Search Results (1,614)

Soft manipulators have garnered significant research attention in recent years due to their flexibility and adaptability. However, the inherent flexibility of these manipulators imposes limitations on their load-bearing capacity and stability. To address this, this study compares various variable stiffness technologies and proposes a novel design concept: leveraging the phase-change characteristics of low-melting-point alloys (LMPAs) with distinct melting points to fulfill the variable stiffness requirements of soft manipulators. The pneumatic structure of the manipulator is fabricated via 3D-printed molds and silicone casting. The manipulator integrates a pneumatic working chamber, variable stiffness chambers, heating devices, sensors, and a central channel, achieving multi-stage variable stiffness through controlled heating of the LMPAs. A steady-state temperature field distribution model is established based on the integral form of Fourier’s law, complemented by finite element analysis (FEA). Subsequently, the operational temperatures at which the variable stiffness mechanism activates, and the bending performance are experimentally validated. Finally, stiffness characterization and kinematic performance experiments are conducted to evaluate the manipulator’s variable stiffness capabilities and flexibility. This design enables the manipulator to switch among low, medium, and high stiffness levels, balancing flexibility and stability, and provides a new paradigm for the design of soft manipulators. Full article

Thermal wick-debinding, commonly used in low-pressure injection molding, remains challenging due to complex interactions between binder transport, capillary forces, and thermal effects. This study presents a numerical simulation of binder removal kinetics by coupling Darcy’s law with the Phase Transport in Porous Media interface in COMSOL Multiphysics. The model was validated and subsequently used to study the influence of key debinding parameters. Contrary to the Level Set method, which predicts isolated binder clusters, the Multiphase Flow in Porous Media method proposed in this work more accurately reflects the physical behavior of the process, capturing a continuous binder extraction throughout the green part and a uniform binder distribution within the wicking medium. The model successfully predicted the experimentally observed decrease in binder saturation with increasing debinding temperature or time, with deviation limited 3–10 vol. % (attributed to a mandatory brushing operation, which may underestimate the residual binder mass). The model was then used to optimize the debinding process: for a temperature of 100 °C and an inter-part gap distance of 5 mm, the debinding time was minimized to 7 h. These findings highlight the model’s practical utility for process design, offering a valuable tool for determining optimal debinding parameters and improving productivity. Full article

This paper is about the design and fabrication of infrared lenses, which are the core components of thermal imaging cameras to be mounted on vehicles. To produce an athermalized optical system, chalcogenide glass (As₄₀Se₆₀) with a lower thermo-optic coefficient (dn/dT) than germanium was adopted as a lens material, and each lens was designed so that defocus occurs in opposite directions depending on temperature. The designed lens was fabricated using a compression molding method, and the molded lenses showed less than 1.5 μm of form error (PV) using a mold iteration process. Through evaluations of MTF and thermal images obtained from the lens module, it was judged that this optical design process is obtainable. Full article

Preserving historical porous materials requires careful monitoring of surface humidity to mitigate deterioration processes like salt crystallization, mold growth, and material decay. While microclimate monitoring is a recognized preventive conservation tool, its role in detecting surface-specific moisture risks remains underexplored. This study evaluates the relationship between indoor microclimate fluctuations and surface moisture dynamics across 13 historical sites in Northern Italy (Lake Como, Valtellina, Valposchiavo), encompassing diverse masonry typologies and environmental conditions. High-resolution sensors recorded temperature and relative humidity for a minimum of 13 months, and eight indicators—including dew point depression, critical temperature–humidity zones, and damp effect indices—were analyzed to assess the moisture risks. The results demonstrate that multivariate microclimate data could effectively predict humidity accumulation. The key findings reveal the impact of seasonal ventilation, thermal inertia, and localized air stagnation on moisture distribution, with unheated alpine sites showing the highest condensation risk. The study highlights the need for integrated monitoring approaches, combining dew point analysis, mixing ratio stability, and buffering performance, to enable early risk detection and targeted conservation strategies. These insights bridge the gap between environmental monitoring and surface moisture diagnostics in porous heritage materials. Full article

The polytetrafluoroethylene/aluminum (PTFE/Al) granular composite, a common formulation in impact-initiated energetic materials, undergoes mechanochemical coupling reactions under sufficiently strong dynamic loading. This investigation discusses the dynamic properties and the constitutive relationship of the PTFE/Al granular composite to provide a preliminary guide for the research on mechanical properties of a series of composite materials based on PTFE/Al as the matrix. Firstly, the 26.5Al-73.5PTFE (wt.%) composite specimens are prepared by preprocessing, mixing, molding, high-temperature sintering, and cooling. Then, the quasi-static compression and Hopkinson bar tests are performed to explore the mechanical properties of the PTFE/Al composite. Influences of the strain rate of loading on the yield stress, the ultimate strength, and the limited strain are also analyzed. Lastly, based on the experimental results, the material parameters in the Johnson–Cook constitutive model are obtained by the method of piecewise fitting to describe the stress–strain relation of the PTFE/Al composite. Combining the experimental details and the obtained material parameters, the numerical simulation of the dynamic compression of the PTFE/Al composite specimen is carried out by using the ANSYS/LS-DYNA platform. The results show that the computed stress–strain curves present a reasonable agreement with the experimental data. It should be declared that this research does not involve the energy release behavior of the 26.5Al-73.5PTFE (wt.%) reactive material because the material is not initiated within the strain rate range of the dynamic test in this paper. Full article

The deformation behavior of polymers is influenced not only by service conditions such as temperature and the strain rate but also significantly by the formation process. However, existing simulation frameworks typically treat injection molding and the in-service mechanical response separately, making it difficult to capture the impact of the thermal history on large deformation behavior. In this study, the deformation behavior of injection-molded polycarbonate (PC) was investigated by accounting for its thermal history during formation, achieved through combined experimental characterization and constitutive modeling. PC specimens were prepared via injection molding followed by annealing at different molding/annealing temperatures and durations. Uniaxial tensile tests were conducted using a Zwick universal testing machine at strain rates of 10⁻³–10⁻¹ s⁻¹ and temperatures ranging from 293 K to 353 K to obtain stress–strain curves. The effects of the strain rate, testing temperature, and annealing conditions were thoroughly examined. Building upon a previously proposed phenomenological model, a new constitutive framework incorporating thermal history effects during formation was developed to characterize the large deformation behavior of PC. This model was implemented in ABAQUS/Explicit using a user-defined material subroutine. Predicted stress–strain curves exhibit excellent agreement with the experimental data, accurately reproducing elastic behavior, yield phenomena, and strain-softening and strain-hardening stages. Full article

We have improved the efficiency of the protection of occupants of cars by effectively reducing the injury and mortality rate caused by accidents when using safety belts. To ensure the protection efficiency of the safety belt outlet cover, we tested and adjusted the following parameters: the filling time, flow-front temperature and switching pressure, injection position pressure, locking force, shear rate, shear force, air hole, melting mark, material flow freezing-layer factor, volume shrinkage rate during jacking out, coolant temperature and flow rate in the cooling stage, part temperature, mold temperature difference, deflection stage, warping deformation analysis, differential cooling, differential shrinkage, and directional effect. Full article

This study presents a breakthrough in sustainable injection molding by uniquely combining a backpropagation neural network (BPNN) with particle swarm optimization (PSO) to overcome traditional optimization challenges. The BPNN’s exceptional ability to learn complex nonlinear relationships between six key process parameters (including melt temperature and holding pressure) and product quality is amplified by PSO’s intelligent search capability, which efficiently navigates the high-dimensional parameter space. Together, this hybrid approach achieves what neither method could accomplish alone: the BPNN accurately models the intricate process-quality relationships, while PSO rapidly converges on optimal parameter sets that simultaneously meet strict quality targets (66–70 g weight, 3–5 mm thickness) and minimize energy consumption. The significance of this integration is demonstrated through three key outcomes: First, the BPNN-PSO combination reduced optimization time by 40% compared to traditional trial-and-error methods. Second, it achieved remarkable prediction accuracy (RMSE 0.8229 for thickness, 1.5123 for weight) that surpassed standalone BPNN implementations. Third, the method’s efficiency enabled SMEs to achieve CAE-level precision without expensive software, reducing setup costs by approximately 25%. Experimental validation confirmed that the optimized parameters decreased energy use by 28% and material waste by 35% while consistently producing parts within specifications. This research provides manufacturers with a practical, scalable solution that transforms injection molding from an experience-dependent craft to a data-driven science. The BPNN-PSO framework not only delivers superior technical results but does so in a way that is accessible to resource-constrained manufacturers, marking a significant step toward sustainable, intelligent production systems. For SMEs, this framework offers a practical pathway to achieve both economic and environmental sustainability, reducing reliance on resource-intensive CAE tools while cutting production costs by an estimated 22% through waste and energy savings. The study provides a replicable blueprint for implementing data-driven sustainability in injection molding operations without compromising product quality or operational efficiency. Full article

The technological process of the centrifugal casting of short and long castings is examined during development. The values of the technological parameters at applying heat-resistant coating on the working surface of metal molds were established. With a high-speed camera, the temperature of the free surface during the pouring of the melts was measured. Research experiments were conducted. A mathematical model of the centrifugal casting process with a horizontal axis was created. Full article

To address the challenges of low density, loose structure, high utilization costs, and inadequate molding effects of corn straw char under ambient temperature and pressure conditions, this study investigated the utilization of waste soybean powder (WSP) as a binder to produce biochar pellets via ultrasonic-assisted processing. A single-factor experiment was initially conducted to assess the effects of key variables. Subsequently, a Central Composite Rotatable Design (CCRD) was employed to evaluate the individual and interactive effects of these variables, in which pellet density and durability served as response indicators. Regression models for both responses were developed and validated using analysis of variance (ANOVA). The results indicated that, at a 0.05 significance level, the mixing ratio of corn straw char to WSP and molding pressure had highly significant effects on pellet density, while pelleting time had a significant effect and ultrasonic power had no significant influence. All four factors significantly affected pellet durability, and their interactions were further analyzed. The optimal conditions were a mixing ratio of 45%, pelleting time of 33 s, an ultrasonic power of 150 W, and a molding pressure of 5 MPa, yielding pellets with a density of 1140.41 kg/m³ and a durability of 98.54%. These results demonstrate that WSP is an effective binder for the ultrasonic-assisted fabrication of biochar pellets. Full article

Although PLA is an attractive biodegradable polymer, its degradation under natural conditions is often slow. This study investigates whether incorporating pounamu (New Zealand jade) particles into PLA can enhance its biodegradation rate under composting conditions at room temperature. PLA composites containing 0 to 15 wt% pounamu were fabricated using both compression molding and 3D printing. A simple, reproducible protocol based on residual mass measurement was developed to monitor the biodegradation process over a 12-month period. The results showed that increasing pounamu content consistently accelerated mass loss of the composite in the compost, indicating enhanced biodegradation. The 3D-printed samples degraded more rapidly than compression-molded ones. This was attributed to the layered structure, internal microcavities, and lower crystallinity of the 3D-printed samples, which provided greater surface area and accessibility for microbial activity. These findings highlight the dual role of pounamu as both a crystallization promoter and a facilitator of biodegradation and underscore the importance of the processing method when designing biodegradable polymer composites for real-world applications. Full article

As semiconductor devices demand higher input–output density and faster signal transmission, fan-out panel-level packaging has emerged as a promising solution for next-generation electronic systems. However, the hygroscopic nature of epoxy molding compounds raises critical reliability concerns under high-temperature and high-humidity conditions. This study investigates the hygrothermal stress of a single fan-out panel-level package unit through experimental characterization and numerical simulation. Thermal–mechanical analysis was conducted at 100 °C and 260 °C to evaluate the strain behavior of two commercial epoxy molding compounds in granule form after moisture saturation. The coefficient of moisture expansion was calculated by correlating strain variation with moisture uptake obtained under 85 °C and 85% relative humidity, corresponding to moisture sensitivity level 1 conditions. These values were directly considered into a moisture -thermal coupled finite element analysis. The simulation results under reflow conditions demonstrate accurate principal stress and failure location predictions, with stress concentrations primarily observed at the die corners. The results confirm that thermal effects influence stress development more than moisture effects. Finally, a structural sensitivity analysis of the single-package configuration showed that optimizing the thickness of the dies and epoxy molding compound can reduce maximum principal stress by up to 12.4%, providing design insights for improving package-level reliability. 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

The formation mechanism of black streak defects in hot-rolled steel sheets was investigated to address the influence of the process parameters on the surface quality during the production of 304 stainless steels. Macro-/microstructural characterization revealed that the defect regions contained necessary mold slag components (Ca, Si, Al, Mg, Na, K) which originated from the initial stage of solidification in the mold region of the continuous casting process, indicating obvious slag entrapment during continuous casting. On this basis, a three-dimensional coupled finite-element model for the molten steel flow–thermal characteristics was established to evaluate the effects of typical casting parameters using the determination of the critical slag entrapment velocity as the criterion. Numerical simulations demonstrated that the maximum surface velocity improved from 0.29 m/s to 0.37 m/s with a casting speed increasing from 1.0 m/min to 1.2 m/min, which intensified the meniscus turbulence. However, the increase in the port angle and the depth of the submerged entry nozzle (SEN) effectively reduced the maximum surface velocity to 0.238 m/s and 0.243 m/s, respectively, with a simultaneous improvement in the slag–steel interface temperature. Through MATLAB (version 2023b)-based reverse optimization combined with critical velocity analysis, the optimal mold slag properties were determined to be 2800 kg/m³ for the density, 4.756 × 10⁻⁶ m²/s for the kinematic viscosity, and 0.01 N/m for the interfacial tension. This systematic approach provides theoretical guidance for process optimization and slag design enhancement in industrial production. Full article

This research aimed to evaluate the biological resistance to xylophagous organisms and the dimensional stability related to water absorption in plastic wood panels manufactured by compression molding and produced with pine wood and recycled thermoplastics. The wood–plastic composites (WPCs) were prepared from 50% pine sawdust and 50% recycled plastics (polyethylene terephthalate-PET, high-density polyethylene-HDPE, and polypropylene-PP). The thickness swelling test was carried out by immersing of the WPC samples in water at room temperature (25–30 °C) and evaluating the total change in WPC thickness after 1500 h (≈9 weeks or two months). In addition, the coefficient of initial swelling was evaluated to verify the variability of the swelling. For the biological resistance evaluation of the WPCs, tests were carried out with soil or arboreal termites (Nasutitermes corniger) and drywood termites (Cryptotermes brevis). The WPC loss of mass and termite mortality were evaluated. The use of PP promoted the best response to thickness swelling. The simple mathematical model adopted offers real predictions to evaluate the thickness of the swelling of the compounds in a given time. For some variables there were no statistical differences. It was shown that treatment 3 (T3) presented visual damage values between 0.4 for drywood termites and 9.4 for soil termites, in addition to 26% termite mortality, represented by the lowest survival time of 12 days. The developed treatments have resistance to termite attacks; these properties can be an important starting point for its use on a larger scale by the panel industries. Full article