Reduce Manufacturing Cost Research Articles

IPSC Technology Revolutionizes CAR-T Cell Therapy for Cancer Treatment

Chimeric Antigen Receptor (CAR)-engineered T (CAR-T) cell therapy represents a highly promising modality within the domain of cancer treatment. CAR-T cell therapy has demonstrated notable efficacy in the treatment of hematological malignancies, solid tumors, and various infectious diseases. However, current CAR-T cell therapy is autologous, which presents challenges related to high costs, time-consuming manufacturing processes, and the necessity for careful patient selection. A potential resolution to this restriction could be found by synergizing CAR-T technology with the induced pluripotent stem cell (iPSC) technology. iPSC technology has the inherent capability to furnish an inexhaustible reservoir of T cell resources. Experimental evidence has demonstrated the successful generation of various human CAR-T cells using iPSC technology, showcasing high yield, purity, robustness, and promising tumor-killing efficacy. Importantly, this technology enables the production of clinical-grade CAR-T cells, significantly reducing manufacturing costs and time, and facilitating their use as allogeneic cell therapies to treat multiple cancer patients simultaneously. In this review, we aim to elucidate essential facets of current cancer therapy, delineate its utility, enumerate its advantages and drawbacks, and offer an in-depth evaluation of a novel and pragmatic approach to cancer treatment.

Solution Deposition Planarization as an Alternative to Electro-Mechanical Polishing for HTS Coated-Conducters

Mechanically flexible substrates are increasingly utilized in electronics and advanced energy technologies like solar cells and high-temperature superconducting coated conductors (HTS-CCs). These substrates offer advantages, such as large surface areas and reduced manufacturing costs through reel-to-reel processing, but often lack the surface smoothness needed for optimal performance. For HTS-CCs, specific orientation and high crystalline quality are essential, requiring buffer layers to prepare the amorphous substrate for superconductor deposition. Techniques, such as mechanical polishing, electropolishing, and chemical-mechanical polishing, can help achieve an optimally levelled surface suitable for the subsequent steps of sputtering and ion-beam-assisted deposition (IBAD) necessary for texturing. This review examines Solution Deposition Planarization (SDP) as a cost-effective alternative to traditional electro-mechanical polishing for HTS coated conductors. SDP achieves surface roughness levels below 1 nm through multiple oxide layer coatings, offering reduced production costs. Comparative studies demonstrate planarization efficiencies of up to 20%. Ongoing research aims to enhance SDP’s efficiency for industrial applications in CC production.

Integrated Wearable Flexible Hydrogel Patch Sensing System for the Detection of Physiological Markers.

Conventional wearable flexible sensing systems typically comprise three components: a flexible substrate that contacts the skin, a signal processing module, and a signal output module. These components function relatively independently, resulting in a complex system that lacks sufficient integration. Therefore, developing an integrated wearable flexible sensing system by combining the flexible substrate, the signal processing module, and the signal output module not only enhances performance and comfort, but also reduces manufacturing costs and the risk of failure. Hydrogel substrates are particularly advantageous due to their excellent biocompatibility, flexibility, and encapsulation capabilities. Herein, we designed an integrated wearable flexible sensing system using an agarose hydrogel to encapsulate biological oxidative enzymes (e.g., glucose oxidase (GOx), lactate oxidase, and ethanol oxidase) and silver nanowires-polydopamine (Ag NWs-PB) as the signal processing module and a color-changing TMB probe as the signal output module. Additionally, we incorporated a polydimethylsiloxane-silicon dioxide patch to collect sweat for detecting physiological markers (e.g., glucose, lactate, and ethanol). An example of the application to facilitate visual detection of glucose in sweat was developed by encapsulating GOx as a biological oxidative enzyme in a sensing system. The system provides results within 3.5 min and operates within a linear range of 0.02 to 5.00 mmol/L, achieving a limit of detection of 0.011 mmol/L. This innovation not only presents a more integrated and portable solution for wearable hydrogel systems, but also introduces a new, feasible method for detecting human physiological markers through a straightforward detection process.

Reference model for the development of prototypes based on C-K theory

Developing prototypes for new products or processes requires interdisciplinary knowledge and complex management. Early-stage development promotes creative thinking and innovation, offering companies significant advantages. The C-K Theory formalises creative thinking by integrating the independent spaces of concepts (C) and knowledge (K), which are independent and present different logical structures. This work proposes a reference model for engineering prototype development based on C-K Theory, utilising Design Science Research methodology. The process began with an initial phase of literature analysis, followed by the proposal of the model, and concluded with its evaluation. The method was evaluated through its use in two different real industrial cases. The results were qualitative in nature, but the method helped define project phases, team roles and design objectives, fostering creativity and knowledge generation. The method leveraged existing knowledge in one case and focused on a new baseboard configuration in the other, resulting in significant cost reductions and accelerated project delivery. The method reduced manufacturing costs, improved design accuracy and minimised delays. However, it requires advanced participant expertise and is less structured than traditional methods. We conclude that the method is user-friendly, aids systematic project development, and enhances knowledge management by recording and correlating information.

Monte Carlo Analysis and Optimization of Inertial Switch Tolerance of a Proximity Fuze

Abstract Aiming at the low operation rate of the firing mechanism of ammunition fuze, robustness analysis and probabilistic design methods were introduced into the fuze design to carry out system simulation research on performance prediction and optimization of the firing mechanism of ammunition fuze. In this paper, the dynamic model of the inertial impact switch of a proximity fuze is established, and the mechanism can be reliably triggered under nominal values by simulation method. Based on the Monte Carlo simulation of dimensional tolerance distribution, the trigger performance is evaluated. The contribution rate of each dimension variable to the target value is obtained by using the optimal Latin hypercube experiment design, and the variable tolerance with greater contribution rate is optimized by Pointer algorithm. After optimization, the range of variable Jdxh_f was optimized from 0.1274 to 0.1666 to 0.1274 to 0.1556. Finally, the optimized results were validated, with a uniform distribution yielding 0.003193517N, a bimodal distribution yielding 0.2230769N, and a normal distribution yielding 0.2778532N. The validation analysis of these results shows that the target value distribution data after optimization meets the design requirements. This study seeks a balance between performance reliability and manufacturing cost, which is of great significance to improve product performance and reduce manufacturing cost.

Exploring the Potential of Cadmium Selenide Nanowires-Based Chalcogenide Devices for Photoelectrochemical Hydrogen Production

Hydrogen, as a clean fuel and vital industrial chemical, plays a pivotal role in our sustainable energy future, particularly in applications such as the fertilizer and steel industry. To meet the growing demand for renewable hydrogen production, our work focuses on the potential of photoelectrochemical (PEC) water splitting technology. The commercialization of PEC hydrogen production hinges on significant advancements in three key areas: (a) improving solar-to-hydrogen (STH) conversion efficiency, (b) reducing manufacturing costs, and (c) enhancing device durability. Technoeconomic analysis highlights high efficiency as a critical metric, but current triple-junction III-V devices, despite achieving >20% STH, suffer from low durability and high costs. Conversely, single junction oxide materials offer stability and low cost but limited STH performance. Recently, dual-junction tandem PEC devices, configured with a buried photovoltaic-electrocatalyst (PV-EC) architecture, have emerged as promising solutions. This approach integrates semiconducting PV materials beneath an electrocatalyst layer with or without a protective encapsulant, improving overall efficiency and stability. The selection of an appropriate dual-junction PEC device centers on achieving a high voltage (VOC > 1.6 V) with substantial current density (JSC > 10 mA/cm²), minimizing additional power losses due to catalysts and membranes. Within this context, cadmium-based chalcogenides, especially cadmium selenide (CdSe) nanowires and cadmium telluride (CdTe) nanowires, hold promise as top and bottom cell candidates. Although Cd-chalcogenides have made significant strides in the PV industry, their application in PEC hydrogen production remains underdeveloped, particularly concerning their integration with electrocatalysts for stable and efficient solar hydrogen production. This talk will address how we mitigate this gap by developing novel device architectures for fault-tolerant CdSe-based PEC devices, demonstrating their manufacturability at various scales i.e. from lab scale to wafer-scale, and finally, the talk will cover the application of electrodeposited cadmium selenide nanowires and investigating their performance in solar water splitting when interfaced with suitable catalysts within the buried PV-EC architecture.

(Invited) Highly Stable Metal-Oxide Thin-Film-Transistors and Circuits for Large-Area Flexible and Stretchable Electronics

Thin-film transistors (TFTs) have been considered as an essential component in modern sensory and displays due to their unique electrical properties for pixel and circuit applications, as well as their compatibility with low-cost manufacturing and large-area substrates. As the thin-film electronics have rapidly advanced toward much complex functionality along with higher resolutions and refresh rates, especially with the emergence of area-scalable wide form factors such as large-area foldable and stretchable displays, the features and materials of the TFT devices must evolve to meet these demands. Metal-oxide (MO) TFTs have emerged as a promising platform to facilitate the evolution of electronic products in terms of uniformity, conformability, and reduced manufacturing costs, while enabling large-area electronics on flexible and stretchable substrates due to their cost-effective fabrication and high uniformity.However, despite these advances expanding the potential applications of MO TFTs, implementing highly robust flexible/stretchable MO TFTs with good electrical performance remains somewhat challenging. In this presentation, recent technologies 1- 4 for the structural and material approaches to achieve robust and stable high-form factor MO TFTs are introduced. Additionally, the envision and outlook for more versatile strategy to advance the development of commercial-level high-form factor electronics will be fully discussed.References Kim, Y.-H and S. K. Park. et al. Flexible metal-oxide devices made by room-temperature photochemical activation of sol-gel films. Nature .. 2012 , 489, -W Jo, J. K. Kim, K.-T. Kim, J.-G. Kang, M.-G. Kim, K.-H. Kim, H. Ko, Y.-H. Kim, and S. K. Park, “Highly stable and imperceptible electronics utilizing photo-activated heterogeneous sol-gel metal-oxide dielectrics and semiconductors”, Advanced Materials , 2015, 27, 1182T. Kim, S. Moon, M. Kim, J.-W. Jo, C. Y. Park, S. H. Kang, Y.-H. Kim, and S. K. Park, “Highly scalable and robust mesa-island structure metal-oxide thin-film-transistors and integrated circuits enabled by stress-diffusive manipulation”, Advanced Materials , 2020, 32, 2003276. H. Kang, J. -W. Jo, J. M. Lee, Y.-H. Kim, J.-W. Kim, S. K. Park, “Full integration of highly stretchable inorganic transistors and circuits within molecular-tailored elastic substrates on a large scale” Nature Communications , 2024, 15, 2814

High Performance of Anion Exchange Membrane Fuel Cells By Introducing Hydrophobic Carbon Nanotube Diffusion Layer

In recent years, anion exchange membrane fuel cells have garnered significant attention due to their ability to utilize low platinum group metal catalysts, thereby reducing manufacturing costs. In contrast to proton exchange membrane fuel cells, anion exchange membrane fuel cells have a distinctive operational characteristic where they produce water at the anode electrode while consuming water on the cathode electrode. The primary challenge hindering their advancement is managing water, specifically addressing the uneven distribution of water between the anode and cathode. As one of the crucial components of the fuel cell, the gas diffusion layer conducts electrons from the catalytic layer to the bipolar plate, transports reaction gases to the catalytic layer for electrochemical reactions, and removes excess water and waste heat generated on the anode electrode. Carbon nanotubes have high specific surface area, superior electrical conductivity, excellent mechanical properties, and inherent hydrophobicity due to their high degree of graphitization, and are considered to be promising materials for optimizing mass transport within gas diffusion layers. Abundant carbon nanotubes are synthesized in situ on carbon fibers to create a three-dimensional network structure, which not only provides more attachment sites for catalytic particles but also facilitates the electron flow path by interlacing carbon nanotubes within the catalytic layer.In this work, the iron-cobalt catalyst was uniformly sprayed onto the gas diffusion substrate through ultrasonic spraying technology. The carbon source atmosphere was ionized and deposited under plasma radio frequency to synthesize abundant carbon nanotubes in the radial direction of the carbon fibers. Contact angle measurements revealed that the carbon nanotube-modified gas diffusion layer exhibited an approximate contact angle of 145°, which was significantly greater than that of the commercial gas diffusion media. Experimental research results indicated that, under various lower relative humidity conditions, when the cathode and anode inlet flow rates were set at 0.3 L/min and 0.5 L/min, respectively, the peak power generated by the membrane electrode assembled with the carbon nanotube-modified gas diffusion layer reached 988.9 mW/cm². This represents a substantial 27.1% increase compared to the performance achieved using the commercial gas diffusion layer. Upon further increasing the cathode and anode inlet flow rates to 0.6 L/min and 1 L/min, respectively, and operating under different higher relative humidity conditions, the membrane electrode assembled with the carbon nanotube-modified gas diffusion layer exhibited a peak power of 1031.7 mW/cm². In stark contrast, the commercial gas diffusion layer achieved only 760.6 mW/cm² under similar conditions. Through equivalent circuit and electrochemical impedance test analysis, it can be seen that the carbon nanotube-modified gas diffusion layer can effectively improve concentration polarization loss and ohmic polarization loss.

Advancing Lithium-Ion Battery Manufacturing Sustainability through Microstructural Analysis of Composite Cathodes

To accelerate electric vehicle (EV) adoption and mitigate transportation emissions, lithium-ion battery (LIB) energy density and rate capability must be improved, advancing EV range and charging speed, respectively. The composite cathode is a major driver of these performance metrics, as its microstructure governs the flow of ions and electrons.1 Intentionally engineering cathode microstructure for efficient ionic transport will enable fast charging, thick cathodes for increased cell energy density. Here, while focusing our efforts on cathode design, we have the opportunity to prioritize sustainable manufacturing. We utilize our understanding of the slurry-cast cathode microstructure to facilitate the transition to solvent-free cathodes. Solvent-free cathode manufacturing promises advancements in performance, environmental safety, and economics, including increased cell energy density and reduced process toxicity, energy consumption and capital costs.2 In this presentation, I will first address relationships we have uncovered between slurry-cast cathode microstructure and resulting battery performance. We use a combination of small-angle neutron scattering (SANS), plasma focused ion beam scanning electron microscopy (PFIB-SEM), and electrochemical impedance spectroscopy (EIS) to elucidate the cathode microstructure in both dry and wet states, at the nanoscale, and over representative volumes. Using SANS, we see an expansion of carbon-binder domain (CBD) microstructure in the wet state and after calendaring. Further, we can deconvolute polymer binder and carbon black surface areas, allowing us to relate a decline in cycling performance to increased electrolyte-accessible carbon black in the CBD. We use these findings to inform the design of cathode microstructure for improved cycling stability.Next, I will discuss how we apply our understanding of slurry-cast microstructures to dry-processed cathodes. The performance principles of dry-processed microstructures remain the same: they must efficiently conduct both lithium ions and electrons. However, the dry microstructure is vastly different than that of slurry-cast cathodes, and thus even less understood. We fabricate dry electrodes via the formation of binder fibers under applied shear, creating matrix with carbon fibers to support the active material particles. Utilizing binder fibers allows us to decrease the mass fraction of binder and increase the thickness of the cathode, increasing cell energy density. We apply the tools discussed here to understand the distinct dry microstructure and its impact on performance. Gaining a nanoscale understanding of both slurry-cast and dry-processed systems allows us to compare fundamental transport processes across various microstructures and manufacturing processes, informing future cathode design while advancing sustainability and reducing manufacturing cost.

(Invited) Mechanisms Governing Lithium Metal and Alloy Anodes in Solid-State Batteries

Solid-state batteries offer the promise of improved energy density and safety compared to lithium-ion batteries, but electro-chemo-mechanical evolution and degradation of materials and interfaces can play an outsized role in limiting their performance. Here, I will present my group’s recent work on understanding structural evolution, interfacial dynamics, and chemo-mechanics in solid-state batteries with both lithium metal and alloy-based anodes. Lithium metal batteries are especially beneficial if used in an “anode-free” configuration in which there is no lithium initially present at the anode current collector. Using X-ray tomography, cryo-FIB, and finite-element modeling, we show that lithium metal anode-free solid-state batteries are intrinsically limited by current concentrations at the end of stripping due to localized lithium depletion. This causes accelerated short circuiting compared to lithium-excess cells. Based on these results, the beneficial influence of metal alloy interfacial layers on controlling lithium evolution and mitigating contact loss from localized lithium depletion will be introduced and discussed. In the second part of the talk, the characteristics of dense, foil-based alloy anodes are introduced. Alloy foils such as aluminum and tin are shown to exhibit improved interfacial stability and better long-term cycling in solid-state batteries compared to liquid-cell batteries due to reduced solid-electrolyte interphase formation. A new design for multiphase aluminum foil alloy anodes is introduced, in which microstructural control over the foil is shown to play a key role in significantly improving reversibility in solid-state batteries. This anode design mitigates chemo-mechanical degradation and offers a paradigm that does away with slurry coating, potentially reducing manufacturing costs. The influence of stack pressure on electrode evolution is investigated. Taken together, these findings show the promise of both lithium metal and alloy anodes for solid-state batteries, with divergent reaction mechanisms giving rise to different operating conditions necessary for each class of materials.

Insights into Crystallography and Electrochemical Performance of Doped Li-Rich Layered Oxides for Lithium-Ion Batteries

The development of new materials is imperative to meet the growing demand for systems delivering higher capacity, energy density, cycle life stability, and safety. Lithium-Rich Layered Oxides (LRLOs) are at the forefront of enabling high-capacity and high energy density positive electrodes for Lithium-Ion Batteries, addressing the challenges of green and safe transportation and sustainable stationary energy storage from renewable sources [1]. LRLOs, with the general formula Li1+xTM1-xO2 (where TM represents a blend of transition metals such as Mn, Co, Ni...), belong to the layered material family but their crystal structure remains elusive [2]. On the other hand, they exhibit excellent reversible performance in aprotic lithium-metal and lithium-ion batteries over numerous charge/discharge cycles. Their higher specific capacity compared to commercial cathodes can be attributed to cumulative cationic and anionic redox processes, wherein anionic redox reactions involve lattice oxygen, balancing lithium extraction with the activation of the O2-/O- redox couple. However, inadequate cycle life stability and capacity retention hinder their commercial adoption, owing to structural rearrangements and phase transitions upon cycling. Moreover, reducing costs and toxicity of raw materials such as cobalt is crucial for large-scale production [3].In this communication, we elucidate the significant influence of extensive defectivity on the description of LRLOs crystal structure. Specifically, we illustrate how the utilization of supercells or defects (antisite defects, stacking faults ...) contribute to a more accurate structural description. Additionally, doping strategies were used to enhance the electrochemical behavior and mitigate the structural rearrangements. Our findings showcase optimized layered materials boasting exceptional electrochemical performance, enhanced environmental compatibility, and reduced manufacturing costs relative to the current state-of-the-art.

(Invited) Investigation of Co-Free Cathode Composited with Proton Conductors for Protonic Ceramic Fuel Cells with Yb-Doped BaZrO3 Electrolyte

Protonic ceramic fuel cells (PCFCs) are expected to gain significant advantage from the use of Co-free cathodes. This shift can lead to reduced manufacturing costs and enhance durability performance. In our previous study, the investigation compared the power generation characteristics of PCFCs with BaZr0.8Yb0.2O3-δ (BZYb) electrolytes utilizing cathodes composed of La0.6Sr0.4FeO3-δ (LSF) as a Co-free cathode material and La0.6Sr0.4CoO3-δ (LSC) or La0.6Sr0.4Co0.2Fe0.8O3-δ (LSCF) as Co-containing cathode materials composited with BZYb. Consequently, the PCFC with an LSF-BZYb cathode exhibited lower performance compared to the PCFCs with LSC-BZYb and LSCF-BZYb cathodes due to the higher electrode polarization resistance.In this study, the challenges associated with achieving high-performance Co-free cathodes that can match the performance of Co-containing cathodes are presented, along with the mechanism to enhance performance. To improve performance, the use of La0.65Ca0.35FeO3-δ (LCaF), as a Co-free cathode, in addition to LSF, which has been reported to demonstrate high performance in SOFCs, was explored. Additionally, LCaF was composited with BaCe0.7Zr0.1Y0.1Yb0.1O3-δ (BCZYYb), known for its higher proton conductivity and easier sinterability than BZYb.When comparing the power generation characteristics of PCFCs with LCaF-BZYb and LSF-BZYb cathodes, the PCFC with LCaF-BZYb cathode exhibited higher ohmic and electrode polarization resistances. These results were attributed to weak adhesion between the electrolyte and cathode, resulting in lower performance than the PCFC with LSF-BZYb cathode.Furthermore, when comparing the power generation characteristic of the PCFC with a composite cathode of LCaF and BCZYYb with the LCaF-BZYb cathode, the ohmic and electrode polarization resistances were significantly lower. This improvement was attributed to the advanced sintering of BCZYYb and the connected percolation of the proton-conducting network. Consequently, the performance of the PCFC with the LCaF-BCZYYb cathode surpassed that of the LCaF-BZYb cathode and was comparable to Co-containing cathodes such as LSC-BCZYYb cathode.In conclusion, for Co-free cathodes in PCFCs, it is crucial to composite them with proton conductors possessing better sinterability, such as BCZYYb, to achieve higher performance.Acknowledgements: This work is based on the results obtained from a project (JPNP20003) commissioned by the New Energy and Industrial Technology Development Organization (NEDO), Japan.

Influence of Microwave Drying on Electrochemical Performance and Morphology of Cathode Catalyst Layers for PEM Fuel Cells

Due to an increasing demand for sustainable energy, the polymer electrolyte membrane fuel cell (PEMFC) and electrolyzer (PEMEL) are considered as a key technology in energy conversion transformation towards climate neutral energy economy. The performance characteristics of a PEMFC is significantly influenced by the microstructure of the catalyst layer, which is formed predominantly during the drying step in the manufacturing process.In order to improve the performance of PEMFC and hence reducing production costs, research effort has increasingly focused on the drying process. Moreover, energy efficiency of the drying step is considered one of the key driver for manufacturing cost reduction during the mass-market introduction of PEM fuel cells and electrolyzers due to increasing energy costs and the need for reduction of environmental impact.In the presented work, a drying process for thin-film catalyst layers by making use of microwave radiation is addressed. Drying is performed by exposing the wet film to microwave radiation, leading to a more energy-efficient heat transfer into the wet film compared to conventional convective or infrared-based drying techniques. The dried catalyst layer is subsequently transferred to a polymer electrolyte membrane in a hot-pressing step and is completed with gas diffusion layers to a membrane electrode assembly (MEA). Electrochemical performance of the MEA is characterized on a fuel cell test bench in single cell configuration. The morphology of the structure obtained from microwave drying is analyzed and compared to samples dried in a conventional convective oven.Although in the microwave drying process at lab scale, an increased tendency to crack formation due to faster drying rate was found , electrochemical performance of the MEAs are comparable to conventionally dried samples. A significant influence of applied pressure during the hot-pressing transfer step on cathode morphology was observed and is discussed with regard to electrochemical performance of the cathode catalyst layers, with a focus on performance in the high current density range.A Systematic investigation of the electrochemical behavior of the MEA is performed by application of protonic conduction measurements and electrochemical impedance spectroscopy. The pore morphology of cathode catalyst layers, investigated by mercury intrusion porosimetry, is discussed with regard to preparation conditions and electrochemical performance.

Isolation and characterization of DNA aptamers against the HlyE antigen of Salmonella Typhi

Aptamers have emerged as prominent ligands in clinical diagnostics because they provide various advantages over antibodies, such as quicker generation time, reduced manufacturing costs, minimal batch-to-batch variability, greater modifiability, and improved thermal stability. In the present study, we isolated and characterized DNA aptamers that can specifically bind to the hemolysin E (HlyE) antigen of Salmonella Typhi for future development of typhoid diagnostic tests. The DNA aptamers against Salmonella Typhi HlyE were isolated using systematic evolution of ligands by exponential enrichment (SELEX), and their binding affinity and specificity were assessed utilizing enzyme-linked oligonucleotide assay (ELONA). A total of 11 distinct aptamers were identified, and the binding affinities and species selectivities of the three most probable aptamers were determined. Kd values were obtained in the nanomolar range, with the highest affinity of 83.6 nM determined for AptHlyE97. In addition, AptHlyE11, AptHlyE45 and AptHlyE97 clearly distinguished S. Typhi HlyE from other tested bacteria, such as Salmonella Paratyphi A, Salmonella Paratyphi B, Shigella flexneri, Klebsiella pneumonia and Escherichia coli, therefore displaying desirable specificity. These novel aptamers could be used as diagnostic ligands for the future development of inexpensive and effective point-of-care tests for typhoid surveillance, especially in developing countries of the tropics and subtropics.

Study on Surface Quality Analysis of an Uncoated Boron Steel and Its Oxide Layer Suppression Method for Hot Stamping.

This study investigates the effects of hot stamping on boron steel surface properties, comparing uncoated steel to Al-Si-coated steel, with a focus on developing atmosphere-controlled hot stamping technology. Experiments using a hat-shaped specimen revealed that uncoated steel formed a thick oxide layer due to exposure to atmospheric oxygen at high temperatures, negatively impacting surface quality and weldability. In contrast, the Al-Si-coated steel showed no oxide formation. Although uncoated steel exhibited higher average Vickers hardness, the detrimental effects of the oxide layer on weld quality necessitate advancements in process technology. A lab-scale hot stamping simulator was developed to control atmospheric oxygen levels, utilizing a donut-shaped induction heating coil to heat the material above 1000 °C, followed by rapid cooling in a forming die. Results demonstrated that maintaining oxygen concentrations below 6% significantly reduced oxide layer thickness, with near-vacuum conditions eliminating oxide formation altogether. These findings emphasize the critical role of oxygen control in enhancing the surface quality and weldability of uncoated boron steel for ultra-high-strength automotive applications, potentially reducing manufacturing costs while ensuring part performance.

Literacy Deep Reinforcement Learning-Based Federated Digital Twin Scheduling for the Software-Defined Factory

As user requirements become increasingly complex, the demand for product personalization is growing, but traditional hardware-centric production relies on fixed procedures that lack the flexibility to support diverse requirements. Although bespoke manufacturing has been introduced, it provides users with only a few standardized options, limiting its ability to meet a wide range of needs. To address this issue, a new manufacturing concept called the software-defined factory has emerged. It is an autonomous manufacturing system that provides reconfigurable manufacturing services to produce tailored products. Reinforcement learning has been suggested for flexible scheduling to satisfy user requirements. However, fixed rule-based methods struggle to accommodate conflicting needs. This study proposes a novel federated digital twin scheduling that combines large language models and deep reinforcement learning algorithms to meet diverse user requirements in the software-defined factory. The large language model-based literacy module analyzes requirements in natural language and assigns weights to digital twin attributes to achieve highly relevant KPIs, which are used to guide scheduling decisions. The deep reinforcement learning-based scheduling module optimizes scheduling by selecting the job and machine with the maximum reward. Different types of user requirements, such as reducing manufacturing costs and improving productivity, are input and evaluated by comparing the flow-shop scheduling with job-shop scheduling based on reinforcement learning. Experimental results indicate that in requirement case 1 (the manufacturing cost), the proposed method outperforms flow-shop scheduling by up to 14.9% and job-shop scheduling by 5.6%. For requirement case 2 (productivity), it exceeds the flow-shop method by up to 13.4% and the job-shop baseline by 7.2%. The results confirm that the literacy DRL scheduling proposed in this paper can handle the individual characteristics of requirements.

Effect of chromium doping on the grain boundary character of WC-Co

The life of cutting tool inserts is critically important for efficient machining, reducing manufacturing cost, embedded energy, and enabling more complex parts to be machined. For these applications, cemented carbide (WC-Co) materials are a prime candidate. The performance of these materials can be limited by early fracture, typically via an intergranular fracture path with respect to carbide grains. This motivates further studies to understand the character of the grain boundary network so that grain boundary engineering (GBE) of WC-Co tools can be used to improve tool life and performance. In this work, we have used Rohrer et al.'s five-parameter grain boundary character distribution (GBCD) analysis to examine the grain boundary network of WC-10wt%Co and WC-10wt%Co-1wt%Cr samples (Rohrer et al., 2004a [1]). It was found that the measured area fraction of the Σ2 boundaries was comparable to the values reported in the literature despite the relatively larger grain sizes (∼14 μm) and higher cobalt contents. The result suggests that chromium doping increases the area fraction of Σ2 boundaries from 12.8 % to 14.8 %. It is proposed that this is a consequence of altering the Σ2 boundary energy, as associated with adding chromium.

Exploring popped-out phenomena in large-scale silicon ingot growth

Silicon wafers are essential for the semiconductor industry, providing the foundation for most integrated circuits. As demand for microelectronics grows, larger silicon wafers, have become crucial for increasing chip production and reducing manufacturing costs. However, the crystal separation phase during Czochralski (CZ) ingot growth is particularly challenging for larger ingots, often resulting in defects due to premature detachment (“popped-out” tails). This study investigates the popping-out stage of 18-inch ingots under varying heater power and ingot pull-out speed conditions. Photoluminescence (PL) imaging and a convolutional neural network (CNN) were used to analyze dislocation density in the silicon wafers. Results show that increasing the pull-out speed after detachment can significantly increase dislocation density, while pausing the ingot near the melt surface minimizes dislocations. Additionally, increasing heater power after detachment reduces dislocation density. The optimal condition for minimizing dislocation was found when heater power was doubled, and the ingot was paused near the melt surface for 30 min.

Cost and Time Reduction of Industrial Mold Design and Manufacturing by Implementing Additive Manufacturing for Premature Neonatal Prong.

For a long time, molding was one of the most important methods of producing metal, ceramic, and polymer materials. The two essential factors in this method were always cost and time. Technology advancements have made it possible to design in 3D using a computer and additive manufacturing. This article covers methods for using 3D printers to save time and money in the process of creating the final product. The "Prong" molds for premature neonatal respiratory aid were designed and produced based on neonatologists' considerations. The study was conducted on fifteen very low birth neonates at Alzahra Hospital in Tabriz University from September 2017 to September 2019. In the first section, we described dental plaster material for molding. When using this material, the printing material must be selected and the parameters, like melting temperature and printer speed, must be controlled to achieve acceptable quality for the final sample. CAD software can be used to print various objects if the final 3D design is appropriate. We used additive manufacturing technology to create a new design and successfully resolved bubble issues at a low cost through a combination of creativity and experimentation. The new mold has cavities that allow the silicon to occupy the entire space and escape any bubbles. The use of 3D printers allows us to achieve the best design for the prong mold while reducing both production costs and time. The ultimate mold made of aluminum was finally produced by the CNC machine. The final product was tested at Al-Zahra Hospital in Tabriz, Iran, and the results were satisfactory, with no reports of necrosis on the babies' noses.

Comparative evaluation of vat photopolymerization and steel tool molds on the performance of injection molded and overmolded tensile specimens

AbstractThis study explores the use of vat polymerization stereolithography (SLA) for fabricating mold tooling, subsequently utilized in injection molding (IM) and overmolding of tensile specimens and directly compared to those produced using metal molds. The results first find the manufacturing time for an SLA‐fabricated mold is remarkably short, approximately 6 h, presenting a substantial improvement over traditional methods. Mechanical testing revealed that the tensile specimens from the SLA‐fabricated molds exhibited the highest tensile strength among all overmolding batches. This performance was consistent with the tensile bars produced using metal molds, demonstrating the viability of SLA‐fabricated molds for overmolding applications and highlighting the potential of FDM to customize the properties of final products. However, variations in mold types impacted the dimensional tolerance and tensile strength of the final specimens. Metal mold‐fabricated tensile bars exhibited superior dimensional accuracy and maximum tensile strength (50.6–61.7 MPa) compared to those produced with SLA‐fabricated molds (46.9–55.9 MPa). These differences are attributed to the rougher surface finish inherent to the layer‐by‐layer construction of SLA and the internal stresses and defects resulting from lower thermal conductivity and uneven cooling. In conclusion, this study underscores the promising future applications of SLA‐fabricated molds in overmolding, offering reduced manufacturing costs and enhanced design freedom. The findings support the potential of SLA to revolutionize mold fabrication, thereby extending its utility and optimizing the production of polymer components with customized properties.Highlights SLA molds compared to metal molds for direct injection molding and overmolding. FFF preforms with varied geometries were overmolded to finalize the specimens. Joint configurations in overmolding improved tensile performance. Overmolding showed better dimensional accuracy than FFF specimens. SLA mold preparation significantly reduced manufacturing costs.