Fabrication Method Research Articles

Recent development towards the novel applications and future prospects for cellulose-metal organic framework hybrid materials: a review.

The hybrid material created by combining cellulose and MOF is highly promising and possesses a wide range of useful properties. Cellulose-based metal-organic frameworks (CelloMOFs) combine the inherent biocompatibility and sustainability of cellulose with the tunable porosity and diverse metal coordination chemistry of MOFs. Cellulose-MOF hybrids have countless applications in various fields, such as energy storage, water treatment, air filtration, gas adsorption, catalysis, and biomedicine. They are particularly remarkable as adsorbents that can eliminate pollutants from wastewater, including metals, oils, dyes, antibiotics, and drugs, and act as catalysts for oxidation and reduction reactions. Furthermore, they are highly efficient air filters, able to remove carbon dioxide, particulate matter, and volatile organic compounds. When it comes to energy storage, these hybrids have demonstrated exceptional results. They are also highly versatile in the realm of biomedicine, with applications such as antibacterial and drug delivery. This article provides an in-depth look at the fabrication methods, advanced applications of cellulose-MOF hybrids, and existing and future challenges.

Impact of Digital Manufacturing Methods on the Accuracy of Ceramic Crowns.

The purpose of this study was to assess the accuracy of full coverage crowns produced by two manufacturing methods: additive 3D printing and subtractive milling utilizing three different predefined cement spaces. Six groups were allocated based on the manufacturing method and the predefined cement space: printed wax with a 20 µm space (PW1); printed wax with a 50 µm space (PW2); printed wax with a 100 µm space (PW3); milled wax with a 20 µm cement space (MW1); milled wax with a 50 µm cement space (MW2); milled wax with a 100 µm cement space (MW3); milled zirconia coping with a 20 µm cement space (MZ1); milled zirconia coping with a 50 µm cement space (MZ2); milled zirconia with a 100 µm cement space (MZ3). All fabricated specimens were scanned using an Identica Blue 3D scanner and saved as standard tessellation language (STL) files. A triple scan method was performed using 3-matic software to assess accuracy. The discrepancy values were recorded in micrometers, and the analysis was conducted using one-way ANOVA. The wax printing method, with a cement gap design of 100 μm, demonstrated a significant improvement in the accuracy compared to the other methods (P<.01). In contrast, the zirconia milling method exhibited significantly lower accuracy relative to the other techniques (P<0.01). Moreover, different cement spaces resulted in various accuracy levels but the only statistically significant difference was observed for the 100 µm cement space in the printed wax group. The additive 3D printing method exhibited greater accuracy than the subtractive milling approach. Furthermore, altering the cement gap was found to impact the accuracy of both techniques, albeit without statistical significance. The accuracy of each CAM technique was investigated in this study, highlighting the promising accuracy of 3D-printed patterns for the lost-wax technique over direct crown milling. However, all methods produced reliable and accurate crown restorations.

Rewritable Broadband Lossy Absorber Based on Laser Induction Technology

AbstractThe tunable and reversible fabrication function of stealth metasurfaces has significant application value in complex electromagnetic environments., but the extremely low fault tolerance of the existing fabrication methods limits their further development and utilization. In this manuscript, a design and fabrication method for rewritable broadband stealth metasurfaces with memory function is proposed. The reversible phase transition is achieved by laser induced germanium telluride (GeTe) film, which provides the possibility for metasurface to realize the rewriting function. The process of laser induced GeTe and the simulation model of GeTe are investigated, and the conclusions are verified by rewritable broadband polarization converter (RBPC) and rewritable broadband lossy absorber (RBLA). The experimental results show that the reflectivity of fabricated RBLA is less than −10 dB in the range of 7.8–16.1 GHz, which is in good agreement with the numerical simulation results. Meanwhile, there is a highly consistent performance effect before and after repeated induction. The research has the advantages of high efficiency, region selectivity, non volatility and high fault tolerance, which can provide new manufacturing ideas and good candidates for tunable metamaterials.

Design of a custom metamaterial insert for improved pressure distribution within transtibial prosthetic sockets.

Uneven pressure distribution within a transtibial prosthetic socket can lead to discomfort, skin degradation, and suspended prosthesis use. Current custom interfaces to improve pressure distribution are often costly, time-intensive to fabricate, or cannot be incorporated into standard socket fabrication methods. In this technical note, we describe the design and preliminary clinical evaluation of a novel transtibial prosthetic socket insert with modifiable mechanical properties, which can be incorporated into the current clinical cycle of care. The custom insert (termed "inlay") relies on a triangular unit cell, which can be modified based on the desired stiffness profile. Inserts are 3D printed in a soft polymer material and inset into shape-matched voids in a socket creating regions of custom offloading. Preliminary clinical efficacy of the inserts was assessed in a pilot long-term cross-over evaluation. After Institutional Review Board approval, 3 pilot participants wore a shape-matched replica of their habitual socket modified for insert use and a shape-matched socket without. Sockets were worn for 4-week each, and inner socket pressures were measured with thin film pressure sensors at the end of the wear period. Peak pressures within the distal tibial region of interest were decreased for 2 of 3 participants during midstance of level-ground walking when wearing the socket with inlays. The technical methods and results presented provide a new method to address high pressure regions within a transtibial prosthetic socket. The 3D-printed inlays can be rapidly produced allowing for easy modification and replacement without require new socket fabrication.

Recent Advances in Additive Manufacturing of Fibre-Reinforced Materials: A Comprehensive Review

Additive manufacturing (AM) plays a significant role in the 4th Industrial Revolution due to its flexibility, allowing AM equipment to be connected, monitored, and controlled in real time. In advance, the minimum waste of material, the agility of manufacturing complex geometries, and the ability to use recycled materials can provide an advantage to this manufacturing method. On the other hand, the poor strength and durability of the thermoplastics used in the manufacturing process are the major drawback that keeps AM behind common production methods such as casting and machining. Fibre-reinforced polymers can enhance mechanical properties, advance AM from the commonly used polymers, and make AM competitive against conventional production methods. The main focus of the current review is to examine the work conducted in the field of reinforced additively manufactured technologies in the literature of recent years. More specifically, this review discusses the conducted research in the composite fibre coextrusion (CFC) additive manufacturing techniques developed over the past years and the materials that can be used. In addition, this study includes an up-to-date comprehensive review of the evaluation of fibre-reinforced 3D printing along with its benefits in terms of mechanical response, namely tensile, flexural, compression and energy absorption, anisotropy, and dynamic properties. Finally, this review highlights possible research gaps regarding fibre-reinforced AM and proposes future directions, such as deeper investigations into energy absorption and anisotropy, to position fibre-reinforced AM as a preferred fabrication method for ready-to-use parts in cutting-edge industries, including automotive, aerospace, and biomedical sectors.

Impact of the Replacement of Pitch Binder by the Environmentally Friendly Binder System Based on Lactose and Tannin on the Properties of Carbon‐Bonded Alumina Filters

Carbon‐bonded alumina filters have been established in the steel industry for decades to increase the quality of cast steel components. The carbon bonding of the filter materials is commonly achieved by using pitches or resins. However, the pyrolysis of both substances results in the release of carcinogenic substances such as free phenols or benzo[a]pyrene. An alternative binder system is provided by lactose and tannin, which is considered to be more environmentally friendly, but they tend to result in insufficient mechanical filter properties.To ensure higher environmental sustainability and good mechanical properties, the effect of the stepwise replacement of the pitch‐binder CarboresP by lactose and tannin is investigated in the present study. Additionally, the impact of semiconductive additives (P‐doped n–Si and SiC) and the filter manufacturing method on the filter properties is analyzed. Based on the most promising filter composition, different lactose/tannin (L/T) ratios (5:1, 4:1, 3:1) are applied and the resulting properties evaluated. The results suggested that the pitch binder can be completely replaced by lactose and tannin by using SiC as additive and adjusting the filter manufacturing process. The variation of the L/T ratio shows no significant impact on the filter prope.

Chain-based lattice printing for efficient robotically-assembled structures.

Due to the nature of their implementation, nearly all low-level fabrication processes produce solidly filled structures. However, lattice structures are significantly stronger for the same amount of material, resulting in structures that are much lighter and more materially efficient. Here we propose an approach for fabricating lattice structures that echoes 3D printing techniques. In it, a modular chain of specially designed links is "extruded" onto a substrate to produce various lattices configurations depending on the chosen assembly algorithm, ranging from rigid regular lattices with nodal connectivity of 12, octet-truss, to significantly less dense configurations. Compared to conventional additive manufacturing methods, our approach allows for efficient use of nearly any material or combination of materials to construct lattices with programmed arrangements. We experimentally demonstrate that a 3x3x2 lattice structure (287 total links) is fabricated in 27 minutes via a modified robotic arm and can support approximately 1000 N in compression testing.

Advances and Challenges of Microneedle Assisted Drug Delivery for Biomedicals Applications: A Review.

Microneedles have been explored as a novel way of delivering active ingredients into the skin. They have various advantages, such as quick and efficient drug delivery, mechanical stability, minimal pain, variable capacity and easy use. Microneedles are enabled for the delivery of vaccine, peptides, medicinal components and in cosmetology, which couldn't go unnoticed. The novel approaches in the transdermal drug delivery system have increased the efficiency of drug delivery into the skin by crossing the skin barriers. This platform has a wide range of applications and can also be used to deliver non-transdermal biomedicals. The variety in the design of microneedles has demanded similar diversity in their methods of fabrication; micro molding and drawing lithography may be useful methods. There are different types of polymers and materials for the fabrication of microneedles. Several synthetic and natural materials are used in the fabrication of microneedles. Unique shapes, materials, and mechanical properties are modified for organ-specific applications in microneedle engineering. In this review, we discuss several factors and their roles to cross the biological barriers for transdermal drug delivery in various sites, such as in ocular, vascular, oral, and mucosal tissue. Additionally, this article highlights the future scope of transdermal drug delivery systems through microneedles.

Investigation of formation, microstructure and hardness of Ti-6Al-4V single tracks via Joule-fused filament additive manufacturing

Purpose This paper aims to investigate a novel additive manufacturing (AM) method for titanium alloy using Joule heat as the single heat source to melt TC4 wire, which intends to provide a new low-power, low-cost solution for the processing of titanium alloys. Design/methodology/approach When current flows through the wire and the substrate, Joule heat will be generated to melt the wire and join the wire with the substrate. By stacking the wire layer by layer, finally a part can be formed. The cross-sectional morphology, microstructure and hardness of TC4 single track deposits formed by Joule heat melting wire AM were investigated by various characterization methods. Findings The melting width and melting penetration decreased with the increase of printing speeds. There is no obvious change in single track morphology with the change of printing pressures. The melting width and melting penetration increased with the increase of printing currents. The observation of the internal microstructure of a single track reveals a decrease in grain size as printing speeds increase. The average hardness of the single track was about 363 HV, which is comparable to the hardness of the parts fabricated by selective laser melting process. The printing power is less than 300 W, which is lower than other AM processes. Originality/value This paper provides a novel solution for the processing of titanium alloy parts. Compared with other expensive energy sources, this work only uses an ordinary DC power supply as the energy source. The printing process is simple and the cost is low. The power is much lower than other AM processes.

A Universal Approach for High-Yield Synthesis of Single-Crystalline Ordered Macro-Microporous Metal-Organic Frameworks.

Despite the excellent properties of single-crystalline ordered macro-microporous MOFs (SOM-MOFs) compared to conventional MOFs, their further development has been hindered by the lack of versatile and high-yielding preparation protocols. This study introduces an innovative universal fabrication method that can easily solve the two major challenges of precursor stabilization and crystallization modulation, enabling the efficient synthesis of various SOM-MOFs with high yields. Notably, our approach has successfully yielded SOM-MIL-88A, a novel MOF showcasing exceptional stability in both water and acidic solutions, a remarkable achievement unprecedented in prior SOM-MOF research. SOM-MIL-88A has demonstrated exponentially improved performance over conventional MIL-88A in adsorption, catalysis, immobilized enzymes, and composite biosensing. Furthermore, our versatile protocol has been successfully applied to synthesize SOM-HKUST-1 and SOM-ZIF-8, resulting in significantly improved yields (increase by about 10-fold and 2-fold, respectively, compared to the previously reported protocol). This groundbreaking achievement marks a pivotal advancement in the preparation of diverse SOM-MOFs with tailored properties, presenting exciting prospects for future research on MOFs.

Vertical silicon nanowedge formation by repetitive dry and wet anisotropic etching combined with 3D self-aligned sidewall nanopatterning

Three-dimensional (3D) stacking of nano-devices is an effective method for increasing areal density, especially as downscaling of lateral device dimensions becomes impractical. This stacking is mainly achieved through plasma processing of stacked layers on top of a silicon (Si) substrate, which offers process flexibility but poses challenges in obtaining vertical sidewalls without plasma induced damage. A novel wafer-scale fabrication method is presented for realizing sub-200 nm vertically stacked Si nanowedges at the wafer scale, using iterative dry etching, wet anisotropic etching, and thermal oxidation. This approach forms nanowedges by the slow etching {111} Si planes, resulting in smooth surfaces at well-defined angles. A silicon nitride (Si3N4) hard mask is used in an iterative (etch-and-deposit) process, with its thickness determining the number of process iterations. By optimizing etch selectivity during dry etching and/or increasing the initial Si3N4 thickness, the number of process iterations can be increased. The periodicity of the nanowedges can be adjusted by varying the etch time of both dry and wet anisotropic etching. A thin silicon dioxide (SiO2) layer (∼6 nm) is grown on the nanowedges during each iteration. 3D sidewall patterning at the sub-20 nm scale is achieved using corner lithography and local oxidation of Si to selectively open the concave corners. Rhombus-shaped structures are formed at each concave corner after wet anisotropic etching of Si. This novel technology platform will allow for the 3D fabrication of high-density nanodevices for electronic, fluidic, plasmonic, and other applications.

Accuracy of 3-dimensional surgical guide for endodontic microsurgery with a new design concept: A cadaver study.

Despite the high success rate of endodontic microsurgery (EMS), it is difficult to suggest EMS as a general treatment option considering the difficulty of the procedure. A surgical guide has been proposed to overcome this problem. This study aimed to evaluate the stability of the surgical guide of a new design concept, as well as the accuracy of root resection, and to introduce the manufacturing method of the newly designed surgical guide. The experiment was conducted on 59 roots (9 in the maxillary and 50 in the mandibular region) of adult human cadavers. The surgical guide was designed using CAD/CAM design software based on cone-beam computed tomography (CBCT) images and optical scan files. Unlike conventional surgical guides, the surgical guide proposed herein was designed to act as a tooth-bone-supported removable appliance. Two different types of guides were prepared: the osteotomy guide (O guide) for separation of the cortical bone above the root tip with a trephine bur with an outer diameter of 6 mm and the root resection guide (R guide) for resection of the root tip with a trephine bur with an outer diameter of 4 mm. For stability evaluation, the guides were pressed at five predetermined locations after installation and checked for the presence of any movement. For accuracy evaluation, the length at which the root tip was cut was measured and examined by overlapping the preoperative and postoperative CBCT images. Of the 15 R guides, 14 were stably installed without mobility. For the R guide group, the root tip was resected with an average of 3.2 mm, showing better results than the no-guide group with an average of 4.0 mm. The newly designed surgical guide of this study can be applied more stably, enabling root resection to be performed more accurately and simply according to the preoperative plan than when performed without a guide.

A Review on Advances and Challenges in Core-Shell Scaffolds for Bone Tissue Engineering: Design, Fabrication, and Clinical Translation.

This review explores core-shell scaffolds in bone tissue engineering, highlighting their osteoconductive and osteoinductive properties critical for bone growth and regeneration. Key design factors include material selection, porosity, mechanical strength, biodegradation kinetics, and bioactivity. Electrospun core-shell nanofibrous scaffolds demonstrate potential in delivering therapeutic agents and enhancing bone regeneration. Critical characterization techniques include structural, surface, chemical composition, mechanical, and degradation analyses. Scaling up production poses challenges, addressed by innovative electrospinning techniques. Future research focuses on regulatory and commercial considerations, while exploring advanced materials and fabrication methods to optimize scaffold performance for improved clinical outcomes.

Scalable Fabrication of Neuromorphic Devices Using Inkjet Printing for the Deposition of Organic Mixed Ionic‐Electronic Conductor

AbstractRecent advancements in artificial intelligence (AI) have highlighted the critical need for energy‐efficient hardware solutions, especially in edge‐computing applications. However, traditional AI approaches are plagued by significant power consumption. In response, researchers have turned to biomimetic strategies, drawing inspiration from the ion‐mediated operating principle of biological synapses, to develop organic neuromorphic devices as promising alternatives. Organic mixed ionic‐electronic conductor (OMIEC) materials have emerged as particularly noteworthy in this field, due to their potential for enhancing neuromorphic computing capabilities. Together with device performance, it is crucial to select devices that allow fabrication via scalable techniques. This study investigates the fabrication of OMIEC‐based neuromorphic devices using inkjet printing, providing a scalable and material‐efficient approach. Employing a commercially available polymer mixed ionic‐electronic conductor (BTEM‐PPV) and a lithium salt, inkjet‐printed devices exhibit performance comparable to those fabricated via traditional spin‐coating methods. These two‐terminal neuromorphic devices demonstrate functionality analogous to literature‐known devices and demonstrate promising frequency‐dependent short‐term plasticity. Furthermore, comparative studies with previous light‐emitting electrochemical cells (LECs) and neuromorphic OMIEC devices validate the efficacy of inkjet printing as a potential fabrication technique. The findings suggest that inkjet printing is suitable for large‐scale production, offering reproducible and stable fabrication processes. By adopting the OMIEC material system, inkjet printing holds the potential for further enhancing device performance and functionality. Overall, this study underscores the viability of inkjet printing as a scalable fabrication method for OMIEC‐based neuromorphic devices, paving the way for advancements in AI hardware.

Synthesis and Characterization of Carbonaceous Materials for Medical Applications: A Comprehensive Review

Carbonaceous materials have gained significant attention in recent years for their various applications in the field of medicine and biotechnology. This comprehensive review explores the synthesis and characterization of carbon-based materials and their potentials in various medical applications. The paper delves into the methods of fabrication of carbon-based nanoparticles, such as carbon nanotubes, biochar, and graphene, while highlighting their unique properties. Characterization techniques, such as microscopy, spectroscopy, and surface analysis, are discussed to provide insights into the chemical and structural properties of these materials. Furthermore, the review examined their wide-ranging medical applications, encompassing tissue engineering, drug delivery, biosensing, and imaging, showcasing the versatility and promising contributions of carbonaceous materials in the healthcare industry. The review outlines the current challenges and prospects in the field, emphasizing the growing significance of carbon-based materials as valuable tools in advancing medical science and technology, as well as public health.

Manufacturing the current flow diverter architecture in REBCO tapes using silver inkjet printing

Abstract A low normal zone propagation velocity (NZPV) combined with critical current inhomogeneities favor the nucleation of destructive hot spots in rare-earth barium copper oxide (REBCO) tapes. Increasing the NZPV using the current flow diverter (CFD) concept is a promising solution to mitigate the risk of developing hot spots. The fabrication method of CFD REBCO tapes implies several steps consisting in masking, silver etching, mask removal, and silver deposition, which takes time and remains a barrier to the implementation of a low-cost industrial production of long-length CFD REBCO tapes. This work presents a cost-effective and maskless CFD fabrication approach that relies on inkjet printing (IJP) of silver patterns directly on top of the REBCO layer to create a non-uniform interfacial resistance between the silver and the REBCO surface, along the width of the tape. The parameters of IJP and oxygen annealing were optimized to obtain highly conductive silver patterns deposited on the surface of the REBCO layer. CFD REBCO tapes were successfully fabricated using commercial REBCO tapes and the proposed method without degrading the superconducting properties. Experimental measurements revealed an increase of the NZPV by a factor of 6-7 compared to commercial REBCO tapes.

Fractal Modelling of Heterogeneous Catalytic Materials and Processes

This review considers the use of fractal concepts to improve the development, fabrication, and characterisation of catalytic materials and supports. First, the theory of fractals is discussed, as well as how it can be used to better describe often highly complex catalytic materials and enhance structural characterisation via a variety of different methods, including gas sorption, mercury porosimetry, NMR, and several imaging modalities. The review then surveys various synthesis and fabrication methods that can be used to create catalytic materials that are fractals or possess fractal character. It then goes on to consider how the fractal properties of catalysts affect their performance, especially their overall activity, selectivity for desired products, and resistance to deactivation. Finally, this review describes how the optimum fractal catalyst material for a given reaction system can be designed on a computer.

Fat Replacers in Food System: A Focus on Ingredients, Fabrication Methods, and Applications in Food Products

Fat Replacers in Food System: A Focus on Ingredients, Fabrication Methods, and Applications in Food Products

Correction: Electronic textiles (E-Textiles): types, fabrication methods, and recent strategies to overcome durability challenges (washability &amp; flexibility)

Correction: Electronic textiles (E-Textiles): types, fabrication methods, and recent strategies to overcome durability challenges (washability &amp; flexibility)

Polymersomes as Next Generation Nanocarriers for Drug Delivery: Recent Advances, Patents, Synthesis and Characterization

Background: Polymersomes (PS), self-assembled nanostructures formed by amphiphilic block copolymers, have garnered significant attention in recent years due to their unique properties and versatile applications in the fields of drug delivery and biomedicine. They are being prepared for a wide range of complex medicinal compounds, including nucleic acids, proteins, and enzymes. Polymersomes have lately been used as vehicles for delivering varied therapeutic substances and regulating ROS (reactive oxygen species). Due to their immunogenic features, polymersomes could play a critical role in enhancing subunit vaccine and drug delivery against COVID-19 infection. Objective: The prime purpose of this manuscript is to furnish an extensive overview of polymersomes, highlighting their recent advances, fabrication methods, characterization techniques, and pharmaceutical applications. Methods: The article has been amassed using several online and offline manuscripts from reputed journals, books, and other resources. Besides this, various user-friendly interfaces, like Pubmed, Google Scholar, etc, have been utilized to gather the latest data about polymersomes. This domain encompasses recent advancements in the realm of innovations about the delivery of drugs through polymeric vesicles. This field involves innovations or developments in nanocarrier systems as they are efficaciously employed to deliver the desired moiety to the targeted site. Results: PS have been discovered to exhibit remarkable promise in addressing various challenges associated with inadequate bioavailability, targeted drug delivery, dosing frequency, and diminished toxic effects. Over the past decade, such nanovesicles have been effectively employed as a complementary approach to address the issues arising from poorly soluble medications. However, this domain still requires further focus on novel breakthroughs. Conclusion: Polymersomes demonstrate unparalleled potential as innovative carriers, exhibiting remarkable versatility and exceptional biocompatibility. This concise review underscores their extraordinary prospects in diverse fields, accentuating their distinctive attributes and opening new avenues for groundbreaking applications.