Manufacturing Strategy Research Articles

Autonomous direct freeform fabrication strategy for multi-axis additive manufacturing

Autonomous direct freeform fabrication strategy for multi-axis additive manufacturing

Aero‐Circularity: Charting the Flight Path Between Circular Economy and Sustainability Performance

ABSTRACTThe aircraft manufacturing industry faces a critical juncture due to the necessity to replace ageing fleets and address the environmental impact of the industry dimension. The high demand for new aircraft and limited production capacity has driven industry leaders to integrate Circular Economy (CE) principles into their manufacturing and maintenance strategies, trying to increase aircraft lifespan.This study examines the specific CE actions implemented by aircraft manufacturers and assesses their impact on sustainability performance. Sustainability reports and non‐financial disclosures were analysed using a taxonomy tailored to the industry to identify CE actions. Econometric models were then employed to analyse the relationship between the number of CE actions adopted and sustainability performance, using REFINITIV's sustainability performance scores as dependent variables.Results indicate that companies are starting to adopt CE actions focused on product life extension and repairability. Furthermore, the analysis demonstrates that companies with more declared CE actions exhibit higher environmental and corporate governance performance. Hence, this study empirically validates the link between adopting CE actions and improved sustainability performance, offering practical guidance for aircraft manufacturers and informing policymakers, investors, and other stakeholders on the benefits of CE actions in the industry.

Tumor-Infiltrating Lymphocyte Therapy: A New Frontier.

Tumor-Infiltrating Lymphocyte Therapy: A New Frontier.

Bottom-up green manufacturing strategy in the wire and cable industry: A Z-DEMATEL approach for identifying critical success criteria

Bottom-up green manufacturing strategy in the wire and cable industry: A Z-DEMATEL approach for identifying critical success criteria

Particulates in CGT Guidance Survey Results – Cell and Gene Therapy Industry Knowledge Awareness

Particulates in CGT Guidance Survey Results – Cell and Gene Therapy Industry Knowledge Awareness

Repair-oriented design and manufacturing strategies for circular electronic products, from mass customization/standardization to scalable repair economy

Repair-oriented design and manufacturing strategies for circular electronic products, from mass customization/standardization to scalable repair economy

Robust fluorinated cellulose composite aerogels incorporating radiative cooling and thermal insulation for regionally adaptable building thermal management.

Robust fluorinated cellulose composite aerogels incorporating radiative cooling and thermal insulation for regionally adaptable building thermal management.

An overview of additive manufacturing strategies of enzyme-immobilized nanomaterials with application incatalysis and biomedicine.

An overview of additive manufacturing strategies of enzyme-immobilized nanomaterials with application incatalysis and biomedicine.

Evaluation and characterization of waste-derived eggshells as filler in polylactic acid filament feedstock for material extrusion additive manufacturing: a step towards circular manufacturing strategies

Evaluation and characterization of waste-derived eggshells as filler in polylactic acid filament feedstock for material extrusion additive manufacturing: a step towards circular manufacturing strategies

Large Scale Printing of Robust HPLC Medium via Layer-by-Layer Stereolithography.

The manufacture of high-performance liquid chromatography (HPLC) medium has long been viewed as an art rather than science; this raised a great challenge in securing separation consistency, method transferability, and scaling-up in purification of biomolecules. Herein, we report a large scale layer-by-layer manufacturing strategy for a high performance chromatography medium utilizing 3D-printing technology. Combining stereolithography 3D printing and porogenic chemistry, the strategy enables parallel production of high-performance separation medium in diverse scales, shapes, and throughput. Between 1,000 printed devices, high performance consistency was demonstrated by column-to-column and batch-to-batch reproducibility (coefficient of variation of retention time, 2.04%). Fast separations of intact proteins were realized in reversed-phase chromatography: within 1 min, resolution > 1.5 was achieved, and nondenatured antibody separation was realized in hydrophobic interaction chromatography. Purification of native proteins was directly amplified by 3 orders of magnitude: 12 mg of hemeproteins was isolated in 8 min at negligible scaling-up cost, supporting liter-scale processing of fermentation within 7 h on one 20 mm i.d. printed column. With advantages in automatic and parallel production capacity, high-fidelity microstructure across dimensions, and highly efficient method transfer and scaling-up, the stereolithographically printed high performance chromatography medium may open a new path to speeding up separation and purification processes from primary analysis to mass-purification of biomolecular entities, as demanded in the biosynthesis and pharmaceutical industries.

Tradeoff between Mechanical Strength and Electrical Conductivity of MXene Films by Nacre-Inspired Subtractive Manufacturing.

Traditional strategies, by additive manufacturing, for integrating monolayer Ti3C2Tx nanosheets into macroscopic films with binders can effectively improve their mechanical strength, but the electrical conductivity is often sacrificed. Herein, inspired by the aligned nano-compacted feature of nacre, a flexible subtractive manufacturing strategy is reported to squeeze the interlayer 2D spacings by removing the nanoconfined water and interface terminations, leading to the improvement of mechanical strength and stability of Ti3C2Tx layered films without sacrificing the electrical conductivity. After the vacuum annealing of Ti3C2Tx films at 300 °C (A300), the interlayer 2D spacing decreased ≈0.1nm with the surface functional groups (═O, ─OH, ─F) and interlayer water molecules greatly removed. The tensile strength (95.59MPa) and Young's modulus (9.59GPa) of A300 are ≈3 and ≈2 times improved, respectively. Moreover, the A300 films maintain a metallic electrical conductivity (2276 Scm-1) and show greatly enhanced stability. Compared to the original films, the mechanical strength of the A300 films is enhanced by increasing the interlayer friction and energy dissipation with the decrease of interlayer 2D spacings. This work provides a new way for engineering the self-assembled films with more functions for broad applications.

Practical Approaches on Cost Saving Strategies for Sustainable Semiconductor Manufacturing

Practical Approaches on Cost Saving Strategies for Sustainable Semiconductor Manufacturing

On-Shore Assembly Solutions for Long-Lifecycle Systems

With the growing instability of overseas semiconductor supply chains, domestic manufacturing solutions provide a secure and steady alternative through flexible and responsive production strategies customized to meet each customer’s unique requirements to ensure stability and reliability. Mature technologies continue to drive volatility for long-lifecycle systems. This paper will explore the technical capabilities and infrastructure investments that allow customized onshore assembly and testing and reduce supply chain risks. Advancing products and developing technologies, such as BGA (Ball Grid Array), QFN (Quad Flat No Leads), and Flip Chip, allow domestic facilities to prototype modern designs, scale pilot volumes, and ramp to high-mix, low-volume production while swiftly adapting to the ever-changing demand landscape. In collaboration with universities and vocational programs, local workforce training nurtures skilled labor pools that excel in handling intricate assembly tasks. By leveraging domestic infrastructure for packaging, testing, reliability analysis, and failure diagnosis, manufacturers can expedite delivery times and just-in-time inventory management for long-life semiconductor products. Manufacturers can ensure that semiconductor components meet the stringent durability and lifespan requirements of long-lifecycle systems by conducting rigorous reliability testing and lifecycle analysis in domestic failure analysis laboratories. Onshore facilities specializing in high-mix, low-volume production provide a reliable solution to combat disruptions in offshore supply chains. With their extensive expertise, well-established infrastructure, and adaptable manufacturing strategies, domestic partners assist companies in navigating through ever-changing market dynamics and uncertainties. This paper will also outline strategies to mitigate risks, streamline production timelines, reduce expenses through consolidating manufacturing in one facility, and establish resilient supply chains for semiconductor systems with long lifecycles. It will shed light on areas that have been overlooked amidst the excitement surrounding the latest semiconductor fabrication technologies and the forefront of the now-defunct Moore’s Law, all while focusing on the practical realities essential for today’s long-term system companies.

Distance-controlled direct ink writing of titanium alloy with enhanced shape diversity and controllable porosity

Porous titanium alloys have been extensively used for diverse engineering applications. However, current additive manufacturing (AM) strategies face significant challenges (e.g., low fabrication efficiency and limited shape diversity) in producing porous titanium alloys. This work aims to develop a distance-controlled direct ink writing (DC-DIW) approach for constructing macroscale 3D architectures from titanium alloy powders. This approach integrates a constant interlayer distance control with traditional DIW, breaking through the angle limit in current porous metal printing from 60° to 30°. Additionally, subsequent heat treatment is applied to control microstructures. To demonstrate the capabilities of this approach, three representative structures, including a bifurcated tube, an orbital implant, and a knee implant, are successfully printed and treated, achieving suitable mechanical properties and high shape fidelity. This work provides a viable and efficient AM strategy for fabricating porous titanium alloys with enhanced shape diversity and controllable porosity suitable for various engineering applications.

Characterization of porous materials with artificial neural networks.

The acoustic modeling of materials is of paramount importance for the accurate prediction of untested configurations and the development of optimal manufacturing strategies. Nevertheless, this task presents significant challenges due to the complexity of the parameters governing materials, such as porous media, each of which demands distinct experimental setups and procedures, often difficult to implement. Inverse methods for parameter estimation rely on physical approximations and require experimental protocols that are highly sensitive to boundary conditions, rendering the process both expensive and time-consuming. This study investigates the efficacy of machine learning techniques, particularly artificial neural networks, in determining the parameters of the Johnson-Champoux-Allard (JCA) model for porous samples, with a specific emphasis on the mutual influence of input features on network performance. Building upon these insights, a hierarchical artificial neural network-based procedure is proposed and validated using experimental data to predict the JCA parameters with minimal error.

Potentially commercializable nerve guidance conduits for peripheral nerve injury: Past, present, and future.

Peripheral nerve injuries are a prevalent global issue that has garnered great concern. Although autografts remain the preferred clinical approach to repair, their efficacy is hampered by factors like donor scarcity. The emergence of nerve guidance conduits as novel tissue engineering tools offers a promising alternative strategy. This review aims to interpret nerve guidance conduits and their commercialization from both clinical and laboratory perspectives. To enhance comprehension of clinical situations, this article provides a comprehensive analysis of the clinical efficacy of nerve conduits approved by the United States Food and Drug Administration. It proposes that the initial six months post-transplantation is a critical window period for evaluating their efficacy. Additionally, this study conducts a systematic discussion on the research progress of laboratory conduits, focusing on biomaterials and add-on strategies as pivotal factors for nerve regeneration, as supported by the literature analysis. The clinical conduit materials and prospective optimal materials are thoroughly discussed. The add-on strategies, together with their distinct obstacles and potentials are deeply analyzed. Based on the above evaluations, the development path and manufacturing strategy for the commercialization of nerve guidance conduits are envisioned. The critical conclusion promoting commercialization is summarized as follows: 1) The optimization of biomaterials is the fundamental means; 2) The phased application of additional strategies is the emphasized direction; 3) The additive manufacturing techniques are the necessary tools. As a result, the findings of this research provide academic and clinical practitioners with valuable insights that may facilitate future commercialization endeavors of nerve guidance conduits.

The Need for a Quality Strategy in Metal Additive Manufacturing Technology

This study investigates the need for a quality strategy in metal additive manufacturing (AM) technology effective for batch production. We carried out two surveys aimed at gathering data from industry experts to understand the challenges and the requirements of quality strategies in metal AM. Survey 1 investigated general quality aspects in metal technology, revealing key areas where quality strategies are required, such as process control, material consistency, and post-processing. It also highlighted challenges that directly impact part quality, including process variability, material inconsistencies, and surface finish issues. Survey 2, focused on batch production, showed that 75% of participants strongly agreed with the need for a specific quality strategy to address challenges specific to metal AM. The respondents highlighted critical processes requiring quality strategies, including powder quality, process optimisation, and defect detection, while identifying ongoing issues with process variability and material inconsistency. Both surveys indicate a need for a standardised and effective quality strategy to enhance production consistency, efficiency, and regulatory compliance. Regardless of a limited sample size of 59 respondents, these results emphasise the need for improved quality strategies in metal AM to reduce defects effectively, meet customer expectations, and ensure scalable production. This study provides insights into the strategic development of quality strategies significant for advancing metal AM technology.

Development of heating strategies to reduce crack formation in the manufacturing process of tool components using directed energy deposition

Abstract Due to the increasing number of product variants, the automotive industry is focusing on additive manufacturing processes to enhance the flexibility in the production process. In this context, the directed energy deposition process (DED) offers the potential to manufacture tool components hybrid-additively with the aim to produce vehicle outer skin parts more cost-effectively. The temperature gradient between substrate and additive build-up, which is caused by the heat input of the laser, is a key factor for a crack-free manufacturing process, as it affects the magnitude of residual stresses in the component. In this paper, an improved manufacturing strategy is developed to reduce the temperature gradient and therefore the formation of cracks in the tool component. For this purpose, welding specimens are manufactured additively at different preheating temperatures. Moreover, the influence of a heating plate for in situ heating of the substrate, as well as the influence of stress relief annealing on the manufacturing process is examined to reduce the hardness in the bonding zone of the specimens. In this context, the crack length and hardness in the bonding zone are measured using a metallographic analysis. Based on these results, a tool component is manufactured hybrid-additively without any defects.

Mycodesign: A new collaboration between mycomaterials and product design as a way to promote material identity

The implementation of the new material culture in the industrial field using biomaterials, currently offers solutions that are disconnected from their origin. Primary sources’ alternative offers functional and expressive identities as part of their potential. New dynamics and specific design strategies are emerging to facilitate project thinking around biomaterials’ qualities, in order to use them in their raw form. This paper presents a case study that validates a customized methodology, M4D, focusing on the application of mycelium-based composites in product design, which are yet limited. We provide a journey throughout the creation process of different prototypes in search of a manufacturing strategy that promotes feasibility and reproducibility. Bio-assemblage was identified as a necessary property in the creation of myco-based modular structures. We further discuss how M4D methodology stresses the natural and expressive identities of myco-materials, and how these can blur as you move forward into designing a viable product.

The Integration of Additive Manufacturing into Industry 4.0 and Industry 5.0: A Bibliometric Analysis (Trends, Opportunities, and Challenges)

This bibliographic analysis explores the evolving landscape of additive manufacturing (AM) in the context of Industry 4.0 and the emerging paradigms of Industry 5.0. This research critically examines the key literature and scholarly works to clarify the evolution, challenges, and opportunities presented by integrating AM technologies with digital transformation and advanced industrial practices. The exploration begins by tracing the foundational concepts of Industry 4.0, emphasizing the role of cyber–physical systems, data analytics, and automation in reshaping manufacturing ecosystems. It then moves to the developments of Industry 5.0, focusing on human-centric approaches, collaborative robotics, and sustainable manufacturing strategies that extend beyond automation. The impact of AM technologies across various sectors, from aerospace and automotive industries to healthcare and consumer goods, is central to this analysis. This article synthesizes empirical studies, case analyses, and theoretical frameworks to discern the synergies, challenges, and prospects of integrating AM into Industry 4.0 and the evolving Industry 5.0. Through this bibliographic journey, readers gain insights into the transformative potential of AM as a catalyst for innovation, agility, and sustainability in the digital age. The findings underscore the need for interdisciplinary collaborations, policy frameworks, and technological advancements to harness AM’s full potential within Industry 4.0 and 5.0.