Search Results (16)

Conventional formwork systems are limited in their ability to efficiently realize complex and free-form concrete geometries, while additive manufacturing (AM)-based formwork faces constraints in casting-stage structural stability and cost-effectiveness, particularly at construction scale. To address these limitations, a hybrid formwork system integrating a structural steel frame with 3D-printed modules is proposed, in which the steel frame resists casting-induced lateral pressure while the printed components define complex mold geometries. The system was fabricated and validated through a full-scale case study structure measuring 3.0 m × 1.7 m × 2.2 m, produced using a large-scale fused deposition modeling (FDM) process with carbon-fiber-reinforced ABS (ABS-CF20). Geometric accuracy was evaluated by comparing design dimensions with as-built measurements across planar, edge, curved, and inclined regions. Construction efficiency and cost performance were assessed through process-based and cost-based comparisons with conventional steel formwork and fully 3D-printed formwork alternatives. The constructed structure reproduced the intended geometry with an average deviation of approximately 3.2 mm and a maximum deviation within ±4 mm, and no notable formwork deformation or damage was observed during concrete casting. Relative to conventional steel formwork, the hybrid system reduced total fabrication duration by about 50% and fabrication cost by about 60% based on a normalized cost index, while also outperforming fully 3D-printed formwork in cost efficiency by about 45%. The modular configuration and bolted connection system further improved transportability, on-site assembly efficiency, and component reusability. These findings demonstrate that the proposed hybrid formwork system provides a practical and resource-efficient pathway for fabricating complex concrete structures, supporting the broader adoption of digital fabrication in sustainable construction practice. Full article

Reducing material usage in plastic products is a key lever for improving resource efficiency and minimizing environmental impact. In thin-walled structures subjected to mechanical loading, material efficiency must be achieved without compromising structural performance. In particular, resistance to buckling, a critical failure mode, must be taken into account during product development. Due to the large number of design and process variables, many of which are interdependent, optimization approaches are uncommon in the blow-molded packaging industry. This paper presents a sensitivity-based optimization approach to improve buckling resistance by modifying the product’s material distribution. Since the sensitivity is nonlinear and depends on the product’s deformation state, various methods are developed and tested to reduce the frame-wise sensitivity data to a single sensitivity vector suitable for optimization. These methods are then tested on common extrusion blow-molded products, achieving improvements in buckling load of up to 60%. This approach is transferable to other thin-walled structures across various engineering domains, offering a pathway toward lightweight yet load-compliant designs. Full article

The curing distortion is a critical determinant of the quality of integrally manufactured composite structures, playing a pivotal role in the design and fabrication of composite. This paper presents two simplified methods in predicting the curing distortion for large-scale composite aircraft structures manufactured through the autoclave process. Firstly, the refined finite element models of the two simplified methods were developed. Then, it was utilized to predict the curing distortion of Ω-shaped composite laminates. The comparative study between the experimental data and numerical results shows that the proposed second simplified method balanced the prediction accuracy and efficiency, which is urgently needed in practice. Finally, using the second simplified method, predictions were conducted for the curing distortion of practical large-scale composite skin structures. The results were in good agreement with the corresponding experiments. This study provides a new solution for the rapid iterative design of large-scale composite structures, as well as the efficient design of frame molds for their manufacturing. Full article

During the process of forming carbon fiber reinforced plastics (CFRP) in an autoclave, deeply understanding the global sensitivity of factors influencing mold surface temperature is of paramount importance for optimizing large frame-type mold thermally and enhancing curing quality. In this study, the convective heat transfer coefficient (CHTC), the thickness of composite laminates (TCL), the thickness of mold facesheet (TMF), the mold material type (MMT), and the thickness of the auxiliary materials layer (TAL) have been quantitatively assessed for the effects on the mold surface temperature. This assessment was conducted by building the thermal–chemical curing model of composite laminates and utilizing the Sobol global sensitivity analysis (GSA) method. Additionally, the interactions among these factors were investigated to gain a comprehensive understanding of their combined effects. The results show that the sensitivity order of these factors is as follows: CHTC > MMT > TMF > TCL > TAL. Moreover, CHTC, MMT, and TMF are the main factors influencing mold surface temperature, as the sum of their first-order sensitivity indices accounts for over 97.3%. The influence of a single factor is more significant than that of the interaction between factors since the sum of the first-order sensitivity indices of the factors is more than 78.1%. This study will support the development of science-based guidelines for the thermal design of molds and associated heating equipment design. Full article

Automated fiber placement (AFP) is a method to manufacture complex composite parts in an automatable and scalable process. Thermoplastic in situ AFP has received more attention in recent years for its use in high-performance, aerospace applications that use low-melting polyaryletherketone (LM-PAEK) composites. Although in situ AFP is a promising technology for the automated and economical manufacturing of composites, the production of a mold is still a considerable expense. Using large-scale additive manufacturing, molds can be manufactured in a short time frame for a fraction of the cost of traditional molds. By using polyamide 6 (PA6), a polymer incompatible with LM-PAEK, a bond can be created, which holds a laminate in the desired form during production and allows for demolding. Due to the thermoplastic nature of PA6, a mold can be manufactured using large-scale, extrusion-based additive manufacturing. This study investigates the suitability of 3D-printed molds composed of PA6 for the AFP of CF/LM-PAEK laminates. To this end, peel tests and shear tests were conducted to investigate the influence of the process temperature, the area of heating and the consolidation pressure on the bond of these incompatible polymers. A shear strength of up to 2.83 MPa and a peel strength of up to 0.173 N·mm⁻¹ were achievable. The principal suitability of PA6 as a mold material for the AFP of CF/LM-PAEK was demonstrated. Full article

Fiber reinforcement orientation in thermoplastic injection-molded components is both a strength as well as a weak point of this largely employed manufacturing process. Optimizing the fiber orientation distribution (FOD) considering the shape of the part and the applied loading conditions allows for enhancing the mechanical performances of the produced parts. Henceforth, this research proposes an algorithm to identify the best injection gate (IG) location/s starting from a 3D model and a user-defined load case. The procedure is composed of a first Visual Basic Architecture (VBA) code that automatically sets and runs Finite Volume Method (FVM) simulations to find the correlation between the fiber orientation tensor (FOT) and the IG locations considering single and multiple gates combinations up to three points. A second VBA code elaborates the results and builds a dataset considering the user-defined loading and constraint conditions, allowing the assignment of a score to each IG solution. Three geometrical components of increasing complexity were considered for a total of 1080 FVM simulations and a total computational time of ~390 h. The search for the best IG location has been further expanded by training a Machine Learning (ML) model based on the Gradient Boosting (GB) algorithm. The training database (DB) is based on FVM simulations and was expanded until a satisfactory prediction accuracy higher than 90% was achieved. The enhancement of the local FOD on the critical regions of three components was verified and showed an average improvement of 26.9% in the stiffness granted by a high directionality of the fibers along the load path. Finite element method (FEM) simulations and laboratory experiments on an industrial pump housing, injection-molded with a polyamide-66 reinforced with 30% of short glass fibers (PA66-30GF) material were also carried out to validate the FVM-FEM simulation frame and showed a 16.4% local stiffness improvement in comparison to the currently employed IG solution. Full article

Due to factors such as casting, mold making, and construction errors, the actual size of the bridge structure will inevitably deviate from the designed size and dimension, and the amount of deviation between the two volumes is generally random and the location of the deviation is not fixed. However, this phenomenon that occurs in the actual practice has not been paid enough attention within existing studies. From a theoretical point of view, the apparent size of concrete will directly affect the cross-sectional stiffness, especially for statically indeterminate structures. This effect will be further reflected in the internal force and stress distribution of the structure. In addition, the variation of the poured volume of the bridge superstructure can also influence the dead-load effect of the bridge structure. Therefore, the influence of pouring concrete volume deviation (PCVD) on the cross-sectional stiffness of large-span continuous reinforced concrete rigid-frame (CRCR) bridges was first stressed and investigated in this paper. Field data of PCVD were monitored by measuring demolished sections with tools that ensure accuracy, and a sensitivity analysis was conducted to analyze the effect of PCVD on the cross-sectional stiffness at different locations. Statistical analysis of the measured data concluded that PCVD has a significant influence on the internal-force distribution and structural stiffness of the bridge, up to 30%. Finally, a theoretical method that considers the influence of PCVD was proposed based on the field monitoring data and the statistical analysis results. Full article

The term “Western Message Petroglyphs” (WMPs) refers to a number of petroglyph sites found scattered among eight western states that are recognized by their shared image content and layout. The imagery is drawn largely from a mash-up of late historic Native American sign-gesture language and picture-writing traditions inter-mixed with pan-cultural imagery from around the world. An increasing number of sites that fit this mold have been reported over the past 85 years or so, currently numbering 39 in all. There is no question that these sites date to post-European contact based on images in some panels that depict Euro-American cultural content (e.g., western-style house, rifle, whiskey keg, horse, etc.). The post-contact era is also apparent in the method used in rendering the engraved images evidenced by the smooth angular lines and chisel strikes produced by metal tools. This paper focuses on narrowing the time frame for these sites based on two additional streams of evidence. First, patterned associations with historic landscape settings tied to the era of western expansion bind the sites together into a coherent whole and set a floor for their oldest probable dates. An example of four sites located in Utah and Arizona illustrates their connection to the last quarter of the nineteenth century and the opening years of the twentieth. Secondly, a study of their imagery supports the proposed dates by revealing a “smoking gun” for the source of many of the individual icons. An example of the methodology used to translate a Western Message Petroglyph panel is described, and a profile of the central author who appears to have acted with a small group of others is suggested in order to aid in the search for this person(s) in the historic record of the American West. Full article

Mold design is one of the important ways to control shrinkage porosity. In this study, four mold forms with different tapers were first designed, the corresponding three-dimensional finite element models were built using the ProCAST software, and the influence of mold design on the filling and solidification processes of Ti-6Al-4V alloy was investigated. The results showed that the titanium alloy ingots exhibit typical characteristics of layer-by-layer solidification, and that the removal of the riser results in: (a) shortening the time it takes for molten metal to reach the bottom of the mold and the time needed to complete mold filling; (b) decreasing the maximum flow velocity and improving the filling stability; and (c) moving the shrinkage cavities up along the central axis of the ingot and decreasing the cavity volume. Meanwhile, it was also found that the shrinkage cavity volume decreases significantly with increasing mold taper, meaning a significant increase in ingot utilization rate. The shrinkage cavity formation mechanism was revealed through macrostructure analysis. During solidification, a grain frame is formed as a large number of equiaxed crystals intersect, thus creating an isolated liquid phase zone. When the liquid in this zone solidifies, the last zone to do so, its volume shrinkage cannot be compensated, thus leading to the formation of a shrinkage cavity. Full article

Cu-Ni-Si alloy is the key raw material for the lead frame of large integrated circuits. The disordered grain orientation of alloy billet, high hardening rate, residual stress, and poor surface quality of cold working strips seriously affect its processability. In order to improve the cold-working properties of Cu-Ni-Si alloy, two kinds of C70250 copper alloy strips were produced through hot mold continuous casting (HMCC) and cold mold continuous casting (CMCC) technology. The effects of solidified microstructure on the cold-working deformation behavior, mechanical properties, and residual stress of the alloy were studied. The results show that C70250 copper alloys with columnar grain and equiaxed grain were prepared through HMCC and CMCC. After a 98% reduction in cold rolling, columnar grain strip surface quality was very good, and the elongation was still as high as 3.2%, which is 2.9 times that of equiaxed grain alloy. The residual stress of equiaxed grain strips reached 363 MPa, which is 2.7 times that of columnar grain strips. During the cold rolling process, equiaxed grain strips are prone to cause intersecting plane dislocations, stacking faults, shear bands, and grain breakage during large deformation cold rolling. The columnar grain strip causes parallel plane dislocations, stacking faults, and shearbands. Furthermore, the deformation structure was found to be uniform, and, ultimately, the alloy formed a fibrous structure. Therefore, the elongation and latter distortion of columnar grain strips improved after being put through large deformation cold rolling, which greatly reduced residual stress. Full article

Plastic injection molding has become one of the most widely used polymer processing methods due to its ability to viably produce large volumes of complex parts in a short time frame. Most of the plastic injection molding machines currently used in industry possess a toggle clamping mechanism that undergoes a repeated clamping and unclamping cycle during operation. This toggle must therefore be properly lubricated to avoid catastrophic failure and eventual machine downtime. To overcome this limitation, the industry currently relies on the experience of a skilled operator, paired with a fixed empirical value, to determine the timing for re-lubrication. This method often leads to the machine operator either wasting lubricant by over-lubricating the toggle, or damaging the toggle by failing to re-lubricate when needed. Herein, we explore the use of vibration analysis to perform real-time condition monitoring of the lubrication condition of the toggle clamping system. In this study, our novel structural response analysis out performed both traditional time domain and frequency domain analyses in isolating the vibrational signatures indicative of lubricant degradation. Additionally, this study confirms that the vibration generated during the unclamping period of the toggle, proved to contain more valuable information relevant to the instantaneous lubricant quality than provided by its corresponding clamping period. Full article

Framing the Circular Bioeconomy, the use of reactive compatibilizers was applied in order to increase the interfacial adhesion and, hence, the physical properties and applications of green composites based on biopolymers and food waste derived lignocellulosic fillers. In this study, poly(butylene succinate) grafted with maleic anhydride (PBS-g-MAH) was successfully synthetized by a reactive melt-mixing process using poly(butylene succinate) (PBS) and maleic anhydride (MAH) that was induced with dicumyl peroxide (DCP) as a radical initiator and based on the formation of macroradicals derived from the hydrogen abstraction of the biopolymer backbone. Then, PBS-g-MAH was used as reactive compatibilizer for PBS filled with different contents of pistachio shell flour (PSF) during melt extrusion. As confirmed by Fourier transform infrared (FTIR), PBS-g-MAH acted as a bridge between the two composite phases since it was readily soluble in PBS and could successfully form new esters by reaction of its multiple MAH groups with the hydroxyl (–OH) groups present in cellulose or lignin of PSF and the end ones in PBS. The resultant compatibilized green composites were, thereafter, shaped by injection molding into 4-mm thick pieces with a wood-like color. Results showed significant increases in the mechanical and thermomechanical rigidity and hardness, meanwhile variations on the thermal stability were negligible. The enhancement observed was related to the good dispersion and the improved filler-matrix interfacial interactions achieved by PBS-g-MAH and also to the PSF nucleating effect that increased the PBS’s crystallinity. Furthermore, water uptake of the pieces progressively increased as a function of the filler content, whereas the disintegration in controlled compost soil was limited due to their large thickness. Full article

Massive composite components manufactured by autoclave curing in large framed molds are extensively used in the aerospace industry. The high temperature performance of the large framed mold is the key to achieving the desired composite part quality. This paper explores and summarizes the important thermal properties of metal and heat transfer fluid materials influencing the heating performance of large framed molds, with the aim of improving the mold temperature distribution. Considering the fluid–thermal–solid interaction inside the autoclave, a reliable computational fluid dynamics (CFD) simulation model was developed and verified by a temperature monitoring experiment to achieve the prediction of the temperature distribution of the large framed mold. Then, numerical simulations were designed on the basis of the CFD model, and the single-variable method was used to study the effects of the material thermal properties on the temperature performance of large framed molds. Our simulation predicts that when copper is used as the mold material, the temperature difference decreases by 30.63% relative to that for steel, and the heating rate increases by 3.45%. Further, when helium is used as the heat transfer medium, the temperature difference decreases by 68.27% relative to that for air, and the heating rate increases by 32.76%. This paper provides a reference for improvement of large framed mold manufacturing and autoclave process in terms of heating rate and temperature uniformity. Full article

The success of an autoclave process is related to the temperature characteristics of the mold. An inhomogeneous temperature field in the mold affects the quality of composite parts, which may lead to residual stress, voids, and other manufacturing defects of composite parts. In order to meet high-quality production demands, the temperature field in a mold should be investigated precisely. The temperature distribution in a large frame mold is critically evaluated in this work. Then, a method to control the temperature distribution in a large frame mold is proposed. A computational fluid dynamics (CFD) model of the autoclave process is developed to predict the temperature evolution of the large frame mold. The model is validated by experimental results, which shows good agreement with a relative difference of 5.92%. The validated CFD model is then applied to analyze the temperature distribution characters in the mold with different control conditions. The results show that the temperature difference decreases by 13.3% when the mold placement angle is changed from 180 to 168°. Full article

In this work, a polymer microlens array (MLA) for a hyperspectral imaging (HSI) system is produced by means of ultraprecision milling (UP-milling) and injection compression molding. Due to the large number of over 12,000 microlenses on less than 2 cm², the fabrication process is challenging and requires full process control. The study evaluates the process chain and optimizes the single process steps to achieve high quality polymer MLAs. Furthermore, design elements like mounting features are included to facilitate the integration into the final HSI system. The mold insert was produced using ultraprecision milling with a diamond cutting tool. The machining time was optimized to avoid temperature drifts and enable high accuracy. Therefore, single immersions of the diamond tool at a defined angle was used to fabricate each microlens. The MLAs were replicated using injection compression molding. For this process, an injection compression molding tool with moveable frame plate was designed and fabricated. The structured mold insert was used to generate the compression movement, resulting in a homogeneous pressure distribution. The characterization of the MLAs showed high form accuracy of the microlenses and the mounting features. The functionality of the molded optical part could be demonstrated in an HIS system by focusing light spectrums onto a CCD image sensor. Full article