Materials

This paper presents a numerical case study on the application of generative design to the shape optimisation of a spur gear body with consideration of manufacturing constraints and material properties. The presented results are obtained using numerical simulation and finite element analysis. A finite element-based generative design workflow was employed to evaluate weight reduction and stiffness performance under different manufacturing routes, including additive manufacturing, machining, and casting. The results show that the application of generative design enabled a gear-body mass reduction of up to 37.46–45.68% compared to the reference geometry while maintaining acceptable deformation levels. Designs constrained for additive manufacturing achieved the highest weight savings, whereas machining-constrained variants exhibited lower deformation values, indicating higher structural stiffness. Casting-oriented constraints resulted in more conservative geometries with locally reinforced regions. The study confirms that manufacturing constraints significantly influence the generated geometry and mechanical response, demonstrating that the manufacturing route acts as an independent design variable within the generative design process. The presented methodology provides practical guidance for the early-stage numerical optimisation of gear bodies and supports informed decision-making with respect to manufacturing technology selection.

Background: Durable bonding to zirconia remains difficult because its chemically inert surface resists acid etching. Additive manufacturing (AM) enables controlled surface morphology, which may enhance micromechanical retention without additional treatments. Methods: Zirconia specimens with three AM-derived surface designs—(1) concave–convex hemispherical patterns, (2) concave hemispherical patterns, and (3) as-printed surfaces—were fabricated using a slurry-based 3D printing system and sintered at 1500 °C. Zirconia specimens fabricated by subtractive manufacturing using CAD/CAM systems, polished with 15 µm diamond lapping film and with or without subsequent alumina sandblasting, served as controls. Surface morphology was analyzed by FE-SEM, and shear bond strength (SBS) was tested after cementation with a resin-based luting agent. Results: SEM revealed regular layered textures and designed hemispherical structures (~300 µm) in AM specimens, along with step-like irregularities (~40 µm) at layer boundaries. The concave–convex AM group showed significantly higher SBS than both sandblasted and polished subtractive-manufactured zirconia (p < 0.05). Vertically printed specimens demonstrated greater bonding strength than those printed parallel to the bonding surface, indicating that build orientation affects resin infiltration and interlocking. Conclusion: AM-derived zirconia surfaces can provide superior and reproducible micromechanical retention compared with conventional treatments. Further optimization of printing parameters and evaluation of long-term durability are needed for clinical application.

This work aims to enhance the stability of the Mg/Al₃Y interface through first-principles investigations of low-cost dopants. Density functional theory calculations were employed to systematically examine the bulk properties of Mg and Al₃Y, as well as the structural stability, electronic characteristics, and alloying element effects at the Mg(0001)/Al₃Y(0001) interface. The calculated lattice parameters, elastic moduli, and phonon spectra demonstrate that both Mg and Al₃Y are dynamically stable. Owing to the similar hexagonal symmetry and a small lattice mismatch (~1.27%), a low-strain semi-coherent Mg(0001)/(2 × 2)Al₃Y(0001) interface can be constructed. Three representative interfacial stacking configurations (OT, MT, and HCP) were examined, among which the MT configuration exhibits significantly higher work of adhesion, indicating superior interfacial stability. Differential charge density and density of states analyses reveal pronounced charge transfer from Mg to Al/Y atoms and strong orbital hybridization, particularly involving Y-d states, which underpins the enhanced interfacial bonding. Furthermore, the segregation behavior and adhesion enhancement effects of typical alloying elements (Si, Ca, Ti, Mn, Cu, Zn, Zr, and Sn) were systematically evaluated. The results show that Mg-side interfacial sites, especially Mg₂ and Mg₃, are thermodynamically favored for segregation, with Zr and Ti exhibiting the strongest segregation tendency and the most significant improvement in interfacial adhesion. These findings provide fundamental insights into interfacial strengthening mechanisms and offer guidance for the alloy design of high-performance Mg-based composites.