Fabrication Method Research Articles

Polydopamine‐Mediated Gold Nanostructure‐Decorated Electrospun Polycaprolactone Fibers for Photocatalytic Dye Degradation

AbstractMetallic nanoparticle (NP)‐decorated electrospun micro/nanofibers as an ideal photocatalytic system for the degradation of organic dyes may provide unique advantages in terms of 3D morphology with high surface area, well‐controlled porosity, low cost, good interconnectivity, and excellent flexibility. However, novel, flexible, low‐cost, and efficient fabrication methods are still demanded to obtain photocatalytic activity. In this report, for the first time, we propose gold NP (AuNP)‐decorated electrospun poly(Ɛ‐caprolactone) (PCL) membrane fibers through a conformal thin layer of polydopamine (PDA). Herein, PDA could reduce the Au3+ ions and enable the adsorption of AuNPs without using any reducing agent or seed material. The proposed system could degrade methylene blue after a 6‐h of daylight exposure with a rate constant of 4.83 × 10−3 and 4.64 × 10−3 min−1 for citrate‐stabilized AuNPs and reduction of Au ions cases, respectively. Even after fifth cycle of usage, AuNP‐decorated electrospun fibers showed reasonable catalytic activity without any significant change in their morphology and chemical content. For the case of rhodamine 6G, the same systems provided 55.2% and 64.1% of dye degradation within a 5‐h exposure. The proposed system presents unique advantages regarding control, flexibility, low cost, and efficiency in various catalytic applications.

Multiscale Analysis of Surface Topography for Engineering Applications in the Casting Industry

This paper presents the results of studies aimed at assessing the impact of the molding process on the variability of surface irregularities of casting models. This research was conducted using a selected multiscale method, i.e., wavelet transformation, in both discrete and continuous perspective. The test samples were made both based on traditional methods of manufacturing casting models, i.e., machining of aluminum and wood, as well as using three additive technologies. The impact of the forming process on the variability of the topography of the produced models was evaluated. This research comprehensively relates to the assessment of the applicability of additive technologies, which are increasingly used in various industrial areas, as well as the impact of the process on surface topography in relation to scale. The statistical assessment based on the ANOVA analysis demonstrated that it is possible to distinguish between the surfaces before and after a specific number of forming cycles. Studies have shown that the impact of the forming process is relatively small, mainly affecting the long-term irregularity components, and there are no functional dependencies in terms of the impact of the forming process on the variation in surface topography in relation to the manufacturing method or its parameters.

Intensify the hindrance to gas entrapment on the construction of Al 5356 thin-walled structure by tuning the WAAM process parameters

Abstract Compared to other metallic additive manufacturing methods, Wire Arc Additive Manufacturing (WAAM) has a number of advantages, such as less equipment capital required and more material composition flexibility. However, uneven welding and feed rates, as well as inadequate gas flow, can result in flaws such oxidation, gas entrapment, and humping. This study aims to reduce gas entrapment, maximize tensile strength, and reduced elastic modulus of the WAAM Al5356 wall by optimizing gas flow rate (13, 16 and 19 l min−1) in conjunction with welding and feed rates. The study highlighted gas flow rate as the most important component in pore formation and used the Entropy approach in conjunction with the COmplex PRoportional ASsessment (COPRAS) tool to identify ideal settings. The reduction in gas entrapment to 0.02%, as shown in the confirmation studies, resulted in a 33.9% rise in tensile strength and a 64.7% rise in elastic modulus. To verify these ideal parameters, elastic modulus mapping was done on the printed WAAM Al5356 wall. Moreover, the damage processes connected to gas entrapment and humping development were examined using fractography. Consequently, the research determined the ideal conditions to generate a multi-layer structure free of defects, improving its practicality in aerospace and automotive sectors.

Innovations in Biodegradable Batteries: A Sustainable Future

The increasing demand for batteries in several industries such as medical and electric car (EV) Industry has led to significant environmental challenges due to the production and disposal of traditional batteries, which are nonbiodegradable and pose risks to ecosystems. This report investigates the potential of biodegradable batteries as a sustainable alternative to traditional batteries, aiming to minimize environmental impact. This study analyzing and comparing the fiber batteries, zinc-molybdenum batteries, plant-based batteries (Flower battery), crab shell battery as well as algal biopolymers battery. It also highlights the key materials, methods for manufacture, and performance characteristics (biodegradability, energy capacity, degradation time) of each type of biodegradable batteries. The findings suggest that biodegradable batteries offer promising solutions for specific applications, such as in biomedical devices, wearable electronics, and precision agriculture, where their biocompatibility and environmental safety are crucial. Future development should focus on enhancing energy density, optimizing degradation timelines, and reducing costs to make these batteries more competitive with traditional options.

Recent Advances of PDMS In Vitro Biomodels for Flow Visualizations and Measurements: From Macro to Nanoscale Applications

Polydimethylsiloxane (PDMS) has become a popular material in microfluidic and macroscale in vitro models due to its elastomeric properties and versatility. PDMS-based biomodels are widely used in blood flow studies, offering a platform for improving flow models and validating numerical simulations. This review highlights recent advances in bioflow studies conducted using both PDMS microfluidic devices and macroscale biomodels, particularly in replicating physiological environments. PDMS microchannels are used in studies of blood cell deformation under confined conditions, demonstrating the potential to distinguish between healthy and diseased cells. PDMS also plays a critical role in fabricating arterial models from real medical images, including pathological conditions such as aneurysms. Cutting-edge applications, such as nanofluid hemodynamic studies and nanoparticle drug delivery in organ-on-a-chip platforms, represent the latest developments in PDMS research. In addition to these applications, this review critically discusses PDMS properties, fabrication methods, and its expanding role in micro- and nanoscale flow studies.

A geometrically scalable method for manufacturing high quality factor mechanical resonators.

We present what we believe to be a novel, geometrically scalable manufacturing method for creating compact, low-resonance frequency, and high quality factor fused silica resonators. These resonators are intended to be used in inertial sensors for measuring external disturbances of sensitive physics experiments. The novel method uses direct bonding and chemical-mechanical polishing (CMP) in order to overcome the limitations of current subtractive manufacturing methods, which face prohibitive cost and complexity as material removal increases, inherently restricting the design flexibility of the resonator. We demonstrate a prototype with a test mass of only 3 g that reaches a quality factor of Q = 118 000 ± 400 at a resonance frequency of below 20 Hz. This advancement is particularly significant for future gravitational wave observatories, such as the Einstein Telescope.

Enhancement of Additive Manufacturing Processes for Thin-Walled Part Production Using Gas Metal Arc Welding (GMAW) with Wavelet Transform

Additive manufacturing encompasses technologies that produce three-dimensional computer-aided design (CAD) models through a layer-by-layer production process. Compared to traditional manufacturing methods, additive manufacturing technologies offer significant advantages in producing intricate components with minimal energy consumption, reduced raw material waste, and shortened production timelines. AM methods based on shielded gas welding have recently piqued the interest of researchers due to their high efficiency and cost-effectiveness in manufacturing critical components. However, one of the most formidable challenges in additive manufacturing methods based on shielded gas welding lies in the irregularity of weld bead height at different points, compromising the precision of components produced using these techniques. In this current research, we aimed to achieve uniform weld heights along the welding path by considering the most influential parameters on weld bead geometry and conducting experimental tests. Input parameters of the process, including nozzle angle, welding speed, wire speed, and voltage, were considered. Simultaneously, image processing and wavelet transform were employed to assess the uniformity of weld bead height. These parameters were applied to produce intricate parts after identifying optimal parameters that yielded the smoothest weld lines. According to the results, the appropriate bead for manufacturing the part was extracted. The results show that the smoothest bead line is achieved in 27 V as the highest level of voltage, at a 90° nozzle position and the maximum wire feed rate. Parts manufactured using this method across different layers exhibited no distortions, and the repeatability of production substantiated the high reliability of this approach for component manufacturing.

Comparative analysis of laser power, pure titanium, and titanium alloy effects on dendrite growth and surface morphology of TiO2-ceramic

Despite several challenges, including the inherent brittleness of ceramics, inadequate melting of the powder, and the formation of microstructural defects, laser powder bed fusion remains a promising method for ceramic fabrication. This research looks at the intricate relationship between laser power as a dominant factor in the energy density, the influence of pure titanium (Ti) and titanium alloy (Ti-6Al-4V) additives on the laser fabrication of TiO2-based ceramics, and the resultant microstructural aspects, with a particular emphasis on dendritic growth and solidification defects. The research findings revealed that changing the laser energy density has a substantial influence on the dendrite growth and solidification rate of TiO2 ceramic. However, in addition to optimizing the laser power, the addition of metal material additives also plays a significant role in regulating the melting state and controlling the part defects in ceramics. The findings support that the mixing of pure titanium showed a relatively favorable influence, enhancing the melting condition of TiO2 and yielding a smooth surface with reduced defects. Conversely, the addition of a titanium alloy (Ti-6Al-4V) has a comparatively lower positive effect and led to the formation of substantial dendrites, solidification shrinkage, and significant fractures. The change in the scanning strategy from zigzag to island has no noticeable effect on the surface morphology and dendrite formation but contributes to controlling the spattering and crack propagation.

Development of Additively Manufactured Embedded Ceramic Temperature Sensors via Vat Photopolymerization

Current additive manufacturing (AM) techniques and methods, such as liquid-crystal display (LCD) vat photopolymerization, offer a wide variety of surface-sensing solutions, but customizable internal sensing is both scarce in presence and narrow in scope. In this work, a fabrication process for novel customizable embedded ceramic temperature sensors is investigated. The fabrication techniques and materials are evaluated, followed by extensive characterization via spectral analysis and thermomechanical testing. The findings indicate that LCD-manufactured ceramic sensors exhibit promising sensing properties, including strong linear thermal sensitivity of 0.23% per °C, with an R2 of at least 0.97, and mechanical strength, with a hardness of 570 HV, making them suitable for adverse environmental conditions. This research not only advances the field of AM for sensor development but also highlights the potential of LCD technology in rapidly producing reliable and efficient ceramic temperature sensors.

Electrospinning as a Method for Fabrication of Nanofibrous Photocatalysts Based on Gallium Oxide

Photocatalysts are currently widely used in various research and industrial fields, from water and air purification to solar energy, from self‐cleaning surfaces to wearable biosensors and electronic devices. Among semiconductors, the growing interest is attracted to gallium oxide, especially β‐Ga2O3, due to the unique physical, chemical (especially acid‐resistance), physical–chemical, photochemical properties, and redox potential. These photocatalysts can be used not only as suspended mixture, but also in the form of films, nanoparticles, and nanofibers. The last one is more challenging due to the high level of surface‐to‐volume ratio, porousness, air and water permeability, and excellent morphological and physical–mechanical properties. Moreover, electrospinning techniques, in comparison with fabrication of nanoparticles, allow to obtain photocatalytic devices without usage of additional carrying base, which simplify the industrial process. However, to date there are limited publications related to the Ga2O3 electrospun nanofibers. The aim of this review is to summarize current results of gallium oxide electrospun nanofibers preparation. Special attention is given to the technological parameters of the electrospinning, the polymer solution receipts, and the properties of such nanomaterials and its potential application. Despite the limited number of publications related to Ga2O3 fibers fabrications, that data collected in this review article demonstrate great potential for practical applications.

The biohybrid assembly

In the field of contemporary architectural design, novel approaches have emerged to redefine the concept of sustainability through the utilization of bio-composites. One area of exploration involves investigating mycelium as an architectural material across various scales and functions. In this context, the presenting research explores the hybrid assembly combining mycelium and custom 3D printing incorporating robotic fabrication techniques. The Biohybrid Assembly project is a double-layered hybrid structure printed by FGF extruder for the inner layer and a customized mycelium extruder for the outer layer. Furthermore, the Biohybrid Assembly project demonstrates the possibility of large-scale construction, addressing challenges associated with existing mycelium applications. Various types of mycelium-based composites were tested to determine their optimal viscosity, growth, and strength, which were subsequently utilized to fabricate the desired model geometry. A specialized 3D printing extruder was designed and manufactured to nozzle the selected composite. Ultimately, a custom workflow, incorporating an industrial robotic arm, was established to fabricate the hybrid structure consisted of organic and inorganic materials. This research significantly contributes to the redefinition of sustainability by exploring biohybrid construction technology. Through establishing a system for a large-scale prototype, it reinterprets the concept of ecofriendliness in architecture and highlights the advantages and potential of innovative bio-integrated fabrication methods.

One-Step Fabrication of 2.5D CuMoOx Interdigital Microelectrodes Using Numerically Controlled Electric Discharge Machining for Coplanar Micro-Supercapacitors

With the increasing market demands for wearable and portable electronic devices, binary metal oxides (BMOs) with a remarkable capacity and good structure stability have been considered as a promising candidate for fabricating coplanar micro-supercapacitors (CMSCs), serving as the power source. However, the current fabrication methods for BMO microelectrodes are complex, which greatly hinder their further development and application in BMO CMSCs. Herein, the one-step fabrication of 2.5D CuMoOx-based CMSCs (CuMoCMSCs) has been realized by numerically controlled electric discharge machining (NCEDM) for the first time. In addition, the controllable capacity of CuMoCMSCs has been achieved by adjusting the NCEDM-machining voltage. The CuMoCMSCs machined by a machining voltage of 60 V (CuMoCMSCs60) showed the best performance. The fabricated CuMoCMSCs60 with binary metal oxides could operate at an ultra-high scanning rate of 10 V s−1, and gained a capacity of 40.3 mF cm−2 (1.1 mA cm−2), which is more than 4 times higher than that of MoOx-based CMSCs (MoCMSCs60) with a single metal oxide. This is because CuMoOx BMOs materials overcome the poor electroconductivity problem of the MoOx single metal oxide. This one-step and numerically controlled fabrication technique developed in this research opens a new vision for preparing BMO materials, BMO microelectrodes, and BMO microdevices in an environmental, automatic, and intelligent way.

Hydrogel 3D printing with direct and indirect extruder

The advancement of additive manufacturing technology or 3-Dimesion printing (3D printing) allows for the creation of parts with intricate designs, resulting in less material waste compared to conventional manufacturing methods. Although current 3D printers primarily use plastic or metal materials, there is a growing interest in using biomaterials for 3D printing. To facilitate this trend, developing and designing 3D printers capable of using hydrogel materials is crucial. In this research, the 3D printer with direct and indirect extruders for hydrogel material is designed, calculated, and manufactured. Then, the 3D printer is tested with conductive sodium alginate 5% + 5% activated carbon by weight. In addition, the electrical conductivity of the material is measured. Through meticulous research and development, a 3D printer capable of printing hydrogel materials has been successfully manufactured, setting the stage for further exploration and the creation of environmentally friendly 3D biomedical printing materials.

3D Printing with Self-Healing Materials and Applications

3D printing also called as the additive manufacturing. It is revolutionizing various industries by enabling the production of complex objects directly from digital models. This technology offers significant advantages over traditional manufacturing methods. Especially in reducing material waste and increased design flexibility. The range of 3D printing application contains healthcare to aerospace, reflecting its growing importance in modern society. Recently, 3D printing advancements have introduced in self-healing (SH) materials, it saved limitations related to the durability and repairability of printed objects. SH materials are categorized into external and internal systems. External SH materials use embedded healing agents that repair damage through chemical reactions, while internal systems rely on dynamic bonding within the material itself. This innovation not only extends the functional life of 3D printed items but also supports trends in mass customization and sustainability. This paper explores the mechanisms, types, and applications of SH materials in 3D printing, and mainly focus on their potential to enhance product longevity and functionality across medical, construction, and consumer goods sectors.

Fabric Defect Detection Method Based on Multi-scale Fusion Attention Mechanisms

Abstract Fabric defect detection is extremely important for the development of the textile industry, but the existing traditional image processing algorithms are not good enough to detect fabric defects, and the detection efficiency and accuracy of the classical deep learning model is not satisfactory, so this paper proposes an improved fabric defect detection method based on multi-scale fusion of attention mechanism YOLOv7-PCBS. Based on the YOLOv7 network structure, some of the standard convolutions of the backbone network are replaced with Partial Convolution (PConv) modules, which reduces the amount of network computation and improves the network detection speed; add Coordinate Attention (CA) to enhance the ability of extracting the positional features of tiny defects in fabrics; reconfiguration of the SPPCSPC module to improve small target detection; optimization of Bidirectional Feature Pyramid Network (BiFPN) and design of Tiny- BiFPN for simple and fast multi-scale feature fusion; finally, a novel loss function SIoU with angular loss is introduced to facilitate the fitting of the true and predicted frames and enhance the accuracy of defect prediction. The results show that the algorithm achieves a mAP value of 94.4% on the detection of defects in solid-colored fabrics of six denim materials, which is an improvement of 15.1% compared to the original YOLOv7 algorithm, while the model achieves a frame rate of 59.5 per second. Compared with other traditional deep learning algorithms SSD and Faster-RCNN, the detection accuracies are improved by 21.6% and 15.2%, and the FPS values are improved by 78.1% and 101.0%, respectively. Therefore, the YOLOv7-PCBS fabric defect detection algorithm proposed in this paper makes the fabric defect detection results more accurate while realizing lightweight, which provides an important technical reference for the subsequent improvement of textile quality.

Synthesis Methods of Si/C Composite Materials for Lithium-Ion Batteries

Silicon anodes present a high theoretical capacity of 4200 mAh/g, positioning them as strong contenders for improving the performance of lithium-ion batteries. Despite their potential, the practical application of Si anodes is constrained by their significant volumetric expansion (up to 400%) during lithiation/delithiation, which leads to mechanical degradation and loss of electrical contact. This issue contributes to poor cycling stability and hinders their commercial viability, and various silicon–carbon composite fabrication methods have been explored to mitigate these challenges. This review covers key techniques, including ball milling, spray drying, pyrolysis, chemical vapor deposition (CVD), and mechanofusion. Each method has unique benefits; ball milling and spray drying are effective for creating homogeneous composites, whereas pyrolysis and CVD offer high-quality coatings that enhance the mechanical stability of silicon anodes. Mechanofusion has been highlighted for its ability to integrate silicon with carbon materials, showing the potential for further optimization. In light of these advancements, future research should focus on refining these techniques to enhance the stability and performance of Si-based anodes. The optimization of the compounding process has the potential to enhance the performance of silicon anodes by addressing the significant volume change and low conductivity, while simultaneously addressing cost-related concerns.

Graphene-Based Wound Dressings for Wound Healing: Mechanism, Technical Analysis, and Application Status.

The development of novel wound dressings is critical in medical care. Graphene and its derivatives possess excellent biomedical properties, making them highly suitable for various applications in medical dressings. This review provides a comprehensive technical analysis and the current application status of graphene-based medical dressings. Initially, we discuss the chemical structure and the fabrication method of graphene and its derivatives. We then provide a detailed summary of the mechanisms by which graphene materials promote wound repair across the four stages of wound healing. Subsequently, we categorize the types of graphene-based wound dressings and analyze corresponding characteristics. Finally, we analyze the challenges encountered at present and propose solutions regarding future development trends. This paper aims to serve as a reference for further research in skin tissue engineering and the development of innovative graphene-based medical dressings.

Plasmonics Meets Perovskite Photovoltaics: Innovations and Challenges in Boosting Efficiency

Perovskite solar cells (PSCs) have garnered immense attention in recent years due to their outstanding optoelectronic properties and cost-effective fabrication methods, establishing them as promising candidates for next-generation photovoltaic technologies. Among the diverse strategies aimed at enhancing the power conversion efficiency (PCE) of PSCs, the incorporation of plasmonic nanoparticles has emerged as a pioneering approach. This review summarizes the latest research advancements in the utilization of plasmonic nanoparticles to enhance the performance of PSCs. We delve into the fundamental principles of plasmonic resonance and its interaction with perovskite materials, highlighting how localized surface plasmons can effectively broaden light absorption, facilitate hot-electron transfer (HET), and optimize charge separation dynamics. Recent strategies, including the design of tailored metal nanoparticles (MNPs), gratings, and hybrid plasmonic–photonic architectures, are critically evaluated for their efficacy in enhancing light trapping, increasing photocurrent, and mitigating charge recombination. Additionally, this review addresses the challenges associated with the integration of plasmonic elements into PSCs, including issues of scalability, compatibility, and cost-effectiveness. Finally, the review provides insights into future research directions aimed at advancing the field, thereby paving the way for next-generation, high-performance perovskite-based photovoltaic technologies.

A Review of Perovskite-based Lithium-Ion Battery Materials

Lithium-ion batteries (Li-ion batteries or LIBs) have garnered significant interest as a promising technology in the energy industry and electronic devices for the past few decades owing to their superior energy and power density profiles, small size, long cycle life, low self-discharge rate, no memory effect, long-lasting power properties, and environmental friendly. The ongoing advancement of electrode and electrolyte materials has contributed significantly to enhancing and spreading the application of lithium-ion battery technology. Among the non-precious metal-based materials, perovskites have emerged as attention over the last decade, holding a prominent position in materials and energy. Due to their unique physical and chemical properties, these materials have garnered particular interest for their potential application in electrochemical energy devices. Perovskite oxides have piqued the interest of researchers as potential catalysts in Li-O₂ batteries due to their remarkable electrochemical stability, high electronic and ionic conductivity, and the ability to modify their properties through doping and element substitution. The purpose of this article is to provide an overview of recent developments in the application of perovskites as lithium-ion battery materials, including the exploration of novel compositions and structures, optimization of fabrication methods, and a deeper understanding of the fundamental mechanisms that can unveil the potential of perovskite materials.

Considerations for digitalisation of nickel electroforming

ABSTRACT This paper is a ‘follow-on’ from a paper previously published in this journal dealing with the laboratory to pilot scaling up approach using Industry 4.0 manufacturing methods. In particular, the paper reports a strategy for developing a model for the electroforming of nickel from a sulphamate electrolyte at laboratory scale which could subsequently provide an educated approach for transferring the process to a larger scale. At the laboratory scale, a rotating disc electrode assembly was used, which is a standard instrument to determine electrochemical parameters. Thereafter, small scale nickel discs were electroplated using this equipment, and a model of this process was developed and validated against those experimental results. These parameters were then used to actually produce electroforms in a prototype, 18 L tank system. Cross-validation between practical experiments and simulations followed which allowed for fine-tuning the model until it was consistently predicting the real process results within an acceptable error. Overall, it was found that a secondary current distribution model could be used for reasonably accurate description for the electroforming process, and could provide a quick virtual tool at a production facility.