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A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: closed (31 March 2025) | Viewed by 20214

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Prof. Dr. Marek Placzek

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Department of Engineering Processes Automation and Integrated Manufacturing Systems, Silesian University of Technology, 44-100 Gliwice, Poland
Interests: piezoelectric materials; vibration damping; energy harvesting; sensors; actuators; smart materials and their applications; pneumatic drives and their energy efficiency; electromagnetic compatibility
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Special Issue Information

Dear Colleagues,

In the era of industry transformation in line with the concept of Industry 4.0, modern manufacturing technologies and modern materials are becoming a subject of interest for an increasing number of scientists, engineers and businesses. Increasing production efficiency and flexible changes to the assortment of products and their personalization pose new challenges. However, modern technologies and materials allow for increasingly rapid development of industry and a change in the way people work as well as their role in production processes. Efficiency, flexibility and production speed translate into increased competitiveness and the reduction of production costs. To achieve this, modern manufacturing technologies are used, including additive manufacturing, systems based on virtual and augmented reality, artificial intelligence, autonomous robots, simulations, and systems integration. Operations on large data sets and cloud computing are becoming necessary, and the industrial Internet of Things is gaining importance, but cybersecurity is also becoming a key element. All these issues are inextricably linked with the concept of modern, smart manufacturing and smart factories.

The concept of increasingly intelligent materials often also refers to the materials used in manufactured products, and as elements of the production systems themselves. Smart materials are gaining in popularity, and are being increasingly used in the modern world. Their applications open completely new paths of technological development and create new possibilities. This leads to the development of modern devices and technologies, and allows the development of new, previously unattainable solutions. It is extremely important to develop concepts and assumptions for action and research in laboratory conditions and on real objects of innovative systems based on the use of smart materials. At the same time, the modeling of technical means in which smart materials are used due to the complexity of the phenomena occurring in them is a complex task. However, the correct description of a given device in the form of a mathematical model, at the design stage, is, the basic condition for its proper operation. The development of mathematical models and algorithms for the analysis and determination of the characteristics of technical measures containing such materials is therefore an important element of scientific research.

For this Special Issue, I invite the submission of original papers and reviews of scientific papers presenting innovative solutions in the field of smart technologies and smart materials. Issues concerning modeling, testing, and applications can be presented. I encourage you to publish studies containing the results of conceptual work and laboratory and real object tests, to present issues including the use of modern modeling and simulation methods.

If you have any questions or doubts, you can contact me by email.

Prof. Dr. Marek Placzek
Guest Editor

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Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

smart technology
smart materials
simulation
modeling
analysis
testing
big data
autonomous robots
system integration
industrial IoT
cybersecurity
cloud computing
additive manufacturing
reverse engineering
virtual and augmented reality
artificial intelligence
piezoelectric transducers
electrostatic materials
magnetostrictive materials
shape memory materials
variable viscosity liquids
thermoelectric materials
light emitting materials

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Related Special Issue

Smart Manufacturing and Materials: 3rd Edition in Applied Sciences

Published Papers (11 papers)

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Research

Jump to: Review

18 pages, 4834 KiB

Open AccessArticle

The Influence of Temporo-Mandibular Joint Support Conditions and Osseintegration on Mastication Load Transfer in a Mandibular Prosthesis

by Jarosław Żmudzki and Magdalena Zorychta-Tomsia

Appl. Sci. 2025, 15(8), 4281; https://doi.org/10.3390/app15084281 - 13 Apr 2025

Viewed by 207

Abstract

In the design of mandibular implants, the application of previous research findings, which highlight the significance of asymmetric occlusal load transfer schemes, is often lacking. The generated identical oblique occlusal force for maximum muscle efficiency may not be the sole criterion for assessing the load-bearing capacity of a mandibular prosthesis. The hypothesis of this study was that the load-bearing capacity of extensive mandibular prostheses is significantly underestimated when assuming mandibular support at the temporomandibular joint on the occlusal side compared to the assumption of perfect osseointegration between the implant and bone. Finite Element Method (FEM) simulation studies were conducted to analyze occlusal load transfer, considering two joint support conditions: support in both temporo-mandibular joints and support in only one joint, opposite the bite side. Additionally, two variants of the implant-bone connection were examined: an optimistic scenario assuming complete osseointegration and a pessimistic scenario assuming no osseointegration, with fixation achieved solely through bone fixation plates. The findings indicated a significant underestimation of the loads transferred by the implant and bone tissue when symmetrical joint support and osseointegration were assumed. Although there is currently no conclusive evidence supporting the complete exclusion of the joint, the computational results demonstrated that, in the absence of precise data regarding the percentage contribution of the joint on the occlusal side, it is preferable to employ more stringent criteria for assessing the load-bearing capacity of mandibular prostheses. This assessment should include the exclusion of joint support on the occlusal side to ensure a more conservative and reliable evaluation of the prosthesis’s mechanical performance. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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18 pages, 11460 KiB

Open AccessArticle

A Computational Sketch-Based Approach Towards Optimal Product Design Solutions

by Paschalis Charalampous

Appl. Sci. 2025, 15(5), 2413; https://doi.org/10.3390/app15052413 - 24 Feb 2025

Viewed by 565

Abstract

This paper presents a numerical sketch-based methodology to achieve optimal product design solutions, bridging the gap between initial conceptual sketches and advanced engineering analyses. The proposed approach enables the transformation of simple hand-drawn sketches into digital models suitable for complex computational simulations and design optimization. Using computer vision algorithms, sketches are processed to generate digital design components that serve as inputs for Finite Element Analysis (FEA). In order to further enhance the overall design process, topology optimization (TO) is also performed, iteratively refining the geometry to achieve optimal material distribution for improved structural performance. Additionally, Adaptive Mesh Refinement (AMR) techniques are applied to ensure computational efficiency and accuracy by dynamically refining the mesh in regions of high complexity or stress concentration. The synergy of sketch-based modeling, FEA, TO, and AMR demonstrates significant potential in reducing design cycles while maintaining high-performance standards. Finally, it should be noted that the proposed pipeline consists of a fully automated procedure, hence it could reduce the learning curve for the designers, enabling companies to onboard employees faster and integrate advanced design techniques into their workflows without extensive training. The above-mentioned modules render the introduced approach particularly suitable for applications in product design development that can be utilized in several industries like mechanical, manufacturing, and furniture. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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37 pages, 5219 KiB

Open AccessArticle

Adaptive Path Planning for UAV-Based Pollution Sampling

by Mateusz Kosior, Piotr Przystałka and Wawrzyniec Panfil

Appl. Sci. 2024, 14(24), 12065; https://doi.org/10.3390/app142412065 - 23 Dec 2024

Cited by 1 | Viewed by 847

Abstract

Unmanned Aerial Vehicles (UAVs) continue to gain popularity in applications such as military reconnaissance, environmental monitoring in remote locations, and package delivery. High-Altitude Long-Endurance (HALE) UAVs can remain airborne for extended periods, enabling air pollution measurements to be conducted across a wide range of altitudes, from a few hundred meters above ground level to the lower stratosphere. However, the challenges posed by dynamic environmental conditions and strict energy limitations necessitate the use of adaptive path planning algorithms that account for UAV and environmental models. To address these challenges, we propose a two-tier Adaptive Path Planner (APP), which comprises a Global Path Planner (GPP) and a Local Path Planner (LPP). The GPP, operating offline, generates obstacle-free, energy-efficient paths that adhere to the UAV’s kinematic constraints, while the LPP dynamically recalculates alternative routes in real time when obstacles arise. The APP leverages a novel data-driven environmental model, integrating terrain, wind, airspace, and measurement maps. Extensive Model-in-the-Loop testing was conducted to evaluate various single-objective optimization algorithms for the GPP. Subsequently, the APP was successfully validated in simulation scenarios inspired by real-world pollution monitoring missions conducted in Poland and the Arctic. Additionally, the proposed approach was tested under real-world conditions, demonstrating significant application potential. A comparative analysis of the generated paths demonstrated that the APP effectively replaces human operators. Further testing confirmed the APP’s capability for adaptive re-planning during mission execution. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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15 pages, 4595 KiB

Open AccessArticle

Evaluating the Impact of Environmental and Operational Conditions on the Characteristics of CFRP Epoxy Composites

by Ewa Kocyan and Mirosław Szczepanik

Appl. Sci. 2024, 14(10), 4312; https://doi.org/10.3390/app14104312 - 20 May 2024

Viewed by 1023

Abstract

The purpose of this study is to determine the material properties of CFRP composites in the form of a fabric for the construction of racing car bodywork. This work focused on the determination of the strength and tribological properties as well as investigating the effects of the operating environment on the developed material. Three material variants, differing in the number of layers used to produce the reinforcement, were used in this study. The tests were carried out on two-/three-/four-layer sheets produced by infusion. Due to the later use of the tested composites for the sheathing of a racing car, the results obtained were analysed in terms of the most favourable strength properties while keeping the weight as low as possible. In this study, the hardness, impact strength, and tensile and bending stresses of the developed composites were examined. In addition to the strength properties, the density, the effects of immersion in water, and the composite’s resistance to staining and friction in the presence of aggressive media were also checked. The structure and the breakthroughs resulting from the strength tests were observed using a stereoscopic microscope. The material’s resistance to sunlight and UVB was also tested. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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13 pages, 2676 KiB

Open AccessArticle

Testing of Permeability of RFID Access Control System for the Needs of Security Management

by Andrej Veľas, Martin Boroš, Radoslav Kuffa and Filip Lenko

Appl. Sci. 2024, 14(10), 4227; https://doi.org/10.3390/app14104227 - 16 May 2024

Cited by 1 | Viewed by 1789

Abstract

Access control systems are part of the overall protection of objects. It is often the first system with which it is necessary to start the contact system; therefore, it is necessary to ensure its proper functioning. In the event of a malfunction, it can cause downtime in production, and it is triggered by a bad replacement of workers. Access control systems have their own specificities that need to be considered when designing security. Poor selection of access control devices can cause inefficient system functionality, resulting in downtime and loss. Based on experimental testing and related work in access control systems, this paper discusses the possibilities of testing the throughput of access control systems. The manuscript presents the design of a unique test device that can be used in the assessment of the reliability and throughput of access control systems. With the help of tests, we were able to determine the probability of downtime due to inappropriately set time intervals for changing employees on a work shift. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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22 pages, 7086 KiB

Open AccessArticle

Methodology Proposal and 3D Model Creation of a Car Steering Wheel

by Miriam Fandáková, Michal Palčák and Pavol Kudela

Appl. Sci. 2023, 13(14), 8054; https://doi.org/10.3390/app13148054 - 10 Jul 2023

Viewed by 2473

Abstract

Currently, the largest milestone to successfully bring products to market is to shorten the production time interval, so the production of any product should be very fast. Customers are far more demanding and recently prefer the option to customize products. A key element in the development of prototypes and the overall shortening of the production process is rapid prototyping, an integral part of which is virtual modeling. Modeling is completed through explicit or parametric 3D CAD software. This article proposes a methodology for creating a 3D virtual model of a car steering wheel and then creates an assembled spatial model in real size. Attention is focused on the theoretical knowledge of the problem, the specification of dimensions, the number of assembly members and the selection of a suiTable 3D CAD application in which the steering wheel is modeled. Many specific software features are also described that are not standardly used and make a significant contribution to a more design-attractive output. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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17 pages, 4698 KiB

Open AccessArticle

The Phenomenon of Loss of Energy Flux Density in Pneumatic and Electromagnetic Generators for EPAT Therapy

by Michał Sawicki, Michał Maćkowski and Marek Płaczek

Appl. Sci. 2022, 12(24), 12939; https://doi.org/10.3390/app122412939 - 16 Dec 2022

Cited by 2 | Viewed by 2381

Abstract

Shock wave therapy involves introducing an acoustic wave into the living organism, whose pro-healing effect promotes the decomposition of stones and calcareous deposits. To generate such a wave, devices converting electrical energy into shock wave energy are used. Two versions of radial wave generators dominate the market: pneumatic and electromagnetic. The quality of the generator components and the design solutions significantly affect the amount of shock wave energy received. In the literature, there is a belief that, unfortunately, due to design limitations, it is not possible to obtain the same portion of energy for increasingly higher frequencies of generating wave pulses. The current study presents the results of a series of experiments carried out on two test benches. Two types of the wave generator were tested: pneumatic and electromagnetic. The obtained results clearly show that the mentioned problem occurs in both types of shock wave generators, regardless of whether it is a pneumatic or electromagnetic solution. This study discusses, in detail, the principle of operation of each type of generator and proposes a hypothesis on the source of the phenomenon. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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14 pages, 1723 KiB

Open AccessArticle

The Study of the Influence of Temperature and Low Frequency on the Performance of the Laminated MFC Piezoelectric Energy Harvester

by Tolera G. Degefa, Marek Łukasz Płaczek and Grzegorz Kokot

Appl. Sci. 2022, 12(23), 12135; https://doi.org/10.3390/app122312135 - 27 Nov 2022

Cited by 6 | Viewed by 2113

Abstract

MFC (Microfiber composite) piezoelectric transducers are one of the smart composite materials used among others in alternative energy sources and autonomous wireless sensors which exploit vibrational energy. This work presents the theoretical and experimental investigations of the integration of MFC piezoelectric transducers on epoxy glass fiber composite material and explores the capacity of power generation based on a variety of ambient temperatures and frequencies. The study examined the use of ambient vibrational energy to power small electronic devices of wireless sensor networks which eliminates the need for external power, periodic battery replacement costs, and chemical waste from conventional batteries. The test was conducted using a laboratory stand equipped with a thermal chamber and an Instron ElectroPulse waveform generator which induces a concentric cyclic load to the laminated beam. Laminated MFC was loaded with a low–frequency range, controlled displacement under different moderate temperatures. The test was conducted at temperatures ranging from 25 to 60 degrees Celsius and at frequencies ranging from 5 to 25 Hz. The results show that the voltage generated by the transducer is highly affected by both temperature and frequency of excitation. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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14 pages, 5178 KiB

Open AccessArticle

A Smart Handheld Welding Torch Device for Manual Spot Laser Welding

by Murat Reis and Emre Şerifağaoğlu

Appl. Sci. 2022, 12(21), 11137; https://doi.org/10.3390/app122111137 - 2 Nov 2022

Cited by 3 | Viewed by 3672

Abstract

In producing custom-made systems, using a robotic welding line that can fine-tune welding parameters is not economical, and laser welding is usually done manually. The most common operator error in manual welding operations is the angular positioning error between the laser beam and the plate surface. This study introduces a smart handheld welding torch device that assists the welding operator with visual warnings. It measures the sheet surface angle to eliminate angular positioning errors, calculates the appropriate torch holding angles accordingly, and helps the laser welding process with the right angle. For this purpose, this study focused on micro-laser spot welding applications of stainless (inox) kitchen and hotel equipment, and the effect of angular positioning errors on the welding quality was investigated experimentally. Experiments show that when the angle between the surface normal and the welding torch is smaller than the critical welding angle, heat-induced traces or micro-deformations occur on the visible surface of the thin stainless material. In addition, there is a significant decrease in the weld quality, since a large enough weld area cannot be created at large values of this angle. The optimum torch angle range was determined using experimental results for the available laser welding parameters. With a standard welding torch and the smart torch, the welding operator was allowed to repeat the same task, and the payloads of the samples prepared in this way were measured. Test results show that using a smart welding torch with an angular positioning assist system significantly improves welding quality. Breaking force values vary in a wide range of welds made with a standard welding torch, and visual problems such as burning, puncture, and swelling are encountered on the visible surfaces of many samples with high strength values. When the developed smart torch was used, the breaking force remained within the desired reference range, and no visual defects were found in any sample. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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20 pages, 5563 KiB

Open AccessArticle

Parametric Optimization of Nozzle Turbine Vane Modal Characteristics by Means of Artificial System

by Rafał Robak, Mirosław Szczepanik and Sebastian Rulik

Appl. Sci. 2022, 12(19), 9724; https://doi.org/10.3390/app12199724 - 27 Sep 2022

Cited by 1 | Viewed by 2698

Abstract

Modal analysis is a fundamental assessment in the design phase of a nozzle guide vane in a low pressure turbine system. Evaluation is crucial for new concept design but also in case of design modification. The technical requirement is to ensure appropriate durability level (number of flight cycles) and the reliability of the system. An understanding of dynamic behavior is one of the key elements in the high cycle fatigue (HCF) evaluation. Finite element method (FEM) analyses are widely used in new product introduction phases to verify modal characteristics with respect to operating range and engine orders (forcing function, excitation). In the process used 2D representation of the nozzle guide vane approximated by axisymmetric and plane stress with thickness FEM plain elements. The optimization process used geometrical parameters (nozzle outer band and casing shell) and surrogate models to find optimal solutions from a frequency placement perspective. A sensitivity analysis and optimization process revealed casing shell thickness to be a major contribution in the modal response and weight. Excluding casing shell parameters led to a lower frequency shift with respect to the reference configuration. The presented optimization framework is very robust and time effective in completing the optimization task together with a sensitivity analysis for the defined design domain. An FEM model validation of the surrogate model showed consistency in the modal analysis results. A promising solution from the component weight standpoint is the optimization with hook position and leaning only. A future research recommendation is to study an extended parameter range to reduce weight impact for this set. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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Review

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39 pages, 12218 KiB

Open AccessReview

The Additive Manufacturing of Glass: A Critical Review

by Mackinley Shaw, Dylan Vlahopoulos, Clara Usma-Mansfield, Jeffrey Sarmiento, Roland Snooks, Tony Koutsonikolas and Nick Birbilis

Appl. Sci. 2025, 15(6), 3414; https://doi.org/10.3390/app15063414 - 20 Mar 2025

Viewed by 772

Abstract

This paper presents a critical review of additive manufacturing (AM) techniques applied to glass, elucidating the current state of the field and identifying key challenges and opportunities. The review identifies various AM methods, as applied to glass fabrication over broad length scales. Critical aspects such as material considerations, process parameters, and postprocessing techniques are presented, offering insights into the evolving landscape of glass AM. A particular emphasis is placed on semi-solid glass processing. The paper assesses the achievements and limitations of existing methodologies, paving the way for future advancements. This review serves as a resource for both researchers and practitioners in the emerging field of the additive manufacturing of glass, including applications in the domain of architecture and art. Full article

(This article belongs to the Special Issue Smart Manufacturing and Materials Ⅱ)

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