Search Results (91)

The gears of helicopter transmission system have strict requirements on machining accuracy, and the accurate prediction of tooth surface grinding force is the key to its manufacturing. The existing model simplifies the micro-contact behavior of the abrasive-workpiece, which limits the accuracy of the grinding load solution. In this paper, the stress state of single abrasive grain at different stages is refined from the micro level, and the grinding force mechanism model of contact area superposition is established. A mechanism-constrained data-driven grinding force prediction algorithm (MCDDP) is proposed. The algorithm integrates the microscopic force mechanism as a physical constraint into the neural network. The experimental results show that the R² of the model for predicting the normal and tangential grinding forces under multiple working conditions is higher than 0.98, and the average error is reduced by about 17% compared with the traditional model. This study reveals the non-uniform force mechanism of abrasive-workpiece, realizes the integration of mechanism model and data-driven method, and provides engineering theoretical and technical support for grinding force prediction and process parameter optimization of aviation precision gears. Full article

Microcontact stamping is a promising microfabrication technique for producing functional patterned thin films on flexible substrates; however, systematic optimization of its process parameters for thermochromic applications remains limited. In this study, we present a comprehensive parametric optimization of the microcontact stamping process to fabricate thermochromic pigment-coated thin films with rapid and reversible color responses. The effects of liquid resin type, SU-8 mold thickness, polydimethylsiloxane (PDMS) mixing ratio, and pattern size on pattern fidelity and thermochromic performance were systematically investigated. The optimal conditions were identified as a UV-curable resin, a 600 µm-thick SU-8 mold, a PDMS base-to-curing-agent ratio of 5:1, and a pattern size of 125 × 125 µm². Under these conditions, the stamped thermochromic films exhibited uniform micro-patterns, rapid response and recovery behavior, and stable reversible color changes over 20 consecutive thermal cycles. This work provides practical guidelines for parameter-controlled microcontact stamping of functional thin films and demonstrates its potential for scalable fabrication of thermochromic micro-patterns. The proposed approach is expected to contribute to the development of flexible and wearable electronic devices, smart displays, and thermally responsive sensing platforms. Full article

Surface-imprinted polymer (SIP)-based biomimetic sensors are promising for direct whole-bacteria detection; however, the commonly used fabrication approach (micro-contact imprinting) often suffers from limited imprint density, heterogeneous template distribution, and poor reproducibility. Here, we introduce a photolithography-defined master stamp featuring E. coli mimics, enabling high-density, well-oriented cavity arrays (3 × 10⁷ imprints/cm²). Crucially, the cavity arrangement is engineered such that the SIP layer functions simultaneously as the bioreceptor and as a diffraction grating, enabling label-free optical quantification by reflectance changes without additional transduction layers. Finite-difference time-domain (FDTD) simulations are used to model and visualize the optical response upon bacterial binding. Proof-of-concept experiments using a differential two-well configuration confirm concentration-dependent detection of E. coli in PBS, demonstrating a sensitive, low-cost, and scalable sensing concept that can be readily extended to other bacterial targets by redesigning the photolithographic master. Full article

Strain-promoted azide–alkyne cycloaddition (SPAAC) is widely used in solution-phase bioconjugation. However, its application in surface chemistry remains limited because substrate-independent azide films that remain stable upon reaction with bulky strained alkynes have not yet been developed. In this study, we address this challenge using a melanin-inspired coating based on tyrosine–azide derivatives with different linkers. In particular, we investigated how differences in linker length and hydrophilicity affect the hydrophobic interactions within the film network and, ultimately, determine film stability. Specifically, Tyr-3-N₃, a tyrosine–azide derivative having an azide group tethered to tyrosine through a short three-carbon alkyl linker, was identified as optimal, forming azide-presenting films via tyrosinase-mediated oxidation and retaining integrity during SPAAC with external dibenzocyclooctyne (DBCO) ligands. The optimized poly(Tyr-3-N₃) coatings enabled efficient methoxypolyethylene glycol (mPEG) immobilization, thereby exhibiting excellent antifouling performance against protein adsorption, and further supported spatially controlled protein patterning through soft lithography techniques such as micromolding in capillaries (MIMIC) and microcontact printing (µCP). The approach was broadly applicable with a range of inorganic and polymeric substrates, as well as living cell surfaces; even after encapsulation and SPAAC-based functionalization, the cells remained viable. Collectively, these findings establish a substrate-independent and biocompatible coating platform that preserves film stability through SPAAC functionalization, supporting applications in antifouling coatings, biosensing, and cell surface engineering. Full article

Lung cancer remains one of the deadliest cancers worldwide, which highlights the urgent need for new diagnostic tools to detect reliable biomarkers. To enable scalable and cost-effective production, we developed reusable PDMS stamps patterned with electrodes to print flexible electrodes on PET substrates using a microcontact printing (µCP) approach. PET was chosen not only for its flexibility but also as a more sustainable alternative to conventional rigid materials. On these electrodes, three sensing platforms were tested for neuron-specific enolase (NSE) detection: APTES-based monolayers, electrospun PVA/alginate nanofibers, and electropolymerized polypyrrole (PPy) films. Voltammetric and fluorescence/AFM analyses confirmed that all three platforms could recognize the target analyte, with the PPy-CdTe configuration showing the strongest signal variation. Impedance spectroscopy further supported this finding, revealing a clear linear correlation between charge transfer resistance (RCT) and NSE concentration. The PPy-CdTe sensor demonstrated high sensitivity and consistent performance for NSE detection, achieving a detection limit (LOD) of 8.05 pg·µL⁻¹ and a quantification limit (LOQ) of 26.84 pg·µL⁻¹. Full article

Tumor Necrosis Factor-alpha (TNF-α) is a pro-inflammatory cytokine strongly associated with the early onset and progression of heart failure (HF). In this study, we present the design and fabrication of a label-free, fluorescence-based biosensor for the detection of TNF-α cytokines. The biosensor is constructed using microcontact printing (μCP) to pattern Triethoxysilylundecanal (TESUD) on oxygen plasma-activated polydimethylsiloxane (PDMS) substrates, forming self-assembled monolayers (SAMs) of microstructures. TNF-α antibodies are then covalently immobilized via imine coupling. Detection of TNF-α cytokines at 50 µg/mL was achieved via an optical “sandwich” immunoassay with rhodamine-labeled secondary antibodies, enabling visualization by fluorescence microscopy. Surface wettability analysis confirmed successful stepwise functionalization, while imaging revealed well-defined microstructures and specific immune binding of TNF-α. This platform demonstrates a proof-of-concept and offers a non-invasive, sensitive, and cost-effective alternative for the early detection of TNF-α in biological fluids, with potential applications in HF monitoring. Full article

Electrical connectors play a vital role in ensuring reliable signal transmission in high-frequency microsystems. This study explores the impact of microscale scratch-induced surface roughness on the alternating current (AC) contact impedance of RF coaxial connectors. Unlike traditional approaches that assume idealized surface conditions, controlled micro-defects were introduced at the central contact interface to establish a quantitative relationship between surface morphology and signal degradation. An equivalent circuit model was constructed to account for local impedance variations and the cumulative effects of cascaded connector interfaces. The model was validated using S-parameter measurements obtained from vector network analyzer (VNA) testing, showing strong agreement with simulation results. Experimental results reveal that the low-roughness (0.4 μm) contact surfaces lead to degraded signal integrity due to insufficient micro-contact formation. In contrast, scratch-induced moderate roughness (0.8–4.8 μm) improves transmission performance, although signal quality declines as roughness increases within this range. These effects are further amplified in multi-connector configurations due to accumulated impedance mismatches. This work provides new insight into the coupling between microscale surface features and frequency-domain transmission characteristics, offering practical guidance for surface engineering, contact design, and the development of miniaturized, high-reliability radio frequency interconnects for next-generation communication systems. Full article

Background/Objectives: Intracranial macroelectrode implantation is a pivotal clinical tool in the evaluation of drug-resistant epilepsy, allowing further insights into the localization of the epileptogenic zone and the delineation of eloquent cortical regions through cortical stimulation. Additionally, it provides an avenue to study brain functions by analyzing cerebral responses during neuropsychological paradigms. By combining macroelectrodes with microelectrodes, which allow recording the activity of individual neurons or smaller neural clusters, recordings could provide deeper insights into neuronal microcircuits and the brain’s transitions in epilepsy and contribute to a better understanding of neuropsychological functions. In this study, one or two hybrid macro-micro electrodes were implanted in the anterior-inferior insular region in patients with refractory epilepsy. We report our experience and share some preliminary results; we also provide some recommendations regarding the implantation procedure for hybrid electrodes in the insular cortex. Methods: Stereoelectroencephalography was performed in 13 patients, with one or two hybrid macro-microelectrodes positioned in the insular region in each patient. Research neuropsychological paradigms could not be implemented in two patients for clinical reasons. In total, 23 hybrid macro-microelectrodes with eight microcontacts each were implanted, of which 20 were recorded. Spiking activity was detected and assessed using WaveClus3. Results: No spiking neural activity was detected in the microcontacts of the first seven patients. After iterative refinement during this process, successful recordings were obtained from 13 microcontacts in the anterior-inferior insula in the last four patients (13/64, 20.3%). Hybrid electrode implantation was uneventful with no complications. Obstacles included the absence of spiking activity signals, unsuccessful microwire dispersion, and the interference of environmental electrical noise in recordings. Conclusions: Human microelectrode recording presents a complex array of challenges; however, it holds the potential to facilitate a more comprehensive understanding of individual neuronal attributes and their specific stimulus responses. Full article

For organ-on-a-chip (OoC) engineering, the use of biocompatible coatings and materials is not only recommended but essential. Extracellular matrix (ECM) components are commonly used as coatings due to their effects on cell orientation, protein expression, differentiation, and adhesion. Among the most frequently used coatings are collagen, fibronectin, and Matrigel, according to the specific cell type and intended OoC application. Additionally, materials such as polydimethylsiloxane (PDMS), thermoplastics, chitosan, and alginate serve as scaffolding components due to their biomechanical properties and biocompatibility. Here, we discuss some of the most employed coating techniques, including SAMs, dip coating, spin coating, microcontact printing, and 3D bioprinting, each offering advantages and drawbacks. Current challenges comprise enhancing biocompatibility, exploring novel materials, and improving scalability and reproducibility. Full article

This study addresses the critical challenge of precise control over active abrasive particles in magnetorheological polishing (MRP) through innovative core–shell particle engineering. A sol–gel synthesized CIP@SiO₂ magnetic composite abrasive with controlled SiO₂ encapsulation (20 nm shell thickness) was developed using tetraethyl orthosilicate (TEOS) as the silicon precursor, demonstrating significant advantages in optical-grade fused silica finishing. Systematic polishing experiments reveal that the core–shell architecture achieves a remarkable 20.16% improvement in surface quality (Ra = 1.03 nm) compared to conventional CIP/SiO₂ mixed abrasives, with notably reduced surface defects despite a modest 8–12% decrease in material removal rate. Through synergistic analysis combining elastic microcontact mechanics modeling and molecular dynamics simulations, we establish that the SiO₂ shell mediates stress distribution at tool–workpiece interfaces, effectively suppressing deep subsurface damage while maintaining nano-scale material removal efficiency. The time-dependent performance analysis further demonstrates that extended polishing durations with CIP@SiO₂ composites progressively eliminate mid-spatial frequency errors without introducing new surface artifacts. These findings provide fundamental insights into designed abrasive architectures for precision finishing applications requiring sub-nanometer surface integrity control. Full article

At the microscale, the three-dimensional morphological features of contact surfaces have a significant impact on the performance of electrical contacts. This paper aims to reconstruct the microscopic contact state of contact groups and to deeply study the effect of contact morphological features on electrical contact performance. To fully obtain multimodal data such as the three-dimensional micro-morphological features and chemical composition distribution of contact surfaces, this paper proposes a contact surface feature-matching method based on entropy rate superpixel seed point adaptive morphological reconstruction. This method can adaptively retain meaningful seed points while filtering out invalid seed points, effectively solving the problem of over-segmentation in traditional superpixel segmentation method. Experimental results show that the proposed method achieves a segmentation accuracy of 92% and reduces over-segmentation by 30% compared to traditional methods. Subsequently, on the basis of the moving and static contact group difference plane model and the W-M model, this paper constructs a three-dimensional surface fractal contact model with an irregular base. This model has the ability to layer simulate multi-parameter elastic and plastic and to extract fractal parameter point cloud height, which can more accurately reflect the actual contact state of the contact group. The model demonstrates a 15% improvement in contact area prediction accuracy and a 20% reduction in contact resistance estimation error compared to existing models. Finally, this paper compares and verifies the theoretical feasibility of the model, providing a new theoretical contact model for the study of the impact of three-dimensional micro-morphology on the electrical contact reliability. Full article

This study presents the challenges arising during the numerical design and simulation of surface-microtextured piston rings. The evaluation of performance is based on the values of asperity and hydrodynamic friction, as well as the lubricant film thickness. The simulation tool AVL Excite Piston & Rings is used to perform the calculations. The aim of this study is to understand how selected surface pre-processing (pre-treatment) steps affect the calculations. Two methods are presented to achieve a realistic surface topography representative of a state after running-in. Pre-treatment is performed through metrological filtering and thresholding of the topography, and Gaussian smoothing of the virtually applied micro-texture array is carried out. The results show the anticipated behavior of decreasing asperity and hydrodynamic friction losses with the concurrent application of both techniques. Full article

Microcontact printing (µCP) has become an emerging method for creating exact patterns on a range of substrates. This short review paper seeks to give a brief summary of the developments, fabrication techniques, applications, and difficulties in the microcontact printing of polymeric devices. In this systematic review, 20 papers from various fields were chosen for study. This review begins by introducing the basics of microcontact printing and discussing its capacity to transfer predetermined patterns with submicron resolution from an elastomeric stamp to substrates. Then, various microcontact printing production techniques for polymeric devices are reviewed. Furthermore, this review explores the broad range of applications enabled by microcontact printing, including electronics, biotechnology, nanotechnology, and surface engineering. Additionally, the potential difficulties and challenges associated with using microcontact printing processes are discussed. This literature review is to give researchers and practitioners a thorough understanding of microcontact printing by integrating the results from a few chosen studies. It promotes additional study and innovation in this promising sector by highlighting the most recent advancements, manufacturing techniques, and difficulties related to the manufacture of polymeric devices. Full article

Alzheimer’s disease (AD) is a neurodegenerative disease characterized by memory loss and progressive deterioration of cognitive functions. Being able to identify reliable biomarkers in easily available body fluids such as blood plasma is vital for the disease. To achieve this, we used a technique that applied human plasma to organotypic brain slice culture via microcontact printing. After a 2-week culture period, we performed immunolabeling for neurofilament and myelin oligodendrocyte glycoprotein (MOG) to visualize newly formed nerve fibers and oligodendrocytes. There was no significant change in the number of new nerve fibers in the AD plasma group compared to the healthy control group, while the length of the produced fibers significantly decreased. A significant increase in the number of MOG+ dots around these new fibers was detected in the patient group. According to our hypothesis, there are factors in the plasma of AD patients that affect the growth of new nerve fibers, which also affect the oligodendrocytes. Based on these findings, we selected the most promising plasma samples and conducted mass spectrometry using a differential approach and we identified three putative biomarkers: aldehyde-dehydrogenase 1A1, alpha-synuclein and protein S100-A4. Our method represents a novel and innovative approach for translating research findings from mouse models to human applications. Full article

Engineering practice has demonstrated that seal failure can result in severe leakage and wear, reducing the efficiency of hydraulic systems and even leading to major safety risks. Currently, analyses of the thermal aspect of seal interfaces are relatively limited, with most studies focusing on mechanical analysis. However, in actual applications, temperature has a significant impact on sealing performance. In this paper, nonlinear elastomechanics, viscous fluid mechanics, micro-contact mechanics, micro-deformation theory, and thermodynamics are coupled to establish a mixed lubrication model considering the thermal effect. The reliability of the mixed lubrication model is verified through experiments, and the temperature distribution of the oil film in the sealing area and the temperature distribution of the seal ring are simulated. Finally, the effects of the reciprocating speed, root mean square roughness, fluid medium pressure, and seal pre-compression on seal friction force and leakage are investigated. The results show that the heat generated in the sealing area accumulates at the bottom of the V-ring. Under the same conditions, compared with the instroke, the temperature-rise area of the outstroke is biased to the left and the increase in temperature is greater. In addition, the piston rod speed and the preliminary compression of the seal ring have a greater impact on the overall seal friction force and leakage. Under a lower seal pre-compression, the RMS roughness has a great influence on the leakage and friction in the outstroke, while the impact of the internal stroke is limited. Full article