Search Results (220)

Perovskite solar cells (PSCs) have emerged as one of the most rapidly advancing photovoltaic technologies of the past decade, progressing from the initial demonstration of 3.8% power conversion efficiency (PCE) in 2009 to certified single-junction efficiencies exceeding 26% and perovskite–silicon tandem efficiencies exceeding 33.9% as of 2024. Their appeal resides in the combination of a broadly tunable bandgap achieved through compositional engineering of the ABX₃ perovskite crystal structure, compatibility with low-temperature solution processing, and the potential for manufacturing costs substantially below those of silicon photovoltaics. However, the translation of laboratory-scale performance to commercially viable modules at industrial throughput remains the central challenge in the field. This review provides a comprehensive and critically organized account of PSC manufacturing, spanning device architectures and material requirements, scalable deposition and coating technologies, charge transport layer integration and interface engineering, process control and crystallization strategies, post-treatment methods, artificial intelligence and machine learning-assisted manufacturing, module fabrication and encapsulation, advanced tandem and flexible device configurations, green chemistry and circular lifecycle strategies, and the critical barriers to commercialization. The review concludes with a strategic assessment of the technological, regulatory, and economic requirements for PSC technology to transition from pilot-scale demonstration to utility-scale deployment. Full article

Modern manufacturing is currently shifting toward highly flexible, high-mix, and low-volume production cycles, requiring small and medium-sized enterprises (SMEs) to adopt reconfigurable automation to remain competitive. However, the adoption of such technologies is often slowed down by the high cost and rigidity of commercial solutions, which typically rely on proprietary toolchains and necessitate specialized expert knowledge for reconfiguration. This study proposes a methodological framework for a modular robotic cell based on an open-architecture approach using ROS2 middleware, designed to be maintained by personnel without deep robotics expertise. The methodology emphasizes the replacement of fixed mechanical fixtures with an AI-driven perception pipeline, utilizing YOLO-based image segmentation to enable the autonomous localization of heterogeneous components. A rigorous tolerance chain analysis defines the design requirements of custom 3D-printed self-aligning fingertips, providing a mathematical and mechanical basis for ensuring assembly feasibility under tight geometric constraints. By adopting a node-based software topology, the framework facilitates rapid task reconfiguration and hardware interoperability. Experimental validation in an industrial-like environment confirms that this integrated approach provides a scalable pathway with the potential to improve cost-effectiveness in high-mix low-volume production scenarios to overcome manual production bottlenecks through intelligent, reconfigurable automation. Full article

Wound healing is a multifaceted biological process comprising the phases of hemostasis, inflammation, proliferation, and remodeling, all of which require supportive microenvironment for optimal tissue regeneration. Biopolymer-based hydrogels, derived from materials such as cellulose and its derivatives, chitosan, alginate, and hyaluronic acid, have emerged as promising wound dressing materials due to their excellent biocompatibility, biodegradability, moisture-retention capacity, and potential to mimic the native extracellular matrix. The structural characteristics, wound healing functions, and underlying mechanisms of these biopolymers are critically examined and summarized in tabular form. The review further highlights the incorporation of natural and synthetic therapeutic agents, growth factors, stem-cell-derived products, and peptides into biopolymer matrices to enhance therapeutic efficacy. The examined research findings indicate significant increases in fluid intake, moisture retention, antibacterial activity, angiogenesis, collagen deposition, tissue regeneration, and wound healing rates. Translational difficulties, regulatory issues, clinical research, and new patent activity pertaining to advanced wound healing biomaterials are also covered in the review. Despite tremendous improvements, issues still exist in bulk manufacturing, long-term safety, reproducibility, mechanical stability, and clinical validation. Future innovations are anticipated to concentrate on smart, multipurpose, and customized hydrogel systems that can integrate drug delivery, biosensing, and regenerative capabilities while reacting dynamically to wound microenvironments. Overall, biopolymer-based hydrogels are a flexible, rapidly developing platform with significant promise to improve next-generation skin tissue engineering and change the treatment of both acute and chronic wounds. Full article

Organic solar cells (OSCs) are a potential photovoltaic technology because they can be manufactured in scalable systems, are lightweight, and have mechanical flexibility. Power conversion efficiencies close to 20% have been achieved in recent years due to the quick development of donor–acceptor material systems. Better control over nanoscale shape and the creation of non-fullerene acceptors are major factors driving this advancement. Nevertheless, there are still complicated connections between morphology, interfacial energetics, and molecular structure. It is yet unclear how these elements interact to affect charge creation and transport. In this review, donor–acceptor interactions in organic solar cells are examined from a fundamental chemical and physical perspective. From conventional fullerene derivatives to contemporary non-fullerene acceptors, we first look at the development of acceptor materials. We demonstrate how molecular engineering has enhanced device efficiency, energy level adjustment, and light absorption. We then examine the energetic alignment at donor–acceptor interfaces, paying particular attention to charge-transfer state creation, border orbital offsets, and the factors influencing voltage losses. We also investigate how intermolecular interactions, including hydrogen bonding, π-π stacking, and noncovalent interactions involving heteroatoms, control electrical coupling and nanoscale shape in bulk heterojunction active layers. We also go over device engineering techniques including processor control, interface engineering, and bulk heterojunction architecture optimization. These tactics demonstrate how improved solar performance might result from molecular design. Lastly, we highlight new possibilities for next-generation OSCs, such as scalable production techniques, adaptive molecular design, and morphological stabilization. This work provides a strong framework for comprehending donor–acceptor interactions and for directing the careful design of high-performance organic photovoltaic systems by combining knowledge from molecular chemistry, morphological control, and device engineering. Full article

Lattice structures are widely utilized in lightweight engineering due to their design flexibility and tailorable mechanical properties. However, polymer lattices often exhibit limited load-bearing capacity and moderate crashworthiness under compression. This study proposes a hybrid reinforcement strategy based on the integration of carbon fiber-reinforced polymer (CFRP) rods into polymeric Kelvin-cell lattices. The specimens were manufactured via masked stereolithography, and the effects of rod placement pattern, the number of rods, and rod-length configuration were systematically investigated under quasi-static compression. Crashworthiness was evaluated in terms of force–displacement response, deformation mode, and crashworthiness metrics. Compared with the empty Kelvin-cell lattice, the best-performing hybrid configuration increased energy absorption, specific energy absorption, and mean crushing force by approximately 356%, 307%, and 356%, respectively. Mechanistically, distributed rod placement promoted more uniform load sharing, while the effect of increasing rod number depended strongly on the rod-length configuration. In addition, delayed or sequential reinforcement strategies provided superior performance and an enhanced balance between energy absorption and force efficiency. Regression models and ANOVA consistently identified rod-length configuration as the dominant design variable. These findings demonstrate that CFRP rod reinforcement can effectively enhance the crashworthiness of polymeric Kelvin-cell lattices, provided that the rod placement pattern, rod number, and rod-length configuration are designed jointly. Full article

Hybrid additive manufacturing (HAM) integrates additive and subtractive processes within a unified production system, combining the geometric flexibility and material efficiency of additive manufacturing with the dimensional accuracy and surface quality of conventional machining. This review provides a comprehensive analysis of HAM technologies through a proposed four-criterion classification framework encompassing process integration strategy, additive manufacturing process type, machine architecture, and application domain. DED-based, PBF-based, and polymer-based hybrid systems are examined alongside integrated hybrid machines, retrofit solutions, and robotic architectures. A comparative analysis of representative commercial platforms evaluates build envelope, integration strategy, and monitoring capability. Documented performance outcomes across aerospace, automotive, energy, and biomedical sectors confirm substantial improvements in surface quality, fatigue performance, dimensional accuracy, and material efficiency relative to conventional manufacturing routes. Current limitations are critically assessed across technical, process integration, and economic dimensions, and a structured near-to-long-term research roadmap is proposed, prioritising in-process sensing and toolpath standardisation, digital twin-based adaptive process planning, and ultimately autonomous hybrid manufacturing cells with lifecycle certification. These findings position HAM as a central enabling technology for intelligent, flexible, and sustainable production within Industry 4.0 and Industry 5.0 paradigms. Full article

DNA vaccines have emerged as a promising immunization platform, offering key advantages over conventional vaccine approaches, including superior stability, a favorable safety profile, rapid and flexible antigen design, and scalable manufacturing. However, their clinical efficacy has remained limited, primarily due to inefficient cellular uptake, poor endosomal escape, and degradation of the plasmid DNA within host cells. Recent advances have highlighted minicircle DNA (mcDNA) as a next-generation alternative to conventional plasmid vectors. mcDNA constructs are compact, backbone-free episomal vectors containing only the expression cassette, including the promoter, transgene, and polyadenylation signal, while lacking bacterial sequences such as antibiotic resistance genes and origins of replication. This reduced vector size reduced vector-driven innate immune activation and susceptibility to epigenetic silencing, thereby improving transfection efficiency and supporting more sustained transgene expression in both dividing and non-dividing cells. This review provides a comprehensive overview of mcDNA technology in the context of vaccine development, discussing its structural design and production principles, mechanistic advantages over conventional plasmid DNA, and current applications across infectious disease and cancer vaccine platforms. In addition, we explore recent delivery strategies to enhance mcDNA transfection and immunogenicity, summarize existing limitations that hinder translation into applications, and outline future directions to optimize mcDNA-based vaccine technologies. Full article

Thin-film solar cells (TFSCs) remain a cornerstone of the global transition toward renewable energy, characterized by consistent reductions in manufacturing costs and steady gains in power conversion efficiency. In addition to electricity generation, TFSCs play an important role in advanced solar thermal cooling, heating, and energy storage systems, where their tunable optical absorption, low thermal mass, and flexibility enable integration with photovoltaic–thermal (PV/T) collectors, thermally driven cooling cycles, and hybrid thermal–electrical storage architectures. This paper provides a comprehensive review of prominent TFSC technologies, including copper indium gallium selenide (CIGS), cadmium telluride (CdTe/CdS), amorphous silicon (a-Si), copper zinc tin sulfide (CZTS), organic photovoltaics (OPVs), and metal halide perovskite solar cells (PSCs), with a focus on their material structures, performance specifications, and current efficiency benchmarks. Compared to state-of-the-art reviews, this article distinguishes itself by addressing next-generation innovations, cross-domain solar thermal–photovoltaic applications, and economic analysis. Specifically, the integration of machine learning and simulation-based material dynamics is examined to accelerate material discovery, process optimization, and the characterization of novel TFPV components relevant to coupled thermal–electrical energy systems. Furthermore, the study explores how additive manufacturing is transforming the industry through the development of high-efficiency electrodes, electrohydrodynamic atomization for thin-film deposition, and the fabrication of flexible solar arrays suitable for thermally integrated and building-scale energy systems, including space applications. By integrating advancements in module efficiency, scalable manufacturing approaches, and techno-economic analysis, this paper positions TFSCs as sustainable, resource-abundant technologies essential for next-generation solar thermal cooling, heating, and energy storage infrastructures. Full article

The Cell Formation Problem plays a fundamental role in cellular manufacturing due to its impact on efficiency, flexibility, and reliability. Its complexity increases under real-world conditions involving alternative process routes and machine reliability constraints, leading to the Generalized Cell Formation Problem with machine reliability. Researchers have classified the Cell Formation Problem as an NP-Hard problem. To address this computational complexity, this study presents a comparative and hybrid evaluation of the Black Widow Optimizer and the Golden Eagle Optimizer for the Generalized Cell Formation Problem with machine reliability, examining whether mechanisms derived from the Black Widow Optimizer can enhance the search behavior of the Golden Eagle Optimizer. The Black Widow Optimizer provides strong intensification through procreation, cannibalism, and mutation mechanisms, whereas the Golden Eagle Optimizer provides a balanced search process through its cruise and attack strategies. Experimental results show that the Black Widow Optimizer achieved better individual performance than the Golden Eagle Optimizer, with average RPD values of 0.855% and 1.068%, respectively. However, the hybrid strategy based on incorporating the mutation mechanism into the Golden Eagle Optimizer produced the best result, reaching an RPD of 0.592%. The study also employed the Wilcoxon–Mann–Whitney statistical test to validate the performance differences among algorithms, and the respective Big-O computational complexity was calculated. These findings highlight the potential of hybrid metaheuristics for designing robust and efficient manufacturing systems. Full article

Synthetic biology is reshaping in vitro diagnostics (IVD) by enabling programmable and modular biosensing elements that can be integrated into point-of-care testing (POCT) platforms. Compared with conventional assays that depend on fixed chemistries and centralized instrumentation, synthetic biology-based systems offer adaptable molecular recognition, tunable signal processing, and flexible readout formats for decentralized diagnostics. In this review, we present synthetic biology-enabled IVD as programmable biosensing platforms organized into four functional layers: molecular recognition, signal transduction and amplification, output generation, and system integration. We discuss four major enabling modules, including cell-free protein synthesis (CFPS) systems, aptamer and riboswitch sensors, CRISPR-Cas diagnostic platforms, and microfluidic integration technologies. We summarize representative clinical applications from 2021 to 2025 in infectious disease detection, cancer biomarker analysis, and drug metabolism/toxicity screening. In addition, we examine practical considerations beyond analytical sensitivity, including matrix tolerance, workflow complexity, manufacturability, quantitative capability, and regulatory readiness. Finally, we highlight future directions for programmable diagnostics, including AI-assisted biosensor design, multimodal readouts, interoperable platform architectures, and real-world clinical validation. Full article

To enhance immersion in virtual reality (VR) environments and improve the fidelity of virtual tactile interaction, this study proposes a perceptually grounded haptic-rendering framework for fine surface-texture simulation. The framework is centred on a Perceptual Haptic Spectrum Model (PHSM), which maps virtual surface attributes, including hardness, elasticity, roughness, friction, and microtexture periodicity, to multi-band tactile targets in perceptual frequency space. A Just Noticeable Difference (JND)-inspired parameterisation strategy is used as a design guideline to avoid imperceptible or redundant actuation, while region-specific response functions adapt the output to the fingertip centre, finger pad, and lateral edge. To improve reproducibility, the revised manuscript now specifies the flexible thin-film force/strain-sensor cell, array quantity, 320 Hz per-cell acquisition setting, signal-conditioning pipeline, contact-state classification rules, delay budget, and dual-actuation scheduling logic. The sensing design is based on a commercial flexible piezoresistive force-sensor cell with microsecond-level response time and a 12-bit ADC acquisition chain that provides a sufficient aggregate sampling margin for a 7–21 cell array. Manufacturer-supported sensor performance and prototype-level acceptance criteria are reported for response time, linearity, repeatability, hysteresis, drift, SNR, contact-state detection, latency, and durability. The system remains a proof-of-concept platform rather than a completed large-scale psychophysical validation. Within these boundaries, the results show coherent integration of perceptual modelling, multi-rate sensing, state monitoring, predictive feedforward control, and coordinated haptic actuation for fine VR texture rendering. Full article

Saposin-like protein 2 (SAP2) exhibits strong immunogenicity as an antigen for immunodiagnosis in ruminant and human fasciolosis. Most available immunodiagnostic test kits are based on polyclonal and monoclonal antibodies against antigens from Fasciola spp. Previous studies demonstrated that polyclonal and monoclonal antibodies against SAP2 showed high specificity and could effectively detect Fasciola spp. infections at an early stage. However, polyclonal antibodies are extremely difficult to produce, and quality control is not possible during production; the procedure also involves considerable financial investment. To overcome these problems, we developed a single-chain variable fragment (scFv) to control quality in each production cycle and reduce the cost of manufacturing immunodiagnostic kits. Our objectives were to produce and characterize an scFv that binds the SAP2 from the liver fluke Fasciola gigantica. We constructed the scFv by genetic engineering: we cloned immunoglobulin genes and linked them with flexible polypeptide linkers composed of repeating glycine and serine residues. We selected an scFv with high affinity for binding SAP2 using the phage-display technique and produced it using a prokaryotic expression system. The scFv was characterized via in silico and in vitro methods to confirm its specificity for SAP2, including IMGT/V-QUEST, IMGT/Collier-de-Perles, HADDOCK 2.4, ELISA, immunoblotting, and immunohistochemistry. The scFv was successfully produced and purified using Ni-NTA affinity chromatography. The purified scFvFgSAP2 was approximately 27 kDa, as confirmed by SDS-PAGE and immunoblot analysis. An indirect ELISA and immunoblotting indicated that scFvFgSAP2 had strong reactivity with F. gigantica compared to other parasite species. Moreover, immunolocalization of scFvFgSAP2 confirmed that it binds specifically to natural SAP2 in the cecal epithelium cells of F. gigantica. Therefore, this scFv targeting SAP2 is an effective material and can be used to develop immunodiagnostic procedures. Full article

Diamond-like carbon (DLC) coatings are increasingly explored as a practical route to enhance the surface performance of biomedical implants and tissue engineering scaffolds, particularly when combined with additive manufacturing. Rather than serving only as protective layers, DLC coatings allow for independent tuning of surface properties without modifying the bulk structure, which is especially relevant for complex 3D-printed components. This flexibility is often what makes them attractive for biomedical design. This review is structured around two main application areas: DLC coatings for prosthetic implants and DLC coatings for tissue engineering scaffolds. Within this context, the influence of DLC structure (e.g., sp²/sp³ bonding, hydrogen content, and doping) on mechanical, tribological, and biological behavior is discussed. Particular attention is given to additively manufactured metallic implants and porous scaffolds, where large surface area and internal architectures complicate coating uniformity and adhesion. Reports show that DLC coatings can improve corrosion resistance, reduce wear, and influence biological responses, such as antibacterial activity and cell interactions. Several challenges remain to be solved, especially in achieving uniform coating penetration in porous networks and in ensuring long-term stability under physiological conditions. The combination of additive manufacturing and DLC coatings has been shown to offer the potential to become an enabling technology for next-generation biomedical devices. Full article

Background: Additive manufacturing provides a rapid and flexible alternative to conventional micromolding for producing microneedle systems. This study evaluates the potential of a cost-effective LCD 3D printer for fabricating microneedle arrays (MNAs) and investigates how the geometry of MNAs and the formulation of hydrogel influence the performance of lidocaine-coated arrays. Methods: Conical and pyramidal MNAs, along with a reservoir plate, were designed and manufactured. Lidocaine-loaded and placebo hydrogels with two different polymer concentrations were prepared for dip-coating using both single and multilayer applications. Mechanical resistance and insertion efficiency were evaluated under controlled compression. The physicochemical behavior of the hydrogels were characterized, including pH, spreadability, adhesiveness, and rheological behavior. The uniformity of the coating was analyzed using 3D confocal microscopy. Drug loading was quantified by HPLC, drug release was studied using Franz diffusion cells, and skin penetration was confirmed by 3D confocal imaging and Raman mapping. Results: Conical microneedles exhibited high mechanical integrity, showing only a 2% reduction in height compared to 4% for pyramidal MNAs. Stronger drug signals were achieved in deeper skin layers with the conical geometry, indicating enhanced penetration, while pyramidal MNAs provided slightly higher lidocaine loading due to their larger lateral surface. Hydrogels with higher polymer content produced more stable, uniform coatings, particularly when applied in three layers. Rapid drug release was observed, with over 70% of the drug delivered within minutes. Conclusions: LCD 3D printing offers a cost-effective approach for fabricating MNAs with suitable structural stability and sharpness. The optimized hydrogel formulation ensured uniform coverage, as well as maximal and consistence penetration, making this platform a promising candidate for the dermal delivery of other potent drugs. Full article

Perovskite solar cells (PSCs) have rapidly evolved into one of the most promising photovoltaic technologies, achieving power conversion efficiencies comparable to established silicon devices while offering unique advantages such as low weight, mechanical flexibility, and low-temperature, solution-based manufacturing. These attributes, combined with recently demonstrated tolerance to high-energy particle irradiation, position PSCs as compelling candidates for next-generation space power systems. This perspective work summarizes recent advances in PSC development for space environments, focusing on their behaviour under key stressors such as radiation (e.g., electrons, protons, gamma rays, and neutrons), ultraviolet exposure, extreme thermal cycling, and ultra-high vacuum. Progress in material design, device architecture, self-healing mechanisms, and encapsulation strategies is discussed, along with early in-orbit and suborbital demonstrations. Remaining challenges, including long-term stability, encapsulation reliability, large-area scalability, and the need for standardized space-qualification protocols, are also outlined. Indeed, PSCs represent a compelling opportunity for next-generation space photovoltaics, provided that targeted materials and engineering solutions address critical issues of encapsulation and durability under combined stressors to ensure reliable operation in harsh extraterrestrial conditions. Full article