Search Results (11,572)

Phosphogypsum (PG) is the main by-product of wet-process phosphoric acid production. Its annual global production reaches about 200 million tons, yet its utilization rate remains low. Consequently, long-term stockpiling of large PG volumes poses immense pressure to the ecological environment. To mitigate negative environmental impacts, the utilization of PG is imperative. Despite progress in PG utilization and 3D-printing technology, there is still a significant lack of understanding about the synergistic activation mechanisms in multi-solid-waste systems. In particular, the composition design, microstructure evolution, and structure–property relationships of 3D-printed PG-based composites are not well-studied, which limits their high-value engineering applications. Three-dimensional-printed phosphogypsum concrete (3DPPGC) is proposed here, promoting PG resource utilization by leveraging the expanding applications of 3D-printed concrete (3DPC). However, the strength of 3DPPGC needs to be enhanced to meet engineering requirements. This study designed the mix proportion of 3DPPGC and fabricated the corresponding test specimens. The optimal Cement Replacement Ratio (CRR) was determined through experimental testing, and the mechanism behind the strength enhancement of the 3DPPGC was elucidated. The results indicated that the 3DPPGC’s mechanical properties peaked at the 70% CRR. Compared with cast specimens, 3DPPGC exhibited a 1.52% increase in 28-day flexural strength in the y-direction, reaching 4.69 MPa. The early-age compressive strength, flexural strength, and later-age compressive strength of 3DPPGC were significantly enhanced when PG, blast-furnace slag (BS), fly ash (FA), and silica fume (SF) were used to partially replace cement. This study provides a theoretical and experimental basis for the large-scale, high-value application of PG in intelligent construction. Full article

Unmanned aerial vehicles open new possibilities for developing technologies that support more sustainable and efficient agriculture. This paper presents a non-invasive method for repelling rodents from crop fields using ultrasound. The proposed system is implemented as a spherical-cap ultrasound loudspeaker array consisting of eight transducers, mounted on a drone that overflies the field while emitting sound in the 20–70 kHz range. The hardware design includes both the loudspeaker array and a custom printed circuit board hosting power amplifiers and a signal generator tailored to drive multiple ultrasonic transducers. In parallel, a genetic algorithm is used to compute flight paths that maximize coverage and increase the probability of driving rodents away from the protected area. As part of the validation phase, artificial intelligence models for rodent detection using a thermal camera are developed to provide quantitative feedback on system performance. The complete prototype is evaluated through a series of experiments conducted both in controlled laboratory conditions and in the field. Field trials highlight which parts of the concept are already effective and identify open challenges that need to be addressed in future work to move from a research prototype toward a deployable product. Full article

Rheology plays an important role in the 3D concrete printing technology, because it directly governs the flowability and shape retention of the material, impacting both the printing process and the final quality of the obtained structure. Local raw materials such as Portland cement, washed sand, and tap water were used for the preparation of 3D-printed concrete mixtures. The solid-state polycarboxylate ether with an anti-foaming agent was used as superplasticizer. The Portland cement was partially replaced (by volume) with a natural zeolite additive in amounts ranging from 0% to 9% in 3D-printed concrete mixtures. A rotational rheometer with coaxial cylinders was used in this research for the determination of rheological characteristics of prepared 3D-printed concrete mixtures. The Herschel–Buckley model was used to approximate experimental flow curves and assess rheological parameters such as yield stress, plastic viscosity, and shear-thinning/thickening index. The additional experiments and calculations, such as water bleeding test and evaluation of the carbon footprint of 3D-printed concrete mixtures, were performed in this work. The replacement of Portland cement with natural zeolite additive positively influenced rheological and stability-related properties of 3D-printed concrete mixtures. Natural zeolite additive consistently reduced water bleeding, enhanced yield stress under increasing shear rates, and lowered plastic viscosity, thereby improving flowability and mixture transportation during the 3D printing process. As the shear-thinning/thickening index remained stable (indicating non-thixotropic behavior in most cases), higher amounts of natural zeolite additive introduced slight thixotropy (especially under decreased shear rates). These changes contributed to better shape retention, layer stability, and the ability to print taller and narrower structures without collapse, making natural zeolite additive suitable for use in the optimized processes of 3D concrete printing. A significant decrease in total carbon footprint (from 3% to 19%) was observed in 3D-printed concrete mixtures with an increase in the mentioned amounts of natural zeolite additive, compared to the mixture without this additive. Full article

This study examines magnesium potassium phosphate cements (MKPCs) modified with industrial wastes for extrusion-based 3D concrete printing, evaluating the rheological properties (workability, setting time), mechanical performance and printability of formulations incorporating secondary materials: Mg dross waste (up to 20 wt.%, replacing MgO), calcined sewage sludge (up to 10 wt.%, replacing KH₂PO₄), alternative fillers such as glass from municipal solid waste glass and from construction and demolition waste and ground blast furnace slag, benchmarked against volcanic ash. The baseline MKPC exhibited initial/final setting times of 34/109 min, good workability and compressive strengths of 29 MPa (1 day)/28 MPa (28 days). Optimal low-waste mixes (e.g., using municipal glass or 20 wt.% Mg dross) shortened the initial setting to 19–25 min (decreasing 24–42%), reduced the slump by 9–18% yet remained printable at laboratory-scale and achieved 1-day strengths > 23 MPa/28-day > 31 MPa (comparable or superior). Glass from municipal waste proved most promising, due to superior workability, lighter aesthetics and strength gains, supporting circular economy goals while substantially reducing material costs; higher waste levels compromised fluidity and buildability. Mineralogical analyses confirmed K-struvite formation alongside residual periclase, validating these formulations for upscaling sustainable 3D printing. Full article

Based on the discrete element method (DEM), a sand particle contact force model and a motion model for the 3D sand printing (3DSP) process were developed. By accounting for the viscous support force and contact force between sand particles, and gravity acting on each individual sand particle, the displacement of sand particles was calculated, enabling the simulation of the 3DSP process using sand particle ensembles. Furthermore, the effects of the ratio of silica sand to ceramsite sand and the recoating speed on sand-recoating performances and mechanical properties were investigated. Irregularly shaped sand particles (primarily silica sand) were constructed via the multi-sphere filling method. The simulation was performed on a virtual sand-recoating device (180 mm in length, 100 mm in width, 70 mm in height) with reference to the EXONE S-MAX printer. Meanwhile, the EXONE S-MAX was utilized to print the bending samples for experimental validation. Simulation and experimental results indicate that as the ratio increases, the porosity first decreases and then increases, whereas mechanical properties exhibit an initial increase followed by a decrease. At a ratio of 3:7, the porosity reaches a minimum of 21.3%; correspondingly, the shear force of bonding bridges peaks at 908 mN, and the bending strength of specimens attains a maximum of 2.87 MPa. With the increasing recoating speed, the porosity rises consistently, while the shear force of bonding bridges and the bending strength of specimens first increase and then decrease, which is primarily attributed to the penetration behavior of the binder under capillary force. At a recoating speed of 160 mm·s⁻¹, the shear force of bonding bridges reaches its maximum, and the specimens achieve a maximum bending strength of 2.89 MPa. The simulation results are well-validated by the experiments. The DEM-based simulation method proposed in this study offers a practical and convenient tool for parameter optimization in 3DSP process. Full article

To meet 2050 climate targets, the construction sector must reduce CO₂ emissions and transition toward circular material flows. Recycled aggregates (RA) derived from construction and demolition waste (CDW) and industrial byproducts such as oil shale ash (OSA) show potential for use in concrete, although their application remains limited by standardisation and performance limitations, particularly in structural uses. This study aims to develop and evaluate low-strength, resource-efficient concrete mixtures with full replacement of natural aggregates (NA) by CDW-derived aggregates, and partial or full replacement of cement CEM II by OSA–metakaolin (MK) binder, targeting non-structural 3D-printing applications. Mechanical performance, printability, cradle-to-gate life cycle assessment, eco-intensity index, and transport-distance sensitivity for RA were assessed to quantify the trade-offs between structural performance and global warming potential (GWP) reduction. Replacing NA with RA reduced compressive strength by ~11–13% in cement-based mixes, while the aggregate type had a negligible effect in cement-free mixtures. In contrast, full cement replacement by OSA-MK binder nearly halved compressive strength. Despite the strength reductions associated with the use of waste-derived materials, RA-based cement-free 3D-printed specimens achieved ~30 MPa in compression and ~5 MPa in flexure. Replacing CEM II with OSA-MK and NA with RA lowered GWP by up to 48%, with trade-offs in the air-emission, toxicity, water and resource categories driven by the OSA supply chain. The cement-free RA mix achieved the lowest GWP and best eco-intensity, whereas the CEM II mix with RA offered the most balanced multi-impact profile. The results show that regionally available OSA and RA can enable eco-efficient, structurally adequate 3D-printed concrete for construction applications. Full article

This study investigated the effects of different types and ratios of plasticizers on the fabrication and properties of hot-melt-extruded filaments and fused deposition modeling (FDM) three-dimensional printed tablets containing theophylline (THEO). Polyethylene glycol (PEG) 1500 and stearic acid (SA) were used as plasticizers to prepare THEO-loaded filaments in a hydroxypropyl cellulose matrix via hot melt extrusion (HME), which were subsequently fabricated into tablets using an FDM 3D printer. The physicochemical properties of the filaments and printed tablets were evaluated using scanning electron microscopy, X-ray powder diffraction, and Fourier transform infrared spectroscopy. Drug release behavior was assessed using four tablet formulations (T1–T4) with different plasticizer types and ratios. All fabricated filaments exhibited sufficient hardness and flexibility for reliable 3D printing, and solid-state analyses confirmed partial molecular dispersion of THEO within the polymer matrix. In dissolution studies, PEG-containing formulations showed faster drug release than SA-based formulations, while all 3D-printed tablets achieved approximately 80% drug release within 6 h. Overall, this study demonstrates that the combined use of HME and FDM-based 3D printing, together with rational plasticizer selection, enables the development of personalized pharmaceutical tablets with tunable immediate and sustained drug release profiles. Full article

A conceptual design study is presented for a hemispherical, two-chamber water Cherenkov detector instrumented with bladder-embedded light traps. The detector consists of a rigid aluminium vessel enclosing a water volume that is divided into an outer, optically black chamber and a inner, reflective chamber lined by a flexible bladder. Arrays of light-trap modules, based on plastic scintillators with wavelength-shifting elements and thin silicon photomultipliers, are integrated into the bladder and selected inner surfaces. This geometry is intended to enhance muon tagging, increase acceptance for inclined air showers, and enable improved discrimination between electromagnetic and hadronic components. The study describes the mechanical and optical layout of the detector, the baseline aluminium housing, and the use of 3D-printed hexagonal prototypes to validate integration of the bladder and readout electronics. A first-order structural assessment based on thin-shell and plate theory is presented, indicating large safety margins for the hemispherical shells and identifying the flat base as the mechanically most loaded component. While GEANT4 simulations for detector response to extensive air showers in the atmosphere and performance measurements are left to future work, the present study establishes a mechanically validated, costed baseline design and outlines the steps needed to assess its impact in air-shower arrays. Full article

Education 4.0 and digital learning have led to a technology-driven transformation in educational methodologies and the roles of teachers, primarily at Higher Education Institutions (HEIs). From an educational standpoint, the extant literature on Education 4.0 highlights its technological features and benefits; however, there is a lack of studies that assess its impact on students’ learning outcomes. Seemingly, Education 4.0 features are taken for granted, as if the technology in itself were enough to guarantee students’ learning, self-efficacy, and engagement. Seeking to address this lack, this study describes the implications of tailoring Education 4.0 tenets and digital learning in an engineering curriculum. Four case studies conducted in the last four years with 119 students are presented, in which technologies such as digital twins, a Modular Production System (MPS), low-cost robotics, 3D printing, generative AI, machine learning, and mobile learning were integrated. With these case studies, an educational methodology with active learning, hands-on activities, and continuous teacher support was designed and deployed to foster cognitive and affective learning outcomes. A mixed-methods study was conducted, utilizing students’ grades, surveys, and semi-structured interviews to assess the approach’s impact. The outcomes suggest that including Education 4.0 tenets and digital learning can enhance discipline-based skills, creativity, self-efficacy, collaboration, and self-directed learning. These results were obtained not only via the technological features but also through the incorporation of reflective teaching that provided several educational resources and oriented the methodology for students’ learning and engagement. The results of this study can help complement the concept of Education 4.0, helping to find a student-centered approach and conceiving a balance between technology, teaching practices, and cognitive and affective learning outcomes. Full article

This work presents the development of a differential-drive wheeled mobile robot educational prototype, manufactured using 3D additive techniques. The robot is powered by an embedded ARM-based computing system and uses open-source software. To validate the prototype, a trajectory-tracking task was successfully implemented. The aim of this contribution is to provide an easily replicable prototype for teaching automatic control and related engineering topics in academic settings. Full article

This study examines whether twisted tape inserts in a pipe system can reduce pipe erosion under a liquid–solid flow regime. Three different twisted tape configurations were designed using 3D printing technology: tapes with one twist, four twists, and four twists with perforations. Experiments were performed using a PVC pipe with a carbon steel plate as the material under investigation. Slurries of water and silica sand were prepared with varying sand concentrations—1%, 3%, and 5%—to induce different erosion rates. The experimental results were backed by Computational Fluid Dynamics (CFD) using the discrete phase model (DPM) to predict particle flow and erosion attributes. Erosion trends were also tested through mass loss and paint loss tests. The analysis outcomes demonstrated that the one-twist, four-twist, and perforated four-twist tapes reduced the erosion rate by 18%, 39%, and 45%, respectively. Among the different configurations, the four-twist tape with holes reduced erosion the most. These results suggest that twisted tape inserts can control erosion, thereby increasing the service life of pipes that handle abrasive flows. Full article

Fused deposition modeling (FDM) suffers from unpredictable mechanical properties in nominally identical prints. Current quality assurance relies on destructive testing or expensive post-process inspection, while existing machine learning approaches focus primarily on printing parameters rather than real-time thermal environments. The objective of this proof-of-concept study is to develop a low-cost, non-destructive framework for predicting tensile strength during FDM printing by directly measuring convective thermal gradients surrounding the print. To accomplish this, we introduce thermal fingerprinting: a novel non-destructive technique that combines Background-Oriented Schlieren (BOS) imaging with machine learning to predict tensile strength during printing. We captured thermal gradient fields surrounding PLA specimens (n = 30) under six controlled cooling conditions using consumer-grade equipment (Nikon D750 camera, household hairdryers) to demonstrate low-cost implementation feasibility. BOS imaging was performed at nine critical layers during printing, generating thermal gradient data that was processed into features for analysis. Our initial dual-model ensemble system successfully classified cooling conditions (100%) and showed promising correlations with tensile strength (initial 80/20 train–test validation: R² = 0.808, MAE = 0.279 MPa). However, more rigorous cross-validation revealed the need for larger datasets to achieve robust generalization (five-fold cross-validation R² = 0.301, MAE = 0.509 MPa), highlighting typical challenges in small-sample machine learning applications. This work represents the first successful application of Schlieren imaging to polymer additive manufacturing and establishes a methodological framework for real-time quality prediction. The demonstrated framework is directly applicable to real-time, non-contact quality assurance in FDM systems, enabling on-the-fly identification of mechanically unreliable prints in laboratory, industrial, and distributed manufacturing environments without interrupting production. Full article

This paper outlines the design and testing of a horizontal-axis tidal turbine (HATT) at a scale of 1:20, employing numerical simulations and experimental validation. The design employed an in-house code based on the Blade Element Momentum (BEM) theory. As reliable lift and drag coefficients for this scale are not present in the literature due to the low Reynolds number of the airfoil, Computational Fluid Dynamics (CFD) simulations were conducted to generate accurate polar diagrams for the NACA 4412 airfoil. The turbine was then 3D-printed and the rotor tested in a subsonic wind tunnel at various fixed rotational speeds to determine the power coefficient. Fluid dynamic similarity was achieved by matching the Reynolds number and tip-speed ratio in air to their values in water. Three-dimensional CFD simulations were also performed, yielding turbine efficiency results that agreed fairly well with the experimental data. However, both the experimental and numerical simulation results indicated a higher power coefficient than that predicted by BEM theory. The CFD results revealed the presence of radial velocity components and vortex structures that could reduce flow separation. The BEM model does not capture these phenomena, which explains why the power coefficient detected by experiments and numerical simulations is larger than that predicted by the BEM theory. Full article

Additive manufacturing has been widely adopted in industry as an alternative to traditional manufacturing processes for complex component production. In fact, a diverse range of materials, particularly polymers, can be processed using 3D printing for biomechanical applications (e.g., prosthetics). However, in-depth evaluation of these materials is necessary to determine their suitability for demanding applications, such as those involving cyclic loading. Following previous work that studied Polylactic Acid (PLA) and Polyethylene Terephthalate Glycol-modified (PETG) under experimental fatigue testing, this study examines the fatigue behaviour of other current 3D-printed polymeric materials, namely Acrylonitrile Styrene Acrylate (ASA), Polycarbonate (PC), Polyamide 12 (Nylon 12), and Polycarbonate–Acrylonitrile Butadiene Styrene (blend) (PC-ABS), for which fatigue data remain limited or even non-existent. The findings revealed performance differences on Tensile Strength (σ_R), Young’s Modulus and Ultimate Strain among tensile specimens made from these materials and characterised S-N curves for both high-cycle (HCF) and low-cycle (LCF) fatigue regimes at room temperature, with a tensile load ratio (R = 0.05). These results establish relationships among fatigue limit and quasi-static mechanical properties, namely 25% × σ_r for ASA (8 MPa), 7% × σ_r for PC (3.6 MPa), 17% × σ_r for Nylon 12 (7.4 MPa), and 15% × σ_r for PC-ABS (4.7 MPa), as well as between mechanical properties and preliminary potential biomechanical applications. Main conclusions were further supported by micro-computed tomography (micro-CT), which revealed levels of porosity in between 4% and 11%, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and Fourier transform infrared spectroscopy (FTIR). Full article

Background and Objectives: Academic point-of-care (POC) manufacturing enables the in-hospital design and production of patient-specific medical devices within certified environments, integrating clinical practice, engineering, and translational research. This model represents a new academic ecosystem that accelerates innovation while maintaining compliance with medical device regulations. Gregorio Marañón University Hospital has established one of the first ISO 13485-certified academic manufacturing facilities in Spain, providing on-site production of anatomical models, surgical guides, and custom implants for oral and maxillofacial surgery. This study presents a retrospective review of all devices produced between April 2017 and September 2025, analyzing their typology, materials, production parameters, and clinical applications. Materials and Methods: A descriptive, retrospective study was conducted on 442 3D-printed medical devices fabricated for oral and maxillofacial surgical cases. Recorded variables included device classification, indication, printing technology, material type, sterilization method, working and printing times, and clinical utility. Image segmentation and design were performed using 3D Slicer and Meshmixer. Manufacturing used fused deposition modeling (FDM) and stereolithography (SLA) technologies with PLA and biocompatible resin (Biomed Clear V1). Data were analyzed descriptively. Results: During the eight-year period, 442 devices were manufactured. Biomodels constituted the majority (approximately 68%), followed by surgical guides (20%) and patient-specific implants (7%). Trauma and oncology were the leading clinical indications, representing 45% and 33% of all devices, respectively. The orbital region was the most frequent anatomical site. FDM accounted for 63% of the printing technologies used, and PLA was the predominant material. The mean working time per device was 3.4 h and mean printing time 12.6 h. Most devices were applied to preoperative planning (59%) or intraoperative use (35%). Conclusions: Academic POC manufacturing offers a sustainable, clinically integrated model for translating digital workflows and additive manufacturing into daily surgical practice. The eight-year experience of Gregorio Marañón University Hospital demonstrates how academic production units can enhance surgical precision, accelerate innovation, and ensure regulatory compliance while promoting education and translational research in healthcare. Full article