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Designs
Volume 10
Issue 3
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Designs, Volume 10, Issue 3 (June 2026) – 21 articles

Cover Story (view full-size image): This review highlights how additive manufacturing can support the design of smart and nature-based construction systems. By combining bibliometric mapping of 103 peer-reviewed publications with qualitative synthesis, the study shows that 3D printing is more than a fabrication method: it is a complementary design capability that can be used for rapid prototyping, customization, visualization, and stakeholder-informed decision-making. The paper also identifies emerging links between smart cities, sustainability, circular economy strategies, and urban planning, while acknowledging key challenges related to scalability, regulation, and integration into construction workflows. View this paper
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27 pages, 6405 KB  
Article
System Design of a Low-Power BLE Smart Label SoC with Dynamic E-Paper for QR Rendering and Temperature Sensing
by Luis Miguel Pires, Ruben Azevedo and Filipa Pires
Designs 2026, 10(3), 65; https://doi.org/10.3390/designs10030065 - 22 Jun 2026
Viewed by 380
Abstract
Smart labels are emerging as a key enabling technology for product traceability, environmental monitoring, and user interaction within Internet of Things (IoT) ecosystems. This work presents the design and experimental validation of a low-power smart label platform integrating Bluetooth Low Energy (BLE) communication, [...] Read more.
Smart labels are emerging as a key enabling technology for product traceability, environmental monitoring, and user interaction within Internet of Things (IoT) ecosystems. This work presents the design and experimental validation of a low-power smart label platform integrating Bluetooth Low Energy (BLE) communication, temperature sensing, and dynamic e-paper visualization based on the HY0020 System-on-Chip (SoC). This platform was implemented on a custom Printed Circuit Board (PCB) designed around a 1.02-inch monochrome e-paper display and incorporates a TXS0108E interface to support reliable display communication. The developed prototype enables wireless user interaction, dynamic QR code rendering, and ambient temperature monitoring while maintaining low average power consumption. Experimental evaluation included BLE communication testing, display operation validation, temperature monitoring assessment using the integrated HY0020 sensor, and energy consumption characterization. Experimental results confirmed reliable BLE connectivity, stable temperature monitoring performance under normal environmental conditions, and an estimated battery lifetime of approximately 54 days under the evaluated operating profile. The presented platform demonstrates the feasibility of integrating sensing, wireless communication, and electrophoretic display technology within a compact battery-powered smart label device. The proposed architecture provides a practical proof-of-concept foundation for future applications involving product traceability, digital information management, and Digital Product Passport (DPP)-oriented services. Full article
(This article belongs to the Special Issue RFID and Applications of RF/Microwave Circuits and Systems)
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33 pages, 32776 KB  
Article
Optimization and Material Enhancement Framework for Improving PSC Motor Efficiency Toward IE2/IE3 Standards
by Wanwinit Wijittemee, Ritthichai Ratchapan, Charnon Chupong, Somchai Biansoongnern, Sirichai Dangeam, Theerapol Muankhaw and Boonyang Plangklang
Designs 2026, 10(3), 64; https://doi.org/10.3390/designs10030064 - 11 Jun 2026
Viewed by 665
Abstract
This paper presented an optimization and material enhancement framework for improving the efficiency of a 1 HP Permanent Split Capacitor (PSC) motor toward IE2/IE3 efficiency classes. The proposed approach integrated Design of Experiments (DOE) using the Taguchi method with loss-based analysis to investigate [...] Read more.
This paper presented an optimization and material enhancement framework for improving the efficiency of a 1 HP Permanent Split Capacitor (PSC) motor toward IE2/IE3 efficiency classes. The proposed approach integrated Design of Experiments (DOE) using the Taguchi method with loss-based analysis to investigate the influence of key design parameters, including stator stack height, capacitor value, and silicon steel grade on PSC motor efficiency. Taguchi L8 and L9 orthogonal arrays were applied to evaluate parameter interactions and identify dominant factors affecting motor performance. To enhance predictive capability, a Response Surface Methodology (RSM) model was developed based on experimental data to establish the relationship between design variables and motor efficiency within the investigated operating range. The resulting efficiency map was used to identify high-efficiency operating regions and support practical PSC motor design evaluation. Experimental validation under multi-load operating conditions confirmed that the optimized motor achieved an efficiency improvement from 76.1% to 80.4% (4.6% absolute increase), with less than 2% deviation between simulation and experimental results. The optimized motor also demonstrated improved operating behavior across varying speed and load conditions while maintaining practical operating stability. The proposed framework provided a practical and simplified approach for PSC motor efficiency improvement under the investigated operating conditions and offers an alternative to computationally intensive optimization approaches for industrial motor applications. Full article
(This article belongs to the Section Electrical Engineering Design)
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28 pages, 10629 KB  
Article
A Frequency–Stress–Ratio Fatigue Index for Polymer Composites
by Jose Luis Valencia-Sanchez, Ciro A. Rodríguez-González, Ulises Figueroa-López, Alvaro Frutos, Jose Guadalupe Rangel-Ramirez and Moises Jimenez-Martinez
Designs 2026, 10(3), 63; https://doi.org/10.3390/designs10030063 - 4 Jun 2026
Viewed by 469
Abstract
Composite materials, known for their enhanced mechanical strength through fiber reinforcement, are increasingly used in industrial applications. However, like metals, they suffer strength degradation from cyclic loading, making fatigue failure a critical concern. The fatigue behavior of polymer composites is strongly influenced by [...] Read more.
Composite materials, known for their enhanced mechanical strength through fiber reinforcement, are increasingly used in industrial applications. However, like metals, they suffer strength degradation from cyclic loading, making fatigue failure a critical concern. The fatigue behavior of polymer composites is strongly influenced by factors such as stress amplitude, stress ratio, and loading frequency. Conventional stress-life approaches often treat these factors independently, which limits their predictive accuracy. This study introduces a novel frequency–stress–ratio fatigue index, integrated into a residual-strength degradation approach, to predict fatigue life under constant amplitude, tension-tension loading conditions. To the best of the authors’ knowledge, the majority of models available in the literature require substantial experimental data to calibrate the parameters essential for their application in real-world scenarios. The proposed model requires only two material parameters and assumes failure occurs when the residual strength degrades to the level of the applied maximum stress. The results demonstrate that the proposed formulation provides a unified representation of fatigue behavior influenced by both cycle-dominated and time-dependent mechanisms, offering robust predictive capabilities. This approach not only addresses a critical need for reliable and practical fatigue prediction methods in composite materials but also contributes significantly to the optimization of engineering design processes. Full article
(This article belongs to the Section Mechanical Engineering Design)
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36 pages, 14468 KB  
Article
Multi-Criteria Design of Industrial Process Heat Solutions, Including Concentrating Solar Thermal Collectors, High Temperature Heat Pumps, and Boilers
by Dimitra Gonidaki, Panagiotis Lykas, Christos Sammoutos, Angeliki Kitsopoulou, Konstantinos Polychronakis, Georgios Mitsopoulos, Christos Tzivanidis and Evangelos Bellos
Designs 2026, 10(3), 62; https://doi.org/10.3390/designs10030062 - 1 Jun 2026
Viewed by 1639
Abstract
Industrial heat demand is a major source of CO2 emissions, making the decarbonization of this sector essential for achieving sustainability. This study explores and compares different methods for supplying useful heat to the industrial sector through a multi-criteria approach that considers technical [...] Read more.
Industrial heat demand is a major source of CO2 emissions, making the decarbonization of this sector essential for achieving sustainability. This study explores and compares different methods for supplying useful heat to the industrial sector through a multi-criteria approach that considers technical performance, economic viability, and environmental impact. Both conventional and alternative systems are examined, aiming to develop sustainable designs. These include solar-based systems using parabolic trough collectors, supported by either electric heaters or natural gas boilers. In addition, a high-temperature heat pump (HTHP) utilizing waste heat is analyzed, also combined with either electric heaters or gas boilers as backup. For reference, a conventional natural gas boiler system is included as a baseline case. In total, five scenarios are evaluated for applications in the chemical industry. Each scenario is assessed in terms of energy and exergy efficiency, cost, and CO2 emissions. A multi-criteria analysis is then applied to determine the most sustainable option under varying electricity and waste heat price conditions. The results indicate that the configuration combining a high-temperature heat pump with electric heaters (Scenario 3) achieves the highest performance, with energy and exergy efficiencies of 0.952 and 0.666, respectively. The lowest CO2 emissions are observed in the case of using solar collectors with electric heaters (Scenario 1), reaching 4154 tons per year. From an economic perspective, Scenario 3 emerges as the most favorable option at lower electricity prices (0.10 €/kWh), with a levelized cost of heating (LCOH) of 0.0555 €/kWh. At higher electricity prices, the optimal design shifts to Scenario 2, which combines solar collectors with a natural gas boiler, resulting in an LCOH of 0.0603 €/kWh. Full article
(This article belongs to the Special Issue Innovative Energy Systems: Thermodynamics, Energy Storage, Performance Assessment and Optimization)
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16 pages, 6264 KB  
Article
Digital Workflow for Customized TSME Manufacturing in Interceptive Orthodontics: A Retrospective Clinical Study
by Lucia Giannini, Antonino Manti and Cinzia Maspero
Designs 2026, 10(3), 61; https://doi.org/10.3390/designs10030061 - 1 Jun 2026
Viewed by 450
Abstract
Interceptive orthodontics plays a key role in the early management of dento-skeletal discrepancies in growing patients, particularly transverse maxillary deficiency. This retrospective clinical study evaluated the dento-skeletal effects of a digitally manufactured, patient-specific Transversal Sagittal Maxillary Expander (TSME). A sample of 45 pediatric [...] Read more.
Interceptive orthodontics plays a key role in the early management of dento-skeletal discrepancies in growing patients, particularly transverse maxillary deficiency. This retrospective clinical study evaluated the dento-skeletal effects of a digitally manufactured, patient-specific Transversal Sagittal Maxillary Expander (TSME). A sample of 45 pediatric patients (mean age 8.5 years) with transverse and sagittal maxillary deficiency was analyzed. All subjects were treated using a customized titanium TSME designed through a multimodal digital workflow combining intraoral scanning, CBCT imaging, and three-dimensional facial acquisition for diagnostic planning and appliance customization. Quantitative treatment outcome assessment was based on standardized lateral cephalometric analysis between pre-treatment (T0) and post-treatment (T1). Statistically significant changes were observed in sagittal and vertical skeletal parameters, including SNA, SNB, ANB, SN–ANS-PNS, SN–GoGn, N–Me, and APDI. The integration of digital technologies and titanium additive manufacturing may support improved appliance customization and workflow standardization. Within the limitations of this retrospective study, digitally manufactured TSME represents a promising approach for patient-specific appliance customization in interceptive orthodontics. Full article
(This article belongs to the Special Issue Advanced Design Methodologies for Additive Manufacturing in Patient-Specific Medical Solutions)
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19 pages, 9438 KB  
Article
A 3D-Printed Nasopharyngeal Swab Prototype with a Helical Tip Design: A Feasibility Study with Numerical/Experimental Correlation
by Francesco Nicassio, Marta De Giorgi, Francesca Lionetto, Zahra Rajabimashhadi, Stefania Villani, Carola Esposito Corcione, Pietro Alifano, Marta Madaghiele and Christian Demitri
Designs 2026, 10(3), 60; https://doi.org/10.3390/designs10030060 - 25 May 2026
Viewed by 614
Abstract
The clinical reliability of swabs is affected by their ability to collect and elute biological samples for further detection. Since elution is particularly critical for swab functionality, the goal of this work was to develop a nasopharyngeal swab prototype that could potentially facilitate [...] Read more.
The clinical reliability of swabs is affected by their ability to collect and elute biological samples for further detection. Since elution is particularly critical for swab functionality, the goal of this work was to develop a nasopharyngeal swab prototype that could potentially facilitate the release of biological specimens through controlled elastic deformation. To this end, a helical swab-head geometry was designed and 3D-printed by means of stereolithography (SLA). A dual post-curing process combining UV and thermal treatment was employed to maximize the mechanical stiffness of the resin—up to about 750 MPa. Microtomography of the 3D-printed prototypes demonstrated the accuracy of SLA printing, with only 0.12% closed porosity due to printing defects. The mechanical deformation of the prototype under compression was then investigated through numerical modeling and experimental analysis. The results of Finite Element (FE) simulations revealed stress localization in the upper coils, with global mechanical integrity. Experimental compression tests validated the predicted deformation behavior, as supported by video tracking and displacement analysis at multiple nodes, showing good agreement between numerical and experimental displacement. Furthermore, preliminary functional tests with P. aeruginosa and S. aureus, both in saline solution and artificial mucus, demonstrated that the swab-tip prototype per se, without any coating or any applied compression, could perform comparably to commercial cotton and flocked swabs. About a 2-log reduction in bacterial load was detected for all swabs compared to the inoculum when used in saline solution, while a bacterial load roughly matching the inoculum was found when the swabs were used in artificial mucus. Overall, these findings demonstrate the feasibility and the potential of the designed swab prototypes. Full article
(This article belongs to the Topic Additive Manufacturing: From Promise to Practice)
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24 pages, 366 KB  
Article
Demonstrators for Industrial Cyber-Physical System Research: A Requirements Hierarchy Driven by Software-Intensive Design
by Uraz Odyurt, Richard Loendersloot and Tiedo Tinga
Designs 2026, 10(3), 59; https://doi.org/10.3390/designs10030059 - 22 May 2026
Viewed by 652
Abstract
One of the challenges apparent in the organisation of research projects is the uncertainties around the subject of demonstrators. A precise and detailed elicitation of the coverage for project demonstrators is often an afterthought and not sufficiently detailed during proposal writing. This practice [...] Read more.
One of the challenges apparent in the organisation of research projects is the uncertainties around the subject of demonstrators. A precise and detailed elicitation of the coverage for project demonstrators is often an afterthought and not sufficiently detailed during proposal writing. This practice leads to continuous confusion and a mismatch between targeted and achievable demonstration of results, hindering progress. The reliance on the Technology Readiness Level (TRL) scale as a loose descriptor does not help either. We propose a demonstrator requirements elaboration framework aiming to evaluate the feasibility of targeted demonstrations, making realistic adjustments, and assist in describing requirements. In doing so, we define five hierarchical levels of demonstration, clearly connected to expectations, e.g., work package interaction, and also connected to the project’s industrial use-cases. The considered application scope in this paper is the domain of software-intensive systems and industrial cyber-physical systems. A complete validation is not accessible, as it would require application of our framework at the start of a project and observing the results at the end, taking 4–5 years. Nonetheless, we have applied it to two research projects from our portfolio, one in the early stages and another in the final stages, revealing its effectiveness. Full article
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24 pages, 6773 KB  
Article
Design and Evaluation of a UAV-Attached Multisampling Device for Water Collection
by Islam Magomedov, Elah Magomedov, Diego Zelaya, Phuc Hau Nguyen, Artur Bagov, Sergey Valeev and Jose Luis Ordoñez Avila
Designs 2026, 10(3), 58; https://doi.org/10.3390/designs10030058 - 21 May 2026
Viewed by 686
Abstract
Unmanned aerial vehicles (UAVs) have emerged as flexible platforms for environmental monitoring, including water sampling in hard-to-reach or hazardous areas. However, most existing UAV-based sampling solutions are limited to single-point collection or rely on complex fluid routing mechanisms that increase the risk of [...] Read more.
Unmanned aerial vehicles (UAVs) have emerged as flexible platforms for environmental monitoring, including water sampling in hard-to-reach or hazardous areas. However, most existing UAV-based sampling solutions are limited to single-point collection or rely on complex fluid routing mechanisms that increase the risk of leakage and cross-contamination. This paper presents a novel ribbon-based multisampling capsule that enables sequential water collection from multiple locations during a single UAV deployment. The proposed mechanism employs a motor-driven ribbon with a single movable orifice that is sequentially aligned with individual sampling containers, allowing controlled intake and closure through a combination of hydrostatic pressure and mechanical sealing. A functional prototype was developed and experimentally evaluated to assess sampling feasibility and operational robustness. Experimental results demonstrate that improvements in sealing significantly reduce leakage events and eliminate dispenser-related carry-over, while enabling repeatable multi-point sampling. In addition, exploratory computational fluid dynamics (CFD) simulations were conducted to characterize hydrodynamic loads acting on the capsule and to support future design iterations, rather than to provide fully converged hydrodynamic validation. The proposed solution offers a practical, lightweight, and mechanically simple approach to UAV-assisted multi-point water sampling, with clear potential for further optimization and field deployment. Full article
(This article belongs to the Collection Editorial Board Members’ Collection Series: Drone Design)
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59 pages, 24188 KB  
Article
Computational Analysis of Tricuspid Heart Valves
by Samikshya Neupane and Tarun Goswami
Designs 2026, 10(3), 57; https://doi.org/10.3390/designs10030057 - 19 May 2026
Viewed by 720
Abstract
Understanding the mechanical behavior of valve materials and the hemodynamic characteristics of blood flow is important for improving prosthetic heart valve design. In this study, a comprehensive computational investigation was conducted to evaluate the biomechanical and hemodynamic behavior of a three-dimensional tricuspid valve [...] Read more.
Understanding the mechanical behavior of valve materials and the hemodynamic characteristics of blood flow is important for improving prosthetic heart valve design. In this study, a comprehensive computational investigation was conducted to evaluate the biomechanical and hemodynamic behavior of a three-dimensional tricuspid valve model constructed from reported prosthetic valve geometries. The structural response of the valve was evaluated using linear elastic, viscoelastic, and hyperelastic constitutive models for four different materials: pyrolytic carbon, polyurethane, porcine tissue, and bovine tissue. The results demonstrated clear material-dependent trends. Pyrolytic carbon exhibited negligible deformation (1.7166 × 10−8 m), confirming its rigid mechanical behavior, whereas biological tissues showed greater compliance, with the largest deformation observed for the bovine hyperelastic model (9.6837 × 10−5 m). Hyperelastic tissue models produced lower peak von Mises stresses (1.3951 × 104–1.8603 × 104 Pa) than the corresponding linear elastic tissue models (2.6842 × 104–2.7017 × 104 Pa), indicating improved stress redistribution under nonlinear deformation. Polyurethane showed intermediate mechanical behavior, with moderate deformation and lower stress under viscoelastic modeling than under the linear elastic assumption, suggesting its potential as a polymeric alternative to traditional valve materials. The Computational Fluid Dynamics (CFD) analysis of the rigid open valve geometry revealed a central velocity jet with a peak velocity of approximately 0.092 m/s, localized vortex formation with a maximum vorticity magnitude of about 177 s−1 and a peak instantaneous wall shear stress of 1.32 Pa near the leaflet edges and valve opening. Overall, the results highlight the trade-off between rigidity, compliance, and durability among prosthetic valve materials and suggest that polyurethane may provide a balanced alternative for tricuspid valve replacement. Full article
(This article belongs to the Section Bioengineering Design)
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16 pages, 1463 KB  
Article
Optimization Design of Variable Speed Induction Motors for Pumping Loads
by Makpal Zharkymbekova, Viktor Petrushyn, Kakimzhan Gali, Nurgul Almuratova, Juriy Plotkin and Rostyslav Yenoktaiev
Designs 2026, 10(3), 56; https://doi.org/10.3390/designs10030056 - 15 May 2026
Viewed by 1019
Abstract
The design of special induction motors for variable-speed drives in pumping systems is carried out using the Design of induction machines for adjustable-speed drives (DIMASDrive 2022) software, based on the motor efficiency criterion. The quality of a variable-speed drive is fully determined [...] Read more.
The design of special induction motors for variable-speed drives in pumping systems is carried out using the Design of induction machines for adjustable-speed drives (DIMASDrive 2022) software, based on the motor efficiency criterion. The quality of a variable-speed drive is fully determined by an innovative criterion of equivalent costs, which takes into account not only the cost and energy efficiency of the drive, but also the costs of compensating for reactive power and distortion power, which characterize the drive’s energy and electromagnetic compatibility with the grid. The MATLAB program enables the calculation of the innovative criterion of the drive’s reduced costs. Currently, the cost component of distortion power compensation is not taken into account in the reduced cost criterion; consequently, the quality of the drive in monetary terms is determined incompletely and is underestimated. A method is proposed for calculating this component and incorporating it into the reduced cost criterion. The presented results were obtained entirely through simulations conducted using validated software. Experimental studies of the prototype will provide the final answer regarding the solution. Full article
(This article belongs to the Topic Advanced Electrical Machines and Drives Technologies, 3rd Edition)
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18 pages, 2632 KB  
Article
A Digital Twin Design and Modeling Method for Steam Turbines Based on Reverse Modeling and Genetic Algorithm Optimization
by Pengfei Han, Botao Liu, Yuanqing Hu, Ming Li, Kedong Xie, Zhiyuan Cheng, Yingwei Liu, Wei Jiang, Minxun Zhang, Youtao Zhang and Junjie Hu
Designs 2026, 10(3), 55; https://doi.org/10.3390/designs10030055 - 13 May 2026
Viewed by 714
Abstract
Monitoring the operating status of steam turbines is critical for efficient and safe power generation. This study proposes a digital twin design and modeling method for steam turbines, integrating reverse modeling techniques with genetic algorithm optimization. Firstly, the geometric design model is reconstructed [...] Read more.
Monitoring the operating status of steam turbines is critical for efficient and safe power generation. This study proposes a digital twin design and modeling method for steam turbines, integrating reverse modeling techniques with genetic algorithm optimization. Firstly, the geometric design model is reconstructed from 3D-scanned point cloud data using point cloud fusion and surface reconstruction technologies, covering 13 stages of high-pressure rotor blades, 9 stages of intermediate-pressure stator blades, and the cylinder. Secondly, a physics-based model suitable for computational fluid dynamics simulations is generated using optimized mesh design parameters. To address unmeasurable parameters, a genetic algorithm is applied for data-driven design optimization, enhancing the dynamic simulation accuracy to 95%. Finally, leveraging a reduced-order model, real-time mapping of key physical fields is achieved. The effectiveness of the design methodology is validated under typical deep peak-shaving operating conditions. Full article
(This article belongs to the Topic Digital Manufacturing Technology)
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18 pages, 1630 KB  
Article
Ecodesign Strategies for Battery Enclosures: A Design-Driven Approach to Modularity, Single-Materiality and Circularity
by Antoni Lara, Albert Cruz, Sylvia Andrea Cruz, Magnus Carl Fredrik Eriksson, Antonio Confalonieri and Andreu Sanz
Designs 2026, 10(3), 54; https://doi.org/10.3390/designs10030054 - 12 May 2026
Viewed by 769
Abstract
The environmental impact of battery systems is strongly influenced by early design decisions related to materials, structural architecture and assembly strategies. While extensive research addresses battery performance and recycling processes, fewer studies focus on how ecodesign principles can be systematically translated into concrete [...] Read more.
The environmental impact of battery systems is strongly influenced by early design decisions related to materials, structural architecture and assembly strategies. While extensive research addresses battery performance and recycling processes, fewer studies focus on how ecodesign principles can be systematically translated into concrete design solutions at the product level. This article presents an ecodesign strategy applied to the development of a battery enclosure from an industrial design perspective. The proposed approach combines the use of aluminium with high recycled content, a modular enclosure based on extruded profiles adaptable to different battery sizes, a single-material architecture enabled by welded joints, and reversible fastened connections to support assembly, disassembly and repairability. The article discusses how ecodesign criteria such as material efficiency, circularity, modularity and design for assembly and disassembly (DfA/DfD) can be embedded into a coherent battery enclosure concept, while also addressing the main limitations and trade-offs of the proposed strategy. Full article
(This article belongs to the Section Mechanical Engineering Design)
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39 pages, 27209 KB  
Review
The Role of Additive Manufacturing in the Design of Smart and Nature-Based Construction Systems: A Critical Review
by Antreas Kantaros, Alexandra Tsatsou, Zoe Kanetaki, Theodore Ganetsos, Constantinos Stergiou, Michail Papoutsidakis and Evangelos Pallis
Designs 2026, 10(3), 53; https://doi.org/10.3390/designs10030053 - 9 May 2026
Viewed by 1206
Abstract
This work examines the contribution of additive manufacturing as an enabling technology in the design and development of smart and sustainable construction systems, with particular emphasis on nature-based solutions. While the existing literature has devoted considerable attention to the material properties of additive [...] Read more.
This work examines the contribution of additive manufacturing as an enabling technology in the design and development of smart and sustainable construction systems, with particular emphasis on nature-based solutions. While the existing literature has devoted considerable attention to the material properties of additive manufacturing, much less emphasis has been placed on its role in design processes, prototyping, and decision-making in construction and urban systems. To address this gap, this study presents a comprehensive bibliometric analysis of the intersection between smart city frameworks and 3D printing technologies, utilizing a dataset of 103 peer-reviewed publications retrieved from the Scopus database. Using keyword co-occurrence analysis and network mapping through VOSviewer, this study identifies dominant thematic structures, core research hubs, and evolving trends within the field. Complementing this bibliometric analysis with qualitative synthesis, it also reveals a significant convergence of digital design, smart cities, and sustainability strategies. This work further highlights the contribution of additive manufacturing to design processes through rapid prototyping, customization, and the exploration of design alternatives. Rather than framing additive manufacturing as a replacement for conventional design practices, this study positions it as a complementary design capability that can enhance the design process, while also acknowledging important challenges related to scaling, regulation, and integration into construction workflows. This review concludes by outlining future research directions for strengthening the design-oriented integration of additive manufacturing within smart construction systems. Full article
(This article belongs to the Special Issue Design Process for Additive Manufacturing, 2nd Edition)
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5 pages, 162 KB  
Editorial
Sustainable Construction: Innovations in Design, Engineering, and the Circular Economy
by Aziz Ahmed
Designs 2026, 10(3), 52; https://doi.org/10.3390/designs10030052 - 8 May 2026
Viewed by 603
Abstract
The construction industry currently operates at a critical threshold [...] Full article
(This article belongs to the Special Issue Sustainable Construction: Innovations in Design, Engineering, and the Circular Economy)
56 pages, 3798 KB  
Article
Simultaneous Integration of Photovoltaic Systems and Capacitor Banks in Radial Distribution Networks via the Grey Wolf Optimizer for Steady-State Voltage Regulation and Active Power Loss Minimization
by Susan Murillo and Alexander Aguila Téllez
Designs 2026, 10(3), 51; https://doi.org/10.3390/designs10030051 - 8 May 2026
Viewed by 660
Abstract
This paper presents a structured planning framework for the coordinated integration of photovoltaic (PV) systems and capacitor banks (CBs) in radial distribution networks to improve steady-state voltage regulation and reduce active-power losses. The proposed methodology combines deterministic power-flow assessment, index-based candidate screening, and [...] Read more.
This paper presents a structured planning framework for the coordinated integration of photovoltaic (PV) systems and capacitor banks (CBs) in radial distribution networks to improve steady-state voltage regulation and reduce active-power losses. The proposed methodology combines deterministic power-flow assessment, index-based candidate screening, and constrained joint placement and sizing using the Grey Wolf Optimizer (GWO) with an embedded CAPEX proxy. Compared with PV-only integration, the coordinated PV–CB strategy provides a more effective improvement in steady-state electrical performance, particularly in terms of slack-bus power factor and voltage regulation. In addition, relative to fixed coordinated PV–CB scenarios, the GWO-based formulation yields more balanced technical–economic solutions by improving power factor and voltage conditions while avoiding unnecessary overdimensioning of installed capacity. On the IEEE 15-bus system, the optimized configuration achieves a 45.9% reduction in active-power losses, improves the slack-bus power factor to 0.947, and reduces the average voltage deviation to 2.57%, with convergence reached in approximately 16 iterations. On the IEEE 34-bus system, the optimized solution yields a 49.8% loss reduction, increases the slack-bus power factor to 0.955, and reduces the average voltage deviation to 2.39%, with convergence reached in approximately 133 iterations. Using an energy price of 8.14 ctUSD/kWh, the corresponding annual loss–cost savings are approximately 19,975 USD and 78,475 USD for the IEEE 15- and 34-bus systems, respectively. The results demonstrate that the proposed GWO-based coordinated planning approach can achieve electrically effective and economically feasible solutions through the combined provision of local active-power injection and reactive-power compensation in radial distribution networks under steady-state operating conditions. Full article
(This article belongs to the Section Energy System Design)
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35 pages, 30281 KB  
Article
Comparative Life Cycle Assessment of Topology Optimization and Generative Design for Sustainable Additively Manufactured Furniture
by Christina Kostopoulou, Vasileios D. Sagias, Paraskevi Zacharia, Antreas Kantaros and Constantinos Stergiou
Designs 2026, 10(3), 50; https://doi.org/10.3390/designs10030050 - 8 May 2026
Viewed by 816
Abstract
Sustainability is an increasingly important objective in design and engineering, yet the environmental implications of advanced computational design methods remain insufficiently quantified. This study examines the contribution of topology optimization to sustainable product development when applied exclusively to a product’s internal structure, while [...] Read more.
Sustainability is an increasingly important objective in design and engineering, yet the environmental implications of advanced computational design methods remain insufficiently quantified. This study examines the contribution of topology optimization to sustainable product development when applied exclusively to a product’s internal structure, while preserving external geometry, mechanical performance, and design intent. The furniture sector was selected as a representative case due to its significant environmental footprint and the strong role of aesthetic requirements within the design methodology. A gate-to-gate Life Cycle Assessment was performed to compare a conventionally designed stool with an internally optimized counterpart, both developed under the same design constraints and manufactured via Fused Deposition Modeling using Carbon Fiber-reinforced PETG (CF-PETG). The results indicate that computational strategies can reduce material waste by 57.8% to 90% compared to traditional subtractive methods. However, these benefits may be partially offset by increased energy demand during additive manufacturing due to geometric complexity. An additional comparative assessment involving generative design demonstrates that alternative computational strategies can achieve more balanced trade-offs between material efficiency and manufacturing energy, supporting sustainability while respecting design methodology constraints. Full article
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24 pages, 4786 KB  
Article
Lightweight, Lateral and Sagittal Plane Symmetrical Biped Robot Design
by Davut Akdaş
Designs 2026, 10(3), 49; https://doi.org/10.3390/designs10030049 - 8 May 2026
Viewed by 556
Abstract
It is commonly noted in the literature that reducing mass and moment of inertia lowers the requirements for powerful electromechanical hardware and improves the overall energy efficiency of legged robots. For this reason, the humanoid robot RB2, the second of its kind at [...] Read more.
It is commonly noted in the literature that reducing mass and moment of inertia lowers the requirements for powerful electromechanical hardware and improves the overall energy efficiency of legged robots. For this reason, the humanoid robot RB2, the second of its kind at Balikesir University, has been developed iteratively. The motivation for this research is to design a lightweight, low-power humanoid robot to gain physical insight into the viability of using Delrin and 3D-printed ABS parts in its support structure and to enhance the robot’s efficiency in terms of weight and, as a result, power requirements. The number of degrees of freedom and the order of the joint motions of the planes are optimised to reduce moments of inertia and increase the range of motion of the robot’s legs. Additionally, the mechanical structure incorporates design features to facilitate assembly and maintenance. The newer robot’s weight is reduced to 25% of our first humanoid robot’s, while maintaining the same joint range of motion. Full article
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27 pages, 11688 KB  
Article
Development of a Preliminary Renewable Energy Planning Tool with Storage and Carbon Footprint Assessment
by Xumiao Lin, Joana Correia, Miguel Marques, Ana Foles, José Silva, Teresa Batista, Carmen Luisa Vásquez Stanescu, Lucas Marinho and Fernando Barros
Designs 2026, 10(3), 48; https://doi.org/10.3390/designs10030048 - 7 May 2026
Viewed by 662
Abstract
The global transition toward a low-carbon economy has accelerated the adoption of renewable energy sources. This paper presents the development of a model-based electronic Decision Support System for renewable energy planning, incorporating energy storage and carbon footprint assessment. The tool assists stakeholders in [...] Read more.
The global transition toward a low-carbon economy has accelerated the adoption of renewable energy sources. This paper presents the development of a model-based electronic Decision Support System for renewable energy planning, incorporating energy storage and carbon footprint assessment. The tool assists stakeholders in the preliminary evaluation of local wind and solar resources. To validate the model’s credibility, a comparative analysis was conducted, using the Port of Sines, Portugal, as an industrial case study. Solar energy estimations were benchmarked against PVSyst, while wind energy simulations were compared with an INEGI technical study. Results indicate consistency in solar estimates, with maximum deviations of 14% for fixed installations and 13% for vertical barriers, primarily due to terrain orography that was not yet integrated into the algorithm. Regarding wind energy, deviations reached 19% to 25%, largely resulting from the use of aggregated mean values in the reference data and generic turbine models. Overall, this work contributes to energy engineering by formalizing a validated workflow that facilitates early-stage sizing and strategic investment decisions under conditions of data scarcity. The tool proves effective for rapid screening of promising investment options while maintaining a balance between computational complexity and practical usability. Full article
(This article belongs to the Section Energy System Design)
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23 pages, 14314 KB  
Review
System-Level Design of Photovoltaic Recycling Infrastructure: A Review of Mechanical, Thermal, Chemical, and Laser-Based Technologies
by Mahmoud Dhimish and Peter Behrensdorff Poulsen
Designs 2026, 10(3), 47; https://doi.org/10.3390/designs10030047 - 29 Apr 2026
Viewed by 978
Abstract
This review paper presents a system-level engineering design perspective on end-of-life (EoL) photovoltaic (PV) recycling, addressing a critical gap in the literature that is predominantly focused on material and process-level analyses. A unified framework is developed to evaluate mechanical, thermal, chemical, and emerging [...] Read more.
This review paper presents a system-level engineering design perspective on end-of-life (EoL) photovoltaic (PV) recycling, addressing a critical gap in the literature that is predominantly focused on material and process-level analyses. A unified framework is developed to evaluate mechanical, thermal, chemical, and emerging laser-based technologies through the lenses of system architecture, process control, and infrastructure integration. The study introduces design-oriented concepts, including optimal processing windows, modular system configurations, and multi-layer control frameworks, to support decision-making in scalable PV recycling systems. Particular emphasis is placed on laser-based recycling (e.g., femtosecond laser technology), which enables non-thermal, high-precision, and interface-selective material separation, representing a paradigm shift towards intelligent and adaptive recycling infrastructures. The paper also highlights the transition from conventional bulk PV processing to precision-controlled, artificial intelligence (AI)-enabled systems, and outlines future research and industrial pathways required to realize sustainable, high-efficiency PV recycling within a circular economy. Full article
(This article belongs to the Section Smart Manufacturing System Design)
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35 pages, 5585 KB  
Article
A General Procedure for Basic Kinematic Chain Formation and Topology Selection for Planar Mechanisms
by Arthur Erdman, John Titus, Mahmud Suhaimi Ibrahim and Sean Mather
Designs 2026, 10(3), 46; https://doi.org/10.3390/designs10030046 - 27 Apr 2026
Viewed by 785
Abstract
In a complete kinematic synthesis process, a designer must select a planar linkage topology that is well suited to their problem situation. This involves weighing a set of competing priorities. For example, is it better to choose a simple topology like a four-bar [...] Read more.
In a complete kinematic synthesis process, a designer must select a planar linkage topology that is well suited to their problem situation. This involves weighing a set of competing priorities. For example, is it better to choose a simple topology like a four-bar mechanism that will be cheaper to produce, or a complex topology like an eight-bar mechanism that can produce intricate motions but will also be more expensive and more difficult to synthesize? The process of selecting the topology is broadly known as type synthesis, or sometimes structure synthesis, and has been studied in the past. However, past works on planar linkage type synthesis have overemphasized isomorphism detection, identifying the complete set of unique topologies up to a certain number of links, while the central problem of choosing the ideal topology has often been overlooked. In this work, a general procedure for forming basic kinematic chains (BKCs), a simplified topological representation, is presented. Then, a set of rules and design principles is provided that can help a designer narrow the infinite possible BKC options down to a manageable set. A few practical examples are provided to demonstrate the concepts and show that the procedure is effective. A literature review is also provided that examines past works, as well as introducing alternative approaches, such as simultaneous algorithmic methods and spatial methods. Full article
(This article belongs to the Section Mechanical Engineering Design)
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16 pages, 3647 KB  
Article
Mitigating Stress Shielding in Dorr C Femurs via Additive Manufacturing: A Proof-of-Concept Numerical Analysis
by Roberta Cromi, Francesca Berti, Matteo Gavazzoni, Luigi La Barbera, Dalila Di Palma, Sara Maggioni, Jacopo Menini, Massimo Franceschini, Stefano Foletti and Tomaso Villa
Designs 2026, 10(3), 45; https://doi.org/10.3390/designs10030045 - 23 Apr 2026
Viewed by 802
Abstract
Bone resorption secondary to stress shielding is a leading cause of hip implant failure, primarily due to the stiffness mismatch between the femur and the prosthesis. Although anatomical stem designs generally provide improved load transfer, Dorr type C femurs often require straight stems [...] Read more.
Bone resorption secondary to stress shielding is a leading cause of hip implant failure, primarily due to the stiffness mismatch between the femur and the prosthesis. Although anatomical stem designs generally provide improved load transfer, Dorr type C femurs often require straight stems to ensure adequate primary stability. This work presents a systematic approach to designing a straight, additively manufactured porous titanium hip stem aimed at minimizing stress shielding. The lattice architecture is customized to replicate the mechanical properties of bone based on patient-specific femoral CT scans. The performance of the resulting porous implant is numerically assessed under simplified physiological gait loading conditions. The implant behavior is evaluated through a homogenization strategy to model the lattice structure, significantly reducing the computational effort and making the methodology easily replicable. Compared to its full counterpart, the porous design achieves a significant reduction in predicted bone loss, suggesting that the proposed framework is a promising proof of concept for patient-specific implants. While further experimental validation and larger cohort studies are required, these findings highlight the potential of mechanically tunable porous structures to mitigate the stress shielding phenomenon in anatomical conditions such as Dorr type C femurs, which require straight stems. Full article
(This article belongs to the Special Issue Advanced Design Methodologies for Additive Manufacturing in Patient-Specific Medical Solutions)
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