Search Results (36)

Metal Injection Molding (MIM) enables complex orthodontic-bracket geometries but can introduce surface and geometric discontinuities that act as initiation sites for crevice and pitting corrosion. The effect of acidic, kombucha-like exposure on corrosion and repassivation was assessed for MIM-316L brackets relative to a commercial comparator, and the coupling between surface quality (roughness and wettability) and localized damage at scanning electron microscopy (SEM)-identified hot-spots was examined. Kombucha was characterized by pH and titratable acidity. Surfaces were characterized by SEM, areal roughness metrics (R_a, S_a, S_z, and A2), and wettability by sessile-drop goniometry. Electrochemical behavior in artificial saliva was measured using open-circuit potential and cyclic potentiodynamic polarization (ASTM F2129/G59), and a qualitative magnetic check was included as a pragmatic quality-assurance screen. Exposure in kombucha reduced breakdown and repassivation potentials and increased passive current density, with the strongest effects co-localizing geometric discontinuities. Commercial brackets exhibited markedly poorer surface quality (notably higher S_z), amplifying acidity-driven susceptibility. These findings indicate that, under acidic challenges, surface/geometry quality dominates corrosion behavior; non-magnetic-phase compliance and simple chairside screening (e.g., magnet test), alongside tighter manufacturing controls on roughness and edge finish, should be incorporated into clinical and industrial quality assurance (QA). Full article

This paper presents the design of a permanent-magnet-assisted synchronous reluctance motor (PMa-SynRM) for compressor applications using Sm-series injection-molded magnets that eliminate heavy rare-earth elements. The high shape flexibility of the injection-molded magnets enables the formation of a curved multi-layer flux-barrier rotor geometry based on the Joukowski airfoil potential, optimizing magnetic flux flow under typical compressor operating conditions. Furthermore, electromagnetic performance, irreversible demagnetization behavior, and rotor stress sensitivity were analyzed with respect to key design variables to derive a model that satisfies the target performance requirements. The validity of the proposed design was confirmed through finite element method (FEM) comparisons with a conventional IPMSM using sintered NdFeB magnets, demonstrating the feasibility of HRE-free PMa-SynRM for high-performance compressor drives. Full article

This study investigates the sustainable production of NdFeB permanent magnets using powder extrusion molding (PEM) with in situ magnetic alignment, utilizing recycled powder from an end-of-life (Eol) wind turbine magnet obtained via hydrogen processing of magnetic scrap (HPMS). Finite Element Method (FEM) simulations were conducted to design and optimize alignment tool geometries and magnetic field parameters. A key challenge in the PEM process is achieving effective particle alignment while the continuous strand moves through the magnetic field during extrusion. To address this, extrusion experiments were performed using three different alignment tool geometries and varying magnetic field strengths to determine the optimal configuration for particle alignment. The experimental results demonstrate a high degree of alignment (B_r/J_s = 0.95), exceeding the values obtained with PEM without an external magnetic field (0.78). The study confirms that optimizing the alignment tool geometry and applying sufficiently strong magnetic fields during extrusion enable the production of anisotropic NdFeB permanent magnets without post-machining, providing a scalable route for permanent magnet recycling and manufacturing. Moreover, PEM with in situ magnetic particle alignment allows for the continuous fabrication of near-net-shape strands with customizable cross-sections, making it a scalable approach for permanent magnet recycling and industrial manufacturing. Full article

In this paper, we report a novel thermally conductive semi-aromatic heat-resistant PA5T-CO-10T/hexagonal boron nitride (PA5T-CO-10T/BN) composite, based on as-synthesized PA5T-CO-10T, which is a copolymer of poly (pentamethylene terephthalamide) (PA5T) and poly (decamethylene terephthalamide) (PA10T). We confirmed the structure of PA5T-CO-10T through a nuclear magnetic resonance carbon spectrometer (¹³C-NMR). The differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) results indicate that PA5T-CO-10T demonstrates a processing window (greater than 90 °C) which is suitable for melt processing and injection molding. Moreover, the PA5T-CO-10T composites with different BN contents were tested by scanning electron microscopy (SEM), a thermal conductivity meter, a rotational rheometer and X-ray diffraction (XRD). The results indicate that as the content of h-BN increases, the thermal conductivity of the PA5T-CO-10T/BN composites is significantly enhanced. When the mass of h-BN reaches 30 wt%, the thermal conductivity of the composite material is 2.5 times that of the original matrix resin. Simultaneously, there is a notable upward trend observed in the storage modulus, loss modulus, complex viscosity and orientation degree of h-BN. This is attributed to the high thermal conductivity and the high orientation degree of h-BN, which ensure the continuous enhancement of the material’s thermal conductivity. Additionally, the introduction of h-BN enhances the degree of connection between the material’s molecular chains. PA5T-CO-10T/BN possesses excellent heat resistance and thermal conductivity, presenting significant application prospects in the fields of electronics, electrical appliances and automobiles. Full article

Background: Melt-based 3D printing technologies are currently extensively evaluated for research purposes as well as for industrial applications. Classical approaches often require intermediates, which can pose a risk to stability and add additional complexity to the process. The Advanced Melt Drop Deposition (AMDD) technology, is a 3D printing process that combines the principles of melt extrusion with pressure-driven ejection, similar to injection molding. This method offers several advantages over traditional melt-based 3D printing techniques, making it particularly suitable for pharmaceutical applications. Objectives: This study evaluates the AMDD printing system for producing solid oral dosage forms, with a primary focus on the thermo-stable polymer polyvinyl alcohol (PVA). The suitability of AMDD technology for creating amorphous solid dispersions (ASDs) is also examined. Finally, the study aims to define the material requirements and limitations of the raw materials used in the process. Methods: The active pharmaceutical ingredients (APIs) indometacin and ketoconazole were used, with PVA 4-88 serving as the carrier polymer. Powders, wet granulates, and pellets were investigated as raw materials and characterized. Dissolution testing and content analyses were performed on the printed dosage forms. Solid-state characterization was conducted using differential scanning calorimetry (DSC) and X-ray diffraction (XRD). Degradation due to thermal and mechanical stress was analyzed using nuclear magnetic resonance spectroscopy (NMR). Results/Conclusions: The results demonstrate that the AMDD 3D printing process is well-suited for producing solid dosage forms. Tablets were successfully printed, meeting mass uniformity standards. Adjusting the infill volume from 30% to 100% effectively controlled the drug release rate of the tablets. Solid-state analysis revealed that the AMDD process can produce amorphous solid dispersions with enhanced solubility compared to their crystalline form. The experiments also demonstrated that powders with a particle size of approximately 200 µm can be directly processed using AMDD technology. Full article

Magnetorheological elastomers (MREs) are in demand in the field of high-tech microindustries and nanoindustries such as biomedical applications and soft robotics due to their exquisite magneto-sensitive response. Among various MRE applications, programmable actuators are emerging as promising soft robots because of their combined advantages of excellent flexibility and precise controllability in a magnetic system. Here, we present the development of magnetically programmable soft magnetic microarray actuators through field-induced injection molding using MREs, which consist of styrene-ethylene/butylene styrene (SEBS) elastomer and carbonyl iron powder (CIP). The ratio of the CIP/SEBS matrix was designed to maximize the CIP fraction based on a critical solids loading. Further, as part of the design of the magnetization distribution in micropillar arrays, the magnetorheological response of the molten composites was analyzed using the static and dynamic viscosity results for both the on and off magnetic states, which reflected the particle dipole interaction and subsequent particle alignment during the field-induced injection molding process. To develop a high-aspect-ratio soft magnetic microarray, X-ray lithography was applied to prepare the sacrificial molds with a height-to-width ratio of 10. The alignment of the CIP was designed to achieve a parallel magnetic direction along the micropillar columns, and consequently, the micropillar arrays successfully achieved the uniform and large bending actuation of up to approximately 81° with an applied magnetic field. This study suggests that the injection molding process offers a promising manufacturing approach to build a programmable soft magnetic microarray actuator. Full article

With the rapid development of wireless communication technologies and the miniaturization trend in the electronics industry, the reduction of electromagnetic interference has become an important issue. To solve this problem, a lot of attention has been focused on polymer composites with combined functional fillers. In this paper, we report a method for creating an acrylonitrile butadiene styrene (ABS) plastic composite with a low amount of conductive carbon and magnetic fillers preparation. Also, we investigate the mechanical, thermophysical, and electrodynamic characteristics of the resulting composites. Increasing the combined filler amount in the ABS composite from 1 to 5 wt % leads to a composite conductivity growth of almost 50 times. It is necessary to underline the temperature decrease of 5 wt % mass loss and, accordingly, the composite heat resistance reduction with an increase in the combined filler from 1 to 5 wt %, while the thermal conductivity remains almost constant. It was established that electrodynamic and physical–mechanical characteristics depend on the agglomeration of fillers. This work is expected to reveal the potential of combining commercially available fillers to construct effective materials with good electromagnetic interference (EMI) protection using mass production methods (extrusion and injection molding). Full article

The applications of Nd-Fe-B-based magnets are experiencing significant diversification to achieve efficiency and miniaturization in different technologies. Metal injection molding (MIM) provides new opportunities to manufacture Nd-Fe-B magnets with high geometrical complexity efficiently. In this study, the impacts of the binder system composition and powder loading on the rheological behavior, contamination, and magnetic properties of the Nd-Fe-B MIM parts were investigated. A high-pressure capillary rheometer was used to measure the apparent viscosity and pressure drops for feedstocks with different binder formulations and powder contents. Also, oxygen and carbon contamination, density, and magnetic properties were measured for different feedstock formulations and powder loadings. From the rheological, density, and magnetic properties points of view, the binder system consisting of 45 vol.% LLDPE as backbone was selected as the optimum formulation. The findings indicated that the sample with this binder system and 55 vol.% powder content had a high density (6.83 g/cm³), remanence (0.591 T), and coercivity (744.6 kA/m) compared to other binder compositions. By using 58 vol.% powder loading, the values of density (7.54 g/cm³), remanence (0.618 T), and carbon residue (982 ppm) improved, and a suitable rheological behavior was still observed. Thus, a suitable feedstock formulation was developed. Full article

Due to their excellent mechanical strength, corrosion resistance, and ease of processing, carbon fiber and carbon-fiber-reinforced plastics are finding wide application in diverse fields, including aerospace, industry, and automobiles. This research explores the feasibility of integrating carbon fiber solutions into the rotors of 85-kilowatt electric vehicle interior permanent magnet synchronous motors. Two novel configurations are proposed: a carbon fiber wire-wound rotor and a carbon fiber injection-molded rotor. A finite element analysis compares the performance of these models against a basic designed rotor, considering factors like no-load back electromotive force, no-load voltage harmonics, cogging torque, load torque, torque ripple, efficiency, and manufacturing cost. Additionally, a comprehensive analysis of system efficiency and energy loss based on hypothetical electric vehicle parameters is presented. Finally, mechanical strength simulations assess the feasibility of the proposed carbon fiber composite rotor designs. Full article

Pedestrian safety is a major concern in urban areas, and crosswalks are one of the most critical locations where accidents can occur. This research introduces an intelligent crosswalk, employing sensor fusion and machine learning techniques to distinguish the presence of pedestrians and drivers. Upon detecting a pedestrian, the system proactively activates a warning light signal. This approach aims to quickly alert nearby people and mitigate potential dangers, thereby strengthening pedestrian safety. The system integrates data from radio detection and ranging sensors and a magnetic field sensor, using a hierarchical classifier. The One-Class support vector machine algorithm is used to classify objects in the radio detection and ranging data, while fuzzy logic is used to filter out targets from the magnetic field sensor. Additionally, this work presents a novel method for the manufacture of the road signaling system, using mixtures of resins, aggregates, and reinforcing fibers that are cold-injected into an aluminum mold. The mechanical, optical, and electrical characteristics were subjected to standardized tests, validating its autonomous operation in real-world conditions. The results revealed the system’s effectiveness in detecting pedestrians with a 99.11% accuracy and a 0.0% false-positive rate, marking a substantial improvement over the previous fuzzy logic-based system with an 81.33% accuracy. Attitude testing revealed a significant 33.33% reduction in pedestrian erratic behavior and a substantial decrease in driver speed (32.83% during the day and 70.6% during the night) compared to conventional crossings. Consequently, this comprehensive work offers a unique solution to pedestrian safety at crosswalks by showcasing the potential of machine learning techniques, particularly the One-Class support vector machine algorithm, in advancing road safety through precise and reliable pattern recognition. Full article

In the search for improved permanent magnets, fueled by the geostrategic and environmental issues associated with rare-earth-based magnets, magnetically hard (high anisotropy)-soft (high magnetization) composite magnets hold promise as alternative magnets that could replace modern permanent magnets, such as rare-earth-based and ceramic magnets, in certain applications. However, so far, the magnetic properties reported for hard-soft composites have been underwhelming. Here, an attempt to further understand the correlation between magnetic and microstructural properties in strontium ferrite-based composites, hard SrFe₁₂O₁₉ (SFO) ceramics with different contents of Fe particles as soft phase, both in powder and in dense injection molded magnets, is presented. In addition, the influence of soft phase particle dimension, in the nano- and micron-sized regimes, on these properties is studied. While Fe and SFO are not exchange-coupled in our magnets, a remanence that is higher than expected is measured. In fact, in composite injection molded anisotropic (magnetically oriented) magnets, remanence is improved by 2.4% with respect to a pure ferrite identical magnet. The analysis of the experimental results in combination with micromagnetic simulations allows us to establish that the type of interaction between hard and soft phases is of a dipolar nature, and is responsible for the alignment of a fraction of the soft spins with the magnetization of the hard. The mechanism unraveled in this work has implications for the development of novel hard-soft permanent magnets. Full article

In this paper, the design of novel slotless permanent magnet synchronous motor (PMSM) for a collaborative robot was studied considering the manufacture process of winding. The winding manufacture process of novel slotless PMSM was proposed in three steps. First, the two types of coil units were manufactured based on the winding jig to assemble the coil units. Second, the coil unit was manufactured using the injection molding based on the plastic material such as polyphenylene sulfide (PPS). Third, the units of the coil were assembled to form a stator winding. Considering this manufacture process of winding, the slotless motor design was studied for the collaborative robot. For the design and analysis of slotless motor, finite element analysis (FEA) was performed through ANSYS Maxwell. The electromagnetic performance was analyzed according to the pole-slot combination. Considering the space of the collaborative robot, the basic model was designed. Based on the basic model, the electromagnetic performance was analyzed according to the design parameters such as the thickness of magnet and yoke and turns per slot. Considering the torque and current density, the final model was designed. To verify the FEA results, the slotless motor was manufactured and the experiment and FEA results were compared. Full article

As the key component of a servo motor, the torque and temperature rise of the brake at the operating temperature affect the production quality of injection molding machines and other equipment. To achieve application of the brake and evaluate its performance at a high operating temperature, a high-torque permanent magnet brake with an axial disc structure is proposed. The permanent magnet consists of six small magnets instead of the traditional monolithic ring magnet. The key parameters of the coil are designed, and the magneto-thermal coupling method is established. The magneto-thermal coupling method considers the effect of temperature on material properties and feeds the temperature back to the electromagnetic field to correct the resistance, permeability, remanence and other coefficients. It then updates the heat source of the temperature field. The temperature rise is calculated iteratively between the electromagnetic field and the temperature field. The simulation results of the one-way method and the magneto-thermal coupling method are obtained and compared with the experimental results. The evaluation errors of the magneto-thermal coupling method for temperature and braking torque are 1.9% and 4.7% respectively, which are lower than the errors of the one-way method. Full article

Polymer nanocomposites have attracted global attention as a metal replacement for electrical and electronic applications. Graphene nanoplatelets (GNPs) are widely used as a nanoreinforcement to enhance the functional and structural properties of thermoset and thermoplastic polymers. In the present study, ABS nanocomposites were prepared by reinforcing 3–15 wt.% GNPs in steps of 3 wt.%. The neat ABS and ABS+GNP nanocomposite specimens for the mechanical test were prepared using injection molding, followed by extrusion, as per American Society for Testing and Materials (ASTM) standards. It was found that the modulus of ABS improved due to the reinforcement of GNPs. Additionally, we noticed higher thermal stability of nanocomposites due to the faster heat-conducting path developed in the nanocomposites by the presence of GNPs. However, observed agglomeration of GNPs at higher concentrations and poor wetting with ABS led to the deterioration of the mechanical properties of the nanocomposites. Moreover, 350 µm thick nanocomposite films were manufactured by compression molding, followed by the extrusion method, and we investigated their electrical conductivity, magnetic permeability, permittivity, and electromagnetic-wave-shielding effectiveness. The developed nanocomposites showed improved conductivity and effective electromagnetic wave shielding by absorption. The 15 wt.% GNP-reinforced ABS composite film showed a maximum shielding effectiveness of 30 dB in the X-band. Full article

The manipulation of delicate objects remains a key challenge in the development of industrial robotic grippers. Magnetic force sensing solutions, which provide the required sense of touch, have been demonstrated in previous work. The sensors feature a magnet embedded within a deformable elastomer, which is mounted on top of a magnetometer chip. A key drawback of these sensors lies in the manufacturing process, which relies on the manual assembly of the magnet–elastomer transducer, impacting both the repeatability of measurements across sensors and the potential for a cost-effective solution through mass-manufacturing. In this paper, a magnetic force sensor solution is presented with an optimized manufacturing process that will facilitate mass production. The elastomer–magnet transducer was fabricated using injection molding, and the assembly of the transducer unit, on top of the magnetometer chip, was achieved using semiconductor manufacturing techniques. The sensor enables robust differential 3D force sensing within a compact footprint (5 mm × 4.4 mm × 4.6 mm). The measurement repeatability of these sensors was characterized over multiple samples and 300,000 loading cycles. This paper also showcases how the 3D high-speed sensing capabilities of these sensors can enable slip detection in industrial grippers. Full article