Search Results (137)

Background: Twin-screw wet granulation (TSWG) is a promising continuous manufacturing technology, featuring high operational flexibility, short residence time and consistent quality. The process development of TSWG relies on the synergy of material characterization, screw configuration, and process parameter optimization. Objective: In order to fully combine various design variables, and to accelerate the process development of TSWG, a material–process–equipment integrated design (MPEID) methodology is first applied to the TSWG process of Guizhi Fuling capsule, a botanical drug product. Methods: First, an equivalent formulation was designed to save trial costs. Second, 3D printing technology was used to customize both conveying and kneading elements with the lead, with the kneading discs stagger angle (SA) and the thickness (thick) as screw element variables. The position of fabricated kneading elements was varied to generate different screw configurations. Then, the critical screw parameters (CSPs) and critical process parameters (CPPs) were identified by a two-step design of experiment (DOE) toward optimizing granule quality. Results: As a result, the SA and thick were identified as CSPs, and the liquid-to-solid ratio was the CPP. Under the optimal TSWG process conditions, the twin-screw granulator could be operated under low torque (i.e., average torque = 1.48 ± 0.06 Nm). The dried granules exhibited superior flowability, as well as highly consistent particle size distribution with industrial batches. After capsule filling, the dissolution test results showed the prepared Guizhi Fuling capsules reached 93.7% cumulative dissolution at 15 min, which approached that of commercial capsules (i.e., 93.0%). Conclusions: This study demonstrated the feasibility of proposed MPEID methodology, supporting the efficient and cost-effective process development of TSWG. Full article

Carbon fiber-reinforced polymer (CFRP) composites are in urgent demand in the aerospace, new energy vehicle, and wind power sectors owing to their superior specific strength, specific modulus, and lightweight potential. However, molding defects, such as voids, dry spots, and delamination, arising from their anisotropy and weak interlaminar bonding, severely constrain their service performance. Advanced molding technologies represent the key to overcoming this bottleneck. This paper systematically reviews typical advanced molding technologies in the field of CFRP composites, including resin transfer molding (RTM) and vacuum-assisted resin transfer molding (VARTM) in liquid composite molding, autoclave molding and compression molding (CM) in prepreg molding, and automated fiber placement (AFP) and material extrusion (ME) in automated molding. From an integrated perspective of “technological evolution–process characteristics–defect mechanisms–optimization strategies,” this review summarizes the technical principles, development trajectories, and core advantages of each process, analyzes the formation mechanisms of typical defects, including voids, dry spots, delamination, wrinkles, warpage, and melt instability, and summarizes multidimensional optimization advances in process parameter regulation, numerical simulation, resin modification, equipment upgrading, path planning, and thermal management. Furthermore, the differences and complementarities among these processes in terms of molding precision, efficiency, cost, and applicable scope are compared. Finally, future development directions, including digital twins, green low-carbon manufacturing, ultra-large integrated structures, multi-process integration, standardized defect characterization, and low-cost collaborative design, are discussed. This paper aims to provide systematic theoretical references and technical support for the optimization and upgrading, process integration, and industrial application of advanced CFRP molding technologies. Full article

Shear Thickening Fluid (STF), as a typical intelligent material, offers a novel approach for developing adaptive protective equipment due to its unique “shear thickening” effect. This review examines STF-based composite materials, encompassing both surface coatings (where STF is dispersed in a polymer matrix applied as a layer) and impregnated structures (where STF is integrated into porous fabric or foam substrates via saturation). It elaborates on design principles, preparation methods, mechanical property modulation, and applications in adaptive protectors for knees, elbows, wrists, ankles, and sports equipment. The review emphasizes how composite strategies overcome STF encapsulation and processing challenges, facilitating laboratory-to-market transition. The core mechanisms underlying the “flexible under normal conditions, rigid upon impact” behavior are discussed at molecular and rheological levels. Key limitations—including fluid leakage, long-term aging, and temperature sensitivity—are critically examined alongside future development trends toward multifunctional, intelligent protective systems. Full article

Additive manufacturing (AM), also known as three-dimensional (3D) printing, has emerged as a revolutionary digital near-net-shape manufacturing technology, offering innovative solutions for the design and fabrication of complex, high-performance structures and equipment. This paper reviews the recent advancements and applications of metal AM technologies in the marine sector. Firstly, the principles and characteristics of three most widely adopted metal AM processes in this field are introduced: laser powder bed fusion (L-PBF), directed energy deposition (DED), and wire arc additive manufacturing (WAAM). Subsequently, the application status of metal AM is summarized in four key marine sectors: propulsion systems, underwater vehicle housings and structures, hull structures and shipboard equipment and components, as well as marine equipment repair and emergency support. Building on this, the major challenges for metal AM applications in the marine environment are further discussed, including the fabrication of large-scale components, standardization of materials and processes, integration of smart manufacturing and digital technologies, and sustainability and circular manufacturing. Finally, future trends are projected toward higher efficiency, intelligence, and environmental sustainability. It is indicated that metal AM will fundamentally reshape the manufacturing mode of marine equipment and support its high-performance, low-cost, intelligent and rapid-response development. Full article

Drag-reducing coating technology is a core approach to enhancing the performance of ice and snow sports equipment. By regulating the interfacial characteristics between the equipment surface and the ice or snow medium, it significantly reduces frictional resistance during motion, thereby optimizing athletes’ speed performance and control precision. This paper aims to review the current research status and challenges in this technological field. The review first elaborates on the fundamental principles of applying drag-reducing coatings to key equipment such as skis, sleds, and ice skates, covering current mainstream coating material systems, key preparation processes, and comprehensive performance evaluation methods. Furthermore, integrating multidisciplinary advances in surface engineering, fluid dynamics, and materials science, this review specifically examines how these disciplines can be harnessed to address the unique tribological challenges of snow/ice interfaces. It focuses on cutting-edge research directions such as micro-nano-structured coatings driven by biomimetic design concepts and smart coatings with environmental responsiveness. By synthesizing existing research achievements and potential technological bottlenecks, this paper aims to provide a systematic, theoretical basis and innovative ideas for the future development of a new generation of high-performance, intelligent ice and snow sports equipment. Full article

This study presents the design, simulation, and experimental validation of a novel sector-shaped thread rolling machine aimed at improving forming efficiency, structural compactness, and process controllability compared with conventional linear thread rolling systems. A systematic engineering framework integrating mechanism design, curved-die implementation, motion control, finite-element simulation, and experimental verification is established. DEFORM-3D simulations are performed to investigate the effects of friction coefficient and die spacing on material flow and thread profile formation, and the results are used to guide machine construction and parameter optimization. Experimental results demonstrate that the proposed mechanism can simultaneously form four screws within a single rotation cycle, significantly enhancing production efficiency. Under optimized parameters, the relative errors of pitch diameter and helix angle are maintained within 5%, showing good agreement with simulation predictions. The findings confirm the feasibility, controllability, and stable forming capability of the proposed system, providing a practical and efficient solution for next-generation compact and high-productivity thread rolling equipment. Full article

Additive manufacturing (AM) is a process that creates a three-dimensional (3D) physical object from a digital design by building layers of material directly from a computer-aided design (CAD) file, allowing for precise and rapid production of parts or prototypes. AM is increasingly recognised as a sustainable production method due to its potential to reduce waste, energy consumption, and environmental impact. The versatility and efficiency of AM have made it an essential tool for rapid prototyping and developing custom parts and components with intricate designs that were previously difficult or impossible to produce. This review highlights the significant progress in utilising AM for the synthesis of organic compounds and the fabrication of organic devices. AM technologies are used in the synthesis of organic compounds, particularly through the use of 3D-printed catalysts, reactors and flow systems. Advances in AM have enabled this technology to be used to synthesise organic compounds and produce low-cost, customised organic equipment. This makes it possible to obtain sophisticated reactors, laboratory equipment or their individual parts, tailored to a specific chemical process in more sustainable way. AM has great potential for advancing green and sustainable chemical processes, with the ability to integrate multiple enabling technologies and facilitate safer and more efficient processes in a cost-effective manner. Overall, the integration of AM in organic synthesis has opened up new possibilities for innovative solutions in the field. Full article

This study involves the design of an integrated machine dedicated to the core processes of classifying, shelling, and cleaning to address the critical drawbacks of existing Camellia oleifera fruit processing equipment, including the high manual labor requirement, low operating efficiency, unsatisfactory shelling and cleaning performance, and severe camellia seed damage. The classifying system employed a slat drum structure, and response surface methodology (RSM) was utilized to determine and optimize its operating parameters: spiral blade speed: 20 rpm; drum speed: 10 rpm; and rise angle: 9.6°. The shelling system employed a horizontal flexible structure, and polyurethane was the core material. We determined through single-factor experiments that the shelling drum rotation speed was 200 rpm. For the cleaning system, a composite mode integrating drum screening and friction separation was adopted, and single-factor experiments further determined the optimal operating parameters: cleaning drum rotation speed: 20 rpm; friction conveyor shaft rotation speed: 150 rpm; and cleaning inclination angle: 25°. The performance test verified that the integrated machine achieved outstanding results: the shelling rate reached 97.52%, the camellia seed breakage rate did not exceed 2.42%, the impurity content rate did not exceed 1.99%, the loss rate was less than 3.66%, and the processing capacity reached 2614 kg/h. Full article

The rapid increase in end-of-life lithium-ion batteries demands sustainable recycling routes for lithium recovery. This work presents a novel integrated hydrometallurgical–electrodialysis process designed specifically for recovering lithium from off-specification NMC cathode materials while enabling full reagent recyclability. Selective leaching with oxalic acid was optimised by setting the water-to-oxalic acid dihydrate ratio (H₂O/OA·2H₂O) to 7.3:1 w/w, achieving 81% lithium extraction at room temperature within 2 h while limiting the co-dissolution of Ni, Co and Mn to 0.2%, 1.6% and 1.7% by weight, respectively. The resulting leachate was processed in a four-chamber electrodialysis cell equipped with two Nafion 117 cation-exchange membranes and one Neosepta AMX-fmg anion-exchange membrane operating at −1.6 V versus Ag/AgCl, enabling 96% lithium recovery and 98% oxalic acid recovery. The regenerated oxalic acid stream (41.8 g L⁻¹) was fully restored to its initial concentration and reused in successive cycles without performance loss. Subsequent precipitation of lithium with Na₂CO₃ yielded 99.3%-pure Li₂CO₃. This combined leaching–electrodialysis–precipitation presents a high selectivity, low-waste, circular recovery system, offering a scientifically original approach that integrates reagent regeneration with high-purity lithium production. Full article

This study focuses on the design and control system of a rotating nozzle for 3D construction printers. The development of a rotating nozzle is motivated by the need to enhance control over extrusion direction and material alignment, thereby improving the mechanical performance of printed structures by the use of non-circular nozzles. The typical 3D construction printer is equipped only with a stationary circular nozzle, which prevents the use of a non-circular nozzle due to the printer’s lack of a rotational mechanical system. This, in turn, limits the opportunity to enhance mechanical properties such as tensile and compressive strengths effectively. The proposed design is developed through computer-aided design (CAD) software, and the printer’s configuration is adjusted for integration of the rotational mechanism’s control system. This design includes a full description of the rotational mechanism and integration steps for the 3D printer. Besides the main motor of the 3D printer, an additional motor is installed next to the nozzle and controlled by a new axis (parameter), which is added into the G-code. A new axis, called “U”, is responsible for the rotation of the nozzle itself. For the development of this axis design, the cosine law is applied. The calculation is based on the three consecutive points in the G-code to obtain an accurate degree of rotation for the nozzle. The effectiveness of the system was confirmed by evaluating the compressive strength depending on printhead type. Based on testing results, one trowel printhead had the highest flexural strength of 5 MPa, and a trapezoidal printhead with teeth had the highest compressive strength of 8 MPa, compared to a circular default nozzle head with 6 MPa and 2 MPa for compressive and flexural strengths, respectively. The new optimized nozzle design is implemented in existing 3D printers, which allows it not only to develop its capability in the printing process but also to make sustainable contributions in the 3D construction industry. Full article

This paper presents a robust multistage optimization framework for the integration of composite laminates into the car body shell of a low-floor light rail vehicle (LRV). While structural design in low-floor vehicles is typically complex, this methodology successfully balances both static and dynamic requirements through a sequential optimization process. Developed in strict accordance with reference European standards, the methodology addresses the structural challenges inherent in low-floor architectures, where complex load paths and redistributed equipment masses require targeted reinforcement. The proposed approach sequentially addresses dynamic and static requirements through a structural optimization process. Two distinct 10-ply laminate configurations, one symmetric and one asymmetric, were investigated. The results demonstrate that the multistage optimization successfully converged to a highly mass-efficient solution, achieving a 66% reduction in laminate thickness compared to the baseline design. This significant result was accomplished while maintaining full regulatory compliance; the failure index increased by approximately 22.5% and 23.3% for the two composite laminate configurations, respectively, effectively maximizing material utilization. A key finding of this study is the preservation of structural dynamic integrity; the fundamental natural frequency was maintained at approximately 16 Hz, with a high correlation across the first ten vibration modes, confirming that the global dynamic behaviour remains unaffected. These observations provide critical insights into the synergy between hybridization and structural constraints, suggesting a systematic pathway for designers to achieve an optimal trade-off between manufacturing costs, weight reduction, and performance in advanced urban transit platforms. Full article

Flat soda–lime–silicate glass is the dominant glass type used in contemporary buildings. This paper provides a comprehensive and integrated review of the scientific principles and technological processes that underpin its manufacture, processing, and structural performance. The discussion spans the glass transition and the nature of the glassy state; the network structure of soda–lime–silicate glass, with its inherent lack of long-range order; and its physical and mechanical properties, including fracture. The industrial production of flat soda–lime–silicate glass (melting, float-forming, and annealing) and its subsequent processing (thermal tempering, chemical strengthening, and coating) are described in detail, with emphasis on how they influence residual stresses, surface and edge quality, and structural reliability. Environmental considerations and ongoing advances in energy efficiency and decarbonisation are also examined. By linking the fundamentals of glass science to modern structural design standards, particularly the forthcoming Eurocode 10 for glass structures, the article seeks to equip structural engineers with an informed understanding of glass as a high-performance material for innovative and sustainable design. Full article

As vital components of urban rail transit networks, subway stations are widely scattered across diverse urban districts, whose sustainability performance exerts a notable impact on the overall urban ecological and environmental quality. This study constructs a three-dimensional numerical model to conduct a comparative assessment of the seismic behavior of subway stations adopting different bearing systems at beam-column joints. The seismic responses of two typical structural configurations, a traditional rigid-jointed subway station and another equipped with rubber isolation bearings, are examined under a series of ground motions, with due consideration of amplitude scaling effects and material nonlinearity. A comprehensive evaluation is carried out on key performance parameters, including structural acceleration responses, column rotation angles, damage evolution processes, and internal force distributions. Based on this analysis, the research clarifies the sustainability implications by establishing quantitative correlations between seismic response indices (i.e., deformation extent, damage degree, and internal force magnitudes) and post-earthquake outcomes, such as repair complexity, material requirements, carbon emissions, and socioeconomic effects. The results can advance the integrated theory of seismic-resilient and sustainable design for underground infrastructure, providing evidence-based guidance for the optimization of future subway station construction projects. Full article

The development of photonic-integrated circuits (PICs) for data communication, sensing, and quantum computing is hindered by the high complexity and cost of traditional fabrication methods, which rely on expensive equipment, limiting accessibility for research and prototyping. This study introduces a Direct Laser Writing (DLW) system designed as a low-cost alternative, utilizing an XY platform for precise substrate movement and an optical system comprising a collimator and lens to focus the laser beam. Operating on a single layer, the system employs SU-8 photoresist to fabricate polymer-based structures on substrates such as ITO-covered glass. Preparation involves thorough cleaning, spin coating with photoresist, and pre- and post-baking to ensure material stability. This approach reduces dependence on costly infrastructure, making it suitable for academic settings and enabling rapid prototyping. A user interface and custom slicer process standard .dxf files into executable commands, enhancing operational flexibility. Experimental results demonstrate a resolution of 10 µm, with successful patterning of structures, including diffraction grids, waveguides, and multimode interference devices. This system aims to transform PIC prototype fabrication into a cost-effective, accessible process. Full article

Agricultural materials frequently undergo fragmentation due to high-stress conditions during processing, storage, and transportation. Throughout these processes, the spatial arrangement and morphology of particles continuously evolve, rendering the breakage behaviour of particle groups particularly complex. Thus, an in-depth understanding of the fracture processes and breakage mechanisms within particle beds holds significant research value. This study systematically investigates the breakage behaviour of rice particle groups under confined compression through an integrated methodology combining experimental testing, X-ray CT imaging, and finite element modelling (FEM) based on the cohesive zone model (CZM). Results demonstrate that, at the granular assembly scale, external loads are transmitted through force chains and progressively attenuate. As compression proceeds, stress disseminates toward peripheral particle regions. At the individual particle level, particle breakage results from the intricate interaction between coordination number (CN) and localized contact stress, with tensile stress playing a predominant role in the fracture process. An increase in coordination number promotes a more uniform stress distribution and inhibits breakage, thereby exhibiting a “protective effect”. These findings provide valuable insights for the design and optimization of grain processing equipment, contributing to a deeper comprehension of particle breakage characteristics. Full article