Search Results (162)

Mixed-flow assembly lines are widely employed in industrial manufacturing to handle diverse production tasks. For mixed flow assembly lines that involve mold changes and greater processing difficulties, there are currently two approaches: batch production and production according to order sequence. The first approach struggles to meet the processing constraints of workpieces with higher production difficulty, while the second approach requires the development of suitable scheduling schemes to balance mold changes and continuous processing. Therefore, under the second approach, developing an excellent scheduling scheme is a challenging problem. This study addresses the mixed-flow assembly shop scheduling problem, considering continuous processing and mold-changing constraints, by developing a multi-objective optimization model to minimize additional production time and customer waiting time. As this NP-hard problem poses significant challenges in solution space exploration, the conventional NSGA-II algorithm suffers from limited local search capability. To address this, we propose an enhanced NSGA-II algorithm (RLVNS-NSGA-II) integrating deep reinforcement learning. Our approach combines multiple neighborhood search operators with deep reinforcement learning, which dynamically utilizes population diversity and objective function data to guide and strengthen local search. Simulation experiments confirm that the proposed algorithm surpasses existing methods in local search performance. Compared to VNS-NSGA-II and SVNS-NSGA-II, the RLVNS-NSGA-II algorithm achieved hypervolume improvements ranging from 19.72% to 42.88% and 12.63% to 31.19%, respectively. Full article

Acoustic tweezers, as advanced micro/nano manipulation tools, play a pivotal role in biomedical engineering, microfluidics, and precision manufacturing. However, piezoelectric-based acoustic tweezers face performance limitations due to multi-physical coupling effects during microfabrication. This study proposes a novel approach using injection molding with embedded electronics (IMEs) technology to fabricate piezoelectric micro-ultrasonic transducers with micron-scale precision, addressing the critical issue of acoustic node displacement caused by thermal–mechanical coupling in injection molding—a problem that impairs wave transmission efficiency and operational stability. To optimize the IME process parameters, a hybrid multi-objective optimization framework integrating NSGA-II and MOPSO is developed, aiming to simultaneously minimize acoustic node displacement, volumetric shrinkage, and residual stress distribution. Key process variables—packing pressure (80–120 MPa), melt temperature (230–280 °C), and packing time (15–30 s)—are analyzed via finite element modeling (FEM) and validated through in situ tie bar elongation measurements. The results show a 27.3% reduction in node displacement amplitude and a 19.6% improvement in wave transmission uniformity compared to conventional methods. This methodology enhances acoustic tweezers’ operational stability and provides a generalizable framework for multi-physics optimization in MEMS manufacturing, laying a foundation for next-generation applications in single-cell manipulation, lab-on-a-chip systems, and nanomaterial assembly. Full article

This study focuses on addressing the issues of water flooding and mass transfer limitations in proton exchange membrane fuel cells (PEMFCs) under high current density conditions. A multi-scale gradient pore gas diffusion layer (GDL) is designed to enhance fuel cell performance. The pore structure is precisely controlled using a self-assembled mold, resulting in the fabrication of a GDL with a gradient distribution of pore diameters ranging from 80 to 170 μm. Experimental results indicate that, with the optimized gradient pore GDL, the peak power density of the fuel cell reaches 1.18 W·cm−², representing a 20% improvement compared to the traditional structure. A mechanism analysis reveals that this structure establishes a concentrated water transport pathway through channels while enabling gas diffusion and transport driven by concentration gradients, thereby achieving the collaborative optimization of gas–liquid transport. This approach offers a novel solution for managing water in PEMFCs operating under high current density conditions, and holds significant implications for advancing the commercialization of PEMFC technology. Full article

To address the data management limitations of traditional ontology models in dynamic industrial settings, this study introduces the Fractal Fuzzy Ontology Modeling (FFOM) framework, a novel methodology for optimizing data management, integration, and decision making. FFOM’s value is rooted in two major contributions: firstly, the strategic use of fractal structures to achieve unparalleled scalability and modularity, which significantly reduces the effort required during data hierarchy updates by enabling self-similar, expandable data architectures. Secondly, FFOM features the synergistic use of fuzzy logic to meticulously manage ambiguity and uncertainty, including the representation of imprecise relationships and support for flexible, rule-based reasoning. The practical value of this integrated approach is demonstrated through a mold assembly case study, which validates FFOM’s effectiveness in structuring complex data hierarchies, managing uncertainty, and enabling automated reasoning. Implemented in the Web Ontology Language (OWL) for standardization and interoperability purposes, FFOM ultimately provides a clear pathway toward developing more intelligent, adaptive, and scalable data ecosystems in demanding manufacturing domains, where real-time data analysis is critical. Full article

Currently, the need for resource efficiency and CO₂ reduction is growing in industrial production, particularly in the automotive sector. To address this, the industry is focusing on lightweight components that reduce weight without compromising mechanical properties, which are essential for passenger safety. Hybrid designs offer an effective solution by combining weight reduction with improved mechanical performance and functional integration. This study focuses on a one-step manufacturing process that integrates forming and bonding of hybrid systems using compression molding. This approach reduces production time and costs compared to traditional methods. Conventional Post-Mold Assembly (PMA) processes require two separate steps to combine fiber-reinforced plastic (FRP) structures with metal components. In contrast, the novel In-Mold Assembly (IMA) process developed in this study combines forming and bonding in a single step. In the IMA process, glass-mat-reinforced thermoplastic (GMT) is simultaneously formed and bonded between two metal belts during compression molding. The GMT core provides stiffening and load transmission between the metal belts, which handle tensile and compressive stresses. This method allows to produce hybrid structures with optimized material distribution for load-bearing and functional performance. The process was validated by producing a lightweight hybrid brake pedal. Demonstrating its potential for efficient and sustainable automotive production, the developed hybrid brake pedal achieved a 35% weight reduction compared to the steel reference while maintaining mechanical performance under quasi-static loading Full article

This study presents a novel approach to manufacture a rigid printed circuit board (PCB) using sustainable polymers. Current PCBs use a fossil-fuel-based substrate, like FR4. This presents recycling challenges due to its composite nature. Replacing the substrate with an environmentally friendly alternative leads to a reduction in negative impacts. Polylactic acid (PLA) and Polyhydroxybutyrate (PHB) biopolymers are used in this study. These two biopolymers have low melting points (130–180 °C, and 170–180 °C, respectively) and cannot withstand the high temperature soldering process (up to 260 °C for standard SAC (SnAgCu, tin/silver/copper) lead free solder processes). Our approach for replacing the PCB substrate is applying the PLA/PHB carrier substrate at the end of the PCB manufacturing process using injection molding technology. This approach involves all the standard PCB processes, including wet etching of the Cu conductors, and component assembly with SAC solder on a thin flexible polyimide (PI) foil with patterned Cu conductors and then overmolding the biopolymer onto the foil to create a rigid base. This study demonstrates the functionality of two test circuits fabricated using this method. In addition, we evaluated the adhesion between the biopolymer and PI to achieve a durable PCB. Moreover, we performed two different end-of-life approaches (debonding and composting) as a part of the end-of-life consideration. By incorporating biodegradable materials into PCB standard manufacturing, the CO₂ emissions and energy consumption are significantly reduced, and installation costs are lowered. Full article

The discovery of efficient and stable nanopesticides with improved water solubility and sustained release effects has become particularly important. Pyrimethanil (Pyr) as a low toxicity fungicide of an aniline pyrimidine group is widely used for the prevention and control of gray mold in crops and ornamental plants, however, poor water solubility hinders its further development. Herein, we use a supramolecular self-assembly process to encapsulate a pyrimethanil in a hydroxypropyl-gamma-cyclodextrin (HPγCD) via electrostatic interactions, thereby constructing the inclusion complex nanofibers. The HPγCD as an environmentally friendly carrier material for pesticide delivery is favorable for facilitating the control efficacy, water solubility, and thermostability with Pyr. The diameter of the prepared inclusion nanofiber is 426.6 ± 82.1 nm. Pyr/HPγCD inclusion complex nanofibers could be completely dissolved in water within 3 s. As predicted, the fungicidal activity of Pyr/HPγCD inclusion complex nanofibers is much higher than that of either Pyr, and the EC₅₀ value of Pyr/HPγCD inclusion nanofibers is 0.437 μg/mL, which is about half of that of Pyr (0.840 μg/mL). The inclusion strategy achieved by Pyr and HPγCD is important for improving the safety of nanopesticides. This work provides a versatile insight to promote the development of water-based pesticide dosage forms and reduce pesticide losses in agricultural production. Full article

Binder jetting is the most widely implemented additive technology for the fabrication of sand molds. However, the use of furan binder-jetting technology in the production of molds for vacuum casting is hindered by the thermal destruction of the furan binder accompanied by violent gas emission that occurs during the mold heating process. This investigation explores the potential of using the molds obtained via furan binder jetting 3D printing and further impregnation in colloidal silica binder and sintering. Two distinct sands, proppant and cenosphere, were utilized in the fabrication of the mold components exhibiting different thermal properties. An examination of the structure of the initial sands and samples produced via different impregnation and sintering regimes was conducted via scanning electron microscopy with energy dispersive X-ray spectroscopy, X-ray diffractometry, thermogravimetric analysis, and micro computed tomography. Furthermore, the bending mechanical properties and linear shrinkage of the samples were determined. The experimental findings demonstrated that the specific impregnation and sintering regimes examined in this study yielded sufficient mechanical properties for the casting molds and the structure with cristobalite bridges. The mold assembly, composed of proppant and cenosphere sands-based parts, was produced, and impeller nickel-based superalloy castings were fabricated. The findings of this study demonstrate that the utilization of a furan binder-jetting technique, in conjunction with impregnation in colloidal silica binder, is a promising technology for the manufacture of high-melting-temperature alloy casting. Full article

The endoscopic transsphenoidal approach (ETA) is a novel approach used by neurosurgeons and otolaryngologists to treat pituitary adenoma, and it has a long learning curve. Training is mostly performed using cadaver heads, but their low availability and cost can limit their use. ETA training models can be used to overcome these limitations. In this panorama, additive manufacturing (AM) technologies represent a more flexible and cost-effective solution to fabricate custom-made training models. Their development involves computed tomography (CT) segmentation, STL file elaboration, direct 3D printing, and rapid parts tooling. This work presents and discusses the entire procedure applied to a modular ETA training model. The procedure starts with selecting the material and AM processes based on a literature review. Accordingly, the parts of the model were designed, 3D printed, or rapid cast. In particular, fused filament fabrication (FFF) was adopted for those tissues whose materials could be directly printed (bones and cartilage), while the rapid casting of silicone was adopted for soft tissues (skin and mucosa) together with FFF to fabricate mold patterns and cores. After fabrication and assembly, the model was finally tested by an experienced neurosurgeon who provided feedback. Moreover, the cost and time of the prototype fabrication were assessed. Results validated the proposed solution from both the surgical and commercial points of view. Moreover, general procedures for designing and rapidly fabricating ETA models were generalized to make them exploitable to more general case studies. Full article

Carbon-fiber-reinforced polyetheretherketone (CF/PEEK) composites are being increasingly used in aerospace, biomedical, and other industries due to their superior mechanical properties. However, CF/PEEK structural components require secondary processing after curing and molding to meet connection and assembly precision requirements. This process, however, often results in defects such as burrs and pits, which significantly compromise the mechanical performance and assembly quality of the structural components. This study first employed finite element simulations to analyze the laser-assisted milling of CF/PEEK composites, investigating the material removal mechanism under thermal coupling, which was then experimentally validated. Variations in the cutting force, cutting heat, surface damage, and fiber fracture mechanisms during milling were investigated. During laser-assisted milling, the fibers fractured mainly in bending at a cutting angle of 0°, in bending shear at a cutting angle of 45°, in compression at a cutting angle of 90°, and in compression shear at a cutting angle of 135°. The experimental findings were generally consistent with the simulation results. In addition, laser-assisted milling effectively reduced the cutting forces, cutting temperatures, and surface damage compared to conventional milling; laser-assisted milling reduced the cutting forces in the 90° fiber direction by 24.8% (total cutting forces) and 16.3% (feed-cutting forces). The fiber integrity was further increased with increasing spindle speed. Full article

Prestressed, precast composite panels are a type of building component that combines prestressing technology with composite materials; but, for most of them, it is difficult to balance structural stress performance and assembly efficiency. This paper proposes a series of novel bidirectional, prestressed, prefabricated, composite slabs, aiming to enhance their bidirectional force characteristics and assembly efficiency. By implanting a kind of specially designed concrete movable core rib with the same geometry as the cavity in the hollow-core slab at medium spacing, the transverse stressing performance of the structure is enhanced without affecting the unidirectional structural performance. Then, in the pre-set transverse apertures, several pieces of unidirectional, prestressed, precast hollow-core slabs that are implanted in the core mold are connected in series with high-strength strands and prestressed; finally, we obtain a bidirectional, prestressed, prefabricated composite slab. Two types of slabs (i.e., 3.3 m × 4.5 m and 4.5 m × 4.5 m) are selected and their mechanical behavior is investigated experimentally and by the finite element method, and the results are in good agreement. The proposed bidirectional, prestressed, precast composite slab not only has better overall bearing performance but also improves the structural stiffness and assembly rate, which can greatly improve the economic benefits and is of great significance for the popularization and application of assembled concrete structures. Full article

This paper presents a comparative study of the fatigue life of solder joints in a board-level Ball Grid Array (BGA) assembly. It specifically contrasts the commonly used SAC305 alloy with the advanced Innolot-based solder alloy, recognized for its superior tensile strength. Through Finite Element Analysis (FEA), we simulate and predict the reliability of these solder joints under harmonic and random vibration conditions. Following the JEDEC (Joint Electronic Device Engineering Council) standards, two different board-level BGA assemblies are used for the analysis. In both assemblies, the dimensions of the substrate, molding compound, and solder balls remain identical; only the board dimensions are changed to observe how they affect stress in the solder joints. The results indicate that using Innolot raises the volume-averaged stress levels by more than 25% on larger boards and about 5% on smaller boards compared to SAC305. This increase in stress levels is due to the Innolot alloy having a less significant stiffening effect than SAC305, which results in higher stress levels under the same excitation conditions. While the stress in the Innolot-based solder joint is greater than that in the SAC305 joint under identical excitation conditions, the fatigue life of the Innolot joint is significantly higher than that of the SAC305 joint. The results show that the Innolot-based alloy exceeds the performance of SAC305, and that it is suitable for use as a solder alloy in extreme vibration conditions. Full article

Traumatic brain injury (TBI) during snowboarding sports is a major concern. A robust evaluation of existing snowboarding helmets is desired. Head kinematics (i.e., linear acceleration, angular velocity, angular acceleration) and associated brain responses (brain pressure, equivalent (von Mises) stress, and maximum principal strain) of the head are a predominant cause of TBI or concussion. The conventional snowboarding helmet, which mitigates linear acceleration, is typically used in snow sports. However, the role of conventional snowboarding helmets in mitigating angular head kinematics is marginal or insignificant. In recent years, new anti-rotational technologies (e.g., MIPS, WaveCel) have been developed that seek to reduce angular kinematics (i.e., angular velocity, angular acceleration). However, investigations regarding the performance of snowboarding helmets in terms of the mitigation of head kinematics and brain responses are either extremely limited or not available. Toward this end, we have evaluated the performance of snowboarding helmets (conventional and anti-rotational technologies) against blunt impact. We also evaluated the performance of newly developed low-cost, silica-based anti-rotational pads by integrating them with conventional helmets. Helmets were mounted on a head surrogate–Hybrid III neck assembly. The head surrogate consisted of skin, skull, dura mater, and brain. The geometry of the head surrogate was based on the GHBMC head model. Substructures of the head surrogate was manufactured using additive manufacturing and/or molding. A linear impactor system was used to simulate/recreate snowfield hazards (e.g., tree stump, rock, pole) loading. Following the ASTM F2040 standard, an impact velocity of 4.6 ± 0.2 m/s was used. The head kinematics (i.e., linear acceleration, angular velocity, angular acceleration) and brain simulant pressures were measured in the head surrogate. Further, using the concurrent simulation, the brain simulant responses (i.e., pressure, von Mises stress, and maximum principal strain) were computed. The front and side orientations were considered. Our results showed that the helmets with anti-rotation technologies (i.e., MIPS, WaveCel) significantly reduced the angular kinematics and brain responses compared to the conventional helmet. Further, the performance of the silica pad-based anti-rotational helmet was comparable to the existing anti-rotational helmets. Lastly, the effect of a comfort liner on head kinematics was also investigated. The comfort liner further improved the performance of anti-rotational helmets. Overall, these results provide important data and novel insights regarding the performance of various snowboarding helmets. These data have utility in the design and development of futuristic snowboarding helmets and safety protocols. Full article

Steel pipeline systems carry about three-quarters of the world’s oil and gas. Such pipelines need to be coated to prevent corrosion and erosion. An alternative to the current epoxy-based coating, a multi-layered composite coating is developed in this research. The composite coatings were made from carbon fiber-reinforced thermoplastic polymer (CFRTP) material. Uniaxial carbon fiber CF/PPS prepreg tape was utilized, where the PPS (polyphenylene sulfide) is employed as a thermoplastic (TP) matrix. Compression molding was used to manufacture three flat panels, each consisting of seven plies: UD (Unidirectional), Biaxial, and Off-axis. Samples of carbon steel were coated with multi-layered composites. The physical, mechanical, and corrosion-resistant properties of steel-composite coated samples were evaluated. A better and more promising lap-shear strength of about 58 MPa was demonstrated. When compared to the Biaxial and Off-axis samples, the UD assembly had the maximum flexural strength (420 MPa); however, the Biaxial coating has the highest corrosion resistance (445 kΩ·cm²) when compared to the Off-axis and UD coatings. Full article

Non-pneumatic tires (NPTs) have garnered significant attention due to their advantages, such as energy efficiency, safety, versatile applications, and superior performance, compared to traditional rubber-based pneumatic tires (PTs). This mini review provides a concise overview of NPTs, beginning with their definition, structural design, and classification based on structural variations. The review then examines recent advancements in the materials used for NPTs, including those for the tread, elastic support structure, skeleton, and adhesives, with a focus on their specific properties. Furthermore, it summarizes various manufacturing techniques such as compression molding, centrifugal casting, injection molding, 3D printing, and mechanical assembly. Lastly, the review outlines the general manufacturing procedures of NPTs, discusses the challenges currently faced by the technology, and offers insights into future development directions. This mini review aims to support NPT researchers and practitioners, particularly in the fields of process and materials engineering, in advancing their work on NPTs. Full article