Journal of Manufacturing and Materials Processing

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

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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24 pages, 7178 KB

Open AccessArticle

Experimental and Numerical Analysis of Thinning in Incremental Sheet Forming (SPIF) of an Aluminum Alloy (AA3003-H14)

by Md Tahjib Rafat, Karl R. Haapala and Zhaoyan Fan

J. Manuf. Mater. Process. 2025, 9(9), 307; https://doi.org/10.3390/jmmp9090307 - 8 Sep 2025

Abstract

This study examines the thinning behavior of AA3003-H14 aluminum alloy during single point incremental sheet forming (SPIF) through a combination of experimental trials and finite element analysis (FEA) using LS-DYNA. A full factorial experimental design was implemented to assess the effects of wall [...] Read more.

This study examines the thinning behavior of AA3003-H14 aluminum alloy during single point incremental sheet forming (SPIF) through a combination of experimental trials and finite element analysis (FEA) using LS-DYNA. A full factorial experimental design was implemented to assess the effects of wall angle (45°, 55°, 65°) and step size (0.25 mm, 0.50 mm, 0.75 mm) on sheet thinning at various forming depths. Thickness measurements were analyzed using a two-way analysis of variance to determine the significance of process parameters and their interactions. Numerical simulations predicted thickness reduction, effective plastic strain, and von Mises stress distributions, with deviations from experimental results generally remaining below 10%. The findings indicate that wall angle has a dominant influence on thinning, while step size exhibits a moderate effect. The validated FEA model accurately captures localized deformation behavior, offering a predictive tool for optimizing SPIF parameters. This work enhances the understanding of AA3003 thinning mechanisms and supports process improvements for broader industrial adoption of SPIF. Full article

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20 pages, 18687 KB

Open AccessArticle

Influence of Stirring Pin Geometry on Weld Appearance and Microstructure in Wire-Based Friction-Stir Additive Manufacturing of EN AW-6063 Aluminium

by Stefan Donaubauer, Stefan Weihe and Martin Werz

J. Manuf. Mater. Process. 2025, 9(9), 306; https://doi.org/10.3390/jmmp9090306 - 5 Sep 2025

Abstract

Additive manufacturing of metal components is predominantly based on fusion-welding processes involving melting and solidification. However, processing high-strength aluminium alloys presents challenges, including reduced mechanical properties and increased susceptibility to hot cracking. To address these issues, alternative solid-state processing methods for aluminium are [...] Read more.

Additive manufacturing of metal components is predominantly based on fusion-welding processes involving melting and solidification. However, processing high-strength aluminium alloys presents challenges, including reduced mechanical properties and increased susceptibility to hot cracking. To address these issues, alternative solid-state processing methods for aluminium are being explored worldwide. One such method is wire-based friction-stir additive manufacturing, which builds on the principles of friction-stir welding. This study focused on assessing a range of pin tool designs to promote improved mixing between the filler material and substrate. The best results were achieved using a two-stirring-probe configuration, which was then employed to fabricate a multilayer wall made of EN AW-6063 aluminium alloy. The resulting structure showed significant grain refinement, with the deposited layers having an average grain size approximately four times smaller than that of the substrate, indicating dynamic recrystallisation. Tensile testing of the intermediate layer revealed a strength of 147 MPa and 10% elongation, corresponding to 77% of the filler wire strength. These findings highlight the potential of the W-FSAM process for producing near-net-shape, high-quality lightweight metal components with refined microstructures and reliable mechanical performance. Full article

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20 pages, 7090 KB

Open AccessArticle

Laser-Based Additive Manufacturing of Alkali Borosilicate Glass Powder: Influence of Laser-Beam Properties on Component Quality

by Anne-Marie Layher, Lisa Tewes, Felix Thumann, Thekla Boeckh, Sharon Koppka, Dirk Enke, Edda Rädlein and Jens Bliedtner

J. Manuf. Mater. Process. 2025, 9(9), 305; https://doi.org/10.3390/jmmp9090305 - 5 Sep 2025

Abstract

Research and development in the field of glass-based laser additive manufacturing continues to receive significant interest within scientific and industrial contexts. In particular, powder bed fusion by laser radiation (PBF-LB) enables the additive manufacturing of porous and vitrified, complex three-dimensional components. The present [...] Read more.

Research and development in the field of glass-based laser additive manufacturing continues to receive significant interest within scientific and industrial contexts. In particular, powder bed fusion by laser radiation (PBF-LB) enables the additive manufacturing of porous and vitrified, complex three-dimensional components. The present study investigates the glass morphology that can be achieved using PBF-LB for components made from alkali borosilicate glass. The investigations focus on the comprehensive analysis of the entire process window, including the characterisation of porous and molten glass morphology. In particular, the influence of different laser-beam diameters, which are achieved through defocusing, and the variation in volume energy density are examined in detail and compared with conventional shaping. It was determined that the process of mechanically stable shaping is constrained to temperatures above the softening temperature and relative component densities within the range of ρrel = 37.8…94.2%. Furthermore, it has been demonstrated that the process-related line-like energy input results in the formation of characteristic vitrification strands. This research contributes to the overall understanding of the producible glass morphology and the process limitations of the PBF-LB process. In addition, the entire range of glass morphologies, ranging from open-pored to closed-melt configurations, could be analysed for the first time. Full article

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12 pages, 9524 KB

Open AccessArticle

Effect of Heat Treatment on High-Temperature Tribological Behavior of WE54 Alloy: An Experimental Study

by Sudharsan Saravanan, Aditya Raman Hattimare, Atharva Bharat Mahadik, Arnav Singh, Uttamchand Narendra Kumar and A. Raja Annamalai

J. Manuf. Mater. Process. 2025, 9(9), 304; https://doi.org/10.3390/jmmp9090304 - 5 Sep 2025

Abstract

This study examines the high-temperature tribological behavior of WE54 Mg alloy under various conditions: as-cast, solution-treated (T4), age-hardened (T6), and secondary aged (S.A). Wear tests were performed using a pin-on-disc setup, applying a normal load of 10 N, with a sliding velocity of [...] Read more.

This study examines the high-temperature tribological behavior of WE54 Mg alloy under various conditions: as-cast, solution-treated (T4), age-hardened (T6), and secondary aged (S.A). Wear tests were performed using a pin-on-disc setup, applying a normal load of 10 N, with a sliding velocity of 1 m/s, a sliding distance of 1000 m, and temperatures from 25 °C to 150 °C. Responses such as the coefficient of friction and volumetric wear rate were recorded. The results indicate that heat treatment significantly influences the wear behavior of the WE54 alloy. The lowest volumetric wear rate (8.16 ± 1.47 mm³) and wear coefficient (0.112 ± 0.02) occurred in the as-cast sample at 100 °C, while the highest volumetric wear rate (14.68 ± 1.59 mm³) and wear coefficient (0.171 ± 0.02) were found in the S.A. sample at 150 °C. Surface characterization of worn samples was conducted using field emission scanning electron microscopy (FESEM) and X-ray diffraction (XRD). The wear mechanisms identified include abrasive wear, oxidative wear, and delamination across all conditions, regardless of temperature. The elevated volumetric wear rate at 150 °C, irrespective of the sample condition, is attributed to oxidation and thermal softening of the material. Full article

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15 pages, 13719 KB

Open AccessArticle

Spot Melting Strategy for Contour Melting in Electron Beam Powder Bed Fusion

by Tobias Kupfer, Lukas Spano, Sebastian Pohl, Carolin Körner and Matthias Markl

J. Manuf. Mater. Process. 2025, 9(9), 303; https://doi.org/10.3390/jmmp9090303 - 4 Sep 2025

Abstract

Spot melting is an emerging alternative to traditional line melting in electron beam powder bed fusion, dividing a layer into thousands of individual spots. This method allows for an almost infinite number of spot arrangements and spot melting sequences to tailor material and [...] Read more.

Spot melting is an emerging alternative to traditional line melting in electron beam powder bed fusion, dividing a layer into thousands of individual spots. This method allows for an almost infinite number of spot arrangements and spot melting sequences to tailor material and part properties. To enhance the productivity of spot melting, the number of spots can be reduced by increasing the beam diameter. However, this results in rough surfaces due to the staircase effect. The classical approach to counteract these effects is to melt a contour that surrounds the infill area. Creating effective contours is challenging because the melted area ought to cover the artifacts from the staircase effect and avoid porosity in the transition area between the infill and contour, all while minimizing additional energy and melt time. In this work, we propose an algorithm for generating a spot melting sequence for contour lines surrounding the infill area. Additionally, we compare three different approaches for combining the spot melting of infill and contour areas, each utilizing a combination of large infill spots and small contour spots. The quality of the contours is evaluated based on optical inspection as well as the porosity between infill and contour using electron optical images, balanced against the additional energy input. The most suitable approach is used to build a complex brake caliper. Full article

(This article belongs to the Special Issue Advances in Powder Bed Fusion Technologies)

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16 pages, 6283 KB

Open AccessArticle

In Situ Investigation of the Frictional Behaviour in Friction-Spinning

by Eugen Wiens, Dina Hijazi, Maik Jüttner, Werner Homberg, Mark Dennis Kensy and Wolfgang Tillmann

J. Manuf. Mater. Process. 2025, 9(9), 302; https://doi.org/10.3390/jmmp9090302 - 1 Sep 2025

Abstract

Friction-spinning is an incremental thermomechanical forming process that has huge potential due to its simple yet effective mechanism of utilising friction between a rotating workpiece and a forming tool to increase the workpiece’s temperature, which reduces the required forces and increases formability during [...] Read more.

Friction-spinning is an incremental thermomechanical forming process that has huge potential due to its simple yet effective mechanism of utilising friction between a rotating workpiece and a forming tool to increase the workpiece’s temperature, which reduces the required forces and increases formability during the forming process. Despite the simplicity of the process’s setup, the thermomechanical loads and high relative velocities involved, especially in the contact zone, make the application of classical methods for characterising friction inaccurate. It is therefore essential to find a way to describe the frictional behaviour under real process conditions to be able to gain a holistic understanding of the process and the effect of the adjustable parameters on the outcome, especially the temperature. To achieve this goal, an experimental setup that considers the actual process boundary conditions in forming tubes made of EN AW-6060 was used to measure in situ normal and frictional forces, in addition to process temperatures, under varying rotational speed and feed rate values. Full article

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28 pages, 6036 KB

Open AccessReview

Green Composites in Additive Manufacturing: A Combined Review and Bibliometric Exploration

by Maria Tănase and Cristina Veres

J. Manuf. Mater. Process. 2025, 9(9), 301; https://doi.org/10.3390/jmmp9090301 - 1 Sep 2025

Abstract

This review provides a comprehensive analysis of recent developments in the additive manufacturing of green composites, with a particular focus on their mechanical behavior. A bibliometric analysis of 482 research articles indexed in the Web of Science Core Collection and published between 2015 [...] Read more.

This review provides a comprehensive analysis of recent developments in the additive manufacturing of green composites, with a particular focus on their mechanical behavior. A bibliometric analysis of 482 research articles indexed in the Web of Science Core Collection and published between 2015 and 2025 reveals a sharp increase in publications, with dominant contributions from countries such as China, India, and the United States, as well as strong collaboration networks centered on materials science and polymer engineering. Thematic clustering highlights a growing emphasis on natural fiber reinforcement, biodegradable matrices, and performance optimization. Despite these advances, few studies have combined bibliometric analysis with a technical evaluation of mechanical performance, leaving a gap in understanding the relationship between research trends and material or process optimization. Building on these insights, the review synthesizes current knowledge on material composition, print parameters, infill design, and post-processing, identifying their combined effects on tensile strength, stiffness, and durability. The study concludes that multi-variable optimization—encompassing fiber-matrix compatibility, print architecture, and thermal control—is essential to achieving eco-efficient and high-performance green composites in additive manufacturing. Full article

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

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30 pages, 48007 KB

Open AccessArticle

Advantages of Femtosecond Laser Microdrilling PDMS Membranes over Conventional Methods for Organ-on-a-Chip

by Chahinez Berrah, Daniel Sanchez-Garcia, Javier Rodriguez Vazquez Aldana and Andres Sanz-Garcia

J. Manuf. Mater. Process. 2025, 9(9), 300; https://doi.org/10.3390/jmmp9090300 - 1 Sep 2025

Abstract

Organ-on-a-chip (OoC) technology aims to replicate the functions of human organs and tissues. This study evaluates femtosecond laser micromachining (FLM) for producing PDMS membranes with controlled porosity as an alternative approach to conventional microfabrication for OoCs. Membranes of varying thicknesses were microdrilled, and [...] Read more.

Organ-on-a-chip (OoC) technology aims to replicate the functions of human organs and tissues. This study evaluates femtosecond laser micromachining (FLM) for producing PDMS membranes with controlled porosity as an alternative approach to conventional microfabrication for OoCs. Membranes of varying thicknesses were microdrilled, and the influence of laser parameters on microhole geometry was assessed, showing that pulse energy strongly affected hole diameter, whereas exposure time had a lesser impact. The heat-affected zone (HAZ) and taper angle, key indicators of microhole geometric quality, were also analyzed and found to be strongly dependent on membrane thickness. Prediction models were developed to guide parameter selection for future laser-based ablation processes. A numerical model that predicts plasma shielding effects provided further insight into the physics of PDMS laser ablation, revealing that higher pulse energies led to a marked increase in crater diameter. The fabricated membranes were integrated into an OoC device, onto which human mesenchymal stem cells were seeded. The results demonstrated strong cell adhesion, the rapid formation of a homogeneous monolayer, and no evidence of cytotoxicity. These findings confirm that FLM is a versatile and flexible technique for microdrilling PDMS membranes, enabling their effective integration into OoC. Full article

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24 pages, 11780 KB

Open AccessArticle

Additive Manufacturing of Carbon Fiber Cores for Sandwich Structures: Optimization of Infill Patterns and Fiber Orientation for Improved Impact Resistance

by Claudio Tosto, Lorena Saitta, Ignazio Blanco, Gabriele Fichera, Mattia Evangelista, Jerin Jose, Alessia Pantaleoni and Irene Bavasso

J. Manuf. Mater. Process. 2025, 9(9), 299; https://doi.org/10.3390/jmmp9090299 - 1 Sep 2025

Abstract

Carbon fiber-reinforced composites (CFRCs) are widely used in aerospace, automotive, and defense applications due to their high strength-to-weight ratio and excellent mechanical performance. In this study, cores and sandwich panels were fabricated via fused filament fabrication (FFF) using co-polyester filaments reinforced with 20 [...] Read more.

Carbon fiber-reinforced composites (CFRCs) are widely used in aerospace, automotive, and defense applications due to their high strength-to-weight ratio and excellent mechanical performance. In this study, cores and sandwich panels were fabricated via fused filament fabrication (FFF) using co-polyester filaments reinforced with 20 wt.% short carbon fibers. The mechanical response of the structures was evaluated under low-velocity impact (LVI) conditions using instrumented drop weight testing at energy levels ranging from 2 to 20 J. A three-factor, three-level full factorial experimental design was employed, considering build orientation (flat vs. upright), infill pattern (trihexagonal vs. triangular), and impact energy as factors. The maximum contact force was selected as the primary response variable. The results revealed that upright-printed specimens exhibited significantly improved impact resistance compared to flat-printed ones, with increases in peak force of up to 28% for cores and over 68% for sandwich structures. Among the tested infill geometries, the triangular pattern outperformed the trihexagonal one across all configurations and energy levels. The combination of upright orientation and triangular infill proved to be the most effective, providing enhanced energy absorption and reduced rear-side damage, especially under higher impact energies. These findings offer valuable insights into the design of lightweight, impact-resistant structures produced by additive manufacturing, with direct implications for structural components in demanding engineering environments. Full article

(This article belongs to the Special Issue Innovative and Sustainable Advances in Polymer Composites for Additive Manufacturing: Processing, Microstructure, Machining, and Mechanical Properties)

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22 pages, 5144 KB

Open AccessArticle

Real-Time Envelope Monitoring of High-Speed Spindle in Commissioning Conditions: Grinding Machine

by Claudiu Bisu, Miron Zapciu and Delia Gârleanu

J. Manuf. Mater. Process. 2025, 9(9), 298; https://doi.org/10.3390/jmmp9090298 - 1 Sep 2025

Abstract

This article addresses the monitoring and diagnosis of high-speed spindles (HSM) used in CNC grinding machines, emphasizing the importance of the real-time evaluation of their dynamic behavior during commissioning. Due to the complexity of these dynamic phenomena, especially at high speeds (up to [...] Read more.

This article addresses the monitoring and diagnosis of high-speed spindles (HSM) used in CNC grinding machines, emphasizing the importance of the real-time evaluation of their dynamic behavior during commissioning. Due to the complexity of these dynamic phenomena, especially at high speeds (up to 150,000 RPM), common faults such as bearing wear, imbalance, or misalignment can lead to catastrophic failures and high repair costs. An original method is proposed, based on synchronous envelope vibration analysis (SEVA) using the Hilbert transform, to detect mechanical defects in both low-frequency domains (imbalance, mechanical looseness) and high-frequency domains (bearing faults). The system includes vibration, temperature, and speed sensors, and the experimental protocol involves step-by-step monitoring from 10,000 to 90,000 RPM. Through synchronous FFT analysis and IFFT, critical frequencies and their impacts on machining quality are identified. The method enables the accurate fault diagnosis of new or refurbished spindles under real industrial conditions, reducing downtime and production losses. The method involves both local and remote real-time monitoring and diagnosis using a remote data center protocol. Full article

(This article belongs to the Special Issue Dynamics and Machining Stability for Flexible Systems)

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38 pages, 4536 KB

Open AccessReview

Emerging Technologies in Augmented Reality (AR) and Virtual Reality (VR) for Manufacturing Applications: A Comprehensive Review

by Nitol Saha, Victor Gadow and Ramy Harik

J. Manuf. Mater. Process. 2025, 9(9), 297; https://doi.org/10.3390/jmmp9090297 - 1 Sep 2025

Abstract

As manufacturing processes evolve towards greater automation and efficiency, the integration of augmented reality (AR) and virtual reality (VR) technologies has emerged as a transformative approach that offers innovative solutions to various challenges in manufacturing applications. This comprehensive review explores the recent technological [...] Read more.

As manufacturing processes evolve towards greater automation and efficiency, the integration of augmented reality (AR) and virtual reality (VR) technologies has emerged as a transformative approach that offers innovative solutions to various challenges in manufacturing applications. This comprehensive review explores the recent technological advancements and applications of AR and VR within the context of manufacturing. This review also encompasses the utilization of AR and VR technologies across different stages of the manufacturing process, including design, prototyping, assembly, training, maintenance, and quality control. Furthermore, this review highlights the recent developments in hardware and software components that have facilitated the adoption of AR and VR in manufacturing environments. This comprehensive literature review identifies the emerging technologies that are driving AR and VR technology toward technological maturity for implementation in manufacturing applications. Finally, this review discusses the major difficulties in implementing AR and VR technologies in the manufacturing sectors. Full article

(This article belongs to the Special Issue Smart Manufacturing in the Era of Industry 4.0, 2nd Edition)

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18 pages, 8428 KB

Open AccessArticle

Effect of Temperature, Heating Rate, and Cooling Rate on Bonding and Nitriding of AlSi10Mg Powder Occurring During Supersolidus Liquid-Phase Sintering

by Alena Kreitcberg, Mohamed Khaled Trigui, Abdelberi Chandoul, Roger Pelletier and Vincent Demers

J. Manuf. Mater. Process. 2025, 9(9), 296; https://doi.org/10.3390/jmmp9090296 - 1 Sep 2025

Abstract

This study investigated the effect of supersolidus liquid-phase sintering conditions on the powder particle bonding and the AlN-phase formation of an AlSi10Mg alloy. Sintering was conducted at temperatures between 550 and 579 °C, with a holding duration of 2 h under a nitrogen [...] Read more.

This study investigated the effect of supersolidus liquid-phase sintering conditions on the powder particle bonding and the AlN-phase formation of an AlSi10Mg alloy. Sintering was conducted at temperatures between 550 and 579 °C, with a holding duration of 2 h under a nitrogen atmosphere. The sintering cycles included four heating segments, performed at rates ranging from 0.2 to 5 °C/min for a total of between 5 and 15 h, and a cooling segment performed at two different cooling rates, 0.15 and 5 °C/min, resulting in durations of 12 and 70 h, respectively. Three powder batches exhibiting different particle size distributions were tested. An X-ray diffractometer, optical microscopy, and scanning electron microscopy were used to characterize phase formation and particle bonding. The results show that higher sintering temperatures and faster heating/cooling rates led to a lower fraction of AlN. In contrast, lower sintering temperatures or slow heating promoted the development of a thicker AlN shell around powder particles, inhibiting the bonding of the AlSi10Mg powder and preventing densification via the sintering process. These findings suggest that sintering at temperatures between 570 and 575 °C, with heating and cooling rates of at least 2 °C/min, constitutes a more favorable window for the densification of AlSi10Mg under a nitrogen atmosphere. Full article

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16 pages, 8988 KB

Open AccessArticle

Controlling the Material Width of Equation-Based Lattices for Large-Scale Additive Manufacturing

by Martha Baldwin, Joseph Bartolai, Joseph W. Fisher and Simon W. Miller

J. Manuf. Mater. Process. 2025, 9(9), 295; https://doi.org/10.3390/jmmp9090295 - 1 Sep 2025

Abstract

Additive manufacturing (AM) developments have been strongly driven by the ability of AM to improve the strength-to-weight ratios of structures, in contrast to traditional manufacturing methods, heavily supported by lattice structures. These motivations have persisted with the development of large-scale additively manufactured structures, [...] Read more.

Additive manufacturing (AM) developments have been strongly driven by the ability of AM to improve the strength-to-weight ratios of structures, in contrast to traditional manufacturing methods, heavily supported by lattice structures. These motivations have persisted with the development of large-scale additively manufactured structures, which can offer more flexibility in manufacturing location and can often be faster than traditional manufacturing. However, current large-scale AM methods are often limited by their precision in order to maintain speed, constraining the method to manufacturing simple structures and often avoiding lattices altogether. This work proposes a mathematical framework for defining an equation-based lattice that splits the lattice into (1) build direction and (2) planar components such that their design can be altered to address AM methods restricted to three degrees of freedom. The framework is applied against a class of lattices called triply periodic minimal surfaces, which are represented using implicit equations, and it is shown that this approach allows for their use in large-scale AM technologies and enables further design control for small-scale AM design. Full article

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Journal of Manufacturing and Materials Processing

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