Innovative Manufacturing Engineering 2024—Processes, Machines, Tooling and Systems Integration

A special issue of Machines (ISSN 2075-1702). This special issue belongs to the section "Advanced Manufacturing".

Deadline for manuscript submissions: 30 September 2025 | Viewed by 3925

Special Issue Editors


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Guest Editor

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Guest Editor
Laboratory of Manufacturing Technology, School of Mechanical Engineering, National Technical University of Athens, Athens, Greece
Interests: additive manufacturing; non-conventional machining processes; numerical modeling methods; FEM; optimization methods; statistical methods
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Department of Manufacturing Systems, Faculty of Mechanical Engineering and Robotics, AGH University of Science and Technology, 30-059 Cracow, Poland
Interests: metal cutting and cutting tools; non-conventional machining; surface topography; surface metrology; materials science; optimization of process parameters; friction stir processes; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The rapid advancement of manufacturing technologies continues to be a cornerstone of innovation and industrial growth. This Special Issue, based on the topics of the IManEE 2024 Conference, is expected to bring together pioneering research and technological advancements in the interdisciplinary field of advanced manufacturing. The issue aims to cover a wide array of topics, including the latest developments in forming processes for both metallic and composite materials, as well as the progress in machining and abrasive processes, with a particular emphasis on the tribological challenges inherent in them. Moreover, sustainability also remains a key focus, as various researchers are still exploring environmentally conscious manufacturing processes alongside non-conventional and emerging techniques. Furthermore, the cutting-edge realms of welding, casting, and additive manufacturing, are other interesting scientific fields that deserve intense investigation in order to highlight their role in modern industry. Apart from individual processes, the integration of manufacturing systems, robotics, and automation should be examined, alongside critical discussions on metrology, quality assurance, and process monitoring and control. Embracing the digital transformation of Industry 4.0, this issue also welcomes contributions relevant to simulation techniques for manufacturing processes and the evolving field of remanufacturing. Together, these contributions can offer a comprehensive perspective on the state-of-the-art in manufacturing science, providing valuable insights for researchers, engineers, and industry professionals.

The Special Issue, derived from the IManEE Conference, is well-aligned with the scope of the MDPI journal Machines, which emphasizes various aspects of machine design, theory, and application. The topics within this issue, such as forming processes of metallic and composite materials, machining, and abrasive processes, are integral to advanced manufacturing, which is a key focus area of the journal. Additionally, the exploration of tribological aspects of forming and machining processes fits directly within the journal's interest in friction and tribology, which are crucial for optimizing machine performance and longevity. The inclusion of content on automation, control, and robotics in manufacturing systems is highly relevant to the journal's emphasis on automation and control, as well as mechatronics and intelligent machines. Furthermore, discussions on process monitoring, control, and metrology tie into the journal's focus on condition monitoring, diagnostics, and ensuring the reliability of machines. Finally, the attention to non-conventional manufacturing processes, sustainability, and Industry 4.0 aligns with the journal’s interest in the future of machine technology, particularly in areas such as electromechatronics and advanced manufacturing. This Special Issue, therefore, can contribute significantly to the journal’s mission by advancing knowledge and innovation in key areas of machine design and application.

Dr. Angelos P. Markopoulos
Prof. Dr. Kai Cheng
Dr. Emmanouil-Lazaros Papazoglou
Dr. Panagiotis Karmiris-Obratański
Guest Editors

Manuscript Submission Information

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. Machines is an international peer-reviewed open access monthly 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

  • forming processes of metallic and composite materials
  • machining and abrasive processes
  • tribological aspects of forming and machining processes
  • sustainability aspects of manufacturing processes
  • non-conventional manufacturing processes
  • advances in welding and casting processes
  • additive manufacturing processes
  • manufacturing systems, robotics and automation
  • process monitoring and control, remanufacturing
  • simulation of manufacturing processes
  • digital/e-manufacturing and digital twin applications
  • ultraprecision and micro/nano manufacturing: machines, processes, tooling and their systematic integration

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Published Papers (5 papers)

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Research

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17 pages, 2587 KiB  
Article
A Cyber Manufacturing IoT System for Adaptive Machine Learning Model Deployment by Interactive Causality-Enabled Self-Labeling
by Yutian Ren, Yuqi He, Xuyin Zhang, Aaron Yen and Guann-Pyng Li
Machines 2025, 13(4), 304; https://doi.org/10.3390/machines13040304 - 8 Apr 2025
Viewed by 256
Abstract
Machine learning (ML) has been demonstrated to improve productivity in many manufacturing applications. To host these ML applications, several software and Industrial Internet of Things (IIoT) systems have been proposed for manufacturing applications to deploy ML applications and provide real-time intelligence. Recently, an [...] Read more.
Machine learning (ML) has been demonstrated to improve productivity in many manufacturing applications. To host these ML applications, several software and Industrial Internet of Things (IIoT) systems have been proposed for manufacturing applications to deploy ML applications and provide real-time intelligence. Recently, an interactive causality-enabled self-labeling method has been proposed to advance adaptive ML applications in cyber–physical systems, especially manufacturing, by automatically adapting and personalizing ML models after deployment to counter data distribution shifts. The unique features of the self-labeling method require a novel software system to support dynamism at various levels. This paper proposes the AdaptIoT system, comprising an end-to-end data streaming pipeline, ML service integration, and an automated self-labeling service. The self-labeling service consists of causal knowledge bases and automated full-cycle self-labeling workflows to adapt multiple ML models simultaneously. AdaptIoT employs a containerized microservice architecture to deliver a scalable and portable solution for small and medium-sized manufacturers. A field demonstration of a self-labeling adaptive ML application is conducted with a makerspace and shows reliable performance with comparable accuracy at 98.3%. Full article
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20 pages, 8714 KiB  
Article
Optimization of Toolpath Planning and CNC Machine Performance in Time-Efficient Machining
by Arbnor Pajaziti, Orlat Tafilaj, Afrim Gjelaj and Besart Berisha
Machines 2025, 13(1), 65; https://doi.org/10.3390/machines13010065 - 17 Jan 2025
Cited by 1 | Viewed by 2300
Abstract
This study explores the optimization of the machining time in CNC milling machines by varying the machine parameters and toolpath strategies. Using the ICAM3D simulation software version 3.1.0, this approach focuses on minimizing the machining time while adhering to operational constraints. In addition, [...] Read more.
This study explores the optimization of the machining time in CNC milling machines by varying the machine parameters and toolpath strategies. Using the ICAM3D simulation software version 3.1.0, this approach focuses on minimizing the machining time while adhering to operational constraints. In addition, a novel approach to the optimization of the G-code in time machining, focusing on reducing the machining time while maintaining the required precision and quality of the finished product, is presented. We propose a method that integrates advanced algorithms to identify and eliminate redundant movements, optimize the toolpaths, and improve the machining strategies. The experimental results demonstrate a significant reduction in the machining time without compromising the machining accuracy, offering substantial cost savings and efficiency improvements for industrial applications. The importance of this work lies in the correct choice of the toolpath strategy. In the P3 project, the optimization process reduced the machining time from 15 min and 23 s to 13 min and 33 s by utilizing the optimized G-code. The initial machining time of 20 min and 2 s corresponds to the completion of the P3 project when the CNC machine was operated at 75% speed. To further enhance efficiency, additional software tools such as ARTCAM and ASPIRE have been utilized to implement a new toolpath strategy. Full article
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16 pages, 3706 KiB  
Article
Development of a Web-Based e-Portal for Freeform Surfaced Lens Design and Manufacturing and Its Implementation Perspectives
by Shangkuan Liu, Kai Cheng and Negin Dianat
Machines 2025, 13(1), 59; https://doi.org/10.3390/machines13010059 - 16 Jan 2025
Cited by 1 | Viewed by 647
Abstract
In modern freeform surfaced optics manufacturing, ultraprecision machining through single-point diamond turning (SPDT) plays a crucial role due to its ability to meet the high accuracy demands of optical design and stringent surface quality requirements of the final optic. The process involves meticulous [...] Read more.
In modern freeform surfaced optics manufacturing, ultraprecision machining through single-point diamond turning (SPDT) plays a crucial role due to its ability to meet the high accuracy demands of optical design and stringent surface quality requirements of the final optic. The process involves meticulous steps, including optic surface modeling and analysis, optic design, machining toolpath generation, and manufacturing. This paper presents an integrated approach to customized precision design and the manufacturing of freeform surfaced varifocal lenses through a web-based e-portal. The approach implements an e-portal-driven manufacturing system that seamlessly integrates lens design, modeling and analysis, toolpath generation for ultraprecision machining, mass personalized customization, and service delivery. The e-portal is specifically designed to meet the stringent demands of personalized mass customization, and to offer a highly interactive and transparent experience for the lens users. By using Shiny and R-script programming for platform development and combining COMSOL Multiphysics for the ray tracing simulation, the e-portal leverages open-source technologies to provide manufacturing service agility, responsiveness, and accessibility. Furthermore, the integration of R-script and Shiny programming allows for advanced interactive information processing, which also enables the e-portal-driven manufacturing system to be well suited for personalized complex products such as freeform surfaced lenses. Full article
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Review

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29 pages, 4987 KiB  
Review
A Review of Recent Advancements in Heat Pump Systems and Developments in Microchannel Heat Exchangers
by Roopesh Chowdary Sureddi, Liang Li, Hongwei Wu, Niccolo Giannetti, Kiyoshi Saito and David Rees
Machines 2025, 13(4), 333; https://doi.org/10.3390/machines13040333 - 18 Apr 2025
Viewed by 142
Abstract
Heating and cooling are the main concerns across a wide range of sectors, including residential buildings, industrial facilities, transportation and commercial enterprises. This being the case, a continuous rise in the cost of energy demands more effective ways to conserve energy. Heat pump [...] Read more.
Heating and cooling are the main concerns across a wide range of sectors, including residential buildings, industrial facilities, transportation and commercial enterprises. This being the case, a continuous rise in the cost of energy demands more effective ways to conserve energy. Heat pump (HP) systems provide the one of the best possible solutions to this problem as they offer an economical and energy-efficient system. In this review, HP systems are overviewed as energy-efficient and cost-effective solutions, focusing on their characteristic properties but also on enhancements, novel techniques and the use of heat exchangers (HXs), and microchannel heat exchangers (MCHEs) in these systems, as well as their development in recent years and their limitations. The main factors contributing to variations in the performance of HP systems are temperature and humidity in the ambient atmosphere. The present study is expected to support numerical and experimental performance analysis, and design miniaturisation via MCHEs. Unique designs or manufacturing techniques in MCHEs; various configurations in HP systems, depending on their load and environmental conditions; various nanofluids; and a comparison of nanofluids with different base metals are presented and discussed. Comparisons between various MCHEs and their respective limitations provide evidence-based guidelines for technology selection and designs for optimised operation at given environmental and load conditions. Full article
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Other

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27 pages, 4974 KiB  
Systematic Review
Engineering Innovations for Polyvinyl Chloride (PVC) Recycling: A Systematic Review of Advances, Challenges, and Future Directions in Circular Economy Integration
by Alexander Chidara, Kai Cheng and David Gallear
Machines 2025, 13(5), 362; https://doi.org/10.3390/machines13050362 - 28 Apr 2025
Viewed by 129
Abstract
Polyvinyl chloride (PVC) recycling poses significant engineering challenges and opportunities, particularly regarding material integrity, energy efficiency, and integration into circular manufacturing systems. This systematic review evaluates recent advancements in mechanical innovations, tooling strategies, and intelligent technologies reshaping PVC recycling. An emphasis is placed [...] Read more.
Polyvinyl chloride (PVC) recycling poses significant engineering challenges and opportunities, particularly regarding material integrity, energy efficiency, and integration into circular manufacturing systems. This systematic review evaluates recent advancements in mechanical innovations, tooling strategies, and intelligent technologies reshaping PVC recycling. An emphasis is placed on machinery-driven solutions—including high-efficiency shredders, granulators, extrusion moulders, and advanced sorting systems employing hyperspectral imaging and robotics. This review further explores chemical recycling technologies, such as pyrolysis, gasification, and supercritical fluid extraction, for managing contamination and additive removal. The integration of Industry 4.0 technologies, notably digital twins and artificial intelligence, is highlighted for its role in predictive maintenance, real-time quality assurance, and process optimisation. A combined PRISMA approach and ontological mapping are applied to classify technological pathways and lifecycle optimisation strategies. Critical engineering constraints—including thermal degradation, additive leaching, and feedstock heterogeneity—are examined alongside emerging innovations, like additive manufacturing and microwave-assisted depolymerisation, offering scalable, low-emission solutions. Regulatory instruments, such as REACH and Extended Producer Responsibility (EPR), are analysed for their influence on machinery compliance and design standards. Drawing from sustainable manufacturing frameworks, this study also promotes energy efficiency, eco-designs, and modular integration in recycling systems. This paper concludes by proposing a digitally optimized, machinery-integrated recycling model aligned with circular economy principles to support the development of future-ready PVC reprocessing infrastructures. This review serves as a comprehensive resource for researchers, practitioners, and policymakers, advancing sustainable polymer recycling. Full article
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