas the total pressure and transference velocity had a greater influence on pore diameter. Reducing the hydrogen ratio and increasing the transference velocity and total pressure reduced the pore diameter and porosity. This optimization of the continuous casting process enables the control of porosity and pore diameter, facilitating the production of lotus-type porous copper with the desired pore structures.