Mechanical Stress Research Articles

Height Control System for Wind Turbines Based on Critical Wind Speed Calculation

The increasing frequency of wind turbine failures due to extreme weather conditions necessitates the implementation of new solutions to enhance their operational reliability. This paper presents an automatic rotor drop system specifically designed for wind turbines equipped with the Onipko rotor. The system aims to protect turbines from damage caused by critical wind speeds, reducing maintenance costs and extending the equipment’s lifespan. The unique design of the Onipko rotor allows it to operate at wind speeds as low as 0.1 m/s. However, its high drag coefficient and lack of aerodynamic optimization make it susceptible to mechanical stress and structural instability under strong gusts, requiring additional protective measures. The paper presents a calculation of the critical wind speed at which protective measures must be initiated. Through mathematical modeling, this study demonstrates the effectiveness of the rotor drop system in ensuring safe operation at wind speeds reaching 23.5 m/s. The optimization of the PI controller parameters provides a rapid response and stability, significantly enhancing the resilience of wind turbines to adverse weather conditions.

Piezoelectricity and flexoelectricity in biological cells: the role of cell structure and organelles.

Living tissues experience various external forces on cells, influencing their behaviour, physiology, shape, gene expression, and destiny through interactions with their environment. Despite much research done in this area, challenges remain in our better understanding of the behaviour of the cell in response to external stimuli, including the arrangement, quantity, and shape of organelles within the cell. This study explores the electromechanical behaviour of biological cells, including organelles like microtubules, mitochondria, nuclei, and cell membranes. A two-dimensional bio-electromechanical model for two distinct cell structures has been developed to analyze the behavior of the biological cell to the external electrical and mechanical responses. The piezoelectric and flexoelectric effects have been included via multiphysics coupling for the biological cell. All the governing equations have been discretized and solved by the finite element method. It is found that the longitudinal stress is absent and only the transverse stress plays a crucial role when the mechanical load is imposed on the top side of the cell through compressive displacement. The impact of flexoelectricity is elucidated by introducing a new parameter called the maximum electric potential ratio ( ). It has been found that depends upon the orientation angle and shape of the microtubules. The magnitude of exhibit huge change when we change the shape and orientation of the organelles, which in some cases (boundary condition (BC)-3) can reach to three times of regular shape organelles. Further, the study reveals that the number of microtubules significantly impacts effective elastic and piezoelectric coefficients, affecting cell behavior based on structure, microtubule orientation, and mechanical stress direction. The insight obtained from the current study can assist in advancements in medical therapies such as tissue engineering and regenerative medicine.

Role of mechanical stress localizations on the radiation hardness of AlGaN/GaN high electron mobility transistors

Abstract Multi-material, multi-layered systems such as AlGaN/GaN high electron mobility transistor (HEMTs) contain residual mechanical stresses that arise from sharp contrasts in device geometry and materials parameters. These stresses, which can be either tensile or compressive, are difficult to detect and eliminate because of their highly localized nature. We propose that their high stored internal energy make potential sites for defect nucleation sites under radiation, particularly if their locations coincide with the electrically sensitive regions of a transistor. In this study, we validate this hypothesis with molecular dynamic simulation and experiments exposing both pristine and annealed HEMTS to 2.8 MeV Au+3 irradiation. Our unique annealing process uses mechanical momentum of electrons, also known as the electron wind force (EWF) to mitigate the residual stress at room temperature. High-resolution transmission electron microscopy (TEM) and cathodoluminescence spectra reveal the reduction of point defects and dislocations near the two-dimensional electron gas region of EWF-treated devices compared to pristine devices. The EWF-treated HEMTs showed relatively higher resilience with approximately 10% less degradation of drain saturation current and ON-resistance and 5% less degradation of peak transconductance. Both mobility and carrier concentration of the EWF-treated devices were less impacted compared to the pristine devices. Our results suggest that the lower density of nanoscale stress localization contributed to the improved radiation tolerance of the EWF-treated devices. Intriguingly, the EWF is found to modulate the defect distribution by moving the defects to electrically less sensitive regions in the form of dislocation networks, which act as sinks for the radiation induced defects and this assisted faster dynamic annealing.

A systematic study on the elevated risk of ankylosing spondylitis in adolescents engaged in intense physical exercise

This study investigates the link between intense physical activity during adolescence and the onset of ankylosing spondylitis (AS), particularly in individuals having the human leukocyte antigen (HLA)-B27 antigen, a known genetic marker for AS. The systematic literature review included studies published between 2014 and 2024. . Keywords and search terms included combinations of "ankylosing spondylitis," "HLA-B27," "adolescence," "intense physical exercise," and "genetic predisposition. Inclusion criteria focused on studies involving adolescents aged 15-24 years with genetic predispositions such as HLA-B27. Exclusion criteria included studies with unrelated outcomes such as individuals not within the target adolescent age range, non-peer-reviewed articles, and those with insufficient data on the target population. Findings revealed that adolescents with the HLA-B27 antigen who engaged in heavy weight exercise were at a heightened threat of developing AS. The mechanical stress from intense physical activity potentially triggered or exacerbated inflammation at entheses in genetically predisposed individuals. However, the onset of AS was not universally observed in all HLA-B27 positive individuals who participated in strenuous exercise, suggesting other genetic and environmental factors’ involvement. The study suggests that strenuous exercise during adolescence may act as a significant contributing factor to the onset of AS in individuals having a genetic predisposition such as HLA-B27. While not all individuals having HLA-B27 develop AS, genetic and environmental factors’ combination, including intense physical activity, may accelerate disease progression.

Heterogeneity of Endothelial Cells Impacts the Functionality of Human Pancreatic In Vitro Models.

Endothelial cells (ECs) play a crucial role in maintaining tissue homeostasis and functionality. Depending on their tissue of origin, ECs can be highly heterogeneous regarding their morphology, gene and protein expression, functionality, and signaling pathways. Understanding the interaction between organ-specific ECs and their surrounding tissue is therefore critical when investigating tissue homeostasis, disease development, and progression. In vitro models often lack organ-specific ECs, potentially limiting the translatability and validity of the obtained results. The goal of this study was to assess the differences between commonly used EC sources in tissue engineering applications, including human umbilical vein ECs (HUVECs), human dermal microvascular ECs (hdmvECs), and human foreskin microvascular ECs (hfmvECs), and organ-specific human pancreatic microvascular ECs (hpmvECs), and test their impact on functionality within an in vitro pancreas test system used for diabetes research. Utilizing high-resolution Raman microspectroscopy and Raman imaging in combination with established protein and gene expression analyses and exposure to defined physical signals within microfluidic cultures, we identified that ECs exhibit significant differences in their biochemical composition, relevant protein expression, angiogenic potential, and response to the application of mechanical shear stress. Proof-of-concept results showed that the coculture of isolated human islets of Langerhans with hpmvECs significantly increased the functionality when compared with control islets and islets cocultured with HUVECs. Our study demonstrates that the choice of EC type significantly impacts the experimental results, which needs to be considered when implementing ECs into in vitro models.

Effect of polydimethylsiloxane content on the electrothermal performance and tensile strength of laser induced graphene films: Experimental and theoretical

BackgroundSince its discovery in 2014, laser induced graphene (LIG) has gained a lot of interest from research institutions and the industry as a result of its single-step fabrication process and tailorable properties. Nonetheless, LIG's brittle nature makes it susceptible to any mechanical disturbances thus shearing off from the polyimide (PI) sheet surface. This limits its applicability in electrothermal heating and other applications requiring high flexibility. Therefore, there is a need to enhance LIG's robustness on the precursor surface. MethodsTo overcome this, LIG films were fabricated from PI using a 10.6 µm CO2 laser machine and polydimethylsiloxane (PDMS) contents were infused into the LIG structure by spin coating to form LIG/PDMS films. Furthermore, the adhesion strength of LIG/PDMS films was further improved by making micro scratches on the substrate surface by pressing the PI sheets in between the jaws of a Universal Testing Machine (UTM). The joule heating of LIG and LIG/PDMS heaters was evaluated before, during, and after mechanical testing. Theoretical models (heat balance and Ansys Finite Element, FE) were also performed to validate experimental results. Significant findingsAt an input DC voltage of 8 V, the LIG/PDMS with 50 μL PDMS and LIG heaters generated saturation temperatures of 250 and 308.86 °C, respectively. Much as the saturation temperatures were lower for LIG/PDMS heaters, their mechanical strength was enhanced in comparison with the LIG heaters. LIG/PDMS films could undergo more bending cycles (4800) than LIG films (2400). Additionally, LIG/PDMS film accommodated more stress (⁓ 0.16 Mpa) than LIG film (⁓ 0.04 Mpa) after tensile tests. Interestingly, the LIG/PDMS heater's electrothermal performance was better than that of LIG heater after tension. The heat balance equation and simulation results showed a tight match with experimental generated temperatures, verifying the approach's trustworthiness. Hence, the demonstrated effectiveness and efficiency of LIG-based heaters with high flexibility under various mechanical stresses open new possibilities for diverse electronic applications.

Air-Processed Efficient Perovskite Solar Cells With Full Lifecycle Management.

Despite the outstanding power conversion efficiency of perovskite solar cells (PSCs) realized over the years, the entire lifecycle from preparation and operation to discarding of PSCs still needs to be carefully considered when it faces the upcoming large-scale production and deployment. In this study, bio-derived chitin-based polymers are employed to realize the full lifecycle regulation of air-processed PSCs by forming multiple coordinated and hydrogen bonds to stabilize the lead iodide and organic salt precursor inks, accelerating the solid-liquid reaction and crystallization of two-step deposition process, then achieving the high crystalline and oriented perovskites with less notorious charge defects in the open air. The air-prepared PSCs exhibit a decent efficiency of 25.18% with high preparation reproducibility and improved operational stability toward the harsh environment and mechanical stress stimuli. The modified PSCs display negligible fatigue behavior with keeping 92% of its initial efficiency after operating for 32 diurnal cycles (ISOS-LC-1 protocol). Meanwhile, closed-loop lead management of end-of-life PSCs including suppression of lead leakage, toxicity evaluation of broken devices, and recycling of lead iodide components are comprehensively investigated. This work sheds light on a promising avenue to realize the entire lifecycle regulation of air-processed efficient and stable PSCs.

Acute contact with profibrotic macrophages mechanically activates fibroblasts via αvβ3 integrin-mediated engagement of Piezo1.

Fibrosis-excessive scarring after injury-causes >40% of disease-related deaths worldwide. In this misguided repair process, activated fibroblasts drive the destruction of organ architecture by accumulating and contracting extracellular matrix. The resulting stiff scar tissue, in turn, enhances fibroblast contraction-bearing the question of how this positive feedback loop begins. We show that direct contact with profibrotic but not proinflammatory macrophages triggers acute fibroblast contractions. The contractile response depends on αvβ3 integrin expression on macrophages and Piezo1 expression on fibroblasts. The touch of macrophages elevates fibroblast cytosolic calcium within seconds, followed by translocation of the transcription cofactors nuclear factor of activated T cells 1 and Yes-associated protein, which drive fibroblast activation within hours. Intriguingly, macrophages induce mechanical stress in fibroblasts on soft matrix that alone suppresses their spontaneous activation. We propose that acute contact with suitable macrophages mechanically kick-starts fibroblast activation in an otherwise nonpermissive soft environment. The molecular components mediating macrophage-fibroblast mechanotransduction are potential targets for antifibrosis strategies.

Michelson interferometer based on a fiber with a germanium-doped core and inner cladding for high-temperature sensing

We proposed and demonstrated a temperature sensor based on a fiber Michelson interferometer. The Michelson Interferometer contains a special fiber with a germanium-doped core and pure silica inner cladding, so the interference spectrum is formed as a result of interference of the mode of the core and one of the modes of the inner cladding. The existence of inner cladding reduces the number of interacting cladding modes. When annealing the sensor for 300 min at a temperature of 600 °C, no thermal hysteresis of the interference spectrum was observed. The temperature sensitivities of the proposed sensor are 48 pm/°C in the range of 20–250 °C and 78 pm/°C in the range of 250–600 °C. But when the sensor was exposed to a constant temperature of 700 °C and above for a few hours, a shift in the wavelength of the dip of the interference spectrum is observed. This wavelength shift, which occurs even at a fixed temperature, depends on the temperature of annealing. It can be explained by a number of processes occurring in glass at high temperatures: the changing fictive temperature of the glass, diffusion of germanium oxide from the core, and formation of mechanical stresses resulting from the difference in thermal expansion coefficients of the core and cladding, and relaxation of these mechanical stresses at an elevated temperature.

Overcoming the Tradeoff of Visible Transparency and Electrical Conductance via Dual Smoothing of Dielectric/Metal Interfaces in Cu-Thin-Layer-Based Transparent Electrodes.

The rapid advancement of flexible optoelectronic devices, such as light-emitting diodes, solar cells, and electrochromic devices, necessitates the development of high-performance flexible transparent electrodes (TEs). Dielectric/metal/dielectric (DMD)-type TEs are promising alternatives to conventional indium tin oxide (ITO) due to the high electrical conductance, excellent visible transparency, and sufficient mechanical flexibility. However, the tradeoff between electrical conductance and visible transparency poses a challenge to performance enhancement. This study introduces an Ar-ion-mediated interface modification method to address this tradeoff by dual smoothing of dielectric/metal interfaces in TiOx/Cu/ZnO TEs. Implementing this dual smoothing methodology significantly enhances both electrical conductance and visible light transmittance, achieving a Haacke figure of merit 200% higher than that of an unmodified otherwise identical structure. The highest figure of merit is 0.113 Ω-1, a record high for Cu-thin-layer-based DMD TEs, far surpassing ITO electrode values. Further, the enhanced optoelectronic performance remains highly durable under severe and simultaneous electrical, thermal, and mechanical stresses, showcasing the potential for significant advances in flexible optoelectronics.

Mathematical Modelling of Tensile Mechanical Behavior of a Bio-Composite Based on Polybutylene-Succinate and Brewer Spent Grains.

A model based on the fitting of stress-strain data by tensile tests of bio-composites made of a bioplastic (polybutylene succinate (PBS)) and brewer spent grain filler (BSGF) is developed. Experimental tests were performed for various concentrations of BSGF in the range from 2% to 30%. The model is suitable for describing the elastic-plastic behavior of these materials in terms of two mechanical parameters, tensile stress and tensile stiffness (or Young's modulus), depending on the filler concentration. The mechanical characteristics, derived from the fit parameters, show good agreement with the experimental data. The mathematical model used here could be an important aid for the experimentation and manufacturing process as it allows the prediction of the mechanical tensile parameters of a mixture with different filler concentrations, avoiding the long and complex preparation cycle of bio-composites, as well as the specific mechanical tests. The physical properties required by the objects created with the PBS-BSGF bio-composite by the partners/stakeholders of the research project co-financing this research can be quite different; therefore, a mathematical model that predicts some of the mechanical properties in terms of the mixture composition may be useful to speed up the selection of the required amount of BSGF in the mixture.

Gelatin-Based Polymers Can Be Processed to Highly Resilient Biocompatible Porous Hydrogel Scaffolds for Soft Tissue Regeneration Applications

Tissue regeneration relies on the mechanical properties of the surrounding environment, and it has already been shown that mechanostimulation is highly dependent on the stiffness of the native biological tissue. The main advantage of injectable hydrogels in medical applications is their ability to be delivered through minimally invasive techniques. Natural polymer-based hydrogels have been widely used in biomedical applications, due to their high biocompatibility, low immunogenicity, and similarity to soft tissues. However, the crucial combination of low stiffness with high resilience has not been achieved for natural polymers. The current study focuses on the development of novel gelatin-based injectable hydrogels for soft tissue regeneration applications, elucidating the effects of the formulation parameters on the resilience, microstructure, biocompatibility, and mechanical properties. Non-foamed hydrogels demonstrated resilience of at least 95%, while porous hydrogels maintained resilience above 90%, allowing them to withstand mechanical stresses and dynamic conditions within the body. The adjustable modulus of these hydrogels provides the necessary flexibility to mimic the mechanical properties of soft and very soft tissues, without compromising resilience. Environmental Scanning Electron Microscopy (ESEM) observations of the porous hydrogels indicated round interconnected pore structures, desired for cell migration and nutrient flow. Biocompatibility tests on fibroblasts and pre-adipocytes confirmed high biocompatibility, both directly and indirectly. In summary, structuring these new hydrogels for achieving adjustable stiffness, along with the excellent resilience and biocompatibility, is expected to enable this new technology to fit various soft tissue regeneration applications.

Investigation of Mechanical Stresses in SiC/Porous-Si Heterostructure

Abstract This study presents an investigation into the properties of SiC/por-Si structures obtained by the method of coordinated substitution of atoms (MCSA). Experimentally, it was determined that during the formation of the SiC layer, the ordered mesoporous structure of the silicon substrate is significantly altered. The morphology and structure of the samples were characterized using scanning electron microscopy, and further characterization of the heterostructure was carried out via glancing angle X-ray diffraction. The mechanical stresses in the SiC/por-Si heterostructure were experimentally determined using both X-ray diffraction and Raman spectroscopy. Finite element modeling was also used to assess the mechanical stresses in the obtained SiC/por-Si structure with the aim of establishing a correlation between theoretical and experimental data.

Enhanced Experimental Setup and Methodology for the Investigation of Corrosion Fatigue in Metallic Biodegradable Implant Materials.

Biodegradable implants as bone fixations may present a safe alternative to traditional permanent implants, reducing the risk of infections, promoting bone healing, and eliminating the need for removal surgeries. Structural integrity is an important consideration when choosing an implant material. As a biodegradable implant is being resorbed, until the natural bone has regrown, the implant material needs to provide mechanical stability. However, the corrosive environment of the human body may affect the fatigue life of the material. Conversely, mechanical stress can have an effect on electrochemical corrosion processes. This is known as corrosion fatigue. In the presented work, an experimental setup and methodology was established to analyze the corrosion fatigue of experimental bioresorbable materials while simultaneously monitoring the electrochemical processes. A double-walled measurement cell was constructed for a three-point bending test in Dulbecco's Phosphate-Buffered Saline (DPBS- -), which was used as simulated body fluid (SBF), at 37 ± 1 °C. The setup was combined with a three-electrode setup for corrosion measurements. Rod-shaped zinc samples were used to validate the setup's functionality. Preliminary static and dynamic bending tests were carried out as per the outlined methodology to determine the test parameters. Open-circuit as well as potentiostatic polarization measurements were performed with and without mechanical loading. For the control, fatigue tests were performed in an air environment. The tested zinc samples were inspected via scanning electron microscopy (SEM). Based on the measured mechanical and electrochemical values as well as the SEM images, the effects of the different environments were investigated, and the setup's functionality was verified. An analysis of the data showed that a comprehensive investigation of corrosion fatigue characteristics is feasible with the outlined approach. Therefore, this novel methodology shows great potential for furthering our understanding of the effects of corrosion on the fatigue of biodegradable implant materials.

Nonlinear Finite Element Analysis of Bone–Implant Contact in Three Short Dental Implant Models with Varying Osseointegration Percentages

Objectives: Dental implants have become a cornerstone of restorative dentistry, providing a long-lasting method for tooth replacement. The degree of osseointegration has a significant effect on biomechanical stability at the bone–implant contact (BIC), determining the continued efficacy of these implants. However, the exact consequences of changing osseointegration levels on different implant designs, especially in bones with variable densities, are not well known. Methods: This study used 3D finite element analysis (FEA) to look at the biomechanical performance of three short dental implants: BioMet 3iT3, Straumann® Standard Plus Short-Regular Neck (SPS-RN), and Straumann® Standard Plus Short-Wide Neck (SPS-WN). This paper tested the implants at four stages of osseointegration: 25%, 50%, 75%, and 100% in both high-density (bone type III) and low-density (bone type IV) cancellous bone. It also created and examined realistic CAD models under static occlusal loading conditions to assess stress distribution and major strains at the bone–implant contact. Results: The study discovered that as osseointegration increases, von Mises stress and principal strains go down significantly for all implant types. The SPS-WN implant had the lowest strain values, especially for bone with low density. These reductions demonstrate increased mechanical stability as the bone–implant interface becomes more capable of dispersing mechanical stresses, minimizing the potential for localized deformation and bone resorption. Conclusions: The results highlight the importance of achieving optimum osseointegration to reduce mechanical stress and increase the lifespan of dental implants. The SPS-WN type implant performed better in biomechanical tests than the others, especially when bone conditions were not ideal. This makes it a great choice for clinical applications that need long-term implant success.

Mechanisms of Action of Exclusive Enteral Nutrition and Other Nutritional Therapies in Crohn's Disease.

Crohn's disease (CD) is an inflammatory bowel disease (IBD) characterized by transmural inflammation and intestinal fibrosis involving mostly the small intestine and colon. The pathogenic mechanisms of CD remain incompletely understood and cures are unavailable. Current medical therapies are aimed at inducing prolonged remission. Most of the medical therapies such as corticosteroids have substantial adverse effects. Consequently, many dietary therapies have been explored for the management of CD. Up to now, exclusive enteral nutrition (EEN) has been considered the only established dietary treatment for IBD, especially CD. In this article, we aim to give a concise review about the current therapeutic options and challenges in the management of CD and aim to compare the efficacy of EEN with other dietary therapies and update on the possible mechanisms of the benefits of EEN and other nutritional therapies. We searched the literature up to August 2024 through PubMed, Web of Science, and other sources using search terms such as EEN, nutritional therapy, IBD, Crohn's disease, ulcerative colitis. Clinical studies in patients and preclinical studies in rodent models of IBD were included in the summary of the therapeutic benefits. EEN involves oral or nasogastric tube feeding of a complete liquid diet with exclusion of normal foods for a defined period (usually 6 to 8 weeks). EEN treatment is demonstrated to have anti-inflammatory and healing effects in CD through various potential pathways, including altering gut bacteria and their metabolites, restoring the barrier function, direct anti-inflammatory action, and indirect anti-inflammatory action by eliminating mechanical stress in the bowel. However, efficacy of other nutritional therapies is not well established in CD, and mechanisms of action are largely unknown.

Bidirectional Allostery Mechanism in Catch-Bond Formation of CD44 Mediated Cell Adhesion.

Catch-bonds, whereby noncovalent ligand-receptor interactions are counterintuitively reinforced by tensile forces, play a major role in cell adhesion under mechanical stress. A basic prerequisite for catch-bond formation, as implicated in classic catch-bond models, is that force-induced remodeling of the ligand binding interface occurs prior to bond rupture. However, what strategy receptor proteins utilize to meet such specific kinetic control remains elusive. Here we report a bidirectional allostery mechanism of catch-bond formation based on theoretical and molecular dynamics simulation studies. Binding of ligand allosterically reduces the threshold force for unlocking of otherwise stably folded force-sensing element (i.e., forward allostery), so that a much smaller tensile force can trigger the conformational switching of receptor protein to high binding-strength state via backward allosteric coupling before bond rupture. Such bidirectional allostery fulfills the specific kinetic control required by catch-bond formation and is likely to be commonly utilized in cell adhesion. The essential thermodynamic and kinetic features of receptor proteins essential for catch-bond formation were identified.

Intracellular dry mass density increases under growth-induced pressure

Cells that proliferate in confined environments develop mechanical compressive stress, referred to as growth-induced pressure, which inhibits growth and division across various organisms. Recent studies have shown that in these confined spaces, the diffusivity of intracellular nanoparticles decreases. However, the physical mechanisms behind this reduction remain unclear. In this study, we use quantitative phase imaging to measure the refractive index and dry mass density of Saccharomyces cerevisiae cells proliferating under confinement in a microfluidic bioreactor. Our results indicate that the observed decrease in diffusivity can be at least attributed to the intracellular accumulation of macromolecules. Furthermore, the linear scaling between cell content and growth-induced pressure suggests that the concentrations of macromolecules and osmolytes are maintained proportionally under such pressure in S. cerevisiae.

Exploring the mechanism of stress-induced passive layer degradation in additively manufactured Ni-Fe-Cr-based alloy 718

This study explores the formation and degradation mechanisms of the passive layer on laser powder bed fusion (L-PBF) processed Ni-Fe-Cr-based alloy 718 using high-resolution submicron analysis and microcapillary electrochemical techniques. The findings provide new insights into passive layer breakdown under tensile loading, revealing the influence of microstructural characteristics, dislocation distribution, and mechanical stresses. Tensile loading caused oxide layer cracking near cell boundaries with higher dislocation density. Detachment of the oxide layer from the matrix created voids, allowing aggressive ions to penetrate, promoting crevice corrosion. Cell boundaries remained mostly intact, as metallic particles within the surface oxide layer.

Structural Design of Hybrid Fillers in a Polymer Matrix for Advanced Electromagnetic Interference Shielding

The rapid development of modern advanced electronic systems has created a pressing need for multifunctional polymer composites that can withstand external adversities such as electromagnetic waves, flames, and mechanical stresses. Although these requirements can be satisfied by incorporating different types of fillers, high filler loadings often lead to issues such as poor processability and increased material costs. Herein, a multifunctional polyamide‐6 composite is introduced using a carbon‐fiber flame‐retardant hybrid filler to design a next‐generation electromagnetic interference (EMI) shielding system. Based on the synergistic effect of the functionality and structural arrangement of these fillers in the composite, the EMI shielding system demonstrates high EMI shielding performance, improved mechanical properties, and excellent flame retardancy despite the low filler content. The scalability and multifunctionality of the proposed system highlight its potential for use in next‐generation applications, such as electric vehicles, aerospace, and 5G/6G telecommunications.