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Additive manufacturing of high-resolution solid microneedles via continuously variable stacked extrusion (CVSE) of conductive thermoplastic using a fused filament fabrication (FFF) printer 使用熔丝制造（FFF）打印机，通过导电热塑性塑料的连续可变堆叠挤压（CVSE）增材制造高分辨率固体微针
IF 1.9
Manufacturing Letters Pub Date : 2025-02-19 DOI: 10.1016/j.mfglet.2025.01.005
Russell Kirk Pirlo, Carter McCrea, Lauren Carothers, Kyle Shrader, Evan Johnson, Trevor Tilly
{"title":"Additive manufacturing of high-resolution solid microneedles via continuously variable stacked extrusion (CVSE) of conductive thermoplastic using a fused filament fabrication (FFF) printer","authors":"Russell Kirk Pirlo,&nbsp;Carter McCrea,&nbsp;Lauren Carothers,&nbsp;Kyle Shrader,&nbsp;Evan Johnson,&nbsp;Trevor Tilly","doi":"10.1016/j.mfglet.2025.01.005","DOIUrl":"10.1016/j.mfglet.2025.01.005","url":null,"abstract":"<div><div>This study introduces Continuously Variable Stacked Extrusion (CVSE), a novel method for fabricating high-resolution microneedles using standard Fused Filament Fabrication (FFF) hardware. Unlike traditional FFF approaches requiring chemical etching, CVSE combines printing and drawing techniques through continuous vertical movement to create smooth, precise microneedles. Using conductive PLA filament, we demonstrated uniform arrays of microneedles with tip diameters under 25 μm and heights of 1185 ± 28 μm. The method showed excellent repeatability and enabled various needle profiles, including barbed and tissue-interlocking designs. This approach represents a significant advancement in microneedle fabrication using widely available FFF equipment.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"44 ","pages":"Pages 1-5"},"PeriodicalIF":1.9,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143561887","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Effect of interlayer TIG arc treatment on porosity of wire arc additive manufactured copper 层间TIG电弧处理对丝弧添加剂合成铜气孔率的影响
IF 1.9
Manufacturing Letters Pub Date : 2025-01-25 DOI: 10.1016/j.mfglet.2025.01.002
Arun Kumar Singh, Shubham Sadhya, Sumit Chorma, Indrasen Singh, Yuvraj K Madhukar
{"title":"Effect of interlayer TIG arc treatment on porosity of wire arc additive manufactured copper","authors":"Arun Kumar Singh,&nbsp;Shubham Sadhya,&nbsp;Sumit Chorma,&nbsp;Indrasen Singh,&nbsp;Yuvraj K Madhukar","doi":"10.1016/j.mfglet.2025.01.002","DOIUrl":"10.1016/j.mfglet.2025.01.002","url":null,"abstract":"<div><div>The presented experimental research explores interlayer arc treatment in wire arc additive manufacturing using TIG (WAAM-TIG) to minimise the porosity which adversely affects the mechanical properties. Copper was chosen for this study due to its extensive utilisation in industries. WAAM-TIG deposition along with interlayer arc treatment was performed in continuous (ATC) and pulsed (ATP) mode, and the results were compared with as-fabricated (AF) samples. Both, arc treated samples showed significant reduction in porosity, however, the ATP mode performed relatively better decreasing from ∼ 16 % to ∼ 1 %. Further arc-treated samples were also exhibited an increase in hardness ensuring improvement in mechanical property.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 70-74"},"PeriodicalIF":1.9,"publicationDate":"2025-01-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157617","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Variations in temperature, residual stress, and distortion in collaborative robot-assisted patterned additive manufacturing 协同机器人辅助模式增材制造中温度、残余应力和变形的变化
IF 1.9
Manufacturing Letters Pub Date : 2025-01-22 DOI: 10.1016/j.mfglet.2025.01.001
Mohammad Arjomandi, Rakshith Reddy Sanvelly, Tuhin Mukherjee
{"title":"Variations in temperature, residual stress, and distortion in collaborative robot-assisted patterned additive manufacturing","authors":"Mohammad Arjomandi,&nbsp;Rakshith Reddy Sanvelly,&nbsp;Tuhin Mukherjee","doi":"10.1016/j.mfglet.2025.01.001","DOIUrl":"10.1016/j.mfglet.2025.01.001","url":null,"abstract":"<div><div>Collaborative robots (COBOT) offer advantages over traditional robots by reducing the need for path programming, enhancing safety for human interaction, and improving user-friendliness and productivity, making them suitable for additive manufacturing of large and complex parts. COBOT simplifies path planning in patterned additive manufacturing by using teaching points where a complex deposition pattern can be represented by a few key coordinates. However, the selection of teaching points significantly affects the temperature fields, deposit geometry, residual stresses, and distortion, and these effects are not well understood. Here we use a combined experimental and computational approach to study the effects of four patterns with different teaching points (4, 5, 6, and 8) during wire arc-directed energy deposition (WA-DED) of stainless steel. Experiments are performed using an in-house COBOT-assisted WA-DED system. Finite element modeling is done to compute temperature fields, deposit geometry, residual stresses, and distortion. We concluded that the distribution of residual stress varies notably with different deposition patterns, even though the maximum stress values are not significantly different. Stress tends to accumulate at sharp corners where the arc heat source stays longer. In addition, thermal distortion is present in all parts due to variations in the temperature field, with the highest distortion occurring farthest from the molten pool. However, overall distortion remains comparable across parts due to a consistent total heat input.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 64-69"},"PeriodicalIF":1.9,"publicationDate":"2025-01-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157616","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
A novel gap flushing insert for sink electrical discharge machining 一种用于槽放电加工的新型间隙冲洗刀片
IF 1.9
Manufacturing Letters Pub Date : 2025-01-10 DOI: 10.1016/j.mfglet.2024.12.001
Samuel Mander, Philip Koshy
{"title":"A novel gap flushing insert for sink electrical discharge machining","authors":"Samuel Mander,&nbsp;Philip Koshy","doi":"10.1016/j.mfglet.2024.12.001","DOIUrl":"10.1016/j.mfglet.2024.12.001","url":null,"abstract":"<div><div>Gap flushing in sink electrical discharge machining (EDM) is generally accomplished by forcing the dielectric fluid through a hole in the tool (through-tool flushing) or by periodically retracting the tool from the machining gap (jump EDM). Through-tool flushing is limited by the stump left on the workpiece from the flushing hole, and jump EDM by the reduced productivity from when the tool is not engaged in machining. In this context, this paper presents an innovation that involves a rotating flushing hole assembly incorporated within a prismatic tool, which can be self-propelled by the dielectric flow. The novel design is shown to essentially eliminate the formation of the said stump, and to correspond to removal rates surpassing jump EDM.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 55-59"},"PeriodicalIF":1.9,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157614","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Novel topological machine learning methodology for stream-of-quality modeling in smart manufacturing 智能制造中质量流建模的新型拓扑机器学习方法
IF 1.9
Manufacturing Letters Pub Date : 2025-01-10 DOI: 10.1016/j.mfglet.2024.12.002
Jay Lee , Dai-Yan Ji , Yuan-Ming Hsu
{"title":"Novel topological machine learning methodology for stream-of-quality modeling in smart manufacturing","authors":"Jay Lee ,&nbsp;Dai-Yan Ji ,&nbsp;Yuan-Ming Hsu","doi":"10.1016/j.mfglet.2024.12.002","DOIUrl":"10.1016/j.mfglet.2024.12.002","url":null,"abstract":"<div><div>This paper presents a topological analytics approach within the 5-level Cyber-Physical Systems (CPS) architecture for the Stream-of-Quality assessment in smart manufacturing. The proposed methodology not only enables real-time quality monitoring and predictive analytics but also discovers the hidden relationships between quality features and process parameters across different manufacturing processes. A case study in additive manufacturing was used to demonstrate the feasibility of the proposed methodology to maintain high product quality and adapt to product quality variations. This paper demonstrates how topological graph visualization can be effectively used for the real-time identification of new representative data through the Stream-of-Quality assessment.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 60-63"},"PeriodicalIF":1.9,"publicationDate":"2025-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157615","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Modeling the influence of fiber undulation in a filament-wound composite tube under radial crushing load 径向破碎载荷下纤维缠绕复合材料管内纤维波动影响的建模
IF 1.9
Manufacturing Letters Pub Date : 2025-01-09 DOI: 10.1016/j.mfglet.2024.12.003
Ivan Komala , Julien van Campen , Daniël Peeters , Sebastian Heimbs
{"title":"Modeling the influence of fiber undulation in a filament-wound composite tube under radial crushing load","authors":"Ivan Komala ,&nbsp;Julien van Campen ,&nbsp;Daniël Peeters ,&nbsp;Sebastian Heimbs","doi":"10.1016/j.mfglet.2024.12.003","DOIUrl":"10.1016/j.mfglet.2024.12.003","url":null,"abstract":"<div><div>This study investigates a filament-wound tube model incorporating fiber undulation from the filament winding process. The model was analyzed using the finite element method in the linear regime, then compared with the shell model and radial crushing experiment. Results showed that the solid model predicts the radial compression stiffness with a higher level of accuracy than the shell model due to the inclusion of the fiber undulation feature. This model is a first step towards the development of a composite pressure vessel model where fiber undulation is more frequent, and also for predicting failure initiation and damage propagation.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 51-54"},"PeriodicalIF":1.9,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157613","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Sustainable assessment of diamond wire sawing for monocrystalline silicon wafers: Conventional and electrophoretic cooling strategies 单晶硅片金刚石线锯的可持续评估：传统和电泳冷却策略
IF 1.9
Manufacturing Letters Pub Date : 2025-01-05 DOI: 10.1016/j.mfglet.2024.12.004
Eyob Messele Sefene , Chao-Chang A. Chen , Jin-Wei Yang
{"title":"Sustainable assessment of diamond wire sawing for monocrystalline silicon wafers: Conventional and electrophoretic cooling strategies","authors":"Eyob Messele Sefene ,&nbsp;Chao-Chang A. Chen ,&nbsp;Jin-Wei Yang","doi":"10.1016/j.mfglet.2024.12.004","DOIUrl":"10.1016/j.mfglet.2024.12.004","url":null,"abstract":"<div><div>Pursuing sustainable advancement in diamond wire sawing (DWS) is crucial for reducing environmental impact and improving manufacturing efficiency in silicon wafer production. However, the existing sawing methods lack eco-friendly cooling strategies that lower energy consumption and carbon dioxide (CO<sub>2</sub>) emissions while maintaining wafer surface quality. This paper evaluates and improves sustainability by integrating machinability characteristics, such as energy consumption, CO<sub>2</sub> emissions, and surface roughness, while slicing monocrystalline silicon (mono-Si) wafers. Traditional DWS (T-DWS) and electrophoretic-assisted reactive (ER-DWS) cooling strategies were implemented to assess and enhance sustainability. Results demonstrate that ER-DWS achieves a 14.16 % reduction in specific cutting energy, a 9.22 % decrease in total CO<sub>2</sub> emissions, and an 8.78 % improvement in surface roughness (Ra) compared to T-DWS. This study addresses the gap by proposing a sustainable cooling strategy in the DWS process, providing insights into eco-friendly and efficient wafer manufacturing techniques.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 46-50"},"PeriodicalIF":1.9,"publicationDate":"2025-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157612","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Experimental investigations on the ductility improvement due to stress relaxation in aluminium alloy 5083 under biaxial loading conditions 双轴加载条件下5083铝合金应力松弛提高塑性的试验研究
IF 1.9
Manufacturing Letters Pub Date : 2024-12-12 DOI: 10.1016/j.mfglet.2024.11.007
Vikram Balaji , Rubal Dongarwar , Hariharan Krishnaswamy , Sushil Mishra
{"title":"Experimental investigations on the ductility improvement due to stress relaxation in aluminium alloy 5083 under biaxial loading conditions","authors":"Vikram Balaji ,&nbsp;Rubal Dongarwar ,&nbsp;Hariharan Krishnaswamy ,&nbsp;Sushil Mishra","doi":"10.1016/j.mfglet.2024.11.007","DOIUrl":"10.1016/j.mfglet.2024.11.007","url":null,"abstract":"<div><div>The influence of stress relaxation on ductility improvement has been extensively studied for metallic materials, primarily through interrupted uniaxial tensile tests. However, components in typical press forming processes are subjected to multiaxial states of stresses. The applied load paths are expected to have a bearing on the failure strain post relaxation, which is infeasible to study under uniaxial loading. Therefore, single relaxation tests are carried out through interrupted planar biaxial tensile tests in cruciform samples of an aluminum alloy. The tests are performed at different load ratios to assess the load path dependency of stress relaxation, which is otherwise neglected.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 37-45"},"PeriodicalIF":1.9,"publicationDate":"2024-12-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143157611","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Simultaneous 4D printing and In-Situ foaming for tailoring shape memory behaviors in polylactic acid foams 同时4D打印和原位发泡定制聚乳酸泡沫的形状记忆行为
IF 1.9
Manufacturing Letters Pub Date : 2024-12-06 DOI: 10.1016/j.mfglet.2024.11.005
Pedram Honari , Davood Rahmatabadi , Abbas Bayati , Erfan Rassi , Ismaeil Ghasemi , Majid Baniassadi , Mahdi Bodaghi , Mostafa Baghani
{"title":"Simultaneous 4D printing and In-Situ foaming for tailoring shape memory behaviors in polylactic acid foams","authors":"Pedram Honari ,&nbsp;Davood Rahmatabadi ,&nbsp;Abbas Bayati ,&nbsp;Erfan Rassi ,&nbsp;Ismaeil Ghasemi ,&nbsp;Majid Baniassadi ,&nbsp;Mahdi Bodaghi ,&nbsp;Mostafa Baghani","doi":"10.1016/j.mfglet.2024.11.005","DOIUrl":"10.1016/j.mfglet.2024.11.005","url":null,"abstract":"<div><div>This study introduces an innovative 4D printing technique combined with in-situ foaming to enhance the shape memory properties of polylactic acid (PLA) foams. By melt mixing PLA with azodicarbonamide (AZO) below its decomposition temperature, followed by direct pellet printing, the research achieves uniform microporous structures and tailored shape memory behaviors. The findings demonstrate that higher AZO content improves shape fixity (∼96 %) but reduces shape recovery. Moreover, the programming temperature significantly influences performance, with hot programming enhancing shape fixity and cold programming boosting shape recovery. This novel approach offers potential applications in lightweight, thermally insulative, and shock-absorbing materials with programmable properties.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 33-36"},"PeriodicalIF":1.9,"publicationDate":"2024-12-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143156523","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Effects of wire feeding direction on the deposition characteristics of 316L stainless steel in laser-directed energy deposition 激光定向能沉积中送丝方向对316L不锈钢沉积特性的影响
IF 1.9
Manufacturing Letters Pub Date : 2024-12-05 DOI: 10.1016/j.mfglet.2024.11.006
Y.N. Aditya , Josip Vincic , Michael J. Benoit
{"title":"Effects of wire feeding direction on the deposition characteristics of 316L stainless steel in laser-directed energy deposition","authors":"Y.N. Aditya ,&nbsp;Josip Vincic ,&nbsp;Michael J. Benoit","doi":"10.1016/j.mfglet.2024.11.006","DOIUrl":"10.1016/j.mfglet.2024.11.006","url":null,"abstract":"<div><div>This study investigates the effect of wire feeding direction on the microstructure of 316 stainless steel during the laser-directed energy deposition (L-DED) process. The process parameters were optimised by varying the scan speed, laser power, and wire feed rate to identify a common parameter set for all feed directions to give desired weld bead geometries. The identified process parameter window has shown that the conduction mode is preferred over the balling and keyhole modes. Comprehensive microstructural characterization using optical and electron microscopy has revealed that for the same parameters, the front wire feed had higher penetration, while the back wire feed had a wider bead with optimal penetration. The current findings are of significance for advancing wire-L-DED additive manufacturing for more complex component designs.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"43 ","pages":"Pages 27-32"},"PeriodicalIF":1.9,"publicationDate":"2024-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143156512","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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