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A special issue of Micromachines (ISSN 2072-666X). This special issue belongs to the section "D：Materials and Processing".

Deadline for manuscript submissions: 31 December 2025 | Viewed by 7908

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Special Issue Editors

Prof. Dr. Jian Cheng

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Guest Editor

State Key Laboratory of Robotics and System, School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China
Interests: precision/ultra-precision processing technology; optical (sub)surface defect detection and integrity evaluation; laser-induced damage mechanism and precision mitigation
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Jianguo Zhang

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Guest Editor

School of Mechanical Science & Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
Interests: ultra-precision machining of difficult-to-machine materials; elliptical vibration diamond cutting and ultra-precision micro-manufacturing of functional micro–nano structures
Special Issues, Collections and Topics in MDPI journals

Dr. Qi Liu

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Guest Editor

Department of Mechanical Engineering, University of Bath, Bath BA2 7AY, UK
Interests: robotic manufacturing processes; ultra-precision and precision machining; subtractive/additive manufacturing processes; surface integrity; digital twin and machine learning
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Digital manufacturing and nano fabrication are reshaping the landscape of modern engineering, driving transformative innovations across industries. At the heart of these advancements lies precision manufacturing, a critical enabler of ultra-fine tolerances, superior surface finishes, and high-performance component production. This Special Issue seeks to highlight the latest research in digital manufacturing, nano fabrication, and precision machining, offering insights into cutting-edge techniques and their practical applications.

The topics covered in this Special Issue include, but are not limited to, advancements in digital twin-driven manufacturing systems, the integration of artificial intelligence and machine learning in machining processes, novel additive and subtractive manufacturing techniques, and the development of advanced materials and tooling for nano fabrication. Furthermore, this Special Issue welcomes research addressing the challenges of sustainability, energy efficiency, and automation, offering innovative solutions that bridge fundamental research and industrial needs.

We encourage the submission of high-quality original research articles, comprehensive reviews, and impactful case studies that advance the state of the art in digital manufacturing and precision machining. This collection of papers aims to serve as a valuable resource for researchers, engineers, and professionals seeking to drive innovation and excellence in these transformative fields.

Prof. Dr. Jian Cheng
Prof. Dr. Jianguo Zhang
Dr. Qi Liu
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. Micromachines 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 2100 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

digital manufacturing
smart manufacturing
nano fabrication
ultra-precision/precision machining
digital twin
advanced manufacturing processes
additive manufacturing
subtractive manufacturing
nano-scale machining
artificial intelligence in manufacturing
sustainable manufacturing

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Published Papers (8 papers)

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Research

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15 pages, 3114 KB

Open AccessArticle

Impact of Extrinsic Defects in Wavelength Separation Coatings on the Process of Laser-Induced Damage

by Shichen Shen, Xinda Zhou, Yinbo Zheng, Jie Li, Tianhao Zhang, Linjie Zhao, Liqun Chai and Mingjun Chen

Micromachines 2025, 16(11), 1191; https://doi.org/10.3390/mi16111191 - 22 Oct 2025

Viewed by 292

Abstract

Wavelength separation coatings can effectively separate the fundamental frequency (1ω) and third harmonic (3ω) laser beams. However, the laser-induced damage threshold (LIDT) of the surface defect-free WS coatings for the 3ω laser is 1.68 J/cm² (obtained in the preliminary experiment), significantly lower than the ideal LIDT of the fused silica substrate (80 J/cm²). This is directly correlated with extrinsic defects such as nanoscale defects and nodular defects introduced during the coating manufacturing process. Moreover, the damage in WS coatings caused by extrinsic defects is a complex physical process involving multiple physical phenomena such as material melting, vaporization, and ejection. The mechanism by which extrinsic defects interact with lasers to form damage is not yet fully elucidated. To address this, a multi-physics coupling model considering photoelectric, thermal and stress was established to simulate the incident laser propagation within coatings, the temperature distribution and thermal stress distribution of the coating material. This model systematically investigates the influence of defect location, type, and size on the laser-induced damage process. It is found that when a 10 nm-diameter defect is located at the 32nd layer of the coatings, the light intensity enhancement factor (LIEF) for 3ω laser can reach up to 5 times that for the 1ω laser. The variation in thermal stress induced by changes in defect size is jointly determined by the defect-induced modulation effect and the interference effect realized by the coating. This work theoretically reveals the mechanism of extrinsic defects in the laser damage. It provides effective guidance for establishing control standards for extrinsic defects during the optical coating process. Full article

(This article belongs to the Special Issue Advances in Digital Manufacturing and Nano Fabrication)

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20 pages, 7927 KB

Open AccessFeature PaperArticle

Achieving High-Quality Formed Hastelloy X Cladding Layers on Heterological 50CrVA Surface by Optimizing Process Parameters in Directed Energy Deposition

by Liming Xia, Hongqin Lei, Enjie Dong, Tingyu Chang, Linjie Zhao, Mingjun Chen, Junwen Lu and Jian Cheng

Micromachines 2025, 16(10), 1110; https://doi.org/10.3390/mi16101110 - 29 Sep 2025

Viewed by 378

Abstract

Hastelloy X exhibits outstanding thermal fatigue resistance, making it a promising material for repairing 50CrVA landing gear via directed energy deposition (DED). However, the substantial differences in composition and thermophysical properties between 50CrVA and Hastelloy X pose challenges by affecting interfacial microstructure and surface quality. This study investigates the effect of DED process parameters (laser power p, powder feed rate f, scanning speed v, and overlap rate) on the dilution ratio (η), microscopic morphology, surface flatness (ζ), and porosity of Hastelloy X claddings on a 50CrVA substrate. An optimization methodology integrating thermal–flow coupled simulation models and orthogonal experiments is developed to fabricate high-quality claddings. Furthermore, the corrosion–wear performance of the claddings is evaluated. The results indicate that the η of a single track increases with higher p or lower f, while it first increases and then decreases with the increase in v. Ablation marks tend to occur at excessive p or insufficient f, while low v causes surface ripples. The ζ of a single layer initially improves and subsequently deteriorates with increasing overlap rate. Porosity is significantly influenced by p and f. The optimal p, f, v, and overlap rate are 1600 W, 2.4 g/min, 240 mm/min, and 55%, respectively. The wear resistance of the cladding is nearly identical to that of the substrate, while corrosion resistance is significantly improved. This work provides a theoretical foundation for high-performance repair of 50CrVA landing gear in aircraft. Full article

(This article belongs to the Special Issue Advances in Digital Manufacturing and Nano Fabrication)

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17 pages, 10881 KB

Open AccessArticle

Femtosecond Laser Precision Etching of Silver Layer on Silica Aerogel Surfaces

by Shengtian Lin, Congyi Wu, Guojun Zhang and Jinjin Wu

Micromachines 2025, 16(10), 1107; https://doi.org/10.3390/mi16101107 - 29 Sep 2025

Viewed by 490

Abstract

Silica fiber-reinforced silica aerogel (SFRSA) has low dielectric constant, light weight and high temperature resistance characteristics, making it one of the preferred materials for heat-resistant absorptive layers on the surfaces of high-speed aircraft. However, due to its ultra-high porosity, poor rigidity, and sensitivity to organic solvents, existing machining and chemical etching processes struggle to achieve patterned preparation of metallic layers on aerogel substrates. In order to address this issue, the present study employs femtosecond laser etching of the metal layer on the SFRSA surface. Orthogonal experiments were conducted to analyze the impact of different laser process parameters on the etching quality. With straightness as the primary factor, the optimal process parameters obtained were a laser power set to 2.15 W, a laser etching speed of 200 mm/s, and a laser etching time of 9. This achieved an etching width of 26.16 μm, a heat-affected zone of 39.16 μm, and straightness of 7.9 μm. Finally, Raman spectroscopy was used to study laser-ablated samples; thermogravimetric analysis (TGA) and Pyrolysis-Gas Chromatography–Mass Spectrometry analysis (Py-GC-MS) were employed to investigate the changes in the metal layer at high temperatures. A compositional analysis was conducted, revealing a decrease in carbon content within the etched region following laser ablation. The production of CO₂ gas and surface oxidation indicated that laser etching primarily operates via a photothermal mechanism. Full article

(This article belongs to the Special Issue Advances in Digital Manufacturing and Nano Fabrication)

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14 pages, 4871 KB

Open AccessArticle

Study on Laser Surface Texturing and Wettability Control of Silicon Nitride Ceramic

by Hong-Jian Wang, Jing-De Huang, Bo Wang, Yang Zhang and Jin Wang

Micromachines 2025, 16(7), 819; https://doi.org/10.3390/mi16070819 - 17 Jul 2025

Viewed by 629

Abstract

Silicon nitride (Si₃N₄) ceramic is widely used in the production of structural components. The surface wettability is closely related to the service life of materials. Laser surface texturing is considered an effective method for controlling surface wettability by processing specific patterns. This research focused on the laser surface texturing of a Si₃N₄ ceramic, employing rectangular patterns instead of the typical dimple designs, as these had promising applications in heat transfer and hydrodynamic lubrication. The effects of scanning speed and number of scans on the change of the morphologies and dimensions of the grooves were investigated. The results indicated that the higher scanning speed and fewer number of scans resulted in less damage to the textured surface. As the scanning speed increased, the width and depth of the grooves decreased significantly first, and then fluctuated. Conversely, increasing the number of scans led to an increase in the width and depth of the grooves, eventually stabilizing. The analysis of the elemental composition of different areas on the textured surface presented a notable increase in oxygen content at the grooves, while Si and N levels decreased. It was mainly caused by the chemical reaction between Si₃N₄ ceramic and oxygen during laser surface texturing in an air environment. This study also assessed the wettability of the textured surface, finding that the contact angle of the water droplet was significantly affected by the groove dimensions. After laser surface texturing, the contact angle increased from 35.51 ± 0.33° to 57.52 ± 1.83°. Improved wettability was associated with smaller groove volume, indicating better hydrophilicity at lower scanning speed and enhanced hydrophobicity with a fewer number of scans. Full article

(This article belongs to the Special Issue Advances in Digital Manufacturing and Nano Fabrication)

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22 pages, 5230 KB

Open AccessArticle

Integrated CAD/CAM Approach for Parametric Design and High Precision Fabrication of Planar Curvilinear Structures

by Jonas T. Churchill-Baird, O. Remus Tutunea-Fatan and Evgueni V. Bordatchev

Micromachines 2025, 16(7), 805; https://doi.org/10.3390/mi16070805 - 11 Jul 2025

Viewed by 670

Abstract

Curvilinear V-grooves are increasingly employed in functional surfaces with applications ranging from fluidics to tribology and optics. Despite their widespread use, the accurate and repeatable fabrication of curvilinear V-grooves remains challenging due to their inherent geometric complexity and the lack of relevant commercial CAD/CAM systems. To address this, the present study proposes a CAD/CAM integrated framework capable of automating the design and fabrication of functional surfaces comprising curvilinear V-grooves generated by multi-axis single-point diamond cutting (SPDC). The framework is organized into three main functional blocks supported by seven secondary modules that encompass the entire process from V-groove geometry definition to cutting. The developed framework was practically validated by fabricating sinusoidal V-grooves on a flat surface and testing the capillary flow functionality of a curvilinear pattern. These results demonstrate the relevance of the integrated framework to curvilinear V-groove fabrication, thereby offering a versatile solution for certain types of surface engineering applications. Full article

(This article belongs to the Special Issue Advances in Digital Manufacturing and Nano Fabrication)

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19 pages, 6895 KB

Open AccessArticle

A Hybrid GRA-TOPSIS-RFR Optimization Approach for Minimizing Burrs in Micro-Milling of Ti-6Al-4V Alloys

by Rongkai Tan, Abhilash Puthanveettil Madathil, Qi Liu, Jian Cheng and Fengtao Lin

Micromachines 2025, 16(4), 464; https://doi.org/10.3390/mi16040464 - 14 Apr 2025

Cited by 2 | Viewed by 784

Abstract

Micro-milling is increasingly recognized as a crucial technique for machining intricate and miniature 3D aerospace components, particularly those fabricated from difficult-to-cut Ti-6Al-4V alloys. However, its practical applications are hindered by significant challenges, particularly the unavoidable generation of burrs, which complicate subsequent finishing processes and adversely affect overall part quality. To optimize the burr formation in the micro-milling of Ti-6Al-4V alloys, this study proposes a novel hybrid-ranking optimization algorithm that integrates Grey Relational Analysis (GRA) with the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). This approach innovatively combines GRA and TOPSIS with a random forest regression (RFR) model, facilitating the exploration of nonlinear and complex relationships between input parameters and machining outcomes. Specifically, the effects of spindle speed, depth of cut, and feed rate per tooth on surface roughness and burr width generated during both down-milling and up-milling processes were systematically investigated using the proposed methodology. The results reveal that the depth of cut is the most influential factor affecting surface roughness, while feed rate per tooth plays a critical role in controlling burr formation. Moreover, the GRA-TOPSIS-RFR method significantly outperforms existing optimization and prediction models, with the integration of the RFR model enhancing prediction accuracy by 42.6% compared to traditional linear regression approaches. The validation experimental results agree well with the GRA-TOPSIS-RFR-optimized outcomes. This research provides valuable insights into optimizing the micro-milling process of titanium components, ultimately contributing to improved quality, performance, and service life across various aerospace applications. Full article

(This article belongs to the Special Issue Advances in Digital Manufacturing and Nano Fabrication)

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20 pages, 24743 KB

Open AccessArticle

Investigation of Chip Morphology in Elliptical Vibration Micro-Turning of Silk Fibroin

by Zhengjian Wang, Xichun Luo, Jining Sun, Wenkun Xie, Yinchuan Piao, Yonghang Jiang and Xiuyuan Chen

Micromachines 2025, 16(1), 110; https://doi.org/10.3390/mi16010110 - 19 Jan 2025

Cited by 1 | Viewed by 1495

Abstract

Silk fibroin, known for its biocompatibility and biodegradability, holds significant promise for biomedical applications, particularly in drug delivery systems. The precise fabrication of silk fibroin particles, specifically those ranging from tens of nanometres to hundreds of microns, is critical for these uses. This study introduces elliptical vibration micro-turning as a method for producing silk fibroin particles in the form of cutting chips to serve as carriers for drug delivery systems. A hybrid finite element and smoothed particle hydrodynamics (FE-SPH) model was used to investigate how vibration parameters, such as frequency and amplitude, influence chip formation and morphology. This research is essential for determining the size and shape of silk fibroin particles, which are crucial for their effectiveness in drug delivery systems. The results demonstrate the superior capability of elliptical vibration micro-turning for producing shorter, spiral-shaped chips in the size range of tens of microns, in contrast to the long, continuous chips with zig-zag folds and segmented edges generated by conventional micro-turning. The unique zig-zag shapes result from the interplay between the high flexibility and hierarchical structure of silk fibroin and the controlled cutting environment provided by the diamond tool. Additionally, higher vibration frequencies and lower vertical amplitudes promote chip curling, facilitate breakage, and improve chip control, while reducing cutting forces. Experimental trials further validate the accuracy of the hybrid model. This study represents a significant advancement in the processing of silk fibroin film, offering a complementary approach to fabricating short, spiral-shaped silk fibroin particles with a high surface-area-to-volume ratio compared to traditional spheroids, which holds great potential for enhancing drug-loading efficiency in high-precision drug delivery systems. Full article

(This article belongs to the Special Issue Advances in Digital Manufacturing and Nano Fabrication)

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Review

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18 pages, 22335 KB

Open AccessReview

Research Progress on Laser-Assisted Precision Machining Technology

by Qimeng Liu, Jie Liu, Zhe Ming, Bo Cui and Jian Wang

Micromachines 2025, 16(2), 173; https://doi.org/10.3390/mi16020173 - 31 Jan 2025

Cited by 2 | Viewed by 2311

Abstract

As a revolutionary advanced manufacturing technology, the core of laser-assisted machining technology lies in the innovation of traditional machining technology. It uses a laser to precisely modify the surface of the workpiece material through clever integration. This process can lead to significant changes in the microstructure, thermodynamic properties, and physical properties of the workpiece’s cutting layer, greatly facilitating the removal of material by the cutting tool. Especially for difficult-to-process materials, this technology can effectively solve the processing problems they face. This not only improves the processing accuracy, but also ensures the processing quality, making it possible to process difficult-to-process materials with high precision and high quality. This article comprehensively summarizes the latest research progress in laser-assisted precision machining technology and deeply summarizes the specific mechanism of laser-assisted machining technology on the surface of workpiece materials. The influence of laser-assisted machining technology on the cutting characteristics of machining materials is elaborated in detail, providing a theoretical basis for the application of this technology. Finally, the future development direction of laser-assisted machining technology is prospected. Full article

(This article belongs to the Special Issue Advances in Digital Manufacturing and Nano Fabrication)

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