Journal of Manufacturing and Materials Processing

15 pages, 1820 KB

Open AccessArticle

Design of a Pneumatic Muscle-Actuated Compliant Gripper System with a Single Mobile Jaw

by Andrea Deaconescu and Tudor Deaconescu

J. Manuf. Mater. Process. 2025, 9(10), 326; https://doi.org/10.3390/jmmp9100326 - 2 Oct 2025

The paper presents an innovative theoretical concept of a bio-inspired soft gripper system with two parallel jaws, a fixed and a mobile one. It is conceived for gripping fragile or soft objects with complex, irregular shapes that are easily deformable. This novel gripper [...] Read more.

The paper presents an innovative theoretical concept of a bio-inspired soft gripper system with two parallel jaws, a fixed and a mobile one. It is conceived for gripping fragile or soft objects with complex, irregular shapes that are easily deformable. This novel gripper is designed for handling small objects of masses up to 0.5 kg. The maximum gripping stroke of the mobile jaw is 13.5 mm. The driving motor is a pneumatic muscle, an actuator with inherently compliant, spring-like behavior. Compliance is the feature responsible for the soft character of the gripper system, ensuring its passive adaptability to the nature of the object to be gripped. The paper presents the structural, kinematic, static, and dynamic models of the novel gripper system and describes the compliant behavior of the entire assembly. The results of the dynamic simulation of the gripper have confirmed the attaining of the imposed motion-related performance. Full article

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25 pages, 6338 KB

Open AccessArticle

Multi-Scale Model of Mid-Frequency Errors in Semi-Rigid Tool Polishing of Diamond-Turned Electroless Nickel Mirror

by Pengfeng Sheng, Jingjing Xia, Jun Yu, Kun Wang and Zhanshan Wang

J. Manuf. Mater. Process. 2025, 9(10), 325; https://doi.org/10.3390/jmmp9100325 - 30 Sep 2025

Abstract

Semi-rigid tool polishing is widely used in the high-precision manufacturing of electroless nickel surface due to its stable material removal and high efficiency in correcting mid- and high-frequency profile errors. However, predicting mid-frequency errors remains challenging due to the complexity of their underlying [...] Read more.

Semi-rigid tool polishing is widely used in the high-precision manufacturing of electroless nickel surface due to its stable material removal and high efficiency in correcting mid- and high-frequency profile errors. However, predicting mid-frequency errors remains challenging due to the complexity of their underlying sources. In this study, a theoretical model for semi-rigid tool polishing was developed based on multi-scale contact theory, incorporating a bridging model, rough surface contact, and Hertzian contact mechanics. The model accounts for the effects of tool surface roughness, polishing force, and path spacing. A series of experiments on diamond-turned electroless nickel mirrors was conducted to quantitatively evaluate the model’s feasibility and accuracy. The results demonstrate that the model can effectively predict mid-frequency errors, reveal the material removal mechanisms in semi-rigid polishing, and guide the optimization of process parameters. Ultimately, a surface with mid-frequency errors of 0.59 nm Rms (measured over a 1.26 mm × 0.94 mm window) was achieved, closely matching the predicted value of 0.64 nm. Full article

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11 pages, 1905 KB

Open AccessArticle

A Psychophysical Methodology for Determining Manufacturing Tolerance of Feature Lines on Automotive Outer Panels

by Yunchan Chung and Mi-Sun Bang

J. Manuf. Mater. Process. 2025, 9(10), 324; https://doi.org/10.3390/jmmp9100324 - 29 Sep 2025

Abstract

This paper presents a methodology for determining manufacturing tolerances of feature lines on automotive outer panels using visual sensory tests. Feature lines—narrow and long curved surfaces on automotive panels—play a critical role in the visual appeal of vehicles. However, achieving precise feature lines [...] Read more.

This paper presents a methodology for determining manufacturing tolerances of feature lines on automotive outer panels using visual sensory tests. Feature lines—narrow and long curved surfaces on automotive panels—play a critical role in the visual appeal of vehicles. However, achieving precise feature lines in mass production is challenging due to material spring-back during the stamping process. Conventional tolerance determination methods are unsuitable for these esthetic elements. To address this, we employed psychophysical sensory tests to find the visual difference thresholds for feature lines. By creating geometric models and conducting controlled sensory tests, we identified the minimum radius variations perceptible to the human eye. Thirty-four participants were tested using the method of constant stimuli, resulting in psychometric functions for feature lines with radii of 8, 10, and 12 mm. The findings suggest manufacturing tolerances of ±1.2 mm, ±1.3 mm, and ±1.5 mm, respectively. This approach provides a quantitative foundation for setting tolerances that balance visual quality with production feasibility. Full article

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21 pages, 10551 KB

Open AccessArticle

Bayesian Model Updating for Chatter in Milling

by Ali Ebrahimi-Tirtashi and Keivan Ahmadi

J. Manuf. Mater. Process. 2025, 9(10), 323; https://doi.org/10.3390/jmmp9100323 - 26 Sep 2025

Abstract

The modal parameters of tooltip vibrations are crucial for determining chatter-free machining conditions. However, conventional methods often depend on measurements taken when the machine is not operating under real cutting conditions or require multiple experiments under chatter conditions, which is time-consuming and impractical [...] Read more.

The modal parameters of tooltip vibrations are crucial for determining chatter-free machining conditions. However, conventional methods often depend on measurements taken when the machine is not operating under real cutting conditions or require multiple experiments under chatter conditions, which is time-consuming and impractical for real-world manufacturing. This paper proposes a Bayesian Model Updating (BMU) approach to improve the chatter model parameters using experimental observations collected during normal, stable milling operations. Operational Modal Analysis (OMA) is adopted to extract the system dynamics from the in-process signals. These results are subsequently integrated into the BMU framework, updating the initial model parameters to reflect actual cutting conditions. The effectiveness of this approach is demonstrated through an experimental case study, highlighting its feasibility and potential for industrial applications. Full article

(This article belongs to the Special Issue New Trends in Precision Machining Processes)

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16 pages, 1406 KB

Open AccessArticle

Enhancing Product Quality Using Artificial Neural Networks and Genetic Algorithms

by Mohamed A. El-Baz and Mohamed S. Abd-Elwahed

J. Manuf. Mater. Process. 2025, 9(9), 322; https://doi.org/10.3390/jmmp9090322 - 22 Sep 2025

Abstract

This study introduces an integrated framework combining Artificial Neural Networks (ANN) and Genetic Algorithms (GA) to optimize quality in multi-component product assemblies. The novelty of this work lies in its closed-loop structure: ANN is used to predict product performance indices based on component [...] Read more.

This study introduces an integrated framework combining Artificial Neural Networks (ANN) and Genetic Algorithms (GA) to optimize quality in multi-component product assemblies. The novelty of this work lies in its closed-loop structure: ANN is used to predict product performance indices based on component configurations, and these predictions are directly used as the fitness criteria in GA-based optimization. Unlike traditional isolated models, the framework enables predictive, data-driven decision-making to improve product quality and resource efficiency in manufacturing environments. Full article

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16 pages, 1148 KB

Open AccessArticle

Refined Cost Calculation Framework for FDM Parts

by Bálint Leon Seregi and Péter Ficzere

J. Manuf. Mater. Process. 2025, 9(9), 321; https://doi.org/10.3390/jmmp9090321 - 22 Sep 2025

Abstract

Fused deposition modeling (FDM) is a widely used additive manufacturing (AM) technology, favored for its design flexibility and suitability for low-volume production. However, precise cost estimation remains a critical challenge, particularly in industrial environments where decision-making depends on accurate financial assessments. This study [...] Read more.

Fused deposition modeling (FDM) is a widely used additive manufacturing (AM) technology, favored for its design flexibility and suitability for low-volume production. However, precise cost estimation remains a critical challenge, particularly in industrial environments where decision-making depends on accurate financial assessments. This study proposes a comprehensive, parameter-based cost calculation model for FDM processes, with a special focus on the wear of machine tooling. Unlike conventional methods, the model separates tooling costs from general machine operation costs and introduces a novel approach to nozzle wear estimation based on extruded material volume rather than printing time. The framework incorporates key cost components—including material usage, support removal, machine operation, tooling degradation, and labor—and links them to quantifiable parameters such as part volume, build time, and energy consumption. The methodology was tested across multiple scenarios with different geometries and production volumes, revealing significant differences between time- and volume-based wear calculations. The results demonstrate that the proposed model provides more accurate and adaptable cost predictions, especially in varied production settings. This approach enhances the financial transparency of FDM workflows and supports better-informed decisions in both prototyping and small-batch manufacturing contexts. Full article

(This article belongs to the Special Issue Innovative Rapid Tooling in Additive Manufacturing Processes)

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18 pages, 7249 KB

Open AccessArticle

Upcycling of Copper Scrap into High-Quality Powder for Additive Manufacturing: Processing, Characterization, and Sustainability Assessment

by Mattia Cabrioli, María Silva Colmenero, Sepideh Gholamzadeh, Matteo Vanazzi, Sasan Amirabdollahian, Matteo Perini, Wojciech Łacisz and Bartosz Kalicki

J. Manuf. Mater. Process. 2025, 9(9), 320; https://doi.org/10.3390/jmmp9090320 - 20 Sep 2025

Abstract

Copper is a critical material for energy transition and green technologies, making its sustainable use increasingly important. Its superior thermal and electrical conductivity make it highly well-suited for additive manufacturing (AM). In this study, copper sourced from offshore electrical cables was upcycled to [...] Read more.

Copper is a critical material for energy transition and green technologies, making its sustainable use increasingly important. Its superior thermal and electrical conductivity make it highly well-suited for additive manufacturing (AM). In this study, copper sourced from offshore electrical cables was upcycled to produce high-quality metal powder for AM. The scrap was processed to separate the metal from plastic and rubber, then refined through ultrasonic atomization, achieving a purity of ~99.5% wt.% with minimal impurities. Characterization demonstrated good flowability, apparent and tap densities, and a well-distributed particle size. To assess its performance in AM, the powder was printed using Directed Energy Deposition (DED) with a laser beam, confirming its high printability and compatibility with the base material. Finally, a comparative Life Cycle Assessment (LCA) revealed a significant environmental advantage of the recycling-based process over conventional mining, reducing global warming potential by more than 70%. These findings highlight the importance of feedstock origin in AM sustainability and support the adoption of circular economy strategies to lower the environmental footprint of advanced manufacturing. Full article

(This article belongs to the Special Issue Additive Manufacturing of Copper-Based Alloys)

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15 pages, 4007 KB

Open AccessArticle

Investigation on the Mechanical Properties of White Layers by Cutting and Burnishing Coupling Effect in BTA Deep Hole Drilling

by Huang Zhang, Pengxiang Yan, Haoran Guo, Ze Chen, Zihao Hou and Yaoming Li

J. Manuf. Mater. Process. 2025, 9(9), 319; https://doi.org/10.3390/jmmp9090319 - 20 Sep 2025

Abstract

The unique cutting–burnishing coupling effect in BTA deep hole drilling generates a high-hardness and -brittleness white layer (ultrafine martensitic layer), which will degrade component performance and accelerate tool wear. This work investigated the formation mechanism and the mechanical properties of the white layer [...] Read more.

The unique cutting–burnishing coupling effect in BTA deep hole drilling generates a high-hardness and -brittleness white layer (ultrafine martensitic layer), which will degrade component performance and accelerate tool wear. This work investigated the formation mechanism and the mechanical properties of the white layer generated in three distinct regions (the cutting edge radius zone, cutting–burnishing corner zone, and guide pad edge zone) through nanoindentation, SEM and BSE. The microstructure and thickness of the white layer under different feedrates are investigated. The correlations between the white layer, the structure of guide pads, and wear behaviors of the TiN- and TiCN/Al₂O₃-coated guide pads are revealed. Variations in hardness are observed across different zones. The white layer undergoes a soft-to-hard transition due to rapid quenching and the cutting–burnishing effect at the sharp corner. The highest hardness (9.758 GPa) was observed in the guide pad zone, accompanied by grain refinement. The chamfered TiN-coated guide pad exhibits superior wear resistance but suffers fatigue cracking and adhesive wear in the initial guiding zone. The TiCN/Al₂O₃-coated pad with rounded corners experiences brittle spalling in the mid-to-rear guiding zone. These findings enhance the understanding of the white layer formation in deep hole drilling and provide a foundation for tool optimization. Full article

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15 pages, 3267 KB

Open AccessArticle

Injection Performance of UHMWPE in Micro-Discs for Prosthetic Applications Using SLA Molds

by Rossella Surace, Francesco Modica, Vito Basile, Vincenzo Bellantone and Irene Fassi

J. Manuf. Mater. Process. 2025, 9(9), 318; https://doi.org/10.3390/jmmp9090318 - 18 Sep 2025

Abstract

Ultra-high molecular weight polyethylene (UHMWPE) is widely used in orthopedic and prosthetic applications due to its excellent wear resistance and biocompatibility. However, its high molecular weight presents significant challenges in terms of processing and formability, particularly at the micro scale. This study investigates [...] Read more.

Ultra-high molecular weight polyethylene (UHMWPE) is widely used in orthopedic and prosthetic applications due to its excellent wear resistance and biocompatibility. However, its high molecular weight presents significant challenges in terms of processing and formability, particularly at the micro scale. This study investigates the flowability characteristics of a new melt-processable UHMWPE in micro-disc geometries to evaluate its suitability for advanced prosthetic applications. Micro-injection molding experiments assessed the material’s behavior under various thermal conditions. The influence of parameters such as temperature, pressure, and disc dimensions has direct effects on the flow behavior of UHMWPE and was analyzed by simulation and experiments. Results indicate that while UHMWPE exhibits limited flow under conventional conditions, optimized processing parameters can enhance discs’ formability without compromising the material’s structural integrity, avoiding defects. These findings provide critical insights for the microfabrication of UHMWPE thin components in next-generation prosthetic devices, enabling improved design precision and functional performance. Full article

(This article belongs to the Special Issue Advances in Injection Molding: Process, Materials and Applications, 2nd Edition)

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23 pages, 8159 KB

Open AccessArticle

Assessment of Pinless Tools Efficiency in FSSW of Thick High-Strength Low-Alloy Steels for Structural Lap Joints

by David Gomes Andrade, Sree Sabari, Carlos Leitão and Dulce M. Rodrigues

J. Manuf. Mater. Process. 2025, 9(9), 317; https://doi.org/10.3390/jmmp9090317 - 17 Sep 2025

Abstract

In this study, the maximum achievable weldable thickness in spot welding with pinless tools was investigated by welding multiple stacks of 1 mm thick high-strength steel HC420LA. This approach allowed for the evaluation of heat dissipation during the welding of progressively thicker sections, [...] Read more.

In this study, the maximum achievable weldable thickness in spot welding with pinless tools was investigated by welding multiple stacks of 1 mm thick high-strength steel HC420LA. This approach allowed for the evaluation of heat dissipation during the welding of progressively thicker sections, as well as for the comparison of the joints strength for increasing welded thicknesses. The methodology used also enabled the identification of the key technical challenges in achieving high-quality welds using very short welding times. Notably, even for a 5 s weld, a four-sheet configuration (4 mm thickness) was successfully joined, achieving a maximum shear load of approximately 10 kN and exhibiting a refined acicular ferritic bainitic microstructure with metallic continuity across the steel interfaces. The highest mechanical performance was obtained in the welds produced within 30 s, which reached a maximum shear load of approximately 16 kN. Importantly, the mechanical strength of these welds was benchmarked against relevant standards for the automotive and construction sectors, demonstrating that the spot welding with pinless tools enable achieving performance levels suitable for structural applications. Full article

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20 pages, 11453 KB

Open AccessArticle

Increasing the Wear Resistance of Stainless Steel Products by Depositing Modifying Coatings Based on Zirconium Nitride with the Addition of Niobium, Hafnium, and Titanium

by Sergey Grigoriev, Marina Volosova, Catherine Sotova, Filipp Milovich, Anton Seleznev, Kirill Makarevich, Pavel Potapov and Alexey Vereschaka

J. Manuf. Mater. Process. 2025, 9(9), 316; https://doi.org/10.3390/jmmp9090316 - 15 Sep 2025

Abstract

To increase wear resistance, (Zr,Nb)N, ZrN and (Zr,Hf)N coatings with columnar structures and (Zr,Ti)N and (Zr,Nb,Hf)N coatings with nanolayer structures were deposited on an AISI 321 stainless steel substrate. The samples with (Zr,Nb)N and ZrN coatings exhibited the best resistance to failure in [...] Read more.

To increase wear resistance, (Zr,Nb)N, ZrN and (Zr,Hf)N coatings with columnar structures and (Zr,Ti)N and (Zr,Nb,Hf)N coatings with nanolayer structures were deposited on an AISI 321 stainless steel substrate. The samples with (Zr,Nb)N and ZrN coatings exhibited the best resistance to failure in the scratch test. The sample with the (Zr,Nb)N coating had the best wear resistance for the first 16,000 s. However, eventually the wear of this sample became notable, and after 20,000 s of testing, the lowest degree of wear was observed in the sample with the (Zr,Nb,Hf)N coating. The wear rate of the uncoated sample was 1.5 times greater than that of the sample with the (Zr,Nb,Hf)N coating. The (Zr,Nb,Hf)N coating also exhibited a low degree of indenter mass loss. The (Zr,Nb,Hf)N and ZrN coatings reduced the coefficient of friction (COF) most (COF of approximately 0.20–0.21, compared to COF = 0.28 for the uncoated sample). Defects (nanocavities) were detected in the interface area between the coatings and the substrate, which in some cases can have a negative effect on the wear resistance of the coating. The (Zr,Nb,Hf)N coating (72.07 at.% Zr, 24.87 at.% Nb and 3.05 at.% Hf) had the best wear resistance and a low friction coefficient. Full article

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15 pages, 4240 KB

Open AccessArticle

Thermomechanical Properties of Sustainable Polymer Composites Incorporating Agricultural Wastes

by Emmanuel Kwaku Aidoo, Abubakar Sumaila, Maryam Jahan, Guoqiang Li and Patrick Mensah

J. Manuf. Mater. Process. 2025, 9(9), 315; https://doi.org/10.3390/jmmp9090315 - 15 Sep 2025

Abstract

Polymer matrix composites have been used extensively in the aerospace and automotive industries. Nevertheless, the growing demand for composites raises concerns about the thermal stability, cost, and environmental impacts of synthetic fillers like graphene and carbon nanotubes. Hence, this study investigates the possibility [...] Read more.

Polymer matrix composites have been used extensively in the aerospace and automotive industries. Nevertheless, the growing demand for composites raises concerns about the thermal stability, cost, and environmental impacts of synthetic fillers like graphene and carbon nanotubes. Hence, this study investigates the possibility of enhancing the thermomechanical properties of polymer composites through the incorporation of agricultural waste as fillers. Particles from walnut, coffee, and coconut shells were used as fillers to create particulate composites. Bio-based composites with 10 to 30 wt.% filler were created by sifting these particles into various mesh sizes and dispersing them in an epoxy matrix. In comparison to the pure polymer, DSC results indicated that the inclusion of 50 mesh 30 wt.% agricultural waste fillers increased the glass transition temperature by 8.5%, from 55.6 °C to 60.33 °C. Also, the TGA data showed improved thermal stability. Subsequently, the agricultural wastes were employed as reinforcement for laminated composites containing woven glass fiber with a 50% fiber volume fraction, eight plies, and varying particle filler weight percentages from 0% to 6% with respect to the laminated composite. The hybrid laminated composite demonstrated improved impact resistance of 142% in low-velocity impact testing. These results demonstrate that fillers made of agricultural wastes can enhance the thermomechanical properties of sustainable composites, creating new environmentally friendly prospects for the automotive and aerospace industries. Full article

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26 pages, 6337 KB

Open AccessArticle

Multi-Response Optimization of Milling Parameters of AISI D2 Steel Using Response Surface Methodology and Desirability Function

by Luis W. Hernández, Yassmin Seid Ahmed, Dagnier A. Curra and Roberto Pérez

J. Manuf. Mater. Process. 2025, 9(9), 314; https://doi.org/10.3390/jmmp9090314 - 13 Sep 2025

Abstract

This study investigates multi-objective optimization of end-milling parameters for AISI D2 cold-worked tool steel using GC1130-coated carbide inserts under wet machining, focusing on cutting speed and feed rate per tooth values beyond manufacturer recommendations. The objective was to identify parameter settings that minimize [...] Read more.

This study investigates multi-objective optimization of end-milling parameters for AISI D2 cold-worked tool steel using GC1130-coated carbide inserts under wet machining, focusing on cutting speed and feed rate per tooth values beyond manufacturer recommendations. The objective was to identify parameter settings that minimize surface roughness while maximizing cutting tool life—two performance criteria that often conflict in practice. A full-factorial design of experiments was implemented, varying the cutting speed (220–310 m/min) and feed rate (0.06–0.25 mm/tooth). Response Surface Methodology (RSM) was used to develop predictive models, and a desirability function approach (DFA) was applied to perform multi-response optimization under three weighting schemes. The statistical models showed strong reliability, with R² values of 81.09% for surface roughness and 95.02% for tool life. The optimal settings—220 m/min cutting speed and 0.25 mm/tooth feed—resulted in a tool life of 11.03 min and surface roughness of 0.587 µm. This yielded the highest desirability index (D = 0.8706) under tool-life-prioritized weighting, outperforming other cases by up to 10.69%. These findings offer a practical balance between quality and durability, especially for applications where tool wear is a limiting factor. Full article

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17 pages, 10657 KB

Open AccessArticle

Ultrashort Pulsed Laser Fabrication of High-Performance Polymer-Film-Based Moulds for Rapid Prototyping of Microfluidic Devices

by Pieter Daniël Haasbroek, Mischa Wälty, Michael Grob and Per Magnus Kristiansen

J. Manuf. Mater. Process. 2025, 9(9), 313; https://doi.org/10.3390/jmmp9090313 - 12 Sep 2025

Abstract

Microfluidic device prototyping demands rapid, cost-effective, and high-precision mould fabrication, yet ultrashort pulsed laser structuring of polymer inserts remains underexplored. This study presents a novel method for fabricating microfluidic mould inserts using femtosecond (fs) laser ablation of polyimide (PI) films, achieving high precision [...] Read more.

Microfluidic device prototyping demands rapid, cost-effective, and high-precision mould fabrication, yet ultrashort pulsed laser structuring of polymer inserts remains underexplored. This study presents a novel method for fabricating microfluidic mould inserts using femtosecond (fs) laser ablation of polyimide (PI) films, achieving high precision from design to prototype. PI films (250 µm) were structured using a 355 nm fs laser (300 fs, 500 kHz, 0.95 J/cm²) in a photochemically dominated ablation regime and bonded to reusable steel plates. Injection moulding trials with cyclic olefin copolymer (COC) and polymethyl methacrylate (PMMA) were conducted with diverse designs, including concentration gradient generators (CGG), organ-on-chip (OOC) with 20 µm bridges, and double emulsion droplet generators (DEDG) with 100–500 µm channels, ensuring robustness across complex geometries. The method achieved near 1:1 replication (errors < 2%, microchannel height tolerances < 1%, Sa = 0.02 µm in channels, 0.26 µm in laser-structured areas), machining times under 2 h, and mould durability over 100 cycles without significant deterioration. The PI’s heat-retarding effect mimicked variothermal moulding, ensuring complete micro-penetration without specialised equipment. By reducing material costs using PI films and reusable steel plates, enabling rapid iterations within hours, and supporting industry-compatible prototyping, this approach lowers barriers for small-scale labs. It enables rapid prototyping of diagnostic lab-on-chip devices and supports decentralised manufacturing for biomedical, chemical, and environmental applications, offering a versatile, cost-effective tool for early-stage development. Full article

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18 pages, 3720 KB

Open AccessArticle

Computational Design and Additive Manufacturing of 3D-Printed Prosthetics for Enhanced Mobility and Performance

by Jahid Hasan and Khalil Khanafer

J. Manuf. Mater. Process. 2025, 9(9), 312; https://doi.org/10.3390/jmmp9090312 - 10 Sep 2025

Abstract

This paper discusses the potential application of computational design and additive manufacturing in veterinary prosthetics, demonstrated with the example of a feline limb. A finite element analysis (FEA)-based design optimization framework was used to develop eight prosthetic leg geometries in CAD and analyze [...] Read more.

This paper discusses the potential application of computational design and additive manufacturing in veterinary prosthetics, demonstrated with the example of a feline limb. A finite element analysis (FEA)-based design optimization framework was used to develop eight prosthetic leg geometries in CAD and analyze them in ANSYS (2024R) under a static loading condition, to evaluate their performance under the loading condition. Structural variations were in the form of grooves, holes and shell reinforcements, which were investigated to see how they affect stiffness, stress distribution and viability of the 3D-printed prosthetics. Design variations were introduced through the inclusion or exclusion of structural attributes such as grooves, holes, and shell reinforcements. The simulations evaluated total deformation, von Mises stress, and equivalent elastic strain to determine the mechanical efficiency of each configuration. Results showed that designs incorporating shells and holes provided the best overall performance, as groove-free designs minimized stress concentrations and achieved the highest stiffness. Notably, the configuration featuring a hole and shell without grooves achieved the lowest mean deformation (14.09 µm) and stress values, making it the most structurally viable and suitable for real-life application. This study highlights the potential of 3D printing to produce cost-effective, patient-specific prosthetics and underscores the importance of structural optimization for improving biomechanical compatibility and mobility. The next stage of this work will involve fabricating the optimized design using 3D printing, followed by mechanical testing to validate the simulation results and assess real-world performance. Future work will also incorporate topology optimization to further reduce weight while maintaining structural integrity. Full article

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19 pages, 1347 KB

Open AccessArticle

Virtual Sensor for Injection Molding Monitoring

by Ronan Le Goff, Sabine Belle, Armelle Chenu, Nils Marchal, Antoine Delacourt, Franck Sellier and Matthieu Ponchant

J. Manuf. Mater. Process. 2025, 9(9), 311; https://doi.org/10.3390/jmmp9090311 - 9 Sep 2025

Abstract

Monitoring the complete injection molding process is becoming critical for manufacturing high-quality polymer products, as it enhances product quality and process efficiency. This study presents the development of a virtual sensor designed to monitor critical parameters of the injection molding process that cannot [...] Read more.

Monitoring the complete injection molding process is becoming critical for manufacturing high-quality polymer products, as it enhances product quality and process efficiency. This study presents the development of a virtual sensor designed to monitor critical parameters of the injection molding process that cannot be measured with existing sensors. The virtual sensor integrates both one-dimensional system simulations and data-driven models to accurately predict the behavior of the complete injection molding process, including the plasticizing steps. In our investigation, the virtual sensor was tested and demonstrated its ability in forecasting key process parameters, namely the injection pressure and the screw displacement. The sensor’s ability to provide real-time melt temperature or shear rate highlights its practical applicability and effectiveness in optimizing the injection molding process. Full article

(This article belongs to the Topic Advanced Composites Manufacturing and Plastics Processing, 2nd Volume)

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16 pages, 4967 KB

Open AccessArticle

Topology Optimization of Polymer-Based Bending Tools Manufactured via Additive Technology: Numerical and Experimental Validation

by Luca Giorleo and Kudret Irem Deniz

J. Manuf. Mater. Process. 2025, 9(9), 310; https://doi.org/10.3390/jmmp9090310 - 9 Sep 2025

Abstract

Sheet metal forming is a widely used manufacturing process, but the high cost and long production time of traditional forming tools limit its flexibility, especially for prototyping and small-batch production. Additive manufacturing offers a promising alternative, enabling the rapid and cost-effective fabrication of [...] Read more.

Sheet metal forming is a widely used manufacturing process, but the high cost and long production time of traditional forming tools limit its flexibility, especially for prototyping and small-batch production. Additive manufacturing offers a promising alternative, enabling the rapid and cost-effective fabrication of customized tools. In this study, bending tools were produced using Fused Filament Fabrication and optimized through a topology optimization approach. A combined experimental and numerical approach was applied to validate standard tool geometries and extract load conditions for use in a topology optimization process. The resulting optimized punch and die achieved a mass reduction of approximately 50% while maintaining structural integrity and safety factors well above critical thresholds. Finite Element Analysis revealed an increase in elastic deformation and stress concentration in non-critical regions, without compromising tool functionality. Experimental tests with the optimized tools confirmed their suitability for sheet metal bending, although a decrease of about 2° in the bending angle and an increase in variability were observed, consistent with simulation results. The study demonstrates the feasibility of using topology-optimized polymer tools for low-volume forming applications, offering a lightweight, cost-effective, and sustainable alternative to traditional metal tooling. Full article

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19 pages, 18634 KB

Open AccessArticle

Microstructure and Mechanical Properties of Al6060/TiB₂ Aluminum Matrix Composites Produced via Ultrasonically Assisted Stir Casting and Radial-Shear Rolling

by Maxat Abishkenov, Ilgar Tavshanov, Nikita Lutchenko, Kairosh Nogayev, Zhassulan Ashkeyev and Siman Kulidan

J. Manuf. Mater. Process. 2025, 9(9), 309; https://doi.org/10.3390/jmmp9090309 - 9 Sep 2025

Cited by 1

Abstract

Lightweight aluminum matrix composites with superior strength and structural integrity are in high demand for next-generation transportation and aerospace applications. In this work, Al6060-based composites reinforced with ≈2 wt.% TiB₂ were produced using a hybrid processing route that combines ultrasonically assisted stir [...] Read more.

Lightweight aluminum matrix composites with superior strength and structural integrity are in high demand for next-generation transportation and aerospace applications. In this work, Al6060-based composites reinforced with ≈2 wt.% TiB₂ were produced using a hybrid processing route that combines ultrasonically assisted stir casting with radial-shear rolling (RSR). This strategy enabled uniform particle dispersion, strong matrix–reinforcement bonding, and substantial microstructural refinement (grain size 4–6 μm) with reduced porosity. Consequently, the Al6060/TiB₂ composites demonstrated substantial gains over the as-cast alloy, combining a yield strength of 108.6 MPa, ultimate tensile strength of 156.9 MPa, and microhardness of 76.3 HV0.2 with a balanced ductility of ~9%. The demonstrated synergy of ultrasound-assisted casting and severe plastic deformation highlights a scalable pathway for fabricating high-performance aluminum composites, positioning them as promising candidates for aerospace, automotive, and other advanced engineering sectors. Full article

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19 pages, 5244 KB

Open AccessArticle

Variable-Orifice-Size Nozzle for 3D Printing

by Jan Bém, Jiří Suder, Aki Mikkola, Tomáš Kot, Jan Maslowski, Ján Babjak and Milan Mihola

J. Manuf. Mater. Process. 2025, 9(9), 308; https://doi.org/10.3390/jmmp9090308 - 9 Sep 2025

Abstract

This paper presents the general framework of the problem and the basis for the proposed idea, which lies in the design of a new extrusion nozzle for fused-deposition 3D printing, featuring a variable orifice that enables adaptive extrusion control to improve printing properties [...] Read more.

This paper presents the general framework of the problem and the basis for the proposed idea, which lies in the design of a new extrusion nozzle for fused-deposition 3D printing, featuring a variable orifice that enables adaptive extrusion control to improve printing properties such as material efficiency, printing speed, and localized control of mechanical properties. The working principle is controlled compression, via a linear actuator, of a silicone sleeve installed inside a metal jacket. Constrained by the metal jacket, the diameter of the silicone sleeve’s through-hole decreases with increasing compression. Three experiments were carried out to verify the functionality of the new nozzle design. The first two explored how the size of the nozzle orifice changes with movement of the linear actuator and the resulting silicone sleeve compression and decompression. In the third experiment, three sample parts were printed to demonstrate how the variable-orifice-size nozzle extruded PLA. The orifice diameter was set to

1.4

mm for the first condition,

0.7

mm for the second condition, and, in the third experiment, the first two conditions were combined. The orifice diameter was set to

1.4

mm for the first half of the object and then abruptly reduced to

0.7

mm for the second half. The prototype variable-orifice-size nozzle system demonstrated the potential of adaptive extrusion control for improved material efficiencies, faster printing times, and localized control of mechanical properties. However, it also revealed hysteresis of the silicone sleeve, a problem that must be addressed. Full article

(This article belongs to the Special Issue Advances in 3D Printing Technologies: Materials, Processes, and Applications)

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