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Editor’s Choice Articles

Editor’s Choice articles are based on recommendations by the scientific editors of MDPI journals from around the world. Editors select a small number of articles recently published in the journal that they believe will be particularly interesting to readers, or important in the respective research area. The aim is to provide a snapshot of some of the most exciting work published in the various research areas of the journal.

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32 pages, 7353 KB  
Article
A Methodology for the Design and Selection of Multifunctional Carbon Fibre-Reinforced Polymer for Aircraft Structures
by Muhammad Hijaaj Tahir, Catherine E. Jones and Robert Ian Whitfield
Designs 2025, 9(6), 146; https://doi.org/10.3390/designs9060146 - 18 Dec 2025
Viewed by 502
Abstract
Multifunctional aerostructures that carry mechanical loadings while conducting electrical currents offer a promising approach to reduce the weight of Electrical Power Systems (EPS) of aircraft. However, Carbon Fibre-Reinforced Polymer (CFRP), when used for aerostructures, presents challenges in achieving multi-functionality due to anisotropic mechanical, [...] Read more.
Multifunctional aerostructures that carry mechanical loadings while conducting electrical currents offer a promising approach to reduce the weight of Electrical Power Systems (EPS) of aircraft. However, Carbon Fibre-Reinforced Polymer (CFRP), when used for aerostructures, presents challenges in achieving multi-functionality due to anisotropic mechanical, electrical, and thermal properties. These properties are interdependent on both laminate-level design factors (fibre/resin choice, fibre volume fraction, stacking sequence, and electrode configuration) and system-level EPS constraints (allowable voltage drop, current, and installation geometry). State-of-the-art material design and selection methods lack a coupled mechanical–electro–thermal design and selection approach to overcome these challenges of a complex design space to enable identification of multifunctional CFRP (MF-CFRP) solutions. This paper presents the first methodology for the design and selection of MF-CFRP with combined electrical, structural, and thermal properties. The methodology integrates requirement capture, laminate layup determination, electro-thermal assessment, option ranking, and manufacturing route selection. The methodology couples laminate-level design factors with system-level EPS constraints and includes iterative loops to refine either the CFRP design or the EPS parameters when no solution initially exists. The methodology is demonstrated to enable the design of a CFRP component to conduct the electrical current as part of the 28 VDC network in an aircraft. This case study demonstrates the value of the methodology to identify knowledge and dataset gaps necessary for MF-CFRP design, alongside enabling the design of MF-CFRP components to enable increased power density of weight-critical EPS. Although the case study focused on a 28 VDC system, the methodology is generalisable to other aircraft electrical architectures since system-level electrical parameters are used within the methodology as adaptable inputs. Full article
(This article belongs to the Section Mechanical Engineering Design)
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25 pages, 4743 KB  
Review
Digital Twins in Development of Medical Products—The State of the Art
by Zhuming Bi, Ruaa Jamal Rabi Salem Alfakawi, Hosni Abu-Mulaweh and Donald Mueller
Designs 2025, 9(6), 140; https://doi.org/10.3390/designs9060140 - 4 Dec 2025
Viewed by 889
Abstract
This article provides a Structured Literature Review (SLR) on the uses of Digital Twins (DT-Is) in the development of medical products. The purposes of our SLR are to find out (1) whether existing DT-I technologies are mature enough to be adopted for new [...] Read more.
This article provides a Structured Literature Review (SLR) on the uses of Digital Twins (DT-Is) in the development of medical products. The purposes of our SLR are to find out (1) whether existing DT-I technologies are mature enough to be adopted for new medical product development, and (2) if the answer to item (1) is no, what existing works can be utilized in developing DT-Is for designs of bone fixations? It is our finding that numerous works are reported on using DT-Is in healthcare applications such as remote surgeries, remote diagnoses, personalized medicines, and assistive technologies. These applications involve one-to-one correspondence of physical and digital entities but exhibit several limitations in (1) inheriting and transferring knowledge from legacy products to new products and (2) a lack of a systematic approach in creating innovations for new product development. We suggest adopting Digital Triad (DT-II) for medical product development. A background study on using DT-II for the design of bone staples is conducted to illustrate the feasibility of the proposed idea. Full article
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24 pages, 6505 KB  
Article
Design and Prototype of L-CADEL.v5 Elbow Assisting Device
by Sergei Kotov and Marco Ceccarelli
Designs 2025, 9(6), 126; https://doi.org/10.3390/designs9060126 - 11 Nov 2025
Viewed by 667
Abstract
A new version of the L-CADEL elbow joint assisting device is presented as version v5. The design is revised based on the experience of previous versions and on the requirements that consider the application for physical exercise for the elderly people at home. [...] Read more.
A new version of the L-CADEL elbow joint assisting device is presented as version v5. The design is revised based on the experience of previous versions and on the requirements that consider the application for physical exercise for the elderly people at home. A laboratory prototype has been created with lightweight, portable and easy-to-use functionality that is confirmed by lab test results. A web interface was developed to manage the device as well as to acquire and elaborate data. Results of lab tests are discussed to validate the design feasibility and to characterize the operation performance for future clinical assessments. Full article
(This article belongs to the Section Bioengineering Design)
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42 pages, 1526 KB  
Article
AI Judging Architecture for Well-Being: Large Language Models Simulate Human Empathy and Predict Public Preference
by Nicholas Boys Smith and Nikos A. Salingaros
Designs 2025, 9(5), 118; https://doi.org/10.3390/designs9050118 - 13 Oct 2025
Viewed by 3050
Abstract
Large language models (LLMs) judge three pairs of architectural design proposals which have been independently surveyed by opinion polls: department store buildings, sports stadia, and viaducts. A tailored prompt instructs the LLM to use specific emotional and geometrical criteria for separate evaluations of [...] Read more.
Large language models (LLMs) judge three pairs of architectural design proposals which have been independently surveyed by opinion polls: department store buildings, sports stadia, and viaducts. A tailored prompt instructs the LLM to use specific emotional and geometrical criteria for separate evaluations of image pairs. Those independent evaluations agree with each other. In addition, a streamlined evaluation using a single descriptor “friendliness” yields the same results while offering a rapid screening measure. In all cases, the LLM consistently selects the more human-centric design, and the results align closely with independently conducted public opinion poll surveys. This agreement is significant in improving designs based upon human-centered principles. AI helps to illustrate the correlational effect: living geometry → positive-valence emotions → public preference. The AI-based model therefore provides empirical evidence for a deep biological link between geometric structure and human emotion that warrants further investigation. The convergence of AI judgments, neuroscience, and public sentiment highlights the diagnostic power of criteria-driven evaluations. With intelligent prompt engineering, LLM technology offers objective, reproducible architectural assessments capable of supporting design approval and policy decisions. A low-cost tool for pre-occupancy evaluation unifies scientific evidence with public preference and can inform urban planning to promote a more human-centered built environment. Full article
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29 pages, 9768 KB  
Article
Design, Construction, and Simulation-Based Validation of a High-Efficiency Electric Powertrain for a Shell Eco-Marathon Urban Concept Vehicle
by Kristaq Hazizi, Suleiman Erateb, Arnaldo Delli Carri, Joseph Jones, Sin Hang Leung, Stefania Sam and Ronnie Yau
Designs 2025, 9(5), 113; https://doi.org/10.3390/designs9050113 - 23 Sep 2025
Cited by 1 | Viewed by 2790
Abstract
This study addresses a documented gap in detailed, cost-effective, and performance-validated electric vehicle (EV) powertrain solutions. It presents the complete design, construction, and simulation-based validation of a high-efficiency electric powertrain for a Shell Eco-marathon Urban Concept vehicle. Novel contributions of this work include [...] Read more.
This study addresses a documented gap in detailed, cost-effective, and performance-validated electric vehicle (EV) powertrain solutions. It presents the complete design, construction, and simulation-based validation of a high-efficiency electric powertrain for a Shell Eco-marathon Urban Concept vehicle. Novel contributions of this work include a unique drivetrain architecture: a BLDC motor with a modular two-stage chain drive and a custom lithium-ion battery pack. The design is optimized for compactness and reliability under stringent budget and packaging constraints. A comprehensive Simulink-based vehicle dynamics model was developed for robust validation. This model enabled the estimation of energy consumption, torque profiles, and battery State of Charge under realistic drive cycles. The system demonstrated a remarkably low energy consumption under competition conditions, signifying high efficiency with <50 Wh/km consumption and full compliance with technical regulations. Furthermore, the hardware is thoroughly documented with detailed build instructions, CAD models, and a full bill of materials. This promotes reproducibility. This research offers a validated, low-cost, and replicable electric powertrain. It provides a transferable framework for future Shell Eco-marathon teams and advances lightweight, cost-effective solutions for real-world low-speed electric mobility applications, such as micro-EVs and urban delivery vehicles. Full article
(This article belongs to the Collection Editorial Board Members’ Collection Series: Designs of New Generation Vehicles)
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25 pages, 4947 KB  
Article
An Application of Reinforcement Learning to the Optimal Design of Road Vehicle Suspension Systems
by Lorenzo De Santanna, Riccardo Malacrida, Gianpiero Mastinu and Massimiliano Gobbi
Designs 2025, 9(5), 108; https://doi.org/10.3390/designs9050108 - 12 Sep 2025
Viewed by 1447
Abstract
This study investigates the application of Multi-Objective Reinforcement Learning–Dominance-Based (MORL–DB) method to the optimal design of complex mechanical systems. The MORL–DB method employs a Deep Deterministic Policy Gradient (DDPG) agent to identify the optimal solutions of the multi-objective problem. By adopting the k [...] Read more.
This study investigates the application of Multi-Objective Reinforcement Learning–Dominance-Based (MORL–DB) method to the optimal design of complex mechanical systems. The MORL–DB method employs a Deep Deterministic Policy Gradient (DDPG) agent to identify the optimal solutions of the multi-objective problem. By adopting the k-optimality metric, which introduces an optimality ranking within the Pareto-optimal set of solutions, a final design solution can be chosen more easily, especially when considering a large number of objective functions. The method is successfully applied to the elasto-kinematic optimisation of a double wishbone suspension system, featuring a multi-body model in ADAMS Car. This complex design task includes 30 design variables and 14 objective functions. The MORL–DB method is compared with two other approaches: the Moving Spheres (MS) method, specifically developed for spatial design tasks, and the genetic algorithm with k-optimality-based sorting (KEMOGA). Comparative results show that the MORL–DB method achieves solutions of higher optimality while requiring significantly fewer objective function evaluations. The results demonstrate that the MORL–DB method is a promising and sample-efficient alternative for multi-objective optimisation, particularly in problems involving high-dimensional design spaces and expensive objective function evaluations. Full article
(This article belongs to the Collection Editorial Board Members’ Collection Series: Designs of New Generation Vehicles)
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35 pages, 8971 KB  
Review
Emerging Insights into the Durability of 3D-Printed Concrete: Recent Advances in Mix Design Parameters and Testing
by James Bradshaw, Wen Si, Mehran Khan and Ciaran McNally
Designs 2025, 9(4), 85; https://doi.org/10.3390/designs9040085 - 7 Jul 2025
Cited by 12 | Viewed by 5010
Abstract
Although 3D-printed concrete (3DPC) offers advantages such as faster construction, reduced labour costs, and minimized material waste, concerns remain about its long-term durability. This review examines these challenges by assessing how the unique layer-by-layer manufacturing process of 3DPC influences key material properties and [...] Read more.
Although 3D-printed concrete (3DPC) offers advantages such as faster construction, reduced labour costs, and minimized material waste, concerns remain about its long-term durability. This review examines these challenges by assessing how the unique layer-by-layer manufacturing process of 3DPC influences key material properties and overall durability. The formation of interfacial porosity and anisotropic microstructures can compromise structural integrity over time, increasing susceptibility to environmental degradation. Increased porosity at layer interfaces and the presence of shrinkage-induced cracking, including both plastic and autogenous shrinkage, contribute to reduced durability. Studies on freeze–thaw performance indicate that 3DPC can achieve durability comparable to cast concrete when proper mix designs and air-entraining agents are used. Chemical resistance, particularly under sulfuric acid exposure, remains a challenge, but improvements have been observed with the inclusion of supplementary cementitious materials such as silica fume. In addition, tests for chloride ingress and carbonation reveal that permeability and resistance are highly sensitive to printing parameters, material composition, and curing conditions. Carbonation resistance, in particular, appears to be lower in 3DPC than in traditional concrete. This review highlights the need for further research and emphasizes that optimizing mix designs and printing processes is critical to improving the long-term performance of 3D-printed concrete structures. Full article
(This article belongs to the Special Issue Design Process for Additive Manufacturing)
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33 pages, 824 KB  
Review
Artificial Intelligence in Generative Design: A Structured Review of Trends and Opportunities in Techniques and Applications
by Owen Peckham, Jonathan Raines, Erik Bulsink, Mark Goudswaard, James Gopsill, David Barton, Aydin Nassehi and Ben Hicks
Designs 2025, 9(4), 79; https://doi.org/10.3390/designs9040079 - 23 Jun 2025
Cited by 7 | Viewed by 12839
Abstract
This review explores the intersection of Artificial Intelligence (AI) and Generative Design (GD) in engineering within the mechanical, industrial, civil, and architectural domains. Driven by advances in AI and computational resources, this intersection has grown rapidly, yielding over 14,000 publications since 2016. To [...] Read more.
This review explores the intersection of Artificial Intelligence (AI) and Generative Design (GD) in engineering within the mechanical, industrial, civil, and architectural domains. Driven by advances in AI and computational resources, this intersection has grown rapidly, yielding over 14,000 publications since 2016. To map the research landscape, this review employed semantic search and Natural Language Processing, parsing 14,355 publications to ultimately select the 88 most relevant studies through clustering and topic modelling. These studies were categorised according to AI and GD techniques, application domains, benefits, and limitations, providing insights into research trends and practical implications. The results reveal a significant growth in the integration of advanced generative AI methods, notably Generative Adversarial Networks for direct design generation, alongside the continued use of genetic algorithms and surrogate models (e.g., Convolutional Neural Networks and Multilayer Perceptrons) to manage computational complexity. Structural and aerodynamic applications were the most common, with benefits including improvements in computational efficiency and design diversity. However, barriers remain, including data generation costs, model accuracy, and interpretability. Research opportunities include the development of generalisable foundation surrogate models, the integration of emerging generative methods such as diffusion models and large language models, and the explicit consideration of manufacturability constraints within generative processes. Full article
(This article belongs to the Special Issue Application of Artificial Intelligence in Smart Factories: From Sensor Networks to Large Language Models)
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16 pages, 2357 KB  
Article
A Novel Integrated CAD-Multibody Approach for TMJ Prosthesis Design
by Talal Bin Irshad, Giulia Pascoletti, Stefano Pagano, Chiara Valenti and Elisabetta Maria Zanetti
Designs 2025, 9(4), 78; https://doi.org/10.3390/designs9040078 - 20 Jun 2025
Cited by 1 | Viewed by 1408
Abstract
This study presents a methodology for optimizing the design of the fossa component in temporomandibular joint (TMJ) prostheses, particularly in cases requiring replacement due to severe pathology or trauma. Leveraging advancements in 3D printing, the research aims to align prosthetic function with natural [...] Read more.
This study presents a methodology for optimizing the design of the fossa component in temporomandibular joint (TMJ) prostheses, particularly in cases requiring replacement due to severe pathology or trauma. Leveraging advancements in 3D printing, the research aims to align prosthetic function with natural jaw movements. A multibody simulation model was used to evaluate different designs based on key performance indicators: range of motion, condylar trajectory accuracy, and contact force magnitudes. Three designs were analyzed: a compact design fossa (CDF) with a spherical condyle, an enhanced design fossa (EDF) with a more anatomically realistic structure, and a simulation-driven design (MEDF) derived from condylar motion patterns. The results indicate that CDF could lead to dislocation at 13° of mouth opening. In contrast, EDF and MEDF safely enabled full opening (20°), closely replicated natural condyle trajectories (with deviations under 2.5 mm in all directions), and reduced contact forces, which can contribute to a longer prosthesis lifespan. MEDF showed the lowest peak contact force (−21% compared to EDF). The study successfully established a framework for evaluating and guiding patient-specific TMJ prosthetic designs, enhancing both functional rehabilitation and mechanical durability by minimizing wear through optimized contact dynamics. Full article
(This article belongs to the Collection Editorial Board Members’ Collection Series: Biomaterials Design)
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16 pages, 14369 KB  
Article
Durability Analysis of a Magneto-Rheological Fluid for Automotive Braking System
by Giovanni Imberti, Henrique de Carvalho Pinheiro, Matteo De Carlo, Guglielmo Peruzzi and Massimiliana Carello
Designs 2025, 9(3), 74; https://doi.org/10.3390/designs9030074 - 17 Jun 2025
Viewed by 974
Abstract
The automotive market is looking for innovative braking solutions that can mitigate or eliminate secondary emissions. For this reason, new braking paradigms have been developed, and magnetorheological brakes could be considered a suitable solution due to their performance and controllability features. Reliability is [...] Read more.
The automotive market is looking for innovative braking solutions that can mitigate or eliminate secondary emissions. For this reason, new braking paradigms have been developed, and magnetorheological brakes could be considered a suitable solution due to their performance and controllability features. Reliability is a key factor for automotive braking systems, so it is essential to analyze the behavior of such technological solutions in iterative cycles to understand their capability of maintaining brake performance throughout their operative lifecycles. This article presents a preliminary experimental durability analysis and defines the testing standard procedures to be used as boundaries for this analysis. Then, a durability test bench is developed and produced to evaluate the magnetorheological fluid over an equivalent distance of 100,000 km. After the tests, the fluid’s characteristics are compared to its original features using a rheometer apparatus and Scanning Electron Microscopy (SEM). Full article
(This article belongs to the Collection Editorial Board Members’ Collection Series: Designs of New Generation Vehicles)
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22 pages, 2918 KB  
Article
Design and Development of a Low-Power IoT System for Continuous Temperature Monitoring
by Luis Miguel Pires, João Figueiredo, Ricardo Martins, João Nascimento and José Martins
Designs 2025, 9(3), 73; https://doi.org/10.3390/designs9030073 - 12 Jun 2025
Cited by 2 | Viewed by 3340
Abstract
This article presents the development of a compact, high-precision, and energy-efficient temperature monitoring system designed for tracking applications where continuous and accurate thermal monitoring is essential. Built around the HY0020 System-on-Chip (SoC), the system integrates two bandgap-based temperature sensors—one internal to the SoC [...] Read more.
This article presents the development of a compact, high-precision, and energy-efficient temperature monitoring system designed for tracking applications where continuous and accurate thermal monitoring is essential. Built around the HY0020 System-on-Chip (SoC), the system integrates two bandgap-based temperature sensors—one internal to the SoC and one external (Si7020-A20)—mounted on a custom PCB and powered by a coin cell battery. A distinctive feature of the system is its support for real-time parameterization of the internal sensor, which enables advanced capabilities such as thermal profiling, cross-validation, and onboard diagnostics. The system was evaluated under both room temperature and refrigeration conditions, demonstrating high accuracy with the internal sensor showing an average error of 0.041 °C and −0.36 °C, respectively, and absolute errors below ±0.5 °C. With an average current draw of just 0.01727 mA, the system achieves an estimated autonomy of 6.6 years on a 1000 mAh battery. Data are transmitted via Bluetooth Low Energy (BLE) to a Raspberry Pi 4 gateway and forwarded to an IoT cloud platform for remote access and analysis. With a total cost of approximately EUR 20 and built entirely from commercially available components, this system offers a scalable and cost-effective solution for a wide range of temperature-sensitive applications. Its combination of precision, long-term autonomy, and advanced diagnostic capabilities make it suitable for deployment in diverse fields such as supply chain monitoring, environmental sensing, biomedical storage, and smart infrastructure—where reliable, low-maintenance thermal tracking is essential. Full article
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24 pages, 3541 KB  
Article
Substructure Optimization for a Semi-Submersible Floating Wind Turbine Under Extreme Environmental Conditions
by Kevin Fletcher, Edem Tetteh, Eric Loth, Chris Qin and Rick Damiani
Designs 2025, 9(3), 68; https://doi.org/10.3390/designs9030068 - 3 Jun 2025
Viewed by 1896
Abstract
A barrier to the adoption of floating offshore wind turbines is their high cost relative to conventional fixed-bottom wind turbines. The largest contributor to this cost disparity is generally the floating substructure, due to its large size and complexity. Typically, a primary driver [...] Read more.
A barrier to the adoption of floating offshore wind turbines is their high cost relative to conventional fixed-bottom wind turbines. The largest contributor to this cost disparity is generally the floating substructure, due to its large size and complexity. Typically, a primary driver of the geometry and size of a floating substructure is the extreme environmental load case of Region 4, where platform loads are the greatest due to the impact of extreme wind and waves. To address this cost issue, a new concept for a floating offshore wind turbine’s substructure, its moorings, and anchors was optimized for a reference 10-MW turbine under extreme load conditions using OpenFAST. The levelized cost of energy was minimized by fixing the above-water turbine design and minimizing the equivalent substructure mass, which is based on the mass of all substructure components (stem, legs, buoyancy cans, mooring, and anchoring system) and associated costs of their materials, manufacturing, and installation. A stepped optimization scheme was used to allow an understanding of their influence on both the system cost and system dynamic responses for the extreme parked load case. The design variables investigated include the length and tautness ratio of the mooring lines, length and draft of the cans, and lengths of the legs and the stem. The dynamic responses investigated include the platform pitch, platform roll, nacelle horizontal acceleration, and can submergence. Some constraints were imposed on the dynamic responses of interest, and the metacentric height of the floating system was used to ensure static stability. The results offer insight into the parametric influence on turbine motion and on the potential savings that can be achieved through optimization of individual substructure components. A 36% reduction in substructure costs was achieved while slightly improving the hydrodynamic stability in pitch and yielding a somewhat large surge motion and slight roll increase. Full article
(This article belongs to the Special Issue Design and Analysis of Offshore Wind Turbines)
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27 pages, 3145 KB  
Review
Potential Designs for Miniature Distributed Optical Fiber Smart Sensors Systems for Use in Aerospace Flight Vehicles
by Graham Wild
Designs 2025, 9(2), 38; https://doi.org/10.3390/designs9020038 - 26 Mar 2025
Cited by 1 | Viewed by 3069
Abstract
This article explores the feasibility of miniaturizing and packaging fiber Bragg grating (FBG)-based distributed optical fiber smart sensors (DOFSS) for future flight trials. It highlights the importance of real-time, high-speed sensing in aerospace, particularly for hypersonic vehicles, and the challenges of conventional system [...] Read more.
This article explores the feasibility of miniaturizing and packaging fiber Bragg grating (FBG)-based distributed optical fiber smart sensors (DOFSS) for future flight trials. It highlights the importance of real-time, high-speed sensing in aerospace, particularly for hypersonic vehicles, and the challenges of conventional system integration. The advantages of FBG technology for structural health monitoring, temperature, and pressure sensing are examined. Potential systems, including light sources, spectral detection, and processing units, are discussed, along with challenges such as temperature fluctuations and vibrations. Innovations in photonic devices, fabrication, and packaging are emphasized, focusing on developing compact and robust FBG interrogation systems. The article proposes designs for integrated photonic circuits in FBG interrogation systems. The trade-offs between miniaturization and performance, considering sensitivity, resolution, and durability are also assessed. Finally, future research directions are outlined to enhance the sensitivity, resolution, and robustness of FBG interrogators while enabling miniaturization and multifunctionality. The article concludes by summarizing the potential for miniaturizing and packaging FBG-based DOFSS for aerospace flight trials. Full article
(This article belongs to the Section Mechanical Engineering Design)
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22 pages, 9803 KB  
Article
Guidelines for Design and Additive Manufacturing Specify the Use of Surgical Templates with Improved Accuracy Using the Masked Stereolithography Technique in the Zygomatic Bone Region
by Paweł Turek, Paweł Kubik, Dominika Ruszała, Natalia Dudek and Jacek Misiura
Designs 2025, 9(2), 33; https://doi.org/10.3390/designs9020033 - 12 Mar 2025
Viewed by 1299
Abstract
The zygomatic bone area experiences frequent mechanical damage in the middle craniofacial region, including the orbital floor. The orbital floor bone is very thin, ranging from 0.74 mm to 1.5 mm. Enhancing digitization, reconstruction, and CAD modeling procedures is essential to improving the [...] Read more.
The zygomatic bone area experiences frequent mechanical damage in the middle craniofacial region, including the orbital floor. The orbital floor bone is very thin, ranging from 0.74 mm to 1.5 mm. Enhancing digitization, reconstruction, and CAD modeling procedures is essential to improving the visualization of this structure. Achieving a homogeneous surface with high manufacturing accuracy is crucial for developing precise surgical models and tools for creating titanium mesh implants to reconstruct the orbital floor geometry. This article improved the accuracy of reconstruction and CAD modeling using the example of the development of a prototype implant to replace the zygomatic bone and a tool to form the geometry of the titanium mesh within the geometry of the orbital floor. The masked stereolithography (mSLA) method was used in the model manufacturing process because it is low-cost and highly accurate. Two manufacturing modes (standard and ultra-light) were tested on an Anycubic Photon M3 Premium 3D printer to determine which mode produced a more accurate representation of the geometry. To verify the geometric accuracy of the manufactured models, a GOM Scan1 structured light scanner was used. In the process of evaluating the accuracy of the model preparation, the maximum deviation, mean deviation, range and standard deviation were determined. The maximum deviations for anatomical structures created using the normal mode ranged from ±0.6 mm to ±0.7 mm. In contrast, models produced with the ultra-light mode showed deviations of ±0.5 mm to ±0.6 mm. Furthermore, the results indicate that the ultra-light mode offers better surface accuracy for die and stamp models. More than 70% of the surface of the models is within the deviation range of ±0.3 mm, which is sufficient for planning surgical procedures. However, the guidelines developed in the presented publication need to optimize the CAD process and select 3D-printing parameters to minimize deviations, especially at the edges of manufactured models. Full article
(This article belongs to the Special Issue Design Process for Additive Manufacturing)
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22 pages, 13198 KB  
Article
Design of an Environment for Virtual Training Based on Digital Reconstruction: From Real Vegetation to Its Tactile Simulation
by Alessandro Martinelli, Davide Fabiocchi, Francesca Picchio, Hermes Giberti and Marco Carnevale
Designs 2025, 9(2), 32; https://doi.org/10.3390/designs9020032 - 10 Mar 2025
Cited by 3 | Viewed by 2084
Abstract
The exploitation of immersive simulation platforms to improve traditional training techniques in the agricultural industry sector would enable year-round accessibility, flexibility, safety, and consistent high-quality training for agricultural operators. An innovative workflow in virtual simulations for training and educational purposes includes an immersive [...] Read more.
The exploitation of immersive simulation platforms to improve traditional training techniques in the agricultural industry sector would enable year-round accessibility, flexibility, safety, and consistent high-quality training for agricultural operators. An innovative workflow in virtual simulations for training and educational purposes includes an immersive environment in which the operator can interact with plants through haptic interfaces, following instructions imparted by a non-playing character (NPC) instructor. This study allows simulating the pruning of a complex case study, a hazelnut tree, reproduced in very high detail to offer agricultural operators a more realistic and immersive training environment than those currently existing. The process of creating a multisensorial environment starts with the integrated survey of the plant with a laser scanner and photogrammetry and then generates a controllable parametric model from roots to leaves with the exact positioning of the original branches. The model is finally inserted into a simulation, where haptic gloves with tactile resistance responsive to model collisions are tested. The results of the experimentation demonstrate the correct execution of this innovative design simulation, in which branches and leaves can be cut using a shear, with immediate sensory feedback. The project therefore aims to finalize this product as a realistic training platform for pruning, but not limited to it, paving the way for high-fidelity simulation for many other types of operations and specializations. Full article
(This article belongs to the Special Issue Mixture of Human and Machine Intelligence in Digital Manufacturing)
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17 pages, 6739 KB  
Article
Real-Time Electroencephalogram Data Visualization Using Generative AI Art
by Andrei Virgil Puiac, Lucian-Ionel Cioca, Gheorghe Daniel Lakatos and Adrian Groza
Designs 2025, 9(1), 16; https://doi.org/10.3390/designs9010016 - 30 Jan 2025
Cited by 1 | Viewed by 7827
Abstract
This study is the result of the need to research the visualization of brainwaves. The aim is based on the idea of using generative AI art systems as a method. Data visualization is an important part of understanding the evolution of the world [...] Read more.
This study is the result of the need to research the visualization of brainwaves. The aim is based on the idea of using generative AI art systems as a method. Data visualization is an important part of understanding the evolution of the world around us. It offers the ability to see a representation that goes beyond numbers. Generative AI systems have gained the possibility of helping the process of visualizing data in new ways. This specific process includes real-time-generated artistic renderings of these data. This real-time rendering falls into the field of brainwave visualization, with the help of the EEG (electroencephalogram), which can serve here as input data for Generative AI systems. The brainwave measurement technology as a form of input to real-time generative AI systems represents a novel intersection of neuroscience and art in the field of neurofeedback art. The main question this paper hopes to address is as follows: How can brainwaves be effectively fed into generative AI art systems, and where can the outcome lead, in terms of progress? EEG data were successfully integrated with generative AI to create interactive art. The installation provided an immersive experience by moving the image with the change in the user’s mental focus, demonstrating the impact of EEG-based art. Full article
(This article belongs to the Section Smart Manufacturing System Design)
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19 pages, 20282 KB  
Article
Design of a System for Driver Drowsiness Detection and Seat Belt Monitoring Using Raspberry Pi 4 and Arduino Nano
by Anthony Alvarez Oviedo, Jhojan Felipe Mamani Villanueva, German Alberto Echaiz Espinoza, Juan Moises Mauricio Villanueva, Andrés Ortiz Salazar and Elmer Rolando Llanos Villarreal
Designs 2025, 9(1), 11; https://doi.org/10.3390/designs9010011 - 13 Jan 2025
Cited by 2 | Viewed by 4004
Abstract
This research explores the design of a system for monitoring driver drowsiness and supervising seat belt usage in interprovincial buses. In Peru, road accidents involving long-distance bus transportation amounted to 5449 in 2022, and the human factor plays a significant role. It is [...] Read more.
This research explores the design of a system for monitoring driver drowsiness and supervising seat belt usage in interprovincial buses. In Peru, road accidents involving long-distance bus transportation amounted to 5449 in 2022, and the human factor plays a significant role. It is essential to understand how the use of non-invasive sensors for monitoring and supervising passengers and drivers can enhance safety in interprovincial transportation. The objective of this research is to develop a system using a Raspberry Pi 4 and Arduino Nano that allows for the storage of monitoring data. To achieve this, a conventional camera and MediaPipe were used for driver drowsiness detection, while passenger supervision was carried out using a combination of commercially available sensors as well as custom-built sensors. RS485 communication was utilized to store data related to both the driver and passengers. The simulations conducted demonstrate a high level of reliability in detecting driver drowsiness under specific conditions and the correct operation of the sensors for passenger supervision. Therefore, the proposed system is feasible and can be implemented for real-world testing. The implications of this research suggest that the system’s cost is not a barrier to its implementation, thus contributing to improved safety in interprovincial transportation. Full article
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16 pages, 3372 KB  
Article
Design of High-Speed Signal Simulation and Acquisition System for Power Machinery Virtual Testing
by Hongyu Liu, Wei Cui, He Li, Xiuyun Shuai, Qingxin Wang, Jingyao Zhang, Feiyang Zhao and Wenbin Yu
Designs 2025, 9(1), 5; https://doi.org/10.3390/designs9010005 - 6 Jan 2025
Viewed by 1780
Abstract
The rapid advancement of model-based simulation has driven the increased adoption of virtual testing in power machinery, raising demands for high accuracy and real-time signal processing. This study introduces a real-time signal simulation and acquisition system leveraging field-programmable gate array (FPGA) technology, designed [...] Read more.
The rapid advancement of model-based simulation has driven the increased adoption of virtual testing in power machinery, raising demands for high accuracy and real-time signal processing. This study introduces a real-time signal simulation and acquisition system leveraging field-programmable gate array (FPGA) technology, designed with flexible scalability and seamless integration with NI hardware-based test systems. The system supports various dynamic signals, including position, injection, and ignition signals, providing robust support for virtual testing and calibration. Comprehensive testing across scenarios involving oscilloscopes, signal generators, and the rapid control prototyping (RCP) platform confirms its high accuracy, stability, and adaptability in multi-signal processing and real-time response. This system is a state-of-the-art and extensively virtual field-tested platform for both power systems and power electronics. Full article
(This article belongs to the Topic Digital Manufacturing Technology)
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13 pages, 3203 KB  
Article
Effect of Curvature Shape on the Impact Strength of Additively Manufactured Acrylonitrile Butadiene Styrene Parts Produced via Fused Deposition Modeling
by Muhammad Fahad, Waseem Raja, Muhammad Naveed Iqbal and Abdul Waheed Awan
Designs 2024, 8(6), 132; https://doi.org/10.3390/designs8060132 - 8 Dec 2024
Cited by 1 | Viewed by 1625
Abstract
Additive manufacturing (AM) has greatly revolutionized manufacturing due to its ability to manufacture complex shapes without the need for additional tooling. Most AM applications are based on geometries comprising curved shapes subjected to impact loads. The main focus of this study was on [...] Read more.
Additive manufacturing (AM) has greatly revolutionized manufacturing due to its ability to manufacture complex shapes without the need for additional tooling. Most AM applications are based on geometries comprising curved shapes subjected to impact loads. The main focus of this study was on investigating the influence of infill density and the radius of curvature on the impact strength of parts manufactured via an FDM process. Standard geometrical specimens with varying part infill densities and radii of curvature were produced and subjected to Charpy impact tests to evaluate their impact strength. The results suggest that the impact strength increases with the increased density caused by higher amounts of material as well as by the changing cross-sectional areas of the beads. Also, the radius of curvature of the parts shows a clear inverse relationship with the impact energy absorbed by the specimens (i.e., increasing the radius decreased the impact energy of the parts) produced via an FDM process, which can be explained using the beam theory of structural mechanics. The maximum value of impact strength obtained was 287 KJ/m2, and this was achieved at the highest infill density (i.e., solid) and for the smallest radius of curvature. Full article
(This article belongs to the Special Issue Studies in Advanced and Selective Manufacturing Technologies)
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18 pages, 17110 KB  
Article
Contribution of Artificial Intelligence (AI) to Code-Based 3D Modeling Tasks
by Marianna Zichar and Ildikó Papp
Designs 2024, 8(5), 104; https://doi.org/10.3390/designs8050104 - 18 Oct 2024
Cited by 2 | Viewed by 2707
Abstract
The rapid advancement of technology and innovation is also impacting education across different levels. The rise of Artificial Intelligence (AI) is beginning to transform education in various areas, from course materials to assessment systems. This requires educators to reconsider how they evaluate students’ [...] Read more.
The rapid advancement of technology and innovation is also impacting education across different levels. The rise of Artificial Intelligence (AI) is beginning to transform education in various areas, from course materials to assessment systems. This requires educators to reconsider how they evaluate students’ knowledge. It is crucial to understand if and to what extent assignments can be completed using AI tools. This study explores two hypotheses about the risks of using code-based 3D modeling software in education and the potential for students to delegate their work to AI when completing assignments. We selected two tasks that students were able to successfully complete independently and provided the same amount of information (both textual and image) to AI in order to generate the necessary code. We tested the widely used ChatGPT and Gemini AI bots to assess their current performance in generating code based on text prompts or image-based information for the two models. Our findings indicate that students are not yet able to entirely delegate their work to these AI tools. Full article
(This article belongs to the Special Issue Design Process for Additive Manufacturing)
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15 pages, 7363 KB  
Article
Integrating Pneumatic and Thermal Control in 3D Bioprinting for Improved Bio-Ink Handling
by Perrin Woods, Carter Smith, Scott Clark and Ahasan Habib
Designs 2024, 8(4), 83; https://doi.org/10.3390/designs8040083 - 22 Aug 2024
Cited by 7 | Viewed by 3010
Abstract
The rapid advancement of 3D bioprinting has created a need for cost-effective and versatile 3D printers capable of handling bio-inks at various scales. This study introduces a novel framework for a specialized nozzle-holding device designed for an extrusion-based 3D bioprinter, specifically tailored to [...] Read more.
The rapid advancement of 3D bioprinting has created a need for cost-effective and versatile 3D printers capable of handling bio-inks at various scales. This study introduces a novel framework for a specialized nozzle-holding device designed for an extrusion-based 3D bioprinter, specifically tailored to address the rigorous requirements of tissue engineering applications. The proposed system combines a pneumatically actuated plunger mechanism with an adaptive nozzle system, ensuring the safe inhibition and precise dispensing of bio-inks. Rigorous thermal management strategies are employed to maintain consistently low temperatures, thereby preserving bio-ink integrity without changing chemical stability. A key component of this design is a precision-milled aluminum block, which optimizes thermal characteristics while providing a protective barrier. Additionally, a 3D-printed extruder head bracket, fabricated using a high-precision resin printer, effectively mitigates potential thermal inconsistencies. The integration of these meticulously engineered components results in a modified extrusion-based 3D bioprinter with the potential to significantly advance tissue engineering methodologies. This study not only contributes to the advancement of bioprinting technology but also underscores the crucial role of innovative engineering in addressing tissue engineering challenges. The proposed bioprinter design lays a solid foundation for future research, aiming to develop more accurate, efficient, and reliable bioprinting solutions. Full article
(This article belongs to the Special Issue Design Process for Additive Manufacturing)
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26 pages, 4301 KB  
Article
Optimized Floating Offshore Wind Turbine Substructure Design Trends for 10–30 MW Turbines in Low-, Medium-, and High-Severity Wave Environments
by Joseph Habib Dagher, Andrew J. Goupee and Anthony M. Viselli
Designs 2024, 8(4), 72; https://doi.org/10.3390/designs8040072 - 18 Jul 2024
Cited by 8 | Viewed by 5467
Abstract
Floating offshore wind is a promising renewable energy source, as 60% of the wind resources globally are found at depths requiring floating technologies, it minimizes construction at sea, and provides opportunities for industrialization given a lower site dependency. While floating offshore wind has [...] Read more.
Floating offshore wind is a promising renewable energy source, as 60% of the wind resources globally are found at depths requiring floating technologies, it minimizes construction at sea, and provides opportunities for industrialization given a lower site dependency. While floating offshore wind has numerous advantages, a current obstacle is its cost in comparison to more established energy sources. One cost-reduction approach for floating wind is increasing turbine capacities, which minimizes the amount of foundations, moorings, cables, and O&M equipment. This work presents trends in mass-optimized VolturnUS hull designs as turbine capacity increases for various wave environments. To do this, a novel rapid hull optimization framework is presented that employs frequency domain modeling, estimations of statistical extreme responses, industry constructability requirements, and genetic algorithm optimization to generate preliminary mass-optimal VolturnUS hull designs for a given turbine design and set of site conditions. Using this framework, mass-optimized VolturnUS hull designs were generated for 10–30 MW turbines for wave environments of varying severities. These design studies show that scaling up turbine capacities increases the mass efficiency of substructure designs, with decreasing returns, throughout the examined turbine capacity range. Additionally, increased wave environment severity is shown to increase the required mass of a given substructure design. Full article
(This article belongs to the Special Issue Design and Analysis of Offshore Wind Turbines)
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20 pages, 11203 KB  
Article
Dimensional Accuracy in 4D-Printed PLA Objects with Holes: Experimental and Numerical Investigations
by Alexandru-Antonio Ene, Tudor George Alexandru and Diana Popescu
Designs 2024, 8(3), 56; https://doi.org/10.3390/designs8030056 - 6 Jun 2024
Cited by 2 | Viewed by 2286
Abstract
This study investigates the impact of material and process parameters—specifically, filament color, infill density, and pattern—on the dimensional accuracy of 4D-printed polylactic acid (PLA) objects featuring holes of varying diameters (6, 8, and 10 mm) that undergo a heat-induced recovery process. The objective [...] Read more.
This study investigates the impact of material and process parameters—specifically, filament color, infill density, and pattern—on the dimensional accuracy of 4D-printed polylactic acid (PLA) objects featuring holes of varying diameters (6, 8, and 10 mm) that undergo a heat-induced recovery process. The objective was to understand how these factors affect shape retention and the dimensional accuracy of holes through a comparative analysis of the diameters before and after recovery. Increased variability in the hole diameters was noted after recovery, regardless of the values of the independent variables. The objects did not fully return to their original planar shape, and the holes did not completely return to their circular form, resulting in smaller diameters for each sample. No significant differences in the hole diameters could be determined. Additionally, there was no consistent trend in identifying the most influential parameter affecting the accuracy of the recovered holes. However, it was observed that higher infill densities improved shape retention. A quasi-static finite elements analysis model was developed to capture the mechanical behavior of the 4D-printed parts. This model incorporated temperature-dependent material characteristics to predict the strain occurring near the holes. Nodal displacements were defined according to the deformed shape. A correlation was established between the observed strains and the post-recovery dimensional accuracy of the specimens. The importance of this work was demonstrated through a case study involving a two-sieve filtering device for small objects. Full article
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19 pages, 13288 KB  
Article
Monitoring the Center of Gravity of a Vehicle Seat to Detect the Occupant Position
by Alberto Vergnano, Claudio Giorgianni and Francesco Leali
Designs 2024, 8(3), 44; https://doi.org/10.3390/designs8030044 - 15 May 2024
Cited by 4 | Viewed by 3529
Abstract
Deploying an airbag when a vehicle occupant is too close to it can cause injury. An adaptive Airbag Control Unit (ACU) would improve the effectiveness of the safety system, provided it is aware of the actual position of the occupants once the crash [...] Read more.
Deploying an airbag when a vehicle occupant is too close to it can cause injury. An adaptive Airbag Control Unit (ACU) would improve the effectiveness of the safety system, provided it is aware of the actual position of the occupants once the crash is going to occur. Occupants can be monitored with vision-based and radar-based sensing in the vehicle, but the research question is whether other reliable devices exist. In this research, a real seat is equipped with four sensors in the supports from the floor, as well as an Inertial Measurement Unit (IMU) and a microcontroller. The device is capable of identifying correct position or different Out of Position (OP) conditions and inform an adaptive ACU. The paper presents the seat layout in detail and its testing in extensive driving experiments with multiple participants. Depending on the position of the driver, the identification is correct 45–100% of the time. Monitoring the occupant position by a sensorized seat is feasible and can improve the reliability of the onboard safety system when integrated with other occupant monitoring devices. Full article
(This article belongs to the Section Vehicle Engineering Design)
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20 pages, 8159 KB  
Article
Towards a Sustainable Laser Powder Bed Fusion Process via the Characterisation of Additively Manufactured Nitinol Parts
by Muhannad Ahmed Obeidi, Paul Healy, Hasan Alobaidi, Declan Bourke and Dermot Brabazon
Designs 2024, 8(3), 45; https://doi.org/10.3390/designs8030045 - 15 May 2024
Cited by 6 | Viewed by 3313
Abstract
Is additive manufacturing (AM) a sustainable process? Can the process be optimised to produce sustainable AM parts and production techniques? Additive manufacturing offers the production of parts made of different types of materials in addition to the complex geometry that is difficult or [...] Read more.
Is additive manufacturing (AM) a sustainable process? Can the process be optimised to produce sustainable AM parts and production techniques? Additive manufacturing offers the production of parts made of different types of materials in addition to the complex geometry that is difficult or impossible to produce by using the traditional subtractive methods. This study is focused on the optimisation of laser powder bed fusion (L-PBF), one of the most common technologies used in additive manufacturing and 3D printing. This research was carried out by modulating the build layer thickness of the deposited metal powder and the input volumetric energy density. The aim of the proposed strategy is to save the build time by maximizing the applied layer thickness of nitinol powder while retrieving the different AM part properties. The saving in the process time has a direct effect on the total cost of the produced part as a result of several components like electric energy, inert gas consumption, and labour. Nickel-rich nitinol (52.39 Ni at.%) was selected for investigation in this study due to its extremely high superplastic and shape memory properties in addition to the wide application in various industries like aerospace, biomedical, and automotive. The results obtained show that significant energy and material consumption can be found by producing near full dens AM parts with limited or no alteration in chemical and mechanical properties. Full article
(This article belongs to the Section Mechanical Engineering Design)
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21 pages, 10990 KB  
Article
Electromagnetic Interaction Model between an Electric Motor and a Magnetorheological Brake
by Sidorela Caushaj, Giovanni Imberti, Henrique de Carvalho Pinheiro and Massimiliana Carello
Designs 2024, 8(2), 25; https://doi.org/10.3390/designs8020025 - 14 Mar 2024
Cited by 3 | Viewed by 2903
Abstract
This article focuses on modelling and validating a groundbreaking magnetorheological braking system. Addressing shortcomings in traditional automotive friction brake systems, including response delays, wear, and added mass from auxiliary components, the study employs a novel brake design combining mechanical and electrical elements for [...] Read more.
This article focuses on modelling and validating a groundbreaking magnetorheological braking system. Addressing shortcomings in traditional automotive friction brake systems, including response delays, wear, and added mass from auxiliary components, the study employs a novel brake design combining mechanical and electrical elements for enhanced efficiency. Utilizing magnetorheological (MR) technology within a motor–brake system, the investigation explores the influence of external magnetic flux from the nearby motor on MR fluid movement, particularly under high-flux conditions. The evaluation of a high-magnetic-field mitigator is guided by simulated findings with the objective of resolving potential issues. An alternative method of resolving an interaction between an electric motor and a magnetorheological brake is presented. In addition, to test four configurations, multiple absorber materials are reviewed. Full article
(This article belongs to the Special Issue Design and Manufacture of Electric Vehicles)
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73 pages, 35413 KB  
Review
A Review of Novel and Non-Conventional Propulsion Integrations for Next-Generation Aircraft
by Karim Abu Salem, Giuseppe Palaia, Pedro D. Bravo-Mosquera and Alessandro A. Quarta
Designs 2024, 8(2), 20; https://doi.org/10.3390/designs8020020 - 20 Feb 2024
Cited by 18 | Viewed by 9829
Abstract
The aim of this review paper is to collect and discuss the most relevant and updated contributions in the literature regarding studies on new or non-conventional technologies for propulsion–airframe integration. Specifically, the focus is given to both evolutionary technologies, such as ultra-high bypass [...] Read more.
The aim of this review paper is to collect and discuss the most relevant and updated contributions in the literature regarding studies on new or non-conventional technologies for propulsion–airframe integration. Specifically, the focus is given to both evolutionary technologies, such as ultra-high bypass ratio turbofan engines, and breakthrough propulsive concepts, represented in this frame by boundary layer ingestion engines and distributed propulsion architectures. The discussion focuses mainly on the integration effects of these propulsion technologies, with the aim of defining performance interactions with the overall aircraft, in terms of aerodynamic, propulsive, operating and mission performance. Hence, this work aims to analyse these technologies from a general perspective, related to the effects they have on overall aircraft design and performance, primarily considering the fuel consumption as a main metric. Potential advantages but also possible drawbacks or detected showstoppers are proposed and discussed with the aim of providing as broad a framework as possible for the aircraft design development roadmap for these emerging propulsive technologies. Full article
(This article belongs to the Special Issue Advances in Aircraft Propulsion System Modelling, Design and Simulation)
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21 pages, 847 KB  
Article
Incorporating a Load-Shifting Algorithm for Optimal Energy Storage Capacity Design in Smart Homes
by Ruengwit Khwanrit, Yuto Lim, Saher Javaid, Chalie Charoenlarpnopparut and Yasuo Tan
Designs 2024, 8(1), 11; https://doi.org/10.3390/designs8010011 - 22 Jan 2024
Cited by 6 | Viewed by 3153
Abstract
In today’s power system landscape, renewable energy (RE) resources play a pivotal role, particularly within the residential sector. Despite the significance of these resources, the intermittent nature of RE resources, influenced by variable weather conditions, poses challenges to their reliability as energy resources. [...] Read more.
In today’s power system landscape, renewable energy (RE) resources play a pivotal role, particularly within the residential sector. Despite the significance of these resources, the intermittent nature of RE resources, influenced by variable weather conditions, poses challenges to their reliability as energy resources. Addressing this challenge, the integration of an energy storage system (ESS) emerges as a viable solution, enabling the storage of surplus energy during peak-generation periods and subsequent release during shortages. One of the great challenges of ESSs is how to design ESSs efficiently. This paper focuses on a distributed power-flow system within a smart home environment, comprising uncontrollable power generators, uncontrollable loads, and multiple energy storage units. To address the challenge of minimizing energy loss in ESSs, this paper proposes a novel approach, called energy-efficient storage capacity with loss reduction (SCALE) scheme, that combines multiple-load power-flow assignment with a load-shifting algorithm to minimize energy loss and determine the optimal energy storage capacity. The optimization problem for optimal energy storage capacity is formalized using linear programming techniques. To validate the proposed scheme, real experimental data from a smart home environment during winter and summer seasons are employed. The results demonstrate the efficacy of the proposed algorithm in significantly reducing energy loss, particularly under winter conditions, and determining optimal energy storage capacity, with reductions of up to 11.4% in energy loss and up to 62.1% in optimal energy storage capacity. Full article
(This article belongs to the Special Issue Smart Home Design, 2nd Edition)
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12 pages, 6993 KB  
Article
Experimental Tests of the Piston Axial Pump with Constant Pressure and Variable Flow
by Radovan Petrović, Andrzej Banaszek, Maja Andjelković, Hana R. Qananah and Khalefa A. Alnagasa
Designs 2024, 8(1), 5; https://doi.org/10.3390/designs8010005 - 30 Dec 2023
Cited by 6 | Viewed by 3872
Abstract
Constant pressure variable flow reciprocating axial pumps (CPAP) are used in various applications, where a constant output pressure is maintained when the flow rate changes. When the hydraulic system is at rated pressure or less, the swash plate has maximum tilt, and the [...] Read more.
Constant pressure variable flow reciprocating axial pumps (CPAP) are used in various applications, where a constant output pressure is maintained when the flow rate changes. When the hydraulic system is at rated pressure or less, the swash plate has maximum tilt, and the pump delivers maximum flow. The swash plate comes into this position thanks to the action of a reactive piston in which there are two springs. However, when the pressure rises above the nominal pressure value, the piston of the hydraulic pressure transducer (HPT) distributes the fluid under pressure to the hydraulic cylinder (HC), which causes a decrease in the tilt angle of the swash plate and a decrease in flow. The CPAP was selected as a component of the hydraulic system of the aircraft for the experimental tests in this paper. The experimental tests covered the structural and working parameters of the pump and analyzed their performance, efficiency and reliability. Experimental tests of structural and operating parameters of the CPAP were carried out in the Laboratory for Hydraulics and Pneumatics “PPT-Namenska” Trstenik on the hydraulic system, which simulated the real conditions prevailing in the hydraulic system of the aircraft. A system was used for data acquisition and recording of pump characteristics, which were obtained during experimental testing. The results of the measurement and testing of the structural parameters of the CPAP are shown in tabular form, and the experimental tests of static characteristics and dynamic behavior are shown diagrammatically. Full article
(This article belongs to the Section Mechanical Engineering Design)
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29 pages, 4284 KB  
Article
Development and Performance Evaluation of Fibrous Pseudoplastic Quaternary Cement Systems for Aerial Additive Manufacturing
by Barrie Dams, Paul Shepherd and Richard J. Ball
Designs 2023, 7(6), 137; https://doi.org/10.3390/designs7060137 - 27 Nov 2023
Cited by 5 | Viewed by 2611
Abstract
Aerial additive manufacturing (AAM) represents a paradigm shift in using unmanned aerial vehicles (UAVs, often called ‘drones’) in the construction industry, using self-powered and untethered UAVs to extrude structural cementitious material. This requires miniaturisation of the deposition system. Rheological properties and known hydration [...] Read more.
Aerial additive manufacturing (AAM) represents a paradigm shift in using unmanned aerial vehicles (UAVs, often called ‘drones’) in the construction industry, using self-powered and untethered UAVs to extrude structural cementitious material. This requires miniaturisation of the deposition system. Rheological properties and known hydration times are important material parameters. Calcium aluminate cement (CAC) systems can be advantageous over purely ordinary Portland cement (OPC) binders as they promote hydration and increase early strength. A quaternary OPC/pulverised fuel ash (PFA)/CAC/calcium sulphate (CS) system was combined with polyvinyl alcohol (PVA) fibres and pseudoplastic hydrocolloids to develop a novel AAM material for miniaturised deposition. CAC hydration is affected by environmental temperature. Intending material to be extruded in situ, mixes were tested at multiple temperatures. OPC/PFA/CAC/CS mixes with PVA fibres were successfully extruded with densities of ≈1700 kg/m3, yield stresses of 1.1–1.3 kPa and a compressive strength of 25 MPa. Pseudoplastic OPC/PFA/CAC/CS quaternary cementitious systems are demonstrated to be viable for AAM, provided mixes are modified with retarders as temperature increases. This study can significantly impact industry by demonstrating structural material which can be extruded using UAVs in challenging or elevated in situ construction, reducing safety risks. Full article
(This article belongs to the Special Issue Additive Manufacturing – Process Optimisation)
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26 pages, 7961 KB  
Article
Field Experiment for a Prequalification Scheme for a Distribution System Operator on Distributed Energy Resource Aggregations
by Jung-Sung Park and Bal-Ho Kim
Designs 2023, 7(6), 134; https://doi.org/10.3390/designs7060134 - 17 Nov 2023
Cited by 2 | Viewed by 2126
Abstract
The purpose of this paper is to summarize and share the field experiment results of KEPCO’s project consortium to create a TSO-DSO-DERA interaction scheme. The field experiment was conducted based on the prequalification algorithm proposed in previous research from the same consortium, and [...] Read more.
The purpose of this paper is to summarize and share the field experiment results of KEPCO’s project consortium to create a TSO-DSO-DERA interaction scheme. The field experiment was conducted based on the prequalification algorithm proposed in previous research from the same consortium, and was designed to verify the validity of the algorithm under realistic grid conditions. In addition, during the course of the field experiment, it was found that points that were missed or not given much importance in the existing prequalification algorithm could affect the completeness of the overall system, and then practical improvements were made to improve this. The demonstration results confirm that the proposed algorithm is effective in real-world grid environments and can help DSOs to ensure the reliability of the distribution system while supporting DERA’s participation in the wholesale market using the proposed prequalification scheme. Full article
(This article belongs to the Collection Editorial Board Members’ Collection Series: Smart Energy Systems Design)
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22 pages, 8629 KB  
Article
Rheological Behaviour of ABS/Metal Composites with Improved Thermal Conductivity for Additive Manufacturing
by Vicente F. Moritz, Harald Prévost, Janaína S. Crespo, Carlos A. Ferreira and Declan M. Devine
Designs 2023, 7(6), 133; https://doi.org/10.3390/designs7060133 - 17 Nov 2023
Cited by 3 | Viewed by 3590
Abstract
Metal-reinforced polymer composites are suitable materials for applications requiring special thermal, electrical or magnetic properties. Three-dimensional printing technologies enable these materials to be quickly shaped in any design directly and without the need for expensive moulds. However, processing data correlating specific information on [...] Read more.
Metal-reinforced polymer composites are suitable materials for applications requiring special thermal, electrical or magnetic properties. Three-dimensional printing technologies enable these materials to be quickly shaped in any design directly and without the need for expensive moulds. However, processing data correlating specific information on how the metal particles influence the rheological behaviour of such composites is lacking, which has a direct effect on the processability of these composites through melt processing additive manufacturing. This study reports the compounding and characterisation of ABS composites filled with aluminium and copper particulates. Experimental results demonstrated that the tensile modulus increased with the incorporation of metal particles; however, there was also an intense embrittling effect. Mechanical testing and rheological analysis indicated poor affinity between the fillers and matrix, and the volume fraction proved to be a crucial factor for complex viscosity, storage modulus and thermal conductivity. However, a promising set of properties was achieved, paving the way for polymer–metal composites with optimised processability, microstructure and properties in melt processing additive manufacturing. Full article
(This article belongs to the Special Issue Additive Manufacturing – Process Optimisation)
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20 pages, 4648 KB  
Review
A Review of the Current State of the Art of Polyether Ether Ketone (PEEK) Composite Based 3D-Printed Biomedical Scaffolds
by Rajesh Surendran, Sithara Sreenilayam Pavithran, Anugop Balachandran, Sony Vijayan, Kailasnath Madanan and Dermot Brabazon
Designs 2023, 7(6), 128; https://doi.org/10.3390/designs7060128 - 10 Nov 2023
Cited by 12 | Viewed by 4912
Abstract
Three-dimensional printing or additive manufacturing (AM) has enabled innovative advancements in tissue engineering through scaffold development. The use of scaffolds, developed by using AM technology for tissue repair (like cartilage and bone), could enable the growth of several cell types on the same [...] Read more.
Three-dimensional printing or additive manufacturing (AM) has enabled innovative advancements in tissue engineering through scaffold development. The use of scaffolds, developed by using AM technology for tissue repair (like cartilage and bone), could enable the growth of several cell types on the same implant. Scaffolds are 3D-printed using polymer-based composites. polyether ether ketone (PEEK)-based composites are ideal for scaffold 3D printing due to their excellent biocompatibility and mechanical properties resembling human bone. It is therefore considered to be the next-generation bioactive material for tissue engineering. Despite several reviews on the application of PEEK in biomedical fields, a detailed review of the recent progress made in the development of PEEK composites and the 3D printing of scaffolds has not been published. Therefore, this review focuses on the current status of technological developments in the 3D printing of bone scaffolds using PEEK-based composites. Furthermore, this review summarizes the challenges associated with the 3D printing of high-performance scaffolds based on PEEK composites. Full article
(This article belongs to the Special Issue Additive Manufacturing – Process Optimisation)
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25 pages, 3748 KB  
Article
A Dynamic Matrix for the Study of Free Vibrations of Thin Circular Cylindrical Shells under Different Boundary Conditions
by Marco Cammalleri and Antonella Castellano
Designs 2023, 7(6), 122; https://doi.org/10.3390/designs7060122 - 26 Oct 2023
Cited by 6 | Viewed by 3256
Abstract
Although free vibrations of thin-walled cylinders have been extensively addressed in the relevant literature, finding a good balance between accuracy and simplicity of the procedures used for natural frequency assessment is still an open issue. This paper proposes a novel approach with a [...] Read more.
Although free vibrations of thin-walled cylinders have been extensively addressed in the relevant literature, finding a good balance between accuracy and simplicity of the procedures used for natural frequency assessment is still an open issue. This paper proposes a novel approach with a high potential for practical application for rapid esteem of natural frequencies of thin-walled cylinders under different boundary conditions. Starting from Donnell–Mushtari’s shell theory, the differential problem is simplified by using the principle of virtual work and introducing the flexural waveforms of a beam as constrained as the cylinder. Hence, the formulation is reduced to the eigenvalue problem of an equivalent 3 × 3 dynamic matrix, which depends on the cylinder geometry, material, and boundary conditions. Several comparisons with experimental, numerical, and analytical approaches are presented to prove model reliability and practical interest. An excellent balance between fast usability and accuracy is achieved. The user-friendliness of the model makes it suitable to be implemented during the design stage without requiring any deep knowledge of the topic. Full article
(This article belongs to the Section Civil Engineering Design)
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13 pages, 6229 KB  
Article
Effect of Interference Size on Contact Pressure Distribution of Railway Wheel Axle Press Fitting
by Kitesa Akewaq Irena, Hirpa G. Lemu and Yahiya Ahmed Kedir
Designs 2023, 7(5), 119; https://doi.org/10.3390/designs7050119 - 22 Oct 2023
Cited by 5 | Viewed by 8401
Abstract
Mechanical couplings in engineering usually use interference fits to connect the shaft and hub. A railway wheel axle is a press fit that is connected by interference and can be subjected to bending stress. In loaded press fits, a high concentration of contact [...] Read more.
Mechanical couplings in engineering usually use interference fits to connect the shaft and hub. A railway wheel axle is a press fit that is connected by interference and can be subjected to bending stress. In loaded press fits, a high concentration of contact stresses can be generated in the area of the axle-fillet beam, which in most cases leads to the failure of the axle due to fatigue and fretting fatigues. Therefore, it is crucial to determine the ability of the press-fitted joints to provide sufficient frictional resistance that can withstand the loads and torques by evaluating the safety factor, especially when the mechanical or structural system is loaded. In this paper, the contact pressure and stress distribution along the radius of the wheel axle are studied using the analytical calculation of Lame’s equation, and the numerical method used is by ANSYS software. It was found that interference fits have a great influence on the connection strength of interference fits, which are directly related to the contact pressure. Increasing the interference increases the contact pressure, which allows higher torque and load capacity to be transmitted. The finite element analysis showed good agreement for the highest interference value of 230 µm with a relative error of 1.4%, while this error increased to the maximum relative error of 14.33% for a minimum interference of 100 µm. Full article
(This article belongs to the Section Mechanical Engineering Design)
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18 pages, 4747 KB  
Article
3D Printed Voronoi Structures Inspired by Paracentrotus lividus Shells
by Alexandros Efstathiadis, Ioanna Symeonidou, Konstantinos Tsongas, Emmanouil K. Tzimtzimis and Dimitrios Tzetzis
Designs 2023, 7(5), 113; https://doi.org/10.3390/designs7050113 - 29 Sep 2023
Cited by 16 | Viewed by 3200
Abstract
The present paper investigates the mechanical behavior of a biomimetic Voronoi structure, inspired by the microstructure of the shell of the sea urchin Paracentrotus lividus, with its characteristic topological attributes constituting the technical evaluation stage of a novel biomimetic design strategy. A [...] Read more.
The present paper investigates the mechanical behavior of a biomimetic Voronoi structure, inspired by the microstructure of the shell of the sea urchin Paracentrotus lividus, with its characteristic topological attributes constituting the technical evaluation stage of a novel biomimetic design strategy. A parametric design algorithm was used as a basis to generate design permutations with gradually increasing rod thickness, node count, and model smoothness, geometric parameters that define a Voronoi structure and increase its relative density as they are enhanced. Physical PLA specimens were manufactured with a fused filament fabrication (FFF) printer and subjected to quasi-static loading. Finite element analysis (FEA) was conducted in order to verify the experimental results. A minor discrepancy between the relative density of the designed and printed models was calculated. The tests revealed that the compressive behavior of the structure consists of an elastic region followed by a smooth plateau region and, finally, by the densification zone. The yield strength, compressive modulus, and plateau stress of the structure are improved as the specific geometric parameters are enhanced. The same trend is observed in the energy absorption capabilities of the structure while a reverse one characterizes the densification strain of the specimens. A second-degree polynomial relation is also identified between the modulus, plateau stress, and energy capacity when plotted against the relative density of the specimens. Distinct Voronoi morphologies can be acquired with similar mechanical characteristics, depending on the design requirements and application. Potential applications include lightweight structural materials and protective gear and accessories. Full article
(This article belongs to the Collection Editorial Board Members’ Collection Series: Biomaterials Design)
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36 pages, 455 KB  
Article
Enhancing Disassembly Practices for Electric Vehicle Battery Packs: A Narrative Comprehensive Review
by Matteo Beghi, Francesco Braghin and Loris Roveda
Designs 2023, 7(5), 109; https://doi.org/10.3390/designs7050109 - 22 Sep 2023
Cited by 32 | Viewed by 10146
Abstract
In the context of current societal challenges, such as climate neutrality, industry digitization, and circular economy, this paper addresses the importance of improving recycling practices for electric vehicle (EV) battery packs, with a specific focus on lithium–ion batteries (LIBs). To achieve this, the [...] Read more.
In the context of current societal challenges, such as climate neutrality, industry digitization, and circular economy, this paper addresses the importance of improving recycling practices for electric vehicle (EV) battery packs, with a specific focus on lithium–ion batteries (LIBs). To achieve this, the paper conducts a systematic review (using Google Scholar, Scopus, and Web of Science as search engines), considering the last 10 years, to examine existing recycling methods, robotic/collaborative disassembly cells, and associated control techniques. The aim is to provide a comprehensive and detailed review that can serve as a valuable resource for future research in the industrial domain. By analyzing the current state of the field, this review identifies emerging needs and challenges that need to be addressed for the successful implementation of automatic robotic disassembly cells for end-of-life (EOL) electronic products, such as EV LIBs. The findings presented in this paper enhance our understanding of recycling practices and lay the groundwork for more precise research directions in this important area. Full article
(This article belongs to the Special Issue Battery System Design)
28 pages, 9894 KB  
Article
Design and Considerations: Microelectromechanical System (MEMS) Vibrating Ring Resonator Gyroscopes
by Waqas Amin Gill, Ian Howard, Ilyas Mazhar and Kristoffer McKee
Designs 2023, 7(5), 106; https://doi.org/10.3390/designs7050106 - 11 Sep 2023
Cited by 9 | Viewed by 4532
Abstract
Microelectromechanical system (MEMS) vibrating gyroscope design considerations are always intriguing due to their microscale mechanical, electrical, and material behavior. MEMS vibrating ring gyroscopes have become important inertial sensors in inertial measurement units (IMU) for navigation and sensing applications. The design of a MEMS [...] Read more.
Microelectromechanical system (MEMS) vibrating gyroscope design considerations are always intriguing due to their microscale mechanical, electrical, and material behavior. MEMS vibrating ring gyroscopes have become important inertial sensors in inertial measurement units (IMU) for navigation and sensing applications. The design of a MEMS vibrating ring gyroscope incorporates an oscillating ring structure as a proof mass, reflecting unique design challenges and possibilities. This paper presents a comprehensive design analysis of the MEMS vibrating ring gyroscope from the mechanical, electrical, and damping perspectives. The mechanical design of the MEMS vibrating ring gyroscope investigates the various frame designs of the vibrating ring structure, as well as the various beam structures, including rectangular and semicircular beam structures, which are analyzed using mathematical models and finite element analysis (FEA) simulations that provide an in-depth analysis of the stiffness and deflection of the vibrating structures. The electrical designs of the MEMS vibrating ring gyroscope are analyzed using various electrode configurations, electrostatic actuation, and capacitive detection mechanisms. The design analysis of various forms of damping, including viscous, structural, thermoelastic, and anchor damping, is discussed. The variety of design structures is investigated for MEMS vibrating ring gyroscopes’ mechanical, electrical, and damping performance. Full article
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31 pages, 2386 KB  
Review
The Status of On-Board Hydrogen Storage in Fuel Cell Electric Vehicles
by Julián A. Gómez and Diogo M. F. Santos
Designs 2023, 7(4), 97; https://doi.org/10.3390/designs7040097 - 2 Aug 2023
Cited by 73 | Viewed by 20596
Abstract
Hydrogen as an energy carrier could help decarbonize industrial, building, and transportation sectors, and be used in fuel cells to generate electricity, power, or heat. One of the numerous ways to solve the climate crisis is to make the vehicles on our roads [...] Read more.
Hydrogen as an energy carrier could help decarbonize industrial, building, and transportation sectors, and be used in fuel cells to generate electricity, power, or heat. One of the numerous ways to solve the climate crisis is to make the vehicles on our roads as clean as possible. Fuel cell electric vehicles (FCEVs) have demonstrated a high potential in storing and converting chemical energy into electricity with zero carbon dioxide emissions. This review paper comprehensively assesses hydrogen’s potential as an innovative alternative for reducing greenhouse gas (GHG) emissions in transportation, particularly for on-board applications. To evaluate the industry’s current status and future challenges, the work analyses the technology behind FCEVs and hydrogen storage approaches for on-board applications, followed by a market review. It has been found that, to achieve long-range autonomy (over 500 km), FCEVs must be capable of storing 5–10 kg of hydrogen in compressed vessels at 700 bar, with Type IV vessels being the primary option in use. Carbon fiber is the most expensive component in vessel manufacturing, contributing to over 50% of the total cost. However, the cost of FCEV storage systems has considerably decreased, with current estimates around 15.7 $/kWh, and is predicted to drop to 8 $/kWh by 2030. In 2021, Toyota, Hyundai, Mercedes-Benz, and Honda were the major car brands offering FCEV technology globally. Although physical and chemical storage technologies are expected to be valuable to the hydrogen economy, compressed hydrogen storage remains the most advanced technology for on-board applications. Full article
(This article belongs to the Collection Editorial Board Members’ Collection Series: Smart Energy Systems Design)
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25 pages, 2046 KB  
Article
A Unit-Load Approach for Reliability-Based Design Optimization of Linear Structures under Random Loads and Boundary Conditions
by Robert James Haupin and Gene Jean-Win Hou
Designs 2023, 7(4), 96; https://doi.org/10.3390/designs7040096 - 2 Aug 2023
Cited by 2 | Viewed by 2457
Abstract
The low order Taylor’s series expansion was employed in this study to estimate the reliability indices of the failure criteria for reliability-based design optimization of a linear static structure subjected to random loads and boundary conditions. By taking the advantage of the linear [...] Read more.
The low order Taylor’s series expansion was employed in this study to estimate the reliability indices of the failure criteria for reliability-based design optimization of a linear static structure subjected to random loads and boundary conditions. By taking the advantage of the linear superposition principle, only a few analyses of the structure subjected to unit-loads are needed through the entire optimization process to produce acceptable results. Two structural examples are presented in this study to illustrate the effectiveness of the proposed approach for reliability-based design optimization: one deals with a truss structure subjected to random multiple point constraints, and the other conducts shape design optimization of a plane stress problem subjected to random point loads. Both examples were formulated and solved by the finite element method. The first example used the penalty method to reformulate the multiple point constraints as external loads, while the second example introduced an approach to propagate the uncertainty linearly from the nodal displacement vector to the nodal von Mises stress vector. The final designs obtained from the reliability-based design optimization were validated through Monte Carlo simulation. This validation process was completed with only four unit-load analyses for the first example and two for the second example. Full article
(This article belongs to the Special Issue Design Sensitivity Analysis and Engineering Optimization)
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35 pages, 17261 KB  
Article
Peltier Cell Integration in Packaging Design for Minimizing Energy Consumption and Temperature Variation during Refrigerated Transport
by Pedro Fernandes, Pedro D. Gaspar and Pedro D. Silva
Designs 2023, 7(4), 88; https://doi.org/10.3390/designs7040088 - 4 Jul 2023
Cited by 1 | Viewed by 4270
Abstract
This study proposes an innovative approach to reduce temperature fluctuations in refrigerated transport during loading and unloading, aiming to minimize food waste and optimize energy consumption in the food supply chain. The solution involves integrating Peltier cells into secondary and tertiary packaging to [...] Read more.
This study proposes an innovative approach to reduce temperature fluctuations in refrigerated transport during loading and unloading, aiming to minimize food waste and optimize energy consumption in the food supply chain. The solution involves integrating Peltier cells into secondary and tertiary packaging to improve system efficiency and minimize temperature variations. Four distinct tests were conducted: a reference test, continuous Peltier system operation, and two intermittent cooling tests for the hot side of the cells. The results highlight the effectiveness of this approach, particularly in the fourth test where the average final food temperature decreased from 3.2 °C (reference test) to 2.8 °C. Integrating Peltier cells into packaging shows potential benefits in minimizing food waste, reducing energy consumption, and associated emissions during refrigerated transport. This research contributes to the sustainable design and manufacturing of packaging systems, specifically in the context of refrigerated transport. By maintaining a consistent temperature environment during the critical loading and unloading phases, incorporating Peltier cells enhances the overall performance and efficiency of refrigerated transport system. These results point out the significance of exploring innovative solutions for sustainable food preservation and the decrease of waste all along the food supply chain. Full article
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32 pages, 4311 KB  
Review
Design for Additive Manufacturing: Recent Innovations and Future Directions
by Paul F. Egan
Designs 2023, 7(4), 83; https://doi.org/10.3390/designs7040083 - 29 Jun 2023
Cited by 49 | Viewed by 15375
Abstract
Design for additive manufacturing (DfAM) provides a necessary framework for using novel additive manufacturing (AM) technologies for engineering innovations. Recent AM advances include shaping nickel-based superalloys for lightweight aerospace applications, reducing environmental impacts with large-scale concrete printing, and personalizing food and medical devices [...] Read more.
Design for additive manufacturing (DfAM) provides a necessary framework for using novel additive manufacturing (AM) technologies for engineering innovations. Recent AM advances include shaping nickel-based superalloys for lightweight aerospace applications, reducing environmental impacts with large-scale concrete printing, and personalizing food and medical devices for improved health. Although many new capabilities are enabled by AM, design advances are necessary to ensure the technology reaches its full potential. Here, DfAM research is reviewed in the context of Fabrication, Generation, and Assessment phases that bridge the gap between AM capabilities and design innovations. Materials, processes, and constraints are considered during fabrication steps to understand AM capabilities for building systems with specified properties and functions. Design generation steps include conceptualization, configuration, and optimization to drive the creation of high-performance AM designs. Assessment steps are necessary for validating, testing, and modeling systems for future iterations and improvements. These phases provide context for discussing innovations in aerospace, automotives, construction, food, medicine, and robotics while highlighting future opportunities for design services, bio-inspired design, fabrication robots, and machine learning. Overall, DfAM has positively impacted diverse engineering applications, and further research has great potential for driving new developments in design innovation. Full article
(This article belongs to the Special Issue Additive Manufacturing – Process Optimisation)
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35 pages, 13372 KB  
Article
A Structural and Thermal Comparative Review of 3D-Printed Wall Shapes
by Nicholas D. Bello and Ali M. Memari
Designs 2023, 7(3), 80; https://doi.org/10.3390/designs7030080 - 19 Jun 2023
Cited by 3 | Viewed by 3567
Abstract
This article explores several aspects of the three-dimensional concrete printing (3DCP) industry. More specifically, it begins with a literature review discussing the background of this technology. This literature review also explores several of the challenges that the industry is currently facing. In this [...] Read more.
This article explores several aspects of the three-dimensional concrete printing (3DCP) industry. More specifically, it begins with a literature review discussing the background of this technology. This literature review also explores several of the challenges that the industry is currently facing. In this way, a knowledge gap is identified. More specifically, there are few studies that have explored the structural and thermal performance of typical walls printed in this industry. Therefore, we used the simulation tool in SolidWorks to examine the structural behavior of several different wall types when pressure was applied to the exterior face. In addition to this, the thermal performance of different wall types was also studied in SolidWorks by applying a temperature difference between the exterior and interior faces of each wall. For example, one wall shape in this study had minimum factor of safety of approximately 100 due when a load was applied, and the same wall lost approximately 212 W due to the temperature difference applied in this study. Finally, SolidWorks was used to calculate the moment of inertia of the cross sections of several of these walls, which helped to provide a better understanding of each wall’s structural rigidity. Full article
(This article belongs to the Special Issue Additive Manufacturing – Process Optimisation)
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29 pages, 3121 KB  
Review
Electricity Pricing and Its Role in Modern Smart Energy System Design: A Review
by Jiaqi Liu, Hongji Hu, Samson S. Yu and Hieu Trinh
Designs 2023, 7(3), 76; https://doi.org/10.3390/designs7030076 - 16 Jun 2023
Cited by 14 | Viewed by 7162
Abstract
Energy is the foundation for human survival and socio-economic development, and electricity is a key form of energy. Electricity prices are a key factor affecting the interests of various stakeholders in the electricity market, playing a significant role in the sustainable development of [...] Read more.
Energy is the foundation for human survival and socio-economic development, and electricity is a key form of energy. Electricity prices are a key factor affecting the interests of various stakeholders in the electricity market, playing a significant role in the sustainable development of energy and the environment. As the number of distributed energy resources (DERs) increases, today’s power systems no longer rely on a vertical market model and fixed electricity pricing scheme but instead depend on power dispatch and dynamic pricing to match supply and demand. This can help prevent significant fluctuations in supply–load imbalance and maintain system stability. Modern power grids have evolved by integrating information, communication, and intelligent control technologies with traditional power systems, giving rise to the concept of smart electric grids. Choosing an appropriate pricing scheme to manage large-scale DERs and controllable loads in today’s power grid become very important. However, the existing literature lacks a comprehensive review of electricity pricing in power systems and its transformative impact on shaping the energy landscape. To fill this void, this paper provides a survey on the developments, methods, and frameworks related to electricity pricing and energy trading. The review mainly considers the development of pricing in a centralized power grid, peer-to-peer (P2P) and microgrid-to-microgrid (M2M) energy trading and sharing, and various pricing methods. The review will cover the pricing schemes in modern power systems, particularly with respect to renewable energy sources (RESs) and batteries, as well as controllable load applications, and the impact of pricing schemes based on demand-side ancillary services (DSAS) for grid frequency support. Lastly, this review article describes the current frameworks and limitations of electricity pricing in the current energy market, as well as future research directions. This review should offer a great overview and deep insights into today’s electricity market and how pricing methods will drive and facilitate the future establishment of smart energy systems. Full article
(This article belongs to the Collection Editorial Board Members’ Collection Series: Smart Energy Systems Design)
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23 pages, 11598 KB  
Article
From Meaning to Expression: A Dual Approach to Coupling
by Lukas Van Campenhout, Ward Vancoppenolle and Ivo Dewit
Designs 2023, 7(3), 69; https://doi.org/10.3390/designs7030069 - 23 May 2023
Cited by 4 | Viewed by 2816
Abstract
Coupling is a key concept in the field of embodied interaction with digital products and systems, describing how digital phenomena relate to the physical world. In this paper, we present a Research through Design process in which the concept of coupling is explored [...] Read more.
Coupling is a key concept in the field of embodied interaction with digital products and systems, describing how digital phenomena relate to the physical world. In this paper, we present a Research through Design process in which the concept of coupling is explored and deepened. The use case that we employed to conduct our research is an industrial workplace proposed by Audi Brussels and Kuka. Our aim was to enrich this workplace with projection, or Spatial Augmented Reality, while focusing on operator interaction. We went through three successive design iterations, each of which resulted in a demonstrator. We present each of the three demonstrators, focusing on how they propelled our understanding of coupling. We establish a framework in which coupling between different events, be they physical or digital, emerges on four different aspects: time, location, direction, and expression. We bring the first three aspects together under one heading—coupling of meaning—and relate it to ease of use and pragmatic usability. We uncover the characteristics of the fourth aspect—coupling of expression—and link it to the psychological wellbeing of the operator in the workplace. We conclude this paper by highlighting its contribution to the embodied interaction research agenda. Full article
(This article belongs to the Special Issue Mixture of Human and Machine Intelligence in Digital Manufacturing)
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18 pages, 799 KB  
Article
Minimum-Lap-Time Planning of Multibody Vehicle Models via the Articulated-Body Algorithm
by Marcello Domenighini, Lorenzo Bartali, Eugeniu Grabovic and Marco Gabiccini
Designs 2023, 7(3), 65; https://doi.org/10.3390/designs7030065 - 17 May 2023
Cited by 4 | Viewed by 5546
Abstract
Minimum lap-time planning (MLTP) is a well-established problem in the race car industry to provide guidelines for drivers and optimize the vehicle’s setup. In this paper, we tackle the 3D nature of the problem in its full extension, making no simplifying assumptions on [...] Read more.
Minimum lap-time planning (MLTP) is a well-established problem in the race car industry to provide guidelines for drivers and optimize the vehicle’s setup. In this paper, we tackle the 3D nature of the problem in its full extension, making no simplifying assumptions on the mechanics of the system. We propose a multibody vehicle model, described by rigorous dynamical equations. To effectively handle the resulting complexity, we devised an efficient direct dynamics computational method based on Featherstone’s articulated-body algorithm (ABA). To solve the MLTP, we employed a direct-collocation technique, discretizing the problem so that all information of the 3D track is pre-processed and directly embedded into the discrete problem. This discretization approach turns out to be perfectly compatible with our vehicle model, leading to a solution in accessible computational time frames. The high level of detail of the model makes the proposed approach most useful for in-depth vehicle dynamics analyses on complex tracks. To substantiate the analysis, we provide a comparison with the results obtained by a double-track model on the Nürburgring Nordschleife circuit. Consistently with the average trend defined by the double track, the proposed model features a more dynamically rich behavior, realistically capturing the higher-order effects elicited by the sharp corners and the highly variable slope of the track. Full article
(This article belongs to the Section Smart Manufacturing System Design)
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19 pages, 3162 KB  
Article
Designing and Testing a Tool That Connects the Value Proposition of Deep-Tech Ventures to SDGs
by Joppe Schutselaars, A. Georges L. Romme, John Bell, Annelies S. A. Bobelyn and Robin van Scheijndel
Designs 2023, 7(2), 50; https://doi.org/10.3390/designs7020050 - 26 Mar 2023
Cited by 10 | Viewed by 7567
Abstract
Deep-tech startups have enormous potential to solve major societal challenges, but their failure rates are quite high (above 90%). In this respect, deep-tech systems and products have long development times and thus require substantial amounts of investment capital long before the first customer [...] Read more.
Deep-tech startups have enormous potential to solve major societal challenges, but their failure rates are quite high (above 90%). In this respect, deep-tech systems and products have long development times and thus require substantial amounts of investment capital long before the first customer can be served. Moreover, potential investors increasingly expect that the value proposition of a deep-tech venture has a clear sustainability dimension. We therefore designed a tool that serves to develop a convincing value proposition for investors, one that is explicitly connected to the Sustainable Development Goals (SDGs) of the United Nations. We adopted a design science approach to develop and test this tool in the context of a deep-tech venture builder located in the Netherlands. The final tool arising from this study extends and integrates various existing tools with an explicit connection to the SDGs. As such, this tool enables deep-tech entrepreneurs to develop a value proposition that is more likely to attract early-stage investors. Full article
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13 pages, 3513 KB  
Article
On Liquid Flow Maldistribution through Investigation of Random Open-Structure Packings
by Daniela Dzhonova-Atanasova, Konstantina Stefanova and Svetoslav Nakov
Designs 2023, 7(2), 47; https://doi.org/10.3390/designs7020047 - 24 Mar 2023
Cited by 1 | Viewed by 3304
Abstract
The optimal design of packed columns for separation processes is strongly dependent on an accurate prediction of the fluid flows in the packing. Insufficient knowledge about the complex factors and mechanisms governing hydrodynamic effects is compensated for by empirical information. The present study [...] Read more.
The optimal design of packed columns for separation processes is strongly dependent on an accurate prediction of the fluid flows in the packing. Insufficient knowledge about the complex factors and mechanisms governing hydrodynamic effects is compensated for by empirical information. The present study fills the gap in experimental data about the liquid phase distribution in plastic Raschig Super-Ring (RSRP) packing and plastic Ralu–Flow (RF) packing. These belong to the family of widely used random packings with an open lattice structure characterized by high mass transfer efficiency and a low pressure drop. The study was performed using the liquid collection method with a device with concentric annular collection sections at the packing outlet. Large-scale liquid maldistribution in the central and peripheral zones of the packed bed were evaluated in comparison data on competing random and structured packings. The effects of the packing size and the liquid load on the radial distribution of the superficial liquid velocity, wall flow formation and the maldistribution factor were investigated and analyzed. The results contribute to deepening the knowledge about the phenomenon of large-scale liquid flow maldistribution in packed columns, as well as to design enhancement. Full article
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22 pages, 4421 KB  
Article
Water Pumping System Supplied by a PV Generator and with a Switched Reluctance Motor Using a Drive Based on a Multilevel Converter with Reduced Switches
by Vitor Fernão Pires, Daniel Foito, Armando Cordeiro, Tito G. Amaral, Hao Chen, Armando Pires and João F. Martins
Designs 2023, 7(2), 39; https://doi.org/10.3390/designs7020039 - 3 Mar 2023
Cited by 5 | Viewed by 3026
Abstract
Pumping systems play a fundamental role in many applications. One of the applications in which these systems are very important is to pump water. However, in the real world context, the use of renewable energies to supply this kind of system becomes essential. [...] Read more.
Pumping systems play a fundamental role in many applications. One of the applications in which these systems are very important is to pump water. However, in the real world context, the use of renewable energies to supply this kind of system becomes essential. Thus, this paper proposes a water pumping system powered by a photovoltaic (PV) generator. In addition, due to its interesting characteristics, such low manufacturing cost, free of rare-earth elements, simple design and robustness for pumping systems, a switched reluctance motor (SRM) is used. The power electronic system to be used in the PV generator and to control the SRM consists of a DC/DC converter with a bipolar output and a multilevel converter. The adopted DC/DC converter uses only one switch, so its topology can be considered as a derivation of the combination of a Zeta converter with a buck–boost converter. Another important aspect is that this converter allows continuous input current, which is desirable for PV panels. The topology selected to control the SRM is a multilevel converter. This proposed topology was adopted with the purpose of reducing the number of power semiconductors. A maximum power point algorithm (MPPT) associated with the DC/DC converter to obtain the maximum power of the PV panels is also proposed. This MPPT will be developed based on the concept of the time derivative of the power and voltage. It will be verified that with the increase in solar irradiance, the generated power will also increase. From this particular case study, it will be verified that changes in the irradiance from 1000 W/m2 to 400 W/m2 will correspond to a change in the motor speed from 1220 rpm to 170 rpm. The characteristics and operation of the proposed system will be verified through several simulation and experimental studies. Full article
(This article belongs to the Topic Advanced Electrical Machines and Drives Technologies)
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30 pages, 8014 KB  
Article
Automated Solar PV Simulation System Supported by DC–DC Power Converters
by Armando Cordeiro, Miguel Chaves, Paulo Gâmboa, Filipe Barata, Pedro Fonte, Hélio Lopes, Vítor Fernão Pires, Daniel Foito, Tito G. Amaral and João Francisco Martins
Designs 2023, 7(2), 36; https://doi.org/10.3390/designs7020036 - 1 Mar 2023
Cited by 6 | Viewed by 4058
Abstract
Solar photovoltaic simulators are valuable tools for the design and evaluation of several components of photovoltaic systems. They can also be used for several purposes, such as educational objectives regarding operation principles, control strategies, efficiency, maintenance, and other aspects. This paper presents an [...] Read more.
Solar photovoltaic simulators are valuable tools for the design and evaluation of several components of photovoltaic systems. They can also be used for several purposes, such as educational objectives regarding operation principles, control strategies, efficiency, maintenance, and other aspects. This paper presents an automated solar photovoltaic simulation system with the capability to generate automated tests considering different parameters of solar photovoltaic panels and different operation conditions. The proposed simulator is composed of three buck-boost DC–DC power converters controlled in such a way that will behave similarly to solar photovoltaic panels. It allows to introduce additional variable loads and maximum power point tracker algorithms similar to real systems. Some converters are controlled by a DSP microcontroller connected to a single programmable logic controller which generates the automated tests. Thus, using the presented solution, it is possible to implement the I-V and P-V characteristic curves of solar photovoltaic panels and evaluate different maximum power point tracker algorithms considering different meteorological conditions and load variations, being a useful tool to teach subjects related to renewable energy sources and related applications. Several simulation results using Matlab/Simulink and experimental results are presented to validate the operation of the proposed solution. Experimental results achieve a ripple between 2% and 5% of the desired average current in MPP conditions. Full article
(This article belongs to the Topic Power Electronics Converters)
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