Fabrication Technology Research Articles

A Material Design Guideline for Self-assembled Vertically Aligned Nanocomposite Thin Films

Abstract Nanocomposite thin films, comprising two or more distinct materials at nanoscale, have attracted significant research interest considering their potential of integrating multiple functionalities for advanced applications in electronics, energy storage, photonics, photovoltaics, and sensing. Among various fabrication technologies, a one-step pulsed laser deposition (PLD) process enables the self-assembly of materials into vertically aligned nanocomposites (VANs). The demonstrated VAN systems include oxide-oxide, oxide-metal, and nitride-metal VAN films and their growth mechanisms are vastly different. These complexities pose challenges in the designs, materials selection, and prediction of the resulted VAN morphologies and properties. The review examines the key roles that surface energy plays in the VAN growth and provides a generalized materials design guideline combining the two key factors of surface energy and lattice strain / mismatch, along with other factors related to growth kinetics that collectively influence the morphology of VAN films. This review aims to offer valuable guidelines for future material selection and microstructure design in the development of self-assembled VAN films.

Assessing consumer perceptions of sustainable packaging solutions

ABSTRACT Consumer concerns about food and plastic packaging waste have led government and industry to seek alternatives prioritizing the environment while keeping safety, quality, shelf-life, and price. These consumer concerns were examined with a focus on fabrication technologies, current and proposed applications, and consumer acceptance of edible coatings, biodegradable packaging, and nanomaterials. A survey (N = 441) analyzed responses by subpopulations (generation, location, education level, and food-related careers). Consumers prioritize quality (95%), price (83%), and nutritional value (74%), but willingness to consume and pay extra for them varied by generation and location. Younger consumers showed openness to new technologies, indicating an attractive potential niche market for edible coatings. Positive comments highlighted environmental, health, and shelf-life benefits, while concerns include aversion towards new technologies and health risks. Biodegradable packaging is widely accepted, presenting business opportunities to meet sustainable demands, though cost and quality worries remain. Addressing these concerns is crucial for broader adoption.

Bio-inspired cutting tools: Beneficial mechanisms, fabrication technology and coupling design

Bio-inspired cutting tools: Beneficial mechanisms, fabrication technology and coupling design

Layer deposition strategies in FFF technology and their influence on tribological properties

The work focuses on the tribological properties of materials that are not yet fully explored due to their manufacturing technologies. The work focuses on the fabrication of samples produced by Fused Filament Fabrication (FFF) technology and their subsequent testing for abrasive wear. In the second chapter, the thesis deals with an introduction to tribology and a description of all wear occurring on the surfaces of the materials. The aim of the experiment is to compare different coating strategies in FFF technology and their effect on abrasive wear at given process parameters and according to ASTM standardized tests, and then to compare and evaluate the different strategies

Dense integration of chlorocatechols crosslinked polyphenylene sulfide solid-state separator for Li Metal-Free Batteries

Dry electrode film fabrication technology, known for its environmental friendliness and low energy consumption, is recognized as an effective industrial approach for producing highly dense solid-state electrolytes and pore-free separators. It holds promise for applying thin lithium metal and Li metal-free anodes in ultra-high energy density Li-ions batteries. However, the films produced by this method suffer from issues such as poor toughness, low strength, uneven thickness, and difficulties in rewinding, which limit its widespread adoption in the large-scale manufacturing of lithium batteries. In this study, we propose a hydrothermal process to introduce a chlorocatechol-based cross-linker onto the surface of highly crystalline polyphenylene sulfide (PPS) powder. By employing the dry electrode process, a PPS-based solid-state separator (PPS-SSS) is fabricated, featuring a thin profile (18±2 μm), a smoother surface, and a denser structure, significantly enhancing its mechanical properties. Moreover, the dense integration structure and chlorocatechol groups contribute to a higher Li+ transference number and more effectively inhibit the growth of Li dendrites. Li metal-free batteries, constructed with this separator, a Sn-plated Cu 10 μm foil anode, and a thick high-nickel cathode dry electrode, exhibit high discharge areal and specific capacities (5 mAh cm−2 and 200 mAh g−1, respectively) and pouch battery device energy density exceeding 440 Wh kg−1. Impressively, even in the presence of Cu or Fe powder contamination on the CuSn foil anode or cathode, this separator can still achieve uniform electric field distribution and lithium deposition, demonstrating good cycle stability.

Iodine- and Oxygen-Free Sensitization Process for VPD-PbS:IO Detectors

Uncooled lead salt detectors have significant advantages in developing the next generation of infrared detectors with SWaP3 features. Herein, a one-step pure nitrogen (N2) sensitized process is proposed to simplify the fabrication process for a wafer-scale lead sulfide (PbS) film fabricated by a modified low-temperature vapor physical deposition (VPD). A room-temperature peak detectivity of 4 × 1010 Jones is achieved after one-step pure N2 sensitization process carried out for VPD-PbS:IO films, which is comparable to the detectors fabricated from the standard chemical bath deposition (CBD) process. The VPD fabrication technology with an iodine-free sensitization process provides an available route for promoting the commercial application of uncooled infrared detectors.

The possibility of modeling on mannequin using liquid fabric to develop fashion design and displaying it using digital programs (3D)

Abstract With the technological advancements in fashion design and the textile industry, the research explores the integration of three main axes: the formation axis on the mannequin, the liquid fabric axis, and the digital fashion axis. These are interconnected through the establishment of a robust technological infrastructure that enables work in the realms of textile technology and digital transformation in the field of fashion design. Despite these advantages, there are obstacles limiting its full potential. Can this technology be applied to the mannequin in a room with a temperature resembling the human body to safeguard and showcase it using 3D virtual displays? Thus, the research problem emerges, leading to the following question: What is the extent of the possibility of molding the mannequin using liquid fabric to contribute to the development of fashion design and presenting these designs using digital fashion? Its application in the field of fashion design? Since the liquid textile industry is modern in the fashion world, this research aims to study the possibility of using liquid fabric in the development of the fashion industry and formation of mannequin instead of the human body in a way that helps preserve the environment. This is done by conducting an experimental and descriptive study to achieve some liquid texture strategies shaping the mannequin in the fashion design industry and by linking them to digital fashion using the experimental method and the descriptive method to compare and analyze the results. The results were as follows: 1. Obtain multiple and varied creations in the field of fashion design 2. Speed up the design and production of models 3. Save time, effort, and money. 4. Use modern technology in applying the world of virtual fashion with ease, facilitating electronic commerce. 5. Easily recycle liquid fabric after obtaining the raw material of its product into a liquid material that can be re-sprayed and reshaped, thereby preserving the environment from pollution. Keywords: Liquid fabric, Sculpting on the mannequin, Digital fashion.

Advancements in textile techniques for cardiovascular tissue replacement and repair.

In cardiovascular therapeutics, procedures such as heart transplants and coronary artery bypass graft are pivotal. However, an acute shortage of organ donors increases waiting times of patients, which is reflected in negative effects on the outcome for the patient. Post-procedural complications such as thrombotic events and atherosclerotic developments may also have grave clinical implications. To address these challenges, tissue engineering is emerging as a solution, using textile technologies to synthesize biomimetic scaffolds resembling natural tissues. This comprehensive analysis explains methodologies including electrospinning, electrostatic flocking, and advanced textile techniques developed from weaving, knitting, and braiding. These techniques are evaluated in the context of fabricating cardiac patches, vascular graft constructs, stent designs, and state-of-the-art wearable sensors. We also closely examine the interaction of distinct process parameters with the biomechanical and morphological attributes of the resultant scaffolds. The research concludes by combining current findings and recommendations for subsequent investigation.

A Comparative Study of Precision Surface Grinding Using Additively Fabricated Acrylonitrile-Butadiene-Styrene (ABS) Wheels with Continuous and Serrated Working Surfaces.

Nowadays, high requirements imposed by mechanical components make it necessary to develop modern production methods. Additive technologies have been dynamically developing in recent years, showing many advantages associated with the fabrication of elements with complex geometries and structures. One of the areas where the potential of additive technologies is exploited is the rapid tooling sector, which is based on the rapid production of tools and components used in various manufacturing methods. Currently, apart from industrial additive fabrication using metal and plastic powders, desktop and low-cost devices for additive manufacturing are gaining more and more importance in the production of functional elements. This paper presents the experimental results obtained from testing the micro-abrasive acrylonitrile-butadiene-styrene ABS tools fabricated by fused filament fabrication (FFF) technology and reinforced with SD 28/20 diamond grains uniformly distributed on the working surface of the tools after they were made. Precision surface grinding operations of 41Cr4 alloy steel were carried out on a portable five-axis CNC milling machine using wheels with continuous and serrated working surfaces. The tool with a serrated working surface enabled a more efficient material removal and produced a better surface finish. In particular, a low wear rate of both FFF-printed tools was confirmed after all experiments. Promising results were obtained, showing the potential for a wider industrial application of the tested tools.

Perspectives on Recent Developments and Directions in Tissue Engineering and Regenerative Medicine.

This perspective article draws on lessons learned at the 7th TERMIS World Congress held in Seattle, Washington in June 2024. This gathering of prominent researchers and translational scientists in tissue engineering and regenerative medicine (TERM) from around the world provided a forum to consider the impact of tissue engineering and its future directions. New frontiers are considered in the context of global challenges, including clinical translation and recent advances in pediatric tissue engineering, supercritical fluid technology for scaffold fabrication and sterilization, and learning from successful failures in tissue engineering and regenerative medicine. Bench-to-bedside translational strategies, inclusive research strategies, regulatory hurdles, and ethics linked to navigating responsibilities and innovations, are identified as important drivers in the field.

Green Electrochemical Point-of-Care Devices: Transient Materials and Sustainable Fabrication Methods.

The spread of point-of-care (PoC) diagnostic tests using electrochemical sensors poses a significant environmental challenge, especially in limited-resource settings due to the lack of waste management infrastructure. This issue is expected to intensify with the emergence of the Internet of Medical Things (IoMT), necessitating eco-friendly solutions for disposable devices. This review discusses efforts to develop green and sustainable PoC diagnostic devices, clarifying terms like biodegradability and transient electronics. It explores potential transient and biodegradable materials and fabrication technologies, emphasizing sustainable electronics with low-energy consumption and low-carbon footprint techniques, particularly favoring printing methods. The review highlights examples of necessary electronic components containing biodegradable materials for electrochemical PoC devices and discusses their role in device sustainability. Finally, it examines the feasibility of integrating these components and technologies into comprehensive biodegradable PoC devices, addressing the imminent need for eco-friendly solutions in diagnostic testing. This comprehensive discussion serves as a guide for researchers and developers striving to mitigate the environmental impact of PoC testing in the era of IoMT and personalized medicine.

Comparative study of fibers extracted from the stems and roots of the Cameroonian pennissetum purpureum for their applications in compressed earth brick reinforcement and textile engineering

This work focuses on the extraction and experimental characterization of pennisetum purpureum fibers extracted from stems and roots, harvested in the Batié Kingdom, in the West Region of Cameroon. After extracting fibers using the boiling water technique, they are chemically treated to improve their properties and performance and to facilitate their incorporation into various composite materials. For the physical characterizations, it is measured: the absolute and apparent densities, the linear mass, the water absorption rate, and the diameter via the microscope. The mean values of the diameters and the measure of their frequency distributions are calculated, followed by the statistical analysis using the maximum entropy principle, in order to find the most probable diameter necessary for technological applications. For the mechanical properties, only the tensile tests are performed, with the determination of the young modulus of both the stems and roots. The results thus obtained showed that the fibers of the stems have an absolute density of (1.35 g/cm3), a linear mass of (54.6 tex), an apparent density of (0.45 g/cm3), a water content of (12.73%), an absorption rate of (142.46%), a porosity of (65.91%), a mean diameter of (7 mm), an elastic modulus of (3.98 GPa), a tensile strength of value of (1186.59 MPa) and an elongation of 16.17%, while the root fibers have an absolute density of (1.34 g/cm3), a linear mass (16.76 tex), an apparent density of (0.37845 g/cm3), a water content of (12.25%), an absorption rate of (193.16%), a porosity of (71.92%), a diameter of (4 mm), an elastic modulus of (1.55 GPa), a tensile strength of a value of (1960.35 MPa) and an elongation of 60.6%. Thus, the fibers of the stems have good mechanical properties, which make them an appropriate material in several applications, such as the reinforcement of composite materials.

A scoping review of digital fabrication techniques applied to prosthetics & orthotics: Part 2 of 2—orthotics

Introduction: Traditionally, orthosis manufacturing is time and labor-intensive. Digitalization of some of the fabrication process is already ubiquitous, yet extension across device types could reduce the burden of manual labor and advance automation to help unblock access to assistive technologies globally. It seems, however, that appropriately strong evidence is holding this back. This review looks to thoroughly examine the current state of evidence to make this clear. Objectives: To identify gaps in the literature that create barriers to decision-making on either appropriate uptake by clinical teams or setting research directions, by identifying what forms of evidence the current research literature provides to the orthotics community. Study design: Scoping literature review. Methods: A comprehensive search was completed in the following databases: AMED, MEDLINE, EMBASE, Global Health Archive, CINAHL Plus, Cochrane Library, Web of Science, ACM, IEEE, and Engineering Village, resulting in 3487 articles to be screened. Results: After screening, 121 lower limb orthosis, 104 upper limb orthosis, and 30 spinal orthosis articles were included in this review. For some areas such as CAD/CAM-produced insoles and spinal orthoses, the evidence base is strong. For most additive manufacture articles, long-term, larger-scale studies as well as research into training requirements are lacking. Conclusion: The advantages of digital fabrication technology that could streamline orthotic device production in many cases are still blocked by a lack of strong formal evidence, ie large longitudinal studies with a range of evaluation measures. Increased collaboration between clinicians, patient/service users, academia, and industry could be a route to addressing these gaps and creating a better pathway to market for new technologies.

Precision Macroporous Monoliths Made Using High‐Throughput Microfluidic Emulsification

Materials with pore sizes ranging from micrometers to millimeters find use in thermal insulation, acoustics, separation, and energy‐related applications. While several routes have been developed to manufacture such macroporous materials, current fabrication technologies remain limited in either scalability or pore size control. Herein, a scalable microfluidic approach is reported to create macroporous materials with precisely controlled pore sizes from monodisperse emulsion templates. Emulsion droplets produced in a parallelized step emulsification device are assembled by gravity and converted into macroporous monoliths by polymerization and drying. Microstructural analysis and model filtration experiments show that the pore windows of the bulk macroporous material can be tightly controlled and used for the size‐selective separation of particles from suspensions. By heat treating macroporous structures of selected compositions, one can also create bulk carbon and silica glass monoliths with unique cellular architectures for potential applications as filters, separation membranes, or catalyst supports.

Enhancing Thermoelectrical Properties of Silver-Nanowire-Embedded Heatable Textiles via Sputter-Mediated Nanowire Structural Modulation.

This study addresses the fabrication of flexible, heatable fabrics via the integration of globally interconnected silver nanowires (Ag NWs) with sputter-deposited silver atoms. Conventional heatable fabrics, which utilize macroscale or nanoscale conductive wires, often face challenges in balancing flexibility, comfort, and structural durability. The proposed method leverages the advantages of nanoscale metallic wires and vacuum-based sputtering, maintaining fabric flexibility while enhancing heating efficiency. The fabrication process involves dip-coating polyester fabric with Ag NWs, followed by sputter deposition to modulate the nanowire morphology, thereby improving key electrical properties such as wire resistance and contact resistance between wires. The experimental results demonstrate that sputter-deposited Ag NW fabrics exhibit significantly enhanced heating capability compared to undeposited, otherwise identical counterparts. Further, the fabrics maintain their heating characteristics under repeated mechanical bending and prolonged electrical stress, highlighting their potential for use in wearable electronic applications. This approach offers a promising solution to the limitations of current heatable textile technologies, providing a pathway for the development of comfortable, efficient, and durable heatable fabrics.

Metal Acetate-Enhanced Microwave Pyrolysis of Waste Textiles for Efficient Syngas Production

The production of waste textiles has increased rapidly in the past two decades along with the rapid development of the economy, the majority of which has been either landfilled or incinerated, resulting in energy loss and environmental pollution. Microwave pyrolysis, which can transform heterogeneous and complex waste feedstocks into value-added products, is considered one of the most competitive technologies for processing waste textiles. However, achieving selective product formation during the microwave pyrolysis of waste textiles remains a significant challenge. Herein, sodium acetate, potassium acetate, and nickel acetate were introduced into waste textiles through an impregnation method as raw materials to improve the pyrolysis efficiency. The optimized process parameters indicated that nickel acetate had the most favorable promotional effect of the three acetates. Notably, the waste textiles containing 1.0% Ni exhibited the highest gas production rate, with the hydrogen-containing combustible gas reaching 81.1% and 61.0%, respectively. Using X-ray diffraction (XRD), transmission electron microscopy (TEM), Fourier transform infrared spectroscopy (FTIR), and Raman spectroscopy to characterize the waste textiles before and after pyrolysis, it was found that nickel acetate was converted into metallic nickel (Ni0) during microwave pyrolysis. This active site significantly enhanced the pyrolysis process, and as the gas yield increased, the disorder of the resulting pyrolytic carbon also rose. The proposed Ni0-enhanced microwave pyrolysis mediated by nickel acetate offers a novel method for the efficient disposal and simultaneous resource recovery of waste textiles.

Mid-infrared pulsed fiber laser source at 4.3 µm based on a CO2-filled anti-resonant hollow-core silica fiber

Fiber lasers in the mid-infrared (mid-IR) band are of great interest due to their wide range of applications such as manufacturing, defense, spectroscopy, and free-space communication. Due to the immaturity of the soft glass fiber fabrication technology and the limitation of the type of doped rare earth, laser power scaling and wavelength expansion above 4 µm are greatly limited. Lasers based on gas-filled hollow-core fibers (HCFs) have proved to be an effective way of generating mid-IR lasers. We demonstrate a pulsed 4.3 µm laser source based on a CO2-filled HCF for the first time. The pulse energy characteristics and output spectrum of the mid-IR laser have been investigated. The maximum pulse energy of the mid-IR laser is 236 nJ. The maximum average power of the mid-IR laser is 297.8 mW with a slope efficiency of 17.3%. A step-tunable mid-IR output is achieved from 4293.718 nm to 4392.085 nm including 8 emission lines. Furthermore, the time-domain and frequency-domain properties of the mid-IR laser have been studied to understand laser operation better. This work has an important reference value for the development of pulsed mid-IR fiber gas laser sources.

Pattern-Making and Textile Technologies across Asia

Abstract To consider textiles along the trade routes that traverse Asia is to consider materials, technologies, images and ideas: fibres and filaments, dyestuffs, and the technologies of felt-making, weaving, embroidery, carpet-weaving and block-printing. Pattern-making is affected by all of these factors. And the trajectories of designs, repeated to form patterns, bring us to confront changes in meaning over time and space, relating textiles to the history of ideas. Within the breadth of this vast complexity of cultural exchange on multiple levels, this paper offers a brief exploration of two vexing problems. The first concerns origins and cultural diffusion of a warp-resist patterning technique (ikat). The second concerns the origin, development and transmission of drawloom weaving, resulting in the production of compound textiles with repeat patterns from selvedge to selvedge. These overarching questions relate aspects of pattern-making integral to two textile technologies with a view towards stimulating future research.

Some Memory Devices of Early Chinese Textile Technologies and Artisans’ Transmission of Knowledge

Abstract Patterned silks served as signifiers for rituals and status in early China. They were patterned using different techniques, for example, some sha-silks from Mawangdui dated to 168 CE were repeatedly stamped with motifs while other silks were woven with monochrome or polychrome motifs. The technical knowledge for producing such silks was embodied as internal memory in the artisans who predominantly worked in state- run workshops until the mid-first century BCE. Artisans also invented external memory devices to facilitate their work. Some devices – bronze stamps and pattern-shafts on looms – have been unearthed from Guangzhou and Laoguanshan dated to 122 and 118 BCE respectively. Most techniques did not circulate widely, and over time, some disappeared and were then replaced by others. Lacking artisans’ own accounts, this article examines these external memory devices in the workshop context to suggest the hypothesis that the transmission of the embodied knowledge depended on the mobility and freedom of the artisans.

K/Ka‐Band–GaN–High‐Electron‐Mobility Transistors Technology with 700 mS mm−1 Extrinsic Transconductance

In this study, the impacts of fabrication technology and epitaxial layer design on the transconductance (gm) of radio frequency AlGaN/GaN high‐electron‐mobility transistors (HEMTs) are examined. Optimization of the SiNx passivation and AlGaN barrier design of 150 nm gate HEMTs enhances the extrinsic (at Vds = 10 V) and intrinsic (at Vds = 15 V) transconductance from ≈0.47/0.65 to ≈0.62/1.1 S mm−1. Notably, an extrinsic gm of 0.70 S mm−1 at Vds = 5 V is achieved, setting a new benchmark for the extrinsic transconductance of AlGaN/GaN HEMTs designed for the K/Ka frequency range with a breakdown voltage exceeding 100 V.