Designs

25 pages, 1125 KB

Open AccessArticle

A Process-Mapped Quality Control Framework for Structural Steel Fabrication

by Dario Šokić, Zlata Dolaček-Alduk and Mario Galić

Designs 2026, 10(4), 89; https://doi.org/10.3390/designs10040089 - 19 Aug 2026

Viewed by 878

This paper proposes a process-mapped quality control framework for structural steel fabrication as a proof of concept for integrating normative requirements into a unified operational workflow. The study addresses the fragmentation of quality requirements in steel fabrication, where individual standards are often applied [...] Read more.

This paper proposes a process-mapped quality control framework for structural steel fabrication as a proof of concept for integrating normative requirements into a unified operational workflow. The study addresses the fragmentation of quality requirements in steel fabrication, where individual standards are often applied through separate inspections rather than as part of a coherent process model. The framework links material control, production preparation, assembly, welding, and anticorrosion protection through clearly defined quality gates. The framework is constructed through a qualitative design-oriented approach using SIPOC analysis and a detailed flowchart. It translates normative requirements into a coherent workflow that provides a structured basis for traceability, preventive quality assurance, and future integration with Construction 4.0. The paper suggests that process mapping can serve as a useful method for organizing quality control in steel construction projects and for transforming standards into an operational framework. Full article

(This article belongs to the Special Issue Sustainable Construction: Innovations in Design, Engineering, and the Circular Economy, 2nd Edition)

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19 pages, 3463 KB

Open AccessArticle

Design Strategies for Mixed Unit Cell Lattices: Mechanical Assessment with Biomedical 3D Printing

by A K M Ahasun Habib, Gabriel Briguiet and Paul F. Egan

Designs 2026, 10(4), 88; https://doi.org/10.3390/designs10040088 - 17 Aug 2026

Viewed by 392

Abstract

3D printed lattices have efficient mechanics for wide-ranging engineering applications, especially biomedical domains. In bone tissue engineering, lattices constructed from unit cells enable tunable mechanics and tissue growth by altering unit cell beam diameters and porosity suitable for design personalization. Heterogeneously mixing unit [...] Read more.

3D printed lattices have efficient mechanics for wide-ranging engineering applications, especially biomedical domains. In bone tissue engineering, lattices constructed from unit cells enable tunable mechanics and tissue growth by altering unit cell beam diameters and porosity suitable for design personalization. Heterogeneously mixing unit cells throughout lattices is a promising tuning strategy; however, there remains a need for further systematic investigation linking design decisions to mechanical outcomes. In this study, biocompatible photopolymer resin is used to print Cube, BC (Body-Centered), and BC–Cube lattices with approximately 75% porosity. When tested in compression, these lattices have Elastic Moduli of 202 ± 5.4, 30 ± 1.6 MPa, and 97 ± 4.0 MPa, and yield stresses of 6.0 ± 0.11, 1.1 ± 0.07, and 3.1 ± 0.13 MPa, respectively. Heterogeneous lattices with Cube and BC unit cells in stochastic mixtures (25/75, 50/50, 75/25) and four deterministic layouts (Layers 0°, Layers 90°, Rows 0°, Rows 90°) with equally proportioned unit cells were also designed. Stochastic mixing produced a linear relationship between the Elastic Modulus and Cube unit cell proportion (R² = 0.98), consistent with a rule-of-mixtures. Deterministic heterogeneous layouts bypassed the rule-of-mixtures, with Elastic Moduli spanning 97.6 to 163.4 MPa, with select designs outperforming stochastic configurations. Findings demonstrate the merits of heterogeneous strategies to improve lattice designs, with suitability for biomedical applications. Full article

(This article belongs to the Special Issue Advanced Design Methodologies for Additive Manufacturing in Patient-Specific Medical Solutions)

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33 pages, 1458 KB

Open AccessArticle

Design of a New 3-UPU/S Parallel Ankle Rehabilitation Mechanism

by Assia Abdi, Ridha Kelaiaia, Brahmia Allaoua, Adlen Kerboua and Ameur Latreche

Designs 2026, 10(4), 87; https://doi.org/10.3390/designs10040087 - 13 Aug 2026

Viewed by 343

Abstract

Ankle injuries may lead to severe complications, including chronic instability and reduced mobility. Rehabilitation therefore plays a critical role in restoring normal ankle function and preventing long-term impairment. However, conventional manual physiotherapy presents several limitations, such as limited availability of therapists, variability in [...] Read more.

Ankle injuries may lead to severe complications, including chronic instability and reduced mobility. Rehabilitation therefore plays a critical role in restoring normal ankle function and preventing long-term impairment. However, conventional manual physiotherapy presents several limitations, such as limited availability of therapists, variability in treatment, and reduced accessibility for home-based rehabilitation. Consequently, significant research efforts have been devoted to the development of robotic and mechatronic devices for ankle rehabilitation. In this work, we propose the design of a simple and cost-effective parallel mechanism dedicated to ankle rehabilitation. The proposed device is based on a closed-chain kinematic architecture capable of reproducing the three principal rotational degrees of freedom of the ankle joint. This configuration enables controlled and repeatable rehabilitation exercises while ensuring mechanical stability and compactness. Furthermore, the device is designed to allow patients to perform rehabilitation exercises autonomously, without the continuous assistance of a physiotherapist, both in clinical environments and in home-based rehabilitation settings. Full article

(This article belongs to the Section Mechanical Engineering Design)

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15 pages, 1490 KB

Open AccessReview

Material Selection for Mycelium-Based Composites: A Systematic Review and Opportunities for Chilean Industrial Residues

by Fabián N. Echeverría-Sáez, Alexandre Carbonnel-Torralbo, Matías Mann Elliott-Oyarce and Cristina A. Villamar-Ayala

Designs 2026, 10(4), 86; https://doi.org/10.3390/designs10040086 - 9 Aug 2026

Viewed by 572

Abstract

In response to the health and environmental impacts of particleboard production and use, this research highlights the value of sustainable construction materials. Mycelium-based composites are a promising biobased solution that proposes the substitution of synthetic binders with fungal binders, while valorizing lignocellulosic residues. [...] Read more.

In response to the health and environmental impacts of particleboard production and use, this research highlights the value of sustainable construction materials. Mycelium-based composites are a promising biobased solution that proposes the substitution of synthetic binders with fungal binders, while valorizing lignocellulosic residues. Therefore, the aim of this study is identifying the most suitable material combinations for mycelium-based composite production using Chilean residues through a systematic literature review. The methodology involved a systematic review of 346 scientific publications from Web of Science, Scopus, and PubMed, of which 84 were chosen through a PRISMA-based review. Scientific publications permitted us to determine the most frequently used fungal strains, substrates, and additives. Co-occurrence analysis revealed that Pleurotus ostreatus was the predominant fungal strain (35/84, 41.67%), followed by Ganoderma lucidum (23/84, 27.38%) and Trametes versicolor (19/84, 22.62%). Meanwhile, agro-industrial subproducts (30/84, 35.71%) were the most frequently reported substrate, followed by wood subproducts (26/84, 30.95%). Among the additives, wheat bran (14/84, 16.67%) was the most used, followed by calcium sulfate (12/84, 14.29%) and calcium carbonate (11/84, 13.1%). These findings to demonstrate that Chilean forestry (5–7 million ton/year) and agro-industrial residues (4 million ton/year) can be effectively integrated into scalable mycelium-based composites, considering that, for the most part, they are simply burned as biomass. These residues are circular economy, low-impact and alternative sustainable construction materials that reduce the dependence on fossil-derived binders. Moreover, there is the potential to explore other residue additives that do not compete with the food industry (e.g., wheat ban) and are rich in nutrients (e.g., biological sludge) and regulate pH. Full article

(This article belongs to the Topic Sustainable Building Development and Promotion)

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21 pages, 28761 KB

Open AccessArticle

Engineering Design Methodology and Socio-Technical Assessment of Progressive Temporary Housing with Metabolic Independence and Scaffolding in Vulnerable Areas

by Luis Rios, José Hinostroza-Martínez and María Custodio

Designs 2026, 10(4), 85; https://doi.org/10.3390/designs10040085 - 9 Aug 2026

Viewed by 866

Abstract

Habitat production in informal settlements and vulnerable urban areas faces critical challenges regarding habitability and lack of infrastructure. This article evaluates a prototype for progressive temporary housing based on a modular metal scaffolding structure, conceived as an autonomous housing response unit in the [...] Read more.

Habitat production in informal settlements and vulnerable urban areas faces critical challenges regarding habitability and lack of infrastructure. This article evaluates a prototype for progressive temporary housing based on a modular metal scaffolding structure, conceived as an autonomous housing response unit in the district of Chilca-Huancayo, Peru. Unlike conventional solutions, the proposal integrates metabolic independence systems through photovoltaic generation and rainwater harvesting to guarantee functional autonomy from public utility networks. Adopting a mixed-method, experimental-applied approach, the research articulates technical simulations, full-scale structural load tests, and a social perception assessment. The results demonstrate the technical feasibility of the model: the energy system covers the entirety of basic demand, and the structural component exhibits ductile behavior under seismic demands, guaranteeing stability without brittle failures. Furthermore, the social dimension reveals high acceptability among residents in emergency scenarios. The study concludes that the use of reusable industrial systems enables a resilient and rapidly deployable architecture. It is argued that this model constitutes a viable alternative for risk management and the mitigation of the housing deficit in the context of urban exclusion, highlighting its potential for territorial replicability as a response to the social production of habitat on the periphery. Full article

(This article belongs to the Special Issue Sustainable Construction: Innovations in Design, Engineering, and the Circular Economy, 2nd Edition)

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12 pages, 2221 KB

Open AccessArticle

Development of a Microstrip Triplexer with High Isolation for 5G Sub-6 GHz Applications

by Bhaskarareddy Nallagutlapalli Chandrashekarareddy, Rashmi Ravi and Augustine O. Nwajana

Designs 2026, 10(4), 84; https://doi.org/10.3390/designs10040084 - 9 Aug 2026

Viewed by 592

Abstract

The rapid proliferation of multi-standard fifth-generation (5G) new radio sub-6 GHz systems has intensified the demand for compact, high-isolation multiplexing components capable of simultaneously routing multiple frequency channels through a single shared antenna port without cross-band interference. This article presents the design and [...] Read more.

The rapid proliferation of multi-standard fifth-generation (5G) new radio sub-6 GHz systems has intensified the demand for compact, high-isolation multiplexing components capable of simultaneously routing multiple frequency channels through a single shared antenna port without cross-band interference. This article presents the design and full-wave electromagnetic (EM) simulation of a compact microstrip triplexer operating at 2.2, 2.6, and 3.0 GHz for 5G sub-6 GHz applications. The proposed triplexer employs square open-loop resonators (SOLRs) arranged as three independent three-pole Chebyshev bandpass filter channels. Each channel is synthesized from a standard normalized Chebyshev lowpass filter prototype. The three channels are integrated at a common input port via a T-junction, with the connecting transmission line stubs dimensioned to enforce high inter-channel isolation. The triplexer is implemented on Rogers RT/Duroid 6010LM substrate. Full-wave EM simulation results demonstrate return losses of 21.1, 23.1, and 22.8 dB; insertion losses of 1.08, 1.01, and 0.98 dB; and inter-channel isolations of 45.7, 45.2, and 45.7 dB for ports S₃₂, S₄₂, and S₄₃, respectively. The achieved inter-channel isolation exceeding 45 dB represents a significant improvement over the majority of recently reported microstrip triplexers operating in the sub-6 GHz range. The device occupies a compact circuit area of 0.34λg × 0.52λg. λg is the guided wavelength for the microstrip line impedance at the 2.6 GHz centre frequency of the triplexer. Full article

(This article belongs to the Special Issue RFID and Applications of RF/Microwave Circuits and Systems)

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22 pages, 633 KB

Open AccessArticle

Design Limits of Voltage Unbalance Mitigation in Passive Single-Phase to Three-Phase Converters via Transformer Tap Optimization

by Rogelio Alfredo Orizondo Martínez

Designs 2026, 10(4), 83; https://doi.org/10.3390/designs10040083 - 6 Aug 2026

Viewed by 456

Abstract

Passive single-phase to three-phase conversion represents an attractive alternative for low-power applications, particularly in isolated systems and rural electrification scenarios where simplicity, robustness, and low cost are essential. However, these passive topologies inherently produce voltage unbalance whose magnitude strongly depends on load characteristics. [...] Read more.

Passive single-phase to three-phase conversion represents an attractive alternative for low-power applications, particularly in isolated systems and rural electrification scenarios where simplicity, robustness, and low cost are essential. However, these passive topologies inherently produce voltage unbalance whose magnitude strongly depends on load characteristics. This work analyzes a passive single-phase to three-phase converter based on reactive elements and a transformer, focusing on the limits of voltage unbalance mitigation through discrete transformer tap optimization. The study is conducted under steady-state sinusoidal conditions using phasor modeling and symmetrical component analysis. The voltage unbalance factor (VUF) is adopted as the primary optimization metric, while the current unbalance factor (IUF), neutral current, and converter losses are used as complementary performance indicators. Results indicate that transformer tap optimization can reduce voltage unbalance for specific load conditions, although low residual unbalance is achieved only near the nominal operating point. Higher residual unbalance is observed as the load becomes more inductive within the investigated power-factor range. The findings indicate that passive single-phase to three-phase conversion can be technically viable for low-power applications with relatively stable load conditions. However, applications requiring high power quality or dynamic regulation may benefit from active converter solutions based on power electronics. Full article

(This article belongs to the Section Electrical Engineering Design)

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36 pages, 12695 KB

Open AccessArticle

An MBSE-Oriented Framework for the Development and Simulation of Bidirectional EV Charging Systems

by Vlad Andrei Scarlatache, Ovidiu Ivanov, Florina Scarlatache, Marius Andrei Olariu, Tudor Alexandru Filip and Sebastian Aradoaei

Designs 2026, 10(4), 82; https://doi.org/10.3390/designs10040082 - 1 Aug 2026

Viewed by 508

Abstract

Developing bidirectional EV charging systems requires a structured engineering methodology that preserves traceability from system requirements to executable simulation models. This paper proposes a Model-Based Systems Engineering (MBSE)-oriented framework for the development and validation of grid-connected energy systems integrating vehicle-to-grid (V2G) and grid-to-vehicle [...] Read more.

Developing bidirectional EV charging systems requires a structured engineering methodology that preserves traceability from system requirements to executable simulation models. This paper proposes a Model-Based Systems Engineering (MBSE)-oriented framework for the development and validation of grid-connected energy systems integrating vehicle-to-grid (V2G) and grid-to-vehicle (G2V) capabilities. The proposed approach is structured into a problem space and a solution space. The problem space defines system requirements and functional behavior using SysML requirement and use case diagrams developed in Eclipse Papyrus. The solution space transforms these functions into logical activity diagrams, physical architectures in MATLAB R2024b System Composer, and executable simulation models in MATLAB R2024b/Simulink. The framework is validated through a bidirectional EV charging case study connected to a low-voltage electrical grid. The simulation results confirm stable G2V and V2G operation and demonstrate the traceability between requirements, architecture, and executable simulation models. The proposed workflow supports consistency, interoperability, and early validation for EV-integrated energy systems. Full article

(This article belongs to the Collection Editorial Board Members’ Collection Series: Designs of New Generation Vehicles)

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25 pages, 5337 KB

Open AccessFeature PaperArticle

Effect of Ply Orientation and Face-Sheet Thickness on PSD-Based Random Vibration Response of Honeycomb Sandwich Structures

by Siddhanth Santhosh, Ananya Manjusha Raulkar, Pratham Gupta, Shah Mohammed Abdul Khader, Sathish Rao Udupi, Subash Acharya, Aruna Prabhu, Jonathan Monteiro, Divya Bhaskar and Ashwin Kumar Devaraj

Designs 2026, 10(4), 81; https://doi.org/10.3390/designs10040081 - 1 Aug 2026

Viewed by 521

Abstract

Electric vehicle battery enclosure systems under vibrational loading may experience structural damage, reducing the lifespan of lithium-ion cells. Honeycomb sandwich structures are widely used in EV battery systems due to their high stiffness-to-weight ratio and superior vibration performance. The present study is undertaken [...] Read more.

Electric vehicle battery enclosure systems under vibrational loading may experience structural damage, reducing the lifespan of lithium-ion cells. Honeycomb sandwich structures are widely used in EV battery systems due to their high stiffness-to-weight ratio and superior vibration performance. The present study is undertaken to investigate the dynamic behaviour of honeycomb sandwich panels using ANSYS Workbench. A three-dimensional model of a sandwich structure consisting of an aluminium core and composite face sheets is developed in ANSYS. Modal analysis and power spectral density-based random vibration analysis are performed to examine the impact of face-sheet thickness (0.5–2.5 mm) and layup configuration on structural performance. The modal analysis reveals that the natural frequencies increase considerably with thickness up to 1.5 mm due to increased bending stiffness. The results of random vibration analysis demonstrate a substantial reduction in total deformation and equivalent stress with increasing thickness. Among the configurations studied, the [0C/0G]/Core/[0G/0C] layup demonstrates the most favourable response under the present PSD loading condition due to fibre alignment with the principal loading direction. The findings are further converted into practical design guidelines for electric vehicle battery enclosures, including an appropriate face-sheet thickness range of 1.0–1.5 mm and fibre orientations aligned with the principal loading direction, while considering the associated mass penalty. These findings provide a design-oriented framework for selecting thickness and layup configuration to achieve a practical balance between vibration resistance and weight. Full article

(This article belongs to the Section Mechanical Engineering Design)

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19 pages, 3840 KB

Open AccessArticle

A Structural-Comfort Integrated Approach to Optimized Geometries for In-Wheel Suspensions in Urban Micromobility Vehicles

by Michelangelo-Santo Gulino, Giovanni Zonfrillo, Mirko Rinchi, Gregorio Dori and Dario Vangi

Designs 2026, 10(4), 80; https://doi.org/10.3390/designs10040080 - 30 Jul 2026

Viewed by 413

Abstract

The development of suspension systems for urban micro-mobility vehicles, such as bicycles and e-bikes, requires balancing effective road filtering with structural simplicity. Traditional solutions, such as telescopic forks and rear shock absorbers, face significant challenges related to weight, bulk, and mechanical complexity, which [...] Read more.

The development of suspension systems for urban micro-mobility vehicles, such as bicycles and e-bikes, requires balancing effective road filtering with structural simplicity. Traditional solutions, such as telescopic forks and rear shock absorbers, face significant challenges related to weight, bulk, and mechanical complexity, which increase production and maintenance costs. The integration of in-wheel motors into wheel hubs further complicates the design by increasing unsprung mass and vertical vibrations, negatively affecting ride comfort. The In-Wheel Suspension (IWS) system offers an innovative solution by incorporating elastic and damping elements directly into the wheel rim, eliminating the need for frame modifications and reducing overall weight. This study proposes an integrated approach to optimising the internal geometries of IWS elastic elements, using structural analyses with LS-Dyna and dynamic simulations in the Simulink environment for comfort assessment. Results demonstrate that optimising the geometry of spokes and rims significantly reduces stiffness variations and self-induced vibrations, with enhancements in ride comfort and resistance to fatigue. The optimized IWS design minimises discomfort peaks at critical speeds and improves vibration attenuation. However, the high average stiffness limits filtering performance at speeds above 10 km/h. While IWS systems represent a promising alternative to traditional suspensions due to their advantages in weight reduction, compactness, and construction simplicity, further improvements—such as the use of composite materials and alternative geometries—are necessary to further increase comfort and to ensure structural resistance to variable loads. Full article

(This article belongs to the Collection Editorial Board Members’ Collection Series: Designs of New Generation Vehicles)

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21 pages, 4052 KB

Open AccessArticle

Design and Characteristics of De-Constructable Shelter with Biodegradable Materials

by Youssef T. Khairy, Kareem K. Mostafa, Mohamed E. Batah, Mohamed S. Shatat, Mohamed Darwish, Tamer Shoeib, Matab Nadim, Khaled Nassar and Mohamed N. Abou-Zeid

Designs 2026, 10(4), 79; https://doi.org/10.3390/designs10040079 - 27 Jul 2026

Viewed by 934

Abstract

This research directly addresses three critical global challenges, construction waste generation, forced displacement and housing shortage, through the design and development of a regenerative, modular housing system utilizing biodegradable composite materials synthesized from locally abundant agricultural waste, specifically rice straw. Bio-based panels were [...] Read more.

This research directly addresses three critical global challenges, construction waste generation, forced displacement and housing shortage, through the design and development of a regenerative, modular housing system utilizing biodegradable composite materials synthesized from locally abundant agricultural waste, specifically rice straw. Bio-based panels were manufactured and used together with Casuarina Glauca wood to fabricate sandwich panels to be used as roofs and walls. Four configurations of the sandwich panels were manufactured and tested to select the strongest of them to be used within the proposed structure. Through systematic material testing, structural analysis, and lifecycle environmental assessment, this work demonstrates that locally sourced agricultural waste can form the foundation of dignified, low-carbon temporary shelters with minimal environmental impact at end-of-life when compared with conventional reinforced-concrete construction. The 3 m × 3 m bio-based shelter, designed for complete disassembly and reuse, achieves 88% lower embodied carbon than its conventional reinforced-concrete counterpart while maintaining adequate structural performance for temporary housing applications. Furthermore, the designed shelter has a cost that is 64% lower than that of its conventional reinforced-concrete counterpart and 40% lower than that of a refugee housing unit. Full article

(This article belongs to the Special Issue Sustainable Construction: Innovations in Design, Engineering, and the Circular Economy, 2nd Edition)

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20 pages, 14371 KB

Open AccessArticle

Balancing Minimalism and Manufacturability in Integrated Product Design: A Human-Centred Framework

by Hamid Naghdbishi, Seyed Behbood Issa-Zadeh and Claudia Lizette Garay-Rondero

Designs 2026, 10(4), 78; https://doi.org/10.3390/designs10040078 - 27 Jul 2026

Viewed by 667

Abstract

Designing products that feel simple and intuitive while remaining efficient to manufacture and meaningful across cultures remains a key challenge in contemporary product development. Although minimalist design has achieved commercial success, most methodologies fail to systematically connect aesthetic intentions with engineering, usability, and [...] Read more.

Designing products that feel simple and intuitive while remaining efficient to manufacture and meaningful across cultures remains a key challenge in contemporary product development. Although minimalist design has achieved commercial success, most methodologies fail to systematically connect aesthetic intentions with engineering, usability, and production realities. This study proposes a four-phase iterative framework—Framing, Translation, Materialisation, and Experience that integrates human-centred design, simplicity heuristics—including ‘SHE’ (Shrink, Hide, Embody) tactics, quantitative aesthetic measurement, Design for X methods, and cross-cultural considerations to operationalise minimalist principles such as formal reduction, seriality, and industrial materiality. An empirical case study applied the framework to three competing automotive interior concepts through image-based evaluation by 113 respondents. Results provided preliminary evidence that a balanced hybrid approach consistently outperformed both traditional button-heavy and extreme single-screen minimalist designs across measures of usability, sense of order, trust, and user recommendation. Findings confirm that effective minimalism does not merely remove elements but strategically redistributes complexity into interface logic, production systems, and material quality. The framework offers designers a structured yet flexible path to create manufacturable, user-validated, and culturally sensitive minimalist products. Full article

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18 pages, 6787 KB

Open AccessArticle

Design of High-Precision Visual Localization System for Side-Seam Welding of Power Battery Modules

by Qingshan Sheng, Adisorn Sirikham and Jessada Konpang

Designs 2026, 10(4), 77; https://doi.org/10.3390/designs10040077 - 24 Jul 2026

Viewed by 455

Abstract

Based on the problems of low efficiency, unstable accuracy, and weak anti-interference ability of manual localization for side-seam welding of square power battery module, this article designs a high-precision vision localization system for side seam based on machine vision. This system achieves automatic [...] Read more.

Based on the problems of low efficiency, unstable accuracy, and weak anti-interference ability of manual localization for side-seam welding of square power battery module, this article designs a high-precision vision localization system for side seam based on machine vision. This system achieves automatic solving of welding reference points and start/end points through image preprocessing, an improved skeleton thinning algorithm, gray-scale projection feature separation, and a two-stage straight-line fitting algorithm design. The experimental results show that under the industrial site conditions covered in this experiment (normal lighting and conventional dust levels), the proposed method achieves an average localization error of 0.279 mm and a processing time of 384.3 ms per weld seam. It can meet the industrial requirements for automated welding of power battery modules and provides a referable technical solution for the engineering design of localization systems for side-weld welding of similar battery modules. Full article

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26 pages, 3493 KB

Open AccessReview

AI-Driven Electrical Machine Design: From Surrogate-Assisted Optimization to Trustworthy, Manufacturable, and Sustainable Design Workflows

by Loránd Szabó

Designs 2026, 10(4), 76; https://doi.org/10.3390/designs10040076 - 24 Jul 2026

Cited by 1 | Viewed by 1054

Abstract

Electrical machine design faces growing constraints from power density, wide operating ranges, thermal and mechanical limits, acoustics, manufacturability, cost, and critical material availability. While finite element and multi-physics simulations remain essential, their direct use in population-based or multi-objective optimization is often computationally prohibitive. [...] Read more.

Electrical machine design faces growing constraints from power density, wide operating ranges, thermal and mechanical limits, acoustics, manufacturability, cost, and critical material availability. While finite element and multi-physics simulations remain essential, their direct use in population-based or multi-objective optimization is often computationally prohibitive. AI, spanning surrogate modeling, machine learning, deep learning, physics-informed networks, Bayesian optimization, and emerging generative methods, is increasingly used to accelerate analysis, enlarge design spaces, and support inverse or multi-objective tasks. This review examines AI-assisted electrical machine design from a workflow perspective, distinguishing functional approximation, performance prediction, topology-aware learning, physics-informed modeling, active learning, and robust optimization under uncertainty. It highlights current limitations, including narrow topology coverage, reliance on FEM-generated data, weak extrapolation, limited uncertainty reporting, scarce experimental validation, and insufficient attention to manufacturability and sustainability. A design-readiness framework and minimum reporting checklist are proposed to improve trustworthiness and reusability. The review concludes that AI should serve as a physics-aware, validation-dependent accelerator, complementing, not replacing, electromagnetic expertise, multi-physics simulation, and prototype testing. Full article

(This article belongs to the Topic Advanced Electrical Machines and Drives Technologies, 3rd Edition)

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29 pages, 30450 KB

Open AccessArticle

Designing Before Folding: Morphological Design Principles for Thermally Formed Passive Adaptive Grippers

by Avihai Shurin and Ziv Shefer

Designs 2026, 10(4), 75; https://doi.org/10.3390/designs10040075 - 21 Jul 2026

Viewed by 627

Abstract

This qualitative study develops morphological design principles for thermally formed passive adaptive grippers within an accessible 4D-printing approach. A practice-based morphological exploration was conducted through 18 PLA+ prototypes fabricated by Fused Deposition Modeling and thermally formed through controlled hot-water immersion. The study treats [...] Read more.

This qualitative study develops morphological design principles for thermally formed passive adaptive grippers within an accessible 4D-printing approach. A practice-based morphological exploration was conducted through 18 PLA+ prototypes fabricated by Fused Deposition Modeling and thermally formed through controlled hot-water immersion. The study treats the two-dimensional pre-forming sheet geometry as the central design variable and examines how variations in flat-pattern organization affect the activated three-dimensional gripper. This shifts attention from optimizing a single predefined gripper toward understanding how form variations generate design knowledge. The prototypes were organized into two morphological families: a convergence-based radial gripping family and a guided cylindrical wrapping family. Functional and morphological readings of the catalogue showed that flat-pattern decisions shape grasp typology, functional role distribution, approach geometry, structural continuity, and the behavioral envelope of the activated form. The study proposes seven morphological design principles linking flat-pattern operations to three-dimensional gripping consequences, while also showing that the two families form a continuum of morphological possibilities rather than discrete categories. Across the prototype lineage, design knowledge accumulates through comparison and can be recombined into more resolved configurations. This paper offers a planning vocabulary for developing passive adaptive gripping structures before performance optimization or application-specific engineering begins. Full article

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17 pages, 2420 KB

Open AccessArticle

Computational Analysis of Complexity Thresholds in Incremental Complexity Design of Bidirectional Compliant Constant Force Mechanisms

by Jing Li

Designs 2026, 10(4), 74; https://doi.org/10.3390/designs10040074 - 15 Jul 2026

Viewed by 485

Abstract

In compliant Constant Force Mechanism (CFM) design, superior functionality often necessitates increased structural complexity. While the Incremental Complexity Design (ICD) method has facilitated the development of efficient topologies for Bidirectional compliant Constant Force Mechanisms (Bi-CFMs), its evolution has remained primarily empirical, limited by [...] Read more.

In compliant Constant Force Mechanism (CFM) design, superior functionality often necessitates increased structural complexity. While the Incremental Complexity Design (ICD) method has facilitated the development of efficient topologies for Bidirectional compliant Constant Force Mechanisms (Bi-CFMs), its evolution has remained primarily empirical, limited by the absence of a comprehensive decision-making criterion that integrates functional performance, geometric cost, and mechanical risk. This study proposes a computational framework to identify complexity thresholds, utilizing a multi-objective optimization approach based on finite element analysis (FEA). This framework integrates functional performance (Energy Similarity Index

S_{C F}

) with a Composite Complexity Index that encompasses geometric redundancy and mechanical risk. A sensitivity analysis revealed that Bi-CFM performance is highly sensitive to geometric boundary limitations. Consequently, optimization was conducted under varied constraints. Results show that through this computation-driven design framework, specific optimal complexity thresholds are established for different geometric constraints: 3 nodes for a 140 mm domain, 4 nodes for a 100 mm domain, and 7 nodes for a 60 mm domain. Such findings demonstrate that this threshold is dynamically coupled with the available spatial domain. This work provides a systematic strategy for Bi-CFM designers to balance functional performance and structural complexity, offering a robust foundation for lean design under diverse environmental conditions. Full article

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19 pages, 5869 KB

Open AccessArticle

Rethinking an Everyday Product for Selective Laser Melting: A Generative Design and Topology Optimisation Approach

by Beatriz M. Braga, Ana C. Lopes, Leandro C. Fernandes, Pedro F. Moreira, Álvaro M. Sampaio and António J. Pontes

Designs 2026, 10(4), 73; https://doi.org/10.3390/designs10040073 - 14 Jul 2026

Viewed by 525

Abstract

In recent years, Additive Manufacturing (AM) has transformed the development of new products, enabling more efficient, sustainable, and creative solutions across multiple sectors. Accordingly, this research explores the integration of Selective Laser Melting (SLM) with advanced Computer-Aided (CAx) tools, specifically Generative Design (GD) [...] Read more.

In recent years, Additive Manufacturing (AM) has transformed the development of new products, enabling more efficient, sustainable, and creative solutions across multiple sectors. Accordingly, this research explores the integration of Selective Laser Melting (SLM) with advanced Computer-Aided (CAx) tools, specifically Generative Design (GD) and Topology Optimisation (TO), to rethink an everyday product. The developed concept, an SLM water tap, highlights the seamless synergy between design and product engineering. Reverse Engineering (RE) was applied to analyse the conventional internal mechanism, which was redesigned in accordance with Design for Additive Manufacturing (DfAM) principles. This approach enabled the integration of the internal cartridge architecture into the tap body as a single metal component, reducing system complexity and part count. TO was applied to key components, achieving a 35% mass reduction without compromising the simulated structural performance of the system. GD was employed to generate optimised internal flow channels, resulting in a numerically simulated flow rate of 4.69 L/min. Integrating CAx tools enabled a customisable product with varied surface textures. This work contributes to the deconstruction of traditional manufacturing paradigms and advances the understanding of AM for functionally relevant product design. Full article

(This article belongs to the Special Issue Design Process for Additive Manufacturing, 2nd Edition)

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24 pages, 12348 KB

Open AccessArticle

Virtual and Rapid Prototyping of Personalised Medical Devices in Maxillofacial Surgery: An Engineering Design Approach and Collaborative Platform

by Claudio Favi, Enrica Riva, Giovanni Fortese, Rinaldo Garziera and Andrea Varazzani

Designs 2026, 10(4), 72; https://doi.org/10.3390/designs10040072 - 14 Jul 2026

Viewed by 582

Abstract

This work presents an interdisciplinary engineering framework and a collaborative digital platform supporting the design, optimization, and proof-of-concept validation of patient-specific surgical devices for maxillofacial applications. The proposed methodology starts from computed tomography images and integrates three-dimensional anatomical reconstruction, hybrid CAD modelling, material [...] Read more.

This work presents an interdisciplinary engineering framework and a collaborative digital platform supporting the design, optimization, and proof-of-concept validation of patient-specific surgical devices for maxillofacial applications. The proposed methodology starts from computed tomography images and integrates three-dimensional anatomical reconstruction, hybrid CAD modelling, material characterization, finite element analysis, topology optimization, and additive manufacturing within a unified collaborative environment involving surgeons and engineering specialists. The proposed workflow was validated through a proof-of-concept study performed on patient-specific additively manufactured anatomical replicas. A comparative evaluation between the conventional wafer-based workflow and the proposed device-based approach demonstrated the technical feasibility of the methodology, achieving sub-millimetric positioning accuracy together with an estimated reduction in operative time under identical simulated surgical conditions. Although these results do not represent clinically validated outcomes, they provide representative preclinical estimates supporting the effectiveness of the proposed engineering approach and establish a solid basis for future in vivo investigations. The principal contribution of this work lies in the methodological integration of clinical planning, engineering design, numerical validation, additive manufacturing, and multidisciplinary collaboration within a single digital framework. In addition, a novel patient-specific device for orthognathic surgery is presented as a representative case study demonstrating the applicability of the proposed methodology to the development of customized surgical solutions. Full article

(This article belongs to the Special Issue Advanced Design Methodologies for Additive Manufacturing in Patient-Specific Medical Solutions)

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30 pages, 3837 KB

Open AccessArticle

Lightweight Design of a Snowplow Mounting Frame Through Topology Optimization for Multiple Structural Performance Objectives

by Jing Xu, Asmae Khachan and Hamza Bahloul

Designs 2026, 10(4), 71; https://doi.org/10.3390/designs10040071 - 13 Jul 2026

Cited by 1 | Viewed by 660

Abstract

Snow removal vehicles operate under severe working conditions, and the snowplow mounting frame is a critical structural component responsible for transmitting loads generated during snow-removal operations. To improve material utilization and reduce structural weight without compromising mechanical performance, a lightweight design methodology based [...] Read more.

Snow removal vehicles operate under severe working conditions, and the snowplow mounting frame is a critical structural component responsible for transmitting loads generated during snow-removal operations. To improve material utilization and reduce structural weight without compromising mechanical performance, a lightweight design methodology based on topology optimization was developed. The primary design objective was to achieve at least a 16% reduction in structural mass while maintaining acceptable stress, strain, deformation, and durability performance. First, a three-dimensional model of the mounting frame assembly was established, and finite element analysis was conducted using ANSYS under representative loading conditions. Topology optimization based on compliance minimization with a mass constraint was then performed to identify structurally inefficient regions and generate an optimized material distribution. Based on the optimization results, the mounting frame was reconstructed into a practical and manufacturable CAD model and subsequently re-evaluated through finite element analysis and fatigue assessment. The mass of the mounting frame was successfully reduced from 177.52 kg to 137.77 kg, corresponding to a weight reduction of 22.39%, significantly exceeding the initial design target. Despite this substantial reduction in weight, the maximum stress, strain, and deformation remained within allowable design limits. Furthermore, fatigue analysis predicted no fatigue failure within 1 × 10⁶ loading cycles, while the minimum fatigue safety factor remained greater than unity, confirming the durability and reliability of the redesigned structure. The results demonstrate that topology optimization provides an effective approach for improving material utilization, reducing structural weight, and enhancing the overall structural efficiency of snow-removal equipment. The successful reconstruction of the optimized topology into a manufacturable design further highlights the practical industrial applicability of the proposed methodology. Full article

(This article belongs to the Collection Editorial Board Members’ Collection Series: Designs of New Generation Vehicles)

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48 pages, 8439 KB

Open AccessSystematic Review

Design Methods for Compliant Mechanisms: A Systematic Review Supported by Bibliometric Analysis

by Franciso De Matias-Aguilar, José Martínez-Trinidad, Moisés Jiménez-Martínez, Sergio G. Torres-Cedillo, Luis A. Moreno-Pacheco, Fernando Alonso-Cruz and Ricardo A. García-León

Designs 2026, 10(4), 70; https://doi.org/10.3390/designs10040070 - 6 Jul 2026

Viewed by 2097

Abstract

The design of compliant mechanisms is a multidisciplinary field that integrates structural optimization, kinematics, and materials science to develop systems capable of generating motion through elastic deformation. Over the past six decades, research on compliant mechanisms has grown quickly, encompassing applications ranging from [...] Read more.

The design of compliant mechanisms is a multidisciplinary field that integrates structural optimization, kinematics, and materials science to develop systems capable of generating motion through elastic deformation. Over the past six decades, research on compliant mechanisms has grown quickly, encompassing applications ranging from micro- and nano-manipulation to soft robotics and precision engineering. This study presents a comprehensive historical and thematic overview of compliant mechanism design methods through a bibliometric analysis conducted in accordance with the PRISMA methodology. A bias reduction method is proposed for bibliometric analysis, and its limitations are discussed. A total of 10,425 documents published between 1966 and 2025 were retrieved from the Scopus database, revealing an average annual growth rate of 10.35%. The analysis was performed using the Bibliometrix and VOSviewer software packages to conduct performance analysis and science mapping, enabling the identification of influential authors, key publications, and emerging research clusters. The performance analysis results allow, among other things, the identification of the most cited authors and works, which, in turn, facilitates faster identification of the original authors and ideas that gave rise to subsequent thematic branches. Science mapping identified dominant thematic fields underlying past, present, and future trends in compliant mechanisms and their applications. A reader beginning their exploration of the field of compliance mechanisms will find in this work a guide refined by statistical methods, free from the personal bias of its authors. On the other hand, those seeking to understand thematic trends in the field of compliant mechanisms, as well as niche research opportunities, can use the networks and tables generated to explore new possibilities. Full article

(This article belongs to the Section Mechanical Engineering Design)

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38 pages, 7047 KB

Open AccessReview

Design Frameworks and Tribological Performance of Cold Spray Additively Manufactured Coatings: Materials, Mechanisms, and Engineering Applications

by Lincoln Pinoski, Angus McCarroll and Pradeep L. Menezes

Designs 2026, 10(4), 69; https://doi.org/10.3390/designs10040069 - 30 Jun 2026

Viewed by 968

Abstract

Cold spray additive manufacturing (CS) has emerged as a transformative solid-state deposition technique for designing advanced functional surfaces with tailored tribological performance. By accelerating micron-scale particles to supersonic velocities and depositing them below their melting point, CS enables the fabrication of dense, oxidation-resistant [...] Read more.

Cold spray additive manufacturing (CS) has emerged as a transformative solid-state deposition technique for designing advanced functional surfaces with tailored tribological performance. By accelerating micron-scale particles to supersonic velocities and depositing them below their melting point, CS enables the fabrication of dense, oxidation-resistant coatings with strong metallurgical bonding and beneficial compressive residual stresses. These distinctive attributes create unique opportunities for the design-driven engineering of wear-resistant surfaces across aerospace, automotive, marine, biomedical, and industrial sectors. Despite a growing literature on CS processing and properties, a comprehensive framework linking design principles encompassing material selection, coating architecture, process parameter optimization, and post-processing strategies to tribological outcomes is absent from the field. This review addresses that gap by critically examining the design space of CS coatings and positioning tribological performance as an outcome of deliberate engineering decisions. The relationships between coating architecture and tribological behavior, specifically friction control, wear resistance, adhesion-cohesion integrity, and surface roughness, are examined under varying environmental and loading conditions. Design strategies involving composite and hybrid coatings incorporating solid lubricants, ceramic reinforcements, and nanostructured architectures are discussed in the context of achieving specific functional objectives. The influence of process parameters, such as particle velocity, gas temperature, substrate preparation, and post-treatments including heat treatment, friction stir processing, and laser shock peening, on tribological outcomes is critically synthesized. Environmental performance under high-temperature, corrosive, and extreme wear conditions is analyzed through a design lens. A design decision framework summarizing material-process-property linkages for CS tribological coatings is presented to provide practical guidance for engineers and researchers. Future directions include AI-driven process optimization, multi-material architectures, and the integration of CS within broader design-for-manufacturing workflows. Full article

(This article belongs to the Section Smart Manufacturing System Design)

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19 pages, 3750 KB

Open AccessArticle

Dynamic Direct Voltage Control Under Maximum Torque per Ampere for Interior PMSMs

by Mohamad Alzayed, Hicham Chaoui and Alaref Elhaj

Designs 2026, 10(4), 68; https://doi.org/10.3390/designs10040068 - 29 Jun 2026

Viewed by 584

Abstract

A novel method for controlling the speed of interior permanent magnet synchronous motors (IPMSMs), known as the current-sensing-based dynamic direct voltage control method under the maximum torque per ampere (MTPA) concept, is introduced. This technique achieves precise tracking of machine velocity by determining [...] Read more.

A novel method for controlling the speed of interior permanent magnet synchronous motors (IPMSMs), known as the current-sensing-based dynamic direct voltage control method under the maximum torque per ampere (MTPA) concept, is introduced. This technique achieves precise tracking of machine velocity by determining the optimal combination of voltage amplitude and angle for each specific motor velocity and current/load condition. Unlike previous studies, this approach takes into account the transient model of the machine, resulting in improved accuracy during dynamic operating conditions compared with existing methods in the literature. Moreover, a comparative analysis is conducted involving different direct voltage MTPA speed drive approaches: the current-sensing dynamic direct voltage control (CS-DDVC) methodology, the simplified DDVC technique, and the static direct voltage MTPA control strategy. The well-known field-oriented control method is also included in the analysis. The dynamic methodology employs two tuning parameters to achieve the same MTPA objective while eliminating transient effects. Experimental results and quantitative assessment demonstrate that the proposed MTPA control methodology is a highly effective strategy, offering a respectable alternative to existing MTPA methods for driving IPMSMs. It enables the operation of IPMSMs under MTPA working conditions with high efficiency, making it suitable for a wide range of industrial applications. Experimental results demonstrate a reduction in speed dip from 120 rpm to 50 rpm at full load application and a 128% improvement in IAE compared to conventional DVC. From an engineering design perspective, the proposed control framework simplifies the drive-system architecture by eliminating cascaded current-control loops while maintaining effective transient dynamic performance suitable for embedded electric vehicle applications. Full article

(This article belongs to the Topic Advanced Electrical Machines and Drives Technologies, 3rd Edition)

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18 pages, 2846 KB

Open AccessArticle

Design, Manufacturing and Characterization of Stretchable Silicone-Based Conductive Composites

by Jahnavi Boyapally, Vinod Kumar Darapureddy, Midhun Vorvala and Zahabul Islam

Designs 2026, 10(4), 67; https://doi.org/10.3390/designs10040067 - 26 Jun 2026

Viewed by 789

Abstract

Stretchable conductive composites are important for soft electronics, wearable systems, and adaptive electromechanical devices, yet the mechanisms governing strain-dependent electrical transport remain insufficiently understood, particularly in hybrid filler systems. In this work, the strain-dependent electromechanical behavior of graphite–silicone and hybrid graphite–copper–silicone composites was [...] Read more.

Stretchable conductive composites are important for soft electronics, wearable systems, and adaptive electromechanical devices, yet the mechanisms governing strain-dependent electrical transport remain insufficiently understood, particularly in hybrid filler systems. In this work, the strain-dependent electromechanical behavior of graphite–silicone and hybrid graphite–copper–silicone composites was investigated under uniaxial tensile deformation up to 60% strain. Electrical measurements revealed distinct transport behaviors governed by filler composition and conductive network structure. Graphite-only composites containing 50 wt% and 60 wt% graphite exhibited monotonic resistance increases with increasing strain due to progressive widening of inter-particle tunneling gaps between neighboring graphite platelets. In contrast, hybrid graphite–copper composites showed monotonic resistance decreases under deformation, which is attributed to Poisson-ratio-driven transverse contraction, tunneling-gap reduction, and strain-assisted formation of Cu–Cu and Cu–graphite conductive pathways. Representative volume element (RVE)-based simulations further supported the proposed transport interpretation. From an engineering design perspective, the results show that filler composition and conductive network architecture can be used as design variables to tune strain-dependent electrical responses in stretchable conductive composites. These findings provide design guidance for developing silicone-based conductive composites with tunable electromechanical functionality for soft electronics, wearable sensors, and adaptive devices. Full article

(This article belongs to the Section Smart Manufacturing System Design)

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18 pages, 4457 KB

Open AccessArticle

Engineering Design of Stepped Hull for Planing Vessels Using CFD-Based Evaluation

by Samuel, Serliana Yulianti, Muhammad Iqbal, Davis Rian Kusuma, Ari Wibawa Santosa, Good Rindo, Andi Trimulyono and Ahmad Fitriadhy

Designs 2026, 10(4), 66; https://doi.org/10.3390/designs10040066 - 23 Jun 2026

Viewed by 803

Abstract

The growing demand for high-speed marine transportation requires continuous improvement in ship design to achieve higher hydrodynamic efficiency. From an engineering design perspective, hull form modification is a key approach to optimizing the performance of planing vessels, particularly through the implementation of stepped [...] Read more.

The growing demand for high-speed marine transportation requires continuous improvement in ship design to achieve higher hydrodynamic efficiency. From an engineering design perspective, hull form modification is a key approach to optimizing the performance of planing vessels, particularly through the implementation of stepped hull configurations. This study aims to investigate the effects of step geometry and step position on the resistance and trim characteristics of a planing hull based on Taunton et al.’s Model C, with the objective of improving vessel efficiency. The design methodology integrates hull geometry modification, parametric variation in step position and step height, and numerical performance assessment. In this research, the governing equations are solved using the Reynolds-Averaged Navier–Stokes (RANS) framework with the Finite Volume Method (FVM) as the discretization technique. The turbulence model used is k-ω SST, while the interaction between water and air phases is represented using the Volume of Fluid (VOF) method. From a design performance perspective, the results demonstrate that stepped hull geometry significantly influences resistance and trim characteristics. The optimal design configurations achieved a resistance reduction of up to 17.93% and a trim of 1.53° was achieved with a stepped position of 430 mm from the transom and a stepped height of 25 mm (Model A3) at Fr 2.28. Meanwhile, a resistance reduction of 15.49% and a trim of 1.46° were observed for a stepped position of 860 mm from the transom and a stepped height of 25 mm (Model B3) at Fr 2.72. These findings highlight the importance of step geometry and placement as key design variables in improving planing hull performance. This study demonstrates that CFD-based evaluation can effectively support engineering design decisions for stepped hull optimization, providing a systematic approach for improving hydrodynamic efficiency in high-speed vessel design. Full article

(This article belongs to the Topic Vehicle Dynamics and Control, 2nd Edition)

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Designs, Volume 10, Issue 4 (August 2026) – 24 articles

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