Precise Fabrication Research Articles

Melt Electrowriting of Polyhydroxyalkanoates for Enzymatically Degradable Scaffolds.

Melt electrowriting (MEW) enables precise scaffold fabrication for biomedical applications. With a limited number of processable materials with short and tunable degradation times, polyhydroxyalkanoates (PHAs) present an interesting option. Here, poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) and a blend of PHBV and poly(3-hydroxybutyrate-co-4-hydroxybutyrate) (PHBV+P34HB) are successfully melt electrowritten into scaffolds with various architectures. PHBV+P34HB exhibits greater thermal stability, making it a superior printing material compared to PHBV in MEW. The PHBV+P34HB scaffolds subjected to enzymatic degradation show tunable degradation times, governed by enzyme dilution, incubation time, and scaffold surface area. PHBV+P34HB scaffolds seeded with human dermal fibroblasts (HDFs), demonstrate enhanced cell adherence, proliferation, and spreading. The HDFs, when exposed to the enzyme solutions and enzymatic degradation residues, show good viability and proliferation rates. Additionally, HDFs grown on enzymatically pre-incubated scaffolds do not show any difference in behavior compared those grown on control scaffolds. It is concluded that PHAs, as biobased materials with enzymatically tunable degradability rates, are an important addition to the already limited set of materials available for MEW technology.

Large-scale scattering-augmented optical encryption.

Data proliferation in the digital age necessitates robust encryption techniques to protect information privacy. Optical encryption leverages the multiple degrees of freedom inherent in light waves to encode information with parallel processing and enhanced security features. However, implementations of large-scale, high-security optical encryption have largely remained theoretical or limited to digital simulations due to hardware constraints, signal-to-noise ratio challenges, and precision fabrication of encoding elements. Here, we present an optical encryption platform utilizing scattering multiplexing ptychography, simultaneously enhancing security and throughput. Unlike optical encoders which rely on computer-generated randomness, our approach leverages the inherent complexity of light scattering as a natural unclonable function. This enables multi-dimensional encoding with superior randomness. Furthermore, the ptychographic configuration expands encryption throughput beyond hardware limitations through spatial multiplexing of different scatterer regions. We propose a hybrid decryption algorithm integrating model- and data-driven strategies, ensuring robust decryption against various sources of measurement noise and communication interference. We achieved optical encryption at a scale of ten-megapixel pixels with 1.23 µm resolution. Communication experiments validate the resilience of our decryption algorithm, yielding high-fidelity results even under extreme transmission conditions characterized by a 20% bit error rate. Our encryption platform offers a holistic solution for large-scale, high-security, and cost-effective cryptography.

Self-adjusting voxelated electrochemical three-dimensional printing of metallic microstructures

Abstract Microscale metallic structures enhanced by additive manufacturing technology have attracted extensive attention especially in microelectronics and electromechanical devices. Meniscus-confined electrodeposition (MCED) advances microscale 3D metal printing, enabling simpler fabrication of superior metallic microstructures in air without complex equipment or post-processing. However, accurately predicting growth rates with current MCED techniques remain challenging, which is essential for precise structure fabrication and preventing nozzle clogging. In this work, we present a novel approach to electrochemical 3D printing that utilizes a self-adjusting, voxelated method for fabricating metallic microstructures. Diverging from conventional voxelated printing which focuses on monitoring voxel thickness for structure control, this technique adopts a holistic strategy. It ensures each voxel’s position is in alignment with the final structure by synchronizing the micropipette’s trajectory during deposition with the intended design, thus facilitating self-regulation of voxel position and reducing errors associated with environmental fluctuations in deposition parameters. The method’s ability to print micropillars with various tilt angles, high density, and helical arrays demonstrates its refined control over the deposition process. Transmission electron microscopy analysis reveals that the deposited structures, which are fabricated through layer-by-layer (voxel) printing, contain nanotwins that are widely known to enhance the material’s mechanical and electrical properties. Correspondingly, in situ scanning electron microscopy (SEM) microcompression tests confirm this enhancement, showing these structures exhibit a compressive yield strength exceeding 1 GPa. The indentation tests provided an average hardness of 3.71 GPa, which is the highest value reported in previous work using MCED. The resistivity measured by the four-point probe method was (1.95 ± 0.01) × 10−7 Ω·m, nearly 11 times that of bulk copper. These findings demonstrate the considerable advantage of this technique in fabricating complex metallic microstructures with enhanced mechanical properties, making it suitable for advanced applications in microsensors, microelectronics, and micro-electromechanical systems.

Precise fabrication and superior combustion properties of n-B pomegranate microspheres based on a new dissolution-dispersion-coating method

To enhance the reactivity and combustion efficacy of boron powders, a new dissolution-dispersion-coating (DDC) method of fabricating nano-boron (n-B) pomegranate microspheres were developed. Metal nanoparticles were uniformly encapsulated within n-B microspheres, which varied in size from 2 to 500 μm. The spheroidization mechanism of microsphere structure was investigated. Subsequently, the ignition and combustion performance of the prepared pomegranate microspheres were evaluated by combustion tests at 0.2 and 0.5 MPa, respectively. The results demonstrated that the n-B microspheres of F5 (75 wt% n-B@17 wt% NC@8 wt% n-Ti) exhibited superior performances, achieving the largest flame area, minimal ignition delay time and combustion time. The combustion thermal value and combustion residue analysis indicated that the content of available boron in the F5 microspheres exceeded 72.6 % and the combustion was complete. This study provides a novel approach to enhance the ignition and combustion efficiency of n-B powders.

Chiral Nematic Graphene Films with a mesoporous Structure.

Ordering a crucial material like pure-graphene into the chiral nematic structure can potentially revolutionize the fields of photonics, chiral separation, and energy storage. However, the controlled fabrication of highly ordered graphene films with a long-range chiral nematic mesoporous structure is very challenging and as such, has not been achieved. Here, a chiral-template-directed chemical vapor deposition growth strategy is presented for the precise fabrication of mesoporous chiral nematic graphene films by using nanocrystalline cellulose as templates. It is evidenced that such graphene films possess the left-hand helical ordering, chiral nematic mesoporous structure with adjustable pore sizes (6.4-13.1nm), tailored pitch, excellent electrical conductivity (556 S cm-1), high specific surface area (1508 m2g-1) and mechanical flexibility. By coating Na anode with this film, uniform Na plating is achieved with no dendrite formation, resulting from its unique chiral nematic structure and tunable physicochemical properties. The films also achieved impressive thickness-dependent electromagnetic shielding, i.e., 35-63dB, demonstrating their potentially multi-disciplinary applications.

3D-printed microfluidic and millifluidic devices for cell culture and mechanotransduction studies: A review

The practice of conventional cell culture techniques affects the quality of biological research in mechanobiology by not replicating the cell’s microenvironment adequately. Microfluidic devices resembling 3D in vivo cell culture offer viable alternatives for mechanobiology studies and other applications including cell screening, cell separation, and point-of-care diagnostics. This review highlights recent advances in additive manufacturing (AM) to fabricate microfluidic and millifluidic devices through fast design iterations and cost reduction compared with conventional device manufacturing. Key advances in AM technologies such as fused deposition modeling (FDM), stereolithography apparatus (SLA), and digital light processing (DLP) have allowed the direct manufacture of complex microfluidic devices with master molds and sacrificial structures using multiple material components. Currently, available 3D printed devices for the precise fabrication of milli- and microfluidic devices, essential to mimicking the cellular microenvironment, while economically reducing production costs by eliminating expensive clean-room environments and reducing material waste are highlighted.

Metal–Organic Frameworks for Electrocatalytic CO2 Reduction: From Catalytic Site Design to Microenvironment Modulation

AbstractThe electrochemical reduction of CO2 to high‐value carbon‐based chemicals provides a sustainable approach to achieving an artificial carbon cycle. In the decade, metal–organic frameworks (MOFs), a kind of porous crystalline porous materials featuring well‐defined structures, large surface area, high porosity, diverse components, easy tailorability, and controllable morphology, have attracted considerable research attention, serving as electrocatalysts to drive CO2 reduction. In this review, the reaction mechanisms of electrochemical CO2 reduction and the structure/component advantages of MOFs meeting the requirements of electrocatalysts for CO2 reduction are analyzed. After that, the representative progress for the precise fabrication of MOF‐based electrocatalysts for CO2 reduction, focusing on catalytic site design and microenvironment modulation, are systemically summarized. Furthermore, the emerging applications and promising research for more practical scenarios related to electrochemical CO2 conversion are specifically proposed. Finally, the remaining challenges and future outlook of MOFs for electrochemical CO2 reduction are further discussed.

Characterizing anomalous peaks in the resistance–temperature profile of Bi2Sr2CaCu2O8+δ flakes featuring surface degeneration

Abstract This study focuses on an observed anomalous resistance peak in the temperature-dependent resistance (RT) curves of Bi2Sr2CaCu2O8+δ (BSCCO), attributed to surface degradation and pronounced electrical resistance anisotropy. Employing a standard four-point probe technique on the ab-plane, this research circumvents conventional c-axis testing limitations, enhancing the understanding of BSCCO’s electrical behavior by avoiding contact resistance and etching issues. A comprehensive three-dimensional model, developed using the finite element method, captures the strong resistive anisotropy and correlates the depth of surface degradation with the anomalous resistance peaks, explaining this phenomenon from a quantitative perspective, providing a more specific reference for future analysis of relevant signals. The fabrication process involved pre-patterning and mechanical exfoliation techniques to minimize atmospheric exposure and ensure device integrity. Despite these efforts, surface degradation impacting the superconductivity of surface layers was inevitable. The study’s experimental results, complemented by numerical modeling, reveal the intricate relationship between surface layer thickness and the anomalous resistance peak, providing an approach to gauge the extent of degradation in BSCCO devices. Moreover, it underscores the potential necessity of employing some critical techniques to avoid degradation, such as low-temperature exfoliation in other literatures where degradation signal is notably absent from RT curves. This work advances the understanding of BSCCO’s electrical properties and highlights the critical need for precise fabrication and environmental controls in developing high-temperature superconducting technologies.

Rapid Whole-Plate Cell and Tissue Micropatterning Using a Budget 3D Resin Printer.

The ability to precisely pattern cells and proteins is crucial in various scientific disciplines, including cell biology, bioengineering, and materials chemistry. Current techniques, such as microcontact stamping, 3D bioprinting, and direct photopatterning, have limitations in terms of cost, versatility, and throughput. In this Article, we present an accessible approach that combines the throughput of photomask systems with the versatility of programmable light patterning using a low-cost consumer LCD resin printer. The method involves utilizing a bioinert hydrogel, poly(ethylene glycol) diacrylate (PEGDA), and a 405 nm sensitive photoinitiator (LAP) that are selectively cross-linked to form a hydrogel upon light exposure, creating specific regions that are protein and cell-repellent. Our result highlights that a low-cost LCD resin printer can project virtual photomasks onto the hydrogel, allowing for reasonable resolution and large-area printing at a fraction of the cost of traditional systems. The study demonstrates the calibration of exposure times for optimal resolution and accuracy and shape corrections to overcome the inherent challenges of wide-field resin printing. The potential of this approach is validated through widely studied 2D and 3D stem cell applications, showcasing its biocompatibility and ability to replicate complex tissue engineering patterns. We also validate the method with a cell-adhesive polymer (gelatin methacrylate; GelMA). The combination of low cost, high throughput, and accessibility makes this method broadly applicable across fields for enabling rapid and precise fabrication of cells and tissues in standard laboratory culture vessels.

A piezoresistive dielectric elastomer switch consisting of inkjet-printed carbon black

The piezoresistive effect is a key physical property utilized in soft and stretchable electronics, functioning as intrinsic electromechanical sensors. However, most conventional piezoresistive sensors can only passively measure and quantify external stimuli. To address these limitations, this work integrates an inkjet-printed piezoresistive pattern and a dielectric elastomer actuator (DEA) into a single monolithic dielectric elastomer film, creating a dielectric elastomer switch (DES). This DES can realize dramatic resistance changes along with DEA actuation, leveraging DEA-driven piezoresistivity for active and effective circuit control and signal processing. Theoretically, the DES operates by exhibiting resistance change through the periodic compression induced by DEA actuation. Experimentally, the piezoresistive pattern and the DEA electrodes were fabricated on an acrylic dielectric elastomer (VHB) using inkjet-printed piezoresistive carbon black (CB) and manually brushed conductive grease, respectively. The optimized DES demonstrated approximately 3.77 (±0.11) orders of magnitude in resistance change at a DEA frequency of 0.1 Hz. Compared to previously reported methods (smearing and stamping), inkjet-printed CB patterns showed significant improvements. These included negligible Joule heating impact, precise digital fabrication control, larger resistance change (up to 3.77 orders of magnitude), faster response speeds to DEA actuation (∼0.25 s for 3 orders of magnitude in resistance change), and greater durability (operating at 0.5 Hz for 112 min). Scanning electron microscopy (SEM) characterization revealed that these improvements were attributed to a more uniform distribution of conductive “CB islands” and appropriate non-conductive gap size among them. For demonstrating the applications of DES, it was employed for LED control, DEA-based soft gripper control, and as a multiplexer for signal processing.

Non‐Uniform Electric Field Manipulation of Chromogenic Peptide Amphiphile Assemblies

This work investigates the influence of dielectrophoretic forces on the structural features and the resulting aggregates of a chromogenic model system, peptide‐diacetylene (D3GV‐DA) amphiphiles. Here, we systematically investigate how non‐uniform electric fields impact the (i) peptide‐directed supramolecular assembly stage and (ii) topochemical photopolymerization stage of polydiacetylenes (PDAs) in a quadrupole‐based dielectrophoresis (DEP) device, as well as the (iii) manipulation of D3GV‐DA aggregates in a light‐induced DEP (LiDEP) platform. The conformation‐dependent chromatic phases of peptide‐PDAs are utilized to probe the chain‐level effect of DEP exposure after the supramolecular assembly or after the topochemical photopolymerization stage. Steady‐state spectroscopic and microscopy analyses show that structural features such as the chirality and morphologies of peptidic 1‐D nanoassemblies are mostly conserved upon DEP exposure, but applying mild, non‐uniform fields at the self‐assembly stage is sufficient for fine‐tuning the chromatic phase ratio in peptide‐PDAs and manipulating their aggregates via LiDEP. Overall, this work provides insights into how non‐uniform electric fields offer a controllable approach to fine‐tune or preserve the molecularly preset assembly order of DEP‐responsive supramolecular or biopolymeric assemblies, as well as manipulate their aggregates using light projections, which have future implications for the precision fabrication of macromolecular systems with hierarchical structure‐dependent function.

Harnessing interpretable and ensemble machine learning techniques for precision fabrication of aligned micro-fibers

Electrospinning is a robust technique for producing micro/nano-scale fibrous structures, influenced by intricate interplays of fluid dynamics, aerodynamics, and electromagnetic forces. Depending on the desired outcome, these fibers can adopt various morphologies, including solid, tubular, concentric, and gradient. Such morphologies are modulated by parameters such as collector configuration, flow rate, voltage, solution properties, and nozzle dimensions. However, the task of modeling and predicting these multifaceted morphologies remains complex. Aligned microfibers with 3D orientation hold promise in tissue engineering, regenerative medicine, and drug delivery, necessitating meticulous control over the fabrication parameters. In our research, we tapped into machine learning (ML) to address these challenges. Classification ML models were designed to predict fibrous patterns—aligned, random, or jet branching—based on determinants like voltage, flow rate, and collector configurations. Notably, the Random Forest (RF) and Support Vector Machine (SVM) models, especially with radial kernel-trick, displayed outstanding predictive capabilities on the test data. Furthermore, regression-based ML was harnessed to discern fiber alignment coherency and inter-fiber distances. Models such as Lasso and Ridge regression elucidated predictive coefficients for these characteristics, while ensemble models, like gradient-boosting (GB) decision trees (DT), showcased prowess in regression scenarios. Key findings spotlighted the significance of parameters like plate gap for alignment coherency and needle-to-collector distance for inter-fiber spacing. As we strive to gain granular control over micro/nano feature morphology in electrospinning, understanding predictor-response dynamics is imperative. Our investigation underscores the essential role of ML in enhancing both qualitative and quantitative precision in fabricating advanced fibrous structures. Moreover, fusing ML with real-time process monitoring offers groundbreaking potential, particularly in Bio-Fabrication, regenerative medicine, and tissue engineering, where high-precision manufacturing remains a top priority.

Self-Templating Engineering of Hollow N-Doped Carbon Microspheres Anchored with Ternary FeCoNi Alloys for Low-Frequency Microwave Absorption.

Rational design and precision fabrication of magnetic-dielectric composites have significant application potential for microwave absorption in the low-frequency range of 2-8GHz. However, the composition and structure engineering of these composites in regulating their magnetic-dielectric balance to achieve high-performance low-frequency microwave absorption remains challenging. Herein, a self-templating engineering strategy is proposed to fabricate hollow N-doped carbon microspheres anchored with ternary FeCoNi alloys. The high-temperature pyrolysis of FeCoNi alloy precursors creates core-shell FeCoNi alloy-graphitic carbon nano-units that are confined in carbon shells. Moreover, the anchored FeCoNi alloys play a critical role in maintaining hollow structural stability. In conjunction with the additional contribution of multiple heterogeneous interfaces, graphitization, and N doping to the regulation of electromagnetic parameters, hollow FeCoNi@NCMs exhibit a minimum reflection loss (RLmin) of -53.5dB and an effective absorption bandwidth (EAB) of 2.48GHz in the low-frequency range of 2-8GHz. Furthermore, a filler loading of 20wt% can also be used to achieve a broader EAB of 5.34GHz with a matching thickness of 1.7mm. In brief, this work opens up new avenues for the self-templating engineering of magnetic-dielectric composites for low-frequency microwave absorption.

Development of silk microfiber-reinforced bioink for muscle tissue engineering and in situ printing by a handheld 3D printer

Volumetric muscle loss (VML) presents a significant challenge in tissue engineering due to the irreparable nature of extensive muscle injuries. In this study, we propose a novel approach for VML treatment using a bioink composed of silk microfiber-reinforced silk fibroin (SF) hydrogel. The engineered scaffolds are predesigned to provide structural support and fiber alignment to promote tissue regeneration in situ. We also validated our custom-made handheld 3D printer performance and showcased its potential applications for in situ printing using robotics. The fiber contents of SF and gelatin ink were varied from 1 to 5 %. Silk fibroin microfibers reinforced ink offered increased viscosity of the gel, which enhanced the shape fidelity and mechanical strength of the bulk scaffold. The fiber-reinforced bioink also demonstrated better cell-biomaterial interaction upon printing. The handheld 3D printer enabled the precise and on-demand fabrication of scaffolds directly at the defect site, for personalized and minimally invasive treatment. This innovative approach holds promise for addressing the challenges associated with VML treatment and advancing the field of regenerative medicine.

Experimental investigation on the surface topographical improvement of selective laser melted SS316L using abrasive flow finishing

Selective laser melting (SLM) offers a precise fabrication of intricate geometries that are not achievable with conventional manufacturing processes. However, surface imperfections like adhered powder particles, waviness, and other anomalies impede the intended functional application and demand additional post-processing steps. Abrasive flow finishing (AFF) process is extensively used for enhancing the surface topography of SLM-built parts by reciprocating a viscoelastic polymer abrasive medium. The cost of commercial abrasive media is expensive, needs costlier and heavy equipment, has little tolerability, and releases hazardous gases during its preparation. In this work, a biopolymer-based abrasive media is developed in-house and employed to examine the surface topographical changes of SLM-built SS316L flat features. Compared to commercial abrasive media, the cost of the developed abrasive media is much lower, does not require expensive equipment, and is eco-friendly. The effect of extrusion pressure, number of finishing cycles, and size of the abrasive particles on the percentage change in areal surface roughness (%ΔSa) and waviness (%ΔWa) was studied. From the analysis of variance, irrespective of %ΔSa and %ΔWa, it was found that the number of cycles was the most contributing process parameter, followed by extrusion pressure and abrasive particle size. The optimised process parameters resulted in a maximum %ΔSa and %ΔWa of about 90.1 % and 66.25 %, respectively, from the initial as-built areal surface roughness of 6.6 ± 0.2 μm and areal surface waviness of 7.7 ± 0.4 μm.

Site-Selective Biofunctionalization of 3D Microstructures Via Direct Ink Writing.

Two-photon lithography has revolutionized multi-photon 3D laser printing, enabling precise fabrication of micro- and nanoscale structures. Despite many advancements, challenges still persist, particularly in biofunctionalization of 3D microstructures. This study introduces a novel approach combining two-photon lithography with scanning probe lithography for post-functionalization of 3D microstructures overcoming limitations in achieving spatially controlled biomolecule distribution. The method utilizes a diverse range of biomolecule inks, including phospholipids, and two different proteins, introducing high spatial resolution and distinct functionalization on separate areas of the same microstructure. The surfaces of 3D microstructures are treated using bovine serum albumin and/or 3-(Glycidyloxypropyl)trimethoxysilane (GPTMS) to enhance ink retention. The study further demonstrates different strategies to create binding sites for cells by integrating different biomolecules, showcasing the potential for customized 3D cell microenvironments. Specific cell adhesion onto functionalized 3D microscaffolds is demonstrated, which paves the way for diverse applications in tissue engineering, biointerfacing with electronic devices and biomimetic modeling.

Rationalizing the catalytic surface area of oxygen vacancy‐enriched layered perovskite LaSrCrO4 nanowires on oxygen electrocatalyst for enhanced performance of Li–O2 batteries

AbstractEfficient electrocatalysis at the cathode is crucial to addressing the limited stability and low rate capability of Li−O2 batteries. This study examines the kinetic behavior of Li−O2 batteries utilizing layered perovskite LaSrCrO4 nanowires (NWs) composed of lower oxidation states. Layered perovskite LaSrCrO4 NWs exhibited improved rate capability over a wide range of current densities and longer cycle life in Li−O2 batteries than V‐based layered perovskite (LaSrVO4) and simple perovskite (La0.8Sr0.2CrO3) NWs. X‐ray photoelectron spectroscopy and electrochemical surface area analyses showed that the observed performance variations primarily stemmed from active sites such as oxygen vacancies. In situ Raman analysis showed that these active sites significantly modulate the kinetics of oxygen reduction and evolution, which are related to LiO2 intermediate adsorption. Electrochemical impedance spectroscopy showed that the active sites in layered perovskite LaSrCrO4 NWs contributed to their high charge transfer capability and reduced polarization. This study presents an appealing method for the precise fabrication and analysis of Cr‐based layered perovskites, aimed at achieving highly efficient and stable bifunctional oxygen electrocatalysis.

Enhancing phase modulation and group delay in reflective Huygens metasurfaces via a Fabry-Perot cavity

Huygens metasurfaces exhibit excellent optical properties such as 2π phase modulation and slow light effects. However, they face challenges including wide bandwidth and low group delay due to their high radiation losses. Here, we propose a reflective Huygens metasurface coupled with an F-P cavity. We demonstrate that F-P resonance modes can couple with magnetic-quasi-bound-state (M-QBIC) and electric-quasi-bound-state (E-QBIC) in the Huygens metasurface through constructive interference, significantly enhancing the quality factors of both QBICs. Through structural parameter optimization, our reflective Huygens metasurface achieves 4π phase modulation and a high group delay of up to 166 ps. Compared to the non-coupled Huygens metasurface with the same structural asymmetry, the group delay of the F-P coupled reflective Huygens metasurface is enhanced by up to 30 times. Our design reduces the fabrication precision requirements for Huygens metasurfaces, enabling similar group delays to be achieved in low-symmetry coupling structures as in highly symmetric non-coupling structures. Additionally, the performance of this metasurface shows robustness to changes in incident light polarization. This design highlights the potential for achieving high-quality factors, large phase modulation, and large group delay, offering new avenues for the design of highly sensitive tunable devices, efficient nonlinear optical devices, and narrowband slow light devices.

Fabrication of microchannels on silica glass by femtosecond laser multi-scan: From surface generation mechanism to morphology control

Femtosecond laser processing has become a critical technique for the microfabrication of hard and brittle materials, particularly in microfluidic device applications. This study focuses on the fabrication of microchannels with controllable cross-sectional profiles in silica glass, a material known for its excellent physical and chemical properties. Through a combination of experimental research and theoretical analysis, the surface generation mechanisms governing microchannel morphology are investigated, alongside the influence of various processing parameters on the surface roughness at the microchannel bottom. A comprehensive optimization method is developed to control sidewall taper and surface roughness by adjusting laser scanning paths and modes. Utilizing a composite scanning approach, the study achieves near-rectangular microchannels with average sidewall taper angles below 5° and surface roughness (Sa) of 2.53 μm. These results provide a new strategy for precise control of microchannel morphology in silica glass, offering significant potential to enhance the efficiency and precision of microfluidic device fabrication, with broad applications in both industrial and research settings.

Strategic selection of metal-cutting processes for thick steel plates using a hybrid decision methodology

Metal-cutting is indispensable in manufacturing, enabling precise component fabrication for industries like construction, automotive, aerospace, and shipbuilding, where accurate, efficient cutting of thick steel plates is crucial. This paper introduces a novel case study to strategically determine the optimal metal-cutting process for thick steel plates utilizing a hybrid MOORA-PSI approach. The use of the hybrid MOORA-PSI method simplifies decision-making by integrating weight assignment and ranking of alternatives. Five prominent metal-cutting processes, including oxygen flame, plasma arc, laser, wire EDM (wire electro-discharge machining), and abrasive water jet cutting, are commonly used for cutting thick steel plates, each with unique capabilities and limitations, and are considered potential alternatives. Eight evaluation criteria, capital cost, running cost, accuracy, edge quality, kerf width, maximum thickness, production flexibility, and production rate, are used to assess these metal-cutting alternatives. Wire EDM ranks as the optimal choice for cutting thick steel plates based on defined evaluation criteria, with laser cutting closely trailing, followed by oxygen flame, abrasive water jet, and plasma cutting successively. The results are validated by comparing them with those of other MCDM approaches and by conducting a Spearman’s rank correlation coefficient test, yielding consistent results. Additionally, sensitivity analysis, employing criteria weight exchange and dynamic variations in the decision-making matrix, further confirms the accuracy and reliability of the findings.