Search Results (165)

Additive manufacturing has emerged as a transformative technology for fabricating complex drug-eluting medical devices, offering unprecedented design freedom and functional integration capabilities. This comprehensive review systematically analyzes 3D printing technologies applied to pharmaceutical device manufacturing, focusing on drug-eluting vascular stents as a representative application. This review covers six primary additive manufacturing techniques, ranging from high-resolution vat photopolymerization (25 μm resolution) to direct energy deposition, with a focus on their capabilities for produce pharmaceutical devices with controlled drug release properties. Novel 4D/5D/6D printing technologies introduce stimuli-responsive behaviors enabling programmable drug release profiles and adaptive device functionality. Manufacturing process optimization reveals superior design flexibility compared to conventional methods, with 85–95% reduction in design iteration time and elimination of tooling costs for complex geometries. The material landscape encompasses traditional metals (316L stainless steel, cobalt–chromium), biodegradable polymers (polylactic acid, PLA; polycaprolactone, PCL; poly(lactic-co-glycolic acid), PLGA), shape-memory materials (i.e., polymers and alloys capable of recovering a pre-programmed shape upon exposure to a specific stimulus such as body temperature, moisture, or light), and advanced nanocomposites, each offering distinct drug-loading capacities (100–500 μg/cm²) and release kinetics. Critical challenges include standardization requirements (International Organization for Standardization (ISO) 5840 and American Society for Testing and Materials (ASTM) F2606), pharmaceutical-grade manufacturing protocols, and regulatory pathways for novel drug-device combinations. This review identifies key research priorities including development of biocompatible printing materials, accelerated drug release testing protocols, and scalable manufacturing processes suitable for medical device production. This analysis demonstrates that 3D printing enables integration of multiple pharmaceutical functions within single devices, controlled spatiotemporal drug delivery, and elimination of secondary manufacturing steps for drug coating processes, advancing the development of next-generation therapeutic medical devices. Full article

This study presents an experimental characterization and numerical assessment of Cu–Al–Be (CAB) shape memory alloys (SMAs) for potential applications in U-shaped flexural plate (UFP) seismic dampers. Six alloy compositions were evaluated through monotonic tensile tests, ASTM F2516 superelastic protocols, and increasing-amplitude cyclic loading to identify the material exhibiting stable superelastic behavior at room temperature. Among the tested materials, alloy CAB4.76-A showed the most favorable response, with high transformation stress, stable pseudoelastic behavior, and strain recovery exceeding 95% for strains up to 2.5%. A phenomenological finite element model based on the Auricchio constitutive formulation was calibrated using experimental data within the validated strain range (ε ≤ 0.025), showing good agreement in stiffness and stress prediction. The calibrated model was subsequently applied to simulate the response of a UFP device under orthogonal cyclic loading. The results indicate a strong dependence on loading orientation due to coupled bending–torsion effects, with the 90° direction exhibiting significantly higher strength and energy dissipation capacity. Comparison with analytical formulations originally developed for steel UFPs showed that these expressions provide approximate estimates when applied to SMA-based devices. The results suggest that Cu–Al–Be alloys are a promising alternative for UFP applications, while highlighting the importance of loading orientation and the need for future experimental validation at a device scale. Full article

$\mathrm{T}{\mathrm{i}}_{70}\mathrm{Z}{\mathrm{r}}_{20}\mathrm{T}{\mathrm{a}}_{10}$ alloy is a $\beta$-titanium based shape memory alloy with a high martensitic transformation temperature and large recoverable strain. It is thought to be to develop into a new generation of high-performance high-temperature shape memory alloy materials. By partially replacing the Ta element in the $\mathrm{T}{\mathrm{i}}_{70}\mathrm{Z}{\mathrm{r}}_{20}\mathrm{T}{\mathrm{a}}_{10}$ alloy with Al, Ti-Zr-Ta-Al alloys with different Al contents were prepared. In this study, isothermal oxidation tests at 900 °C were conducted on Ti-Zr-Ta-Al alloys with different Al contents to investigate the effect of Al content on the high-temperature oxidation behavior of the $\mathrm{T}{\mathrm{i}}_{70}\mathrm{Z}{\mathrm{r}}_{20}\mathrm{T}{\mathrm{a}}_{10}$ alloy. The results show that the isothermal oxidation kinetics curves of $\mathrm{T}{\mathrm{i}}_{70}\mathrm{Z}{\mathrm{r}}_{20}\mathrm{T}{\mathrm{a}}_{10-\mathrm{x}}\mathrm{A}{\mathrm{l}}_{\mathrm{x}}$ (x = 0, 0.5, 1, 3 at.%) at 900 °C all follow a parabolic law. The oxide films formed on the alloy surface are mainly composed of $\mathrm{Ti}{\mathrm{O}}_2$, $\mathrm{T}{\mathrm{a}}_2{\mathrm{O}}_5$ and $(\mathrm{Ti},\mathrm{Zr}){\mathrm{O}}_2$. However, the surface of the oxide films is relatively rough. The films are not dense and there are pores and cracks, leading to spallation during the oxidation process. After the addition of Al, the high-temperature oxidation resistance of the Ti-Zr-Ta alloy is improved. When the Al content is 1 at.%, $\mathrm{T}{\mathrm{i}}_{70}\mathrm{Z}{\mathrm{r}}_{20}\mathrm{T}{\mathrm{a}}_9\mathrm{A}{\mathrm{l}}_1$ exhibits the best high-temperature oxidation resistance. Full article

This study investigates the nonlinear dynamic response and chaos evolution of a shape memory alloy hybrid composite (SMAHC) actuator beam under coupled thermal, harmonic, and aerodynamic excitations. A reduced-order nonlinear dynamic model was developed by combining Euler–Bernoulli beam theory, von Karman geometric nonlinearity, the Brinson SMA constitutive relation, and first-order piston-theory aerodynamics. The governing equations were derived from Hamilton’s principle, discretized by the weighted residual method, and solved using the Newmark-beta algorithm. Chaotic evolution was quantified using a largest Lyapunov exponent-based chaos intensity indicator rather than the exact Kolmogorov–Sinai entropy. The reduced-order model was compared with ABAQUS finite element simulations under representative coupled aerodynamic and harmonic loading. The MATLAB prediction and ABAQUS response gave a dominant frequency of approximately 9.50 Hz, close to the prescribed excitation frequency of 9.55 Hz, with peak displacement amplitudes of approximately 0.0285 mm and 0.0324 mm, respectively. A supplementary ABAQUS modal-frequency separation check supported the use of the two-mode reduced-order model for the dominant low-frequency response, while also clarifying its limitation for high-dimensional chaotic modal interactions. The parametric results showed that an increasing excitation amplitude and aerodynamic load promoted frequency broadening and chaotic transitions. The Lyapunov-based indicator rose near γ = 65 under λ* = 100 and near λ* = 328 under γ = 30. Temperature-dependent SMA recovery stress further shifted the transition threshold by modifying the effective stiffness and internal restoring action of the beam. These results provide a reduced-order framework for interpreting nonlinear response transitions in SMAHC actuator beams in thermo-aeroelastic environments. Full article

At particle-level engineering, this study mainly focused on the issues of microstructural heterogeneity and the high oxidation susceptibility of Cu-Al-Ni shape memory alloys (SMAs) suitable for high-temperature actuation. Initial powders of Cu (82–83 wt.%) and Al (14–15 wt.%) were first milled mechanically and the Cu-Al particles were modified using an electroless Nickel (Ni) coating process to achieve a controlled Ni enrichment of 4–5 wt.%. The SEM-EDS, XRD, and TGA findings reveal that the cryogenic milling effectively reforms dendritic Cu and spherical Al particles into a refined composite structure. This process resulted in particle size reduction from 40–70 µm to 5–20 µm, and apparent density values increased from 3.45 g·cm⁻³ to 4.10 g·cm⁻³. Microstructural investigations showed that the continuous Ni layer, without generating unwanted intermetallic phases, was obtained with the help of an electroless coating process. In addition, it was confirmed that the crystallite size decreased from 52.10 nm to 41.71 nm. Additionally, the oxidation of nickel-coated and cryogenically milled powders occurred at temperatures above 350 °C owing to the formation of a protective surface layer. In other words, these powders exhibited higher thermal stability. Consequently, this dual processing procedure represents a very useful method for changing particle shape and interfacial composition. These combined methods can help to create a powder structure with a composition optimum for the making of high-performance Cu-Al-Ni SMAs. Full article

Iron-based shape memory alloy (Fe-SMA) fibers can enhance cementitious composites through both crack bridging and thermally activated recovery stresses. Since fiber pull-out governs load transfer at the micro scale, understanding the combined effects of fiber geometry, inclination, and thermal treatment is essential. This study experimentally investigated the pull-out behavior of hooked-end Fe-SMA fibers embedded in high-performance concrete (HPC). A total of 54 ASTM C307-type briquette specimens were tested using single-hook (3D) and double-hook (4D) fibers at inclination angles of 60°, 75°, and 90° under ambient, 100 °C, and 200 °C conditions. Additional flexural, compressive, and direct tensile tests were conducted on plain HPC exposed to the same thermal regime. At ambient temperature, 4D fibers showed 50–70% higher peak pull-out forces than 3D fibers. Heating to 100 °C further increased pull-out resistance by about 6–17%, and the 4D-60-100 configuration achieved the highest performance. In contrast, exposure to 200 °C reduced pull-out resistance by about 5–12% below ambient values. Overall, a 60° inclination generally provided a better response, while 90° produced the lowest. The results confirm that moderate thermal activation combined with double-hook geometry is the most effective strategy for maximizing Fe-SMA fiber–matrix load transfer in HPC. Full article

Shape memory alloys (SMAs) are materials that, when used as actuators, can generate deformation and force that can be used to perform mechanical work. This actuation capability is driven by temperature variation, which induces a reversible phase transformation between martensite (at low temperature) and austenite (at high temperature). Owing to their advantages, SMAs are widely applied as actuators and, in certain applications, can be more suitable than other actuation technologies. A thorough understanding of SMA actuator characteristics is therefore essential for their effective implementation in practical applications. This article provides an overview of the most important properties of SMA actuators. In addition, it reviews the application potential of SMA actuators in robotics. Based on the survey of the literature, perspectives for further research and development in this field are also presented. Full article

Iron-based shape memory alloys (Fe-SMAs) are promising for structural retrofitting because of their low cost, corrosion resistance, and manufacturability. However, the effect of strain rate on the coupled thermo-microstructural evolution during cyclic training remains underexplored. In this study, samples underwent cyclic tensile training at quasi-static and impact strain rates. After each cycle, DSC was adopted to obtain transformation temperatures and enthalpies, and selected cycles were characterized by EBSD (KAM and IPF) to quantify phase fractions and variant statistics. Results show tensile loading shifts transformation temperatures, with the principal difference between regimes appearing in the evolution of martensite finish temperature. Under impact loading, the transformation enthalpy increases more rapidly (0.18 to 0.8 J/g in absolute value), and the driving force decreases more markedly by the fourth cycle (−0.0578 to −0.1117 J/g), indicating faster thermodynamic changes at high strain rates. Internal stress and dislocation storage accumulate faster under impact, lowering the effective stress (−17.01 MPa) for transformation and promoting martensite nucleation/growth. EBSD reveals increasing lattice distortion; in impact-trained samples, single-variant martensite and higher stored energy reduce interface resistance and enable elastic energy release, accelerating transformation and improving shape recovery. Full article

Nickel–titanium (NiTi) shape memory alloys offer transformative functionality for biomedical and aerospace systems, yet their adoption in additive manufacturing (AM) remains constrained by powder reactivity, compositional sensitivity, and the high energy of feedstock production. This work establishes a unified, data-driven evaluation of how powder-state evolution during reuse and ultrasonic plasma atomization (UPA) affects both functional behavior and environmental performance. Virgin, reused, and UPA-recycled NiTi powders were systematically characterized based on particle-size distribution (PSD), SEM morphology, sphericity, oxygen content (ONH), and differential scanning calorimetry (DSC), and these results were coupled with a process-level life-cycle assessment (LCA) spanning cradle-to-gate feedstock generation. Reused powder showed finer but broadened PSD, surface oxidation, and elevated transformation temperatures; these degradation mechanisms limited its reuse despite reducing energy demand by ~30% relative to virgin powder. UPA provided a more effective regeneration pathway: UPA-recycled NiTi recovered high sphericity and smooth particle surfaces while lowering cradle-to-gate energy from 100 ± 10 to 50 ± 5 MJ·kg⁻¹ (≈50%) and reducing CO₂-equivalent emissions by ≈45%, with ~95% material recovery. Although the UPA condition exhibited a higher oxygen content in this study due to system-level atmosphere limitations, prior work indicates that optimized inert-gas control can suppress oxidation, suggesting clear avenues for improvement. Sustainability Index analysis confirmed UPA as the most favorable route, integrating reductions in energy demand and emissions with recovery of powder morphology and reconditioning of thermal transformation behavior. More broadly, the ability of UPA to promote compositional and microstructural redistribution highlights its potential to deliberately re-tune or “reprogram” transformation temperatures for application-specific requirements when alloying and processing atmospheres are carefully managed. Full article

Shape Memory Alloy (SMA) actuators offer strong potential for compact, lightweight, silent, and compliant robotic grippers; however, their practical deployment is limited by the challenge of controlling nonlinear and hysteretic thermal dynamics. This paper presents a complete Sim-to-Real control framework for precise temperature regulation of a tendon-driven SMA gripper using Deep Reinforcement Learning (DRL). A novel 12-action discrete control space is introduced, comprising 11 heating levels (0–100% PWM) and one active cooling action, enabling effective management of thermal inertia and environmental disturbances. The DRL agent is trained entirely in a calibrated thermo-mechanical simulation and deployed directly on physical hardware without real-world fine-tuning. Experimental results demonstrate accurate temperature tracking over a wide operating range (35–70 °C), achieving a mean steady-state error of approximately 0.26 °C below 50 °C and 0.41 °C at higher temperatures. Non-contact thermal imaging further confirms spatial temperature uniformity and the reliability of thermistor-based feedback. Finally, grasping experiments validate the practical effectiveness of the proposed controller, enabling reliable manipulation of delicate objects without crushing or slippage. These results demonstrate that the proposed DRL-based Sim-to-Real framework provides a robust and practical solution for high-precision SMA temperature control in soft robotic systems. Full article

This study presents a small-scale hip exoskeleton incorporating bi-directional artificial muscles constructed with springs of Shape Memory Alloy (SMA). The prototype can effectively support hip motion in both extension and flexion, spanning an angular range of $-{20}^{°}$ to ${200}^{°}$. Experiments for thermo-mechanical characterization were executed to assess the performance of the SMA muscles throughout the entire motion range. The outcomes not only confirmed the suitability of the SMA muscles for the designed exoskeleton but also provided valuable insights into their behavior and capabilities. System identification experiments were carried out to establish an accurate transfer function, guiding the tuning of Proportional-Integral-Derivative (PID) controllers for enhanced motion-control effectiveness. The safety of the SMA system was addressed with a focus on preventing overheating. Challenges in accurately measuring the temperature of a thin spring were overcome by utilizing two thermocouples for each SMA springs group. Additionally, conventional SMA temperature measurement methods, such as infrared and resistance-based techniques, are limited by high cost, nonlinearity, and small range. This study presents a model-based temperature estimation algorithm that integrates a heat transfer model, electrical input data, and thermocouple data to enable accurate and real-time SMA temperature estimation without additional sensors, offering a cost-effective and reliable alternative. To evaluate the small hip prototype and its controller capabilities, control experiments were executed for both stepping and sinusoidal trajectories. The exoskeleton successfully tracked the desired trajectories, showing its precision. Moreover, system performance under adaptive control was further investigated, revealing an RMSE of $0.{94}^{°}$ in sinusoidal trajectory experiments, indicating reliable disturbance rejection in the angle measurements. Full article

The crystal structure, texture, martensitic transformation, and magnetic properties of magnetic shape-memory Heusler alloys of Ni_51−xMn_33.4In_15.6V_x (x = 0; 0.1; 0.3; 0.5; 1) were investigated. Experimental studies of the magnetic properties and meta-magnetostructural transition (martensitic transition—MT) confirm the main sensitivity of the martensitic transition temperature to vanadium doping and to an applied magnetic field. This makes this family of shape-memory alloys promising for use in numerous applications, such as magnetocaloric cooling and MEMS technology. Diffuse electron scattering was analyzed, and the structures of the austenite and martensite were determined, including the use of TEM in situ experiments during heating and cooling for an alloy with a 0.3 at.% concentration of V. In the austenitic state, the alloys are characterized by a high-temperature-ordered phase of the L2₁ type. The images show nanodomain structures in the form of tweed contrast and contrast from antiphase domains and antiphase boundaries. The alloy microstructure in the temperature range from the martensitic finish to 113 K consists of a six-layer modulated martensite, with 10 M and 14 M modulation observed in local zones. The morphology of the double structure of the modulated martensite structure inherits the morphology of the nanodomain structure in the parent phase. This suggests that it is possible to control the structure of the high-temperature austenite phase and the temperature of the martensitic transition by alloying and/or rapidly quenching from the high-temperature phase. In addition, attention is paid to maintaining fine interface structures. High-resolution transmission electron microscopy showed good coherence along the austenite–martensite boundary. Full article

This study investigates the influence of electrical actuation parameters on the performance of a morphing composite aerodynamic profile actuated by Shape Memory Alloy (SMA) wires. A fully coupled electro-thermo-mechanical finite element model has been developed to simulate the transient response of NiTi SMA, capturing the nonlinear interplay between temperature evolution, phase transformation, and mechanical deformation under Joule heating. The model incorporates phase-dependent material properties, heat effects, and geometric constraints, enabling accurate prediction of actuation dynamics. To validate the model, a morphing spoiler prototype has been fabricated using high-performance additive manufacturing with a carbon fibre-reinforced polymer. The SMA wires have been pretensioned and electrically actuated at different current levels (3 A and 6 A), and the resulting deformation has been recorded through video analysis with embedded timers. Experimental measurements confirmed the model’s ability to predict both actuation time and displacement, with maximum deflections of 33 mm and 40 mm corresponding to different current inputs. This integrated approach demonstrates an efficient and compact solution for active aerodynamic surfaces without the need for mechanical linkages, enabling future developments in adaptive structures for automotive and aerospace applications. Full article

This study presents a phenomenological model for predicting the thermomechanical behaviour of spring-type actuators made of shape memory alloys (SMAs). The model incorporates the kinetics of martensite–austenite phase transitions as a function of temperature and applied stress. The primary innovation is the inclusion of a scalar internal variable that represents the evolution of the phase transformation within a phenomenological macroscopic model. This approach enables the deformation–force–temperature behaviour of SMA-based spring elements under cyclic loading to be accurately described. A set of constitutive equations was derived to describe reversible and residual strains, along with transformation start and finish conditions. Model parameters were calibrated using experimental data from VSP-1 and TN-1K SMA springs that were subjected to thermal cycling. The validation results show a high correlation between the theoretical predictions and the experimental data, with deviation margins of less than 6.5%. The model was then applied to designing and analysing thermosensitive actuator mechanisms for temperature control systems. This yielded accurate deformation–force characteristics, demonstrating low inertia and high repeatability. This approach enables the efficient prediction and improvement of the performance of SMA-based spring elements in actuators, making it relevant for adaptive systems in marine and aerospace applications. Full article

Due to their high energy density and favorable load-to-weight ratio, shape-memory alloy (SMA) materials are ideal actuation sources for soft robots. However, the relatively long cooling time of SMA wires in soft bodies limits their response speed. In this study, we designed and fabricated a novel SMA artificial muscle. When active heat absorption was enabled through thermoelectric modules and the evaporation/dehydration effects of hydrogels, the cooling rate of the SMA wires increased significantly. Simulation and experimental results demonstrate that with the proposed heat-dissipation scheme, the cooling speed of the SMA wires improved notably, with a temperature drop of 9.6 °C within 4 s. Additionally, the designed agar/polyacrylamide hydrogel, which has a porous skeleton structure, achieved a water-absorption expansion rate that was 600% of the previous value. When a PVC elastic substrate was used, the bending angle of the SMA artificial muscle reached 71°, with minimal bending attenuation after 45 consecutive cyclic tests. A soft gripper composed of the novel SMA artificial muscles was capable of manipulating objects of various shapes. Overall, the combination of active and passive heat-dissipation strategies enabled the SMA artificial muscle to achieve excellent durability, rapid heat dissipation, and strong versatility, demonstrating its significant potential for various applications. Full article