Manufacturing LettersPub Date : 2026-03-01Epub Date: 2025-12-04DOI: 10.1016/j.mfglet.2025.11.008
Vikash Kumar, Atosh Kumar Sinha, Susanta Pramanik, Krishna P. Yagati
{"title":"Functionally graded materials fabricated through fused deposition modelling technique-mechanical property evaluation and failure mechanism","authors":"Vikash Kumar, Atosh Kumar Sinha, Susanta Pramanik, Krishna P. Yagati","doi":"10.1016/j.mfglet.2025.11.008","DOIUrl":"10.1016/j.mfglet.2025.11.008","url":null,"abstract":"<div><div>Functionally Graded Material (FGM) was fabricated with three different graded layers (10, 15, and 20 wt% CF-PLA) using Fused Deposition Modelling (FDM) technique. This work investigates compression, impact behavior, and the structure of AM-fabricated FGM. This work compares pure PLA, 20 wt% CF-PLA, and FGM. FGM recorded the highest impact strength of 25 ± 1.3 kJ/m<sup>2</sup> and compressive strength of 121.57 ± 1.7 MPa. The 20 wt% CF-PLA showed the highest compressive strength of 134.98 ± 2.1 MPa. FGMs with strong interlayer bonding between the graded layers were fabricated. Pure PLA and 20 wt% CF-PLA recorded ductile and brittle behaviour, respectively.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"47 ","pages":"Pages 15-19"},"PeriodicalIF":2.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145798341","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}
{"title":"Reconfigurable poly-robots for warehouse transport operations","authors":"Mari Chaikovskaia , Jean-Philippe Gayon , Zine Elabidine Chebab , Jean-Christophe Fauroux","doi":"10.1016/j.mfglet.2025.11.009","DOIUrl":"10.1016/j.mfglet.2025.11.009","url":null,"abstract":"<div><div>We consider a warehouse where loads are transported by a fleet of elementary robots that can be aggregated to form poly-robots. These poly-robots can be dynamically reconfigured to handle various load types. Our work focuses on scheduling this robotic fleet with the goal of minimizing the total time required to complete all transportation operations. We introduce an integer linear programming model for two scenarios, with and without robot reconfiguration. We demonstrate that enabling reconfiguration can greatly reduce execution time in some situations. We also show that the linear programs can be solved for the industrial case study under consideration.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"47 ","pages":"Pages 11-14"},"PeriodicalIF":2.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145749722","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}
Manufacturing LettersPub Date : 2026-03-01Epub Date: 2025-12-06DOI: 10.1016/j.mfglet.2025.12.001
Wei Guo, Kalie Miera, James Nguyen, Alexandra Botts, Paulomi Nandy, Thomas Wenning, Jennifer Travis
{"title":"Key insights from US Department of Energy Better Plants workforce development bootcamps (2022–2025)","authors":"Wei Guo, Kalie Miera, James Nguyen, Alexandra Botts, Paulomi Nandy, Thomas Wenning, Jennifer Travis","doi":"10.1016/j.mfglet.2025.12.001","DOIUrl":"10.1016/j.mfglet.2025.12.001","url":null,"abstract":"<div><div>This study examines the effectiveness of the US Department of Energy’s Better Plants Program Bootcamps, which are designed to enhance participants’ technical skills in improving energy efficiency and optimizing operations in manufacturing facilities. Through the analysis of survey data collected from 529 participants across 9 bootcamps, the research investigates the motivations, benefits, and demographic trends of attendees. The findings reveal that skill acquisition and improvement are primary drivers for participation, with key benefits including hands-on training on diagnostic equipment and software tools, networking opportunities, and access to technical resources. The analysis shows strong participation from sectors characterized by high energy consumption and employment, such as chemical and transportation equipment manufacturing. Over 50% of participants have job titles that include “EHS” or “Energy” showing their key roles in leading energy efficiency and energy management efforts in manufacturing. Furthermore, the analysis highlights the distribution of participants across managerial, engineering, and technical roles, revealing a higher representation of managers and engineers. This observation suggests a need for targeted outreach to engage technicians, equipment operators, maintenance staff, and floor workers to ensure comprehensive workforce development. The post-bootcamp survey showed that the participants highly valued the opportunities for peer learning and idea exchange, and the benefits they gained from them. This research contributes to the advancement of manufacturing education by demonstrating the efficacy of specialized training in addressing critical industry challenges and fostering a more competent and empowered workforce.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"47 ","pages":"Pages 20-24"},"PeriodicalIF":2.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145798342","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}
{"title":"Microwave-Assisted compression moulding of Flax/Bio-PBS composites using an Innovative Spring-Loaded fixture for sustainable manufacturing","authors":"Adil Irshad , Sunny Zafar , Himanshu Pathak , Rajneesh Sharma","doi":"10.1016/j.mfglet.2025.11.006","DOIUrl":"10.1016/j.mfglet.2025.11.006","url":null,"abstract":"<div><div>This study presents a novel spring-loaded fixture for microwave-assisted compression moulding (MACM) of sustainable flax fiber-reinforced bio-based Polybutylene Succinate (bio-PBS) composites. Unlike conventional screw fixtures, the spring system ensures continuous, uniform pressure during rapid microwave curing, preventing relaxation and enhancing fiber–matrix bonding. As a result, composites exhibited superior densification and void reduction (19.50 % to 2.69 % (7.25 times)), confirmed by X-ray micro-CT. The improved consolidation yielded significantly improved mechanical properties. The optimum composite at 0.5 MPa achieved tensile strength of 76 MPa, tensile modulus of 5.75 GPa, flexural strength of 109.5 MPa, and flexural modulus of 15 GPa, improvements of 4.4, 3.3, 2.6, and 3.2 times, respectively, over conventional samples. Overall, the spring-loaded fixture offers a scalable, energy-efficient approach to producing high-performance, low-void fiber reinforced composites, advancing MACM for sustainable manufacturing.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"47 ","pages":"Pages 1-10"},"PeriodicalIF":2.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145705310","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}
Manufacturing LettersPub Date : 2026-03-01Epub Date: 2026-01-10DOI: 10.1016/j.mfglet.2026.01.001
Arivazhagan Anbalagan , John E Graves , Oliver James Curnick , Danijela Rostohar , Margret Anouncia Savarimuthu , Anthony Xavior Michael , Rajkumar Soundarapandiyan , Jeyapandiarajan Paulchamy , Mythili Thirugnanam
{"title":"SEM images data set development of ML models to predict hydrogen embrittlement in welded 316 L/304 L stainless steels","authors":"Arivazhagan Anbalagan , John E Graves , Oliver James Curnick , Danijela Rostohar , Margret Anouncia Savarimuthu , Anthony Xavior Michael , Rajkumar Soundarapandiyan , Jeyapandiarajan Paulchamy , Mythili Thirugnanam","doi":"10.1016/j.mfglet.2026.01.001","DOIUrl":"10.1016/j.mfglet.2026.01.001","url":null,"abstract":"<div><div>This study focuses on the machine learning (ML)-based identification of defects caused by hydrogen embrittlement (H2E) in the welded zones of 316 L/304 L stainless steels. It involves developing a robust SEM image dataset to train ML models for accurate defect identification. Initially, Gas Metal Arc Welding (GMAW) samples were manufactured with weld gap variations of 0.8 mm, 1.2 mm, and 1.5 mm. The welding parameters used were: (i) welding speeds of 15 mm/sec and 10 mm/sec, (ii) wire feed rate of 5.5 m/min, and (iii) voltage of 15.5 V. The samples were then exposed to a hydrogen gas environment at a pressure of 80 bar for 150 h. When analyzed using scanning electron microscopy (SEM) & electron backscatter diffraction (EBSD), H2E was observed on the surfaces of the welded zones (WZ) and heat-affected zones (HAZ). These defects, validated through literature, were segregated / sectioned as defect-based feature images and stored as a dataset. A preliminary analysis of the images validated after with 16 DOE’s using AlexNet, a convolutional neural network (CNN)-based ML model, showed significant identification of these defects with 90 % accuracy. The trained models helped identify areas and understand previously unidentified defects. Through a focused discussion on defect detection, supported by validation using classification (CNN Accuracy, Precision, Recall, and F1-Score) and regression metrics (R2 and Success Rate), the article demonstrates the potential of ML-based approaches in advancing welding diagnostics.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"47 ","pages":"Pages 51-57"},"PeriodicalIF":2.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146037911","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}
Manufacturing LettersPub Date : 2026-03-01Epub Date: 2026-01-04DOI: 10.1016/j.mfglet.2025.12.003
Anna Wąsik , Beata Leszczyńska-Madej , Marcin Madej
{"title":"Enhanced wear resistance in Al–Cu–SiC composites through extrusion-assisted powder metallurgy","authors":"Anna Wąsik , Beata Leszczyńska-Madej , Marcin Madej","doi":"10.1016/j.mfglet.2025.12.003","DOIUrl":"10.1016/j.mfglet.2025.12.003","url":null,"abstract":"<div><div>This study compares the influence of processing route and SiC content on the microstructure, mechanical properties and tribological behavior of Al–4Cu–xSiC (x = 0, 5, 10 wt%) composites. Materials were fabricated by powder metallurgy using two routes: conventional pressing and sintering (PM) and hot extrusion before sintering (HE). Hot extrusion improved particle distribution, grain refinement and oxide film disruption. Relative density decreased from 98.74 % (unreinforced) to 96.29 % (10 wt% SiC) in PM composites, while HE samples showed ∼91.9 % but more uniform density. Hardness rose from 55 to 60 HB with SiC in PM, while extruded materials remained near 56 HB. Tribological tests (dry sliding, 50 N, 500 m) revealed that extrusion enhanced wear resistance and friction stability. The best result was for 5 wt% SiC HE composite, with lowest friction (≈0.27) and minimal loss of mass (0.00123 g). SEM confirmed adhesive and abrasive wear mechanisms.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"47 ","pages":"Pages 25-31"},"PeriodicalIF":2.0,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145926435","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}
Manufacturing LettersPub Date : 2025-12-01Epub Date: 2025-10-25DOI: 10.1016/j.mfglet.2025.10.014
Weihang Zhu , Mariam Manuel , Paige Evans , Peter Weber
{"title":"An engineering design process course for high school preservice teachers based on 3D printer component analysis","authors":"Weihang Zhu , Mariam Manuel , Paige Evans , Peter Weber","doi":"10.1016/j.mfglet.2025.10.014","DOIUrl":"10.1016/j.mfglet.2025.10.014","url":null,"abstract":"<div><div>3D printing (3DP) has been becoming pervasive in the K-16 education system. However, in many schools, new 3D printers arrive, work for a certain period, and before long break down due to lack of maintenance and support. Teachers must develop a deeper understanding of 3D printing to fully realize its potential in engineering design. This course responds to that need by integrating 3D printer dissection with the Engineering Design Process (EDP) and culturally responsive pedagogy (CRP). In this project, the course of engineering design for preservice teachers (PST, current undergraduate students) is developed and implemented with mechanical components from dissected 3D printers. The approach is to dissect a 3D printer’s hardware, explain each component’s function, introduce each component’s manufacturing methods, describe possible defects, and elucidate what works and what does not. This allows the PSTs to develop a better understanding of 3D printing process, have a better idea on how to fix a 3D printer when it breaks down, and design components that are compatible with 3D printing. Findings from pre- and post-course quizzes and course evaluations indicate that preservice teachers not only improved their technical knowledge of 3D printing but also gained confidence in applying EDP and CRP practices, strengthening the sustainability and meaningful use of 3D printing in classrooms.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"46 ","pages":"Pages 88-91"},"PeriodicalIF":2.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145416717","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}
Manufacturing LettersPub Date : 2025-12-01Epub Date: 2025-10-22DOI: 10.1016/j.mfglet.2025.10.016
Tyler Woodard , John Greene , Andrew Honeycutt , Tony Schmitz
{"title":"Design, fabrication, and performance evaluation of low cost, open-source desktop milling machine","authors":"Tyler Woodard , John Greene , Andrew Honeycutt , Tony Schmitz","doi":"10.1016/j.mfglet.2025.10.016","DOIUrl":"10.1016/j.mfglet.2025.10.016","url":null,"abstract":"<div><div>This paper describes the design, fabrication, and performance evaluation of a three-axis computer-controlled desktop milling machine. To increase availability for this technology and provide education and training opportunities for the machining workforce, a primary goal for this machine is to provide a low-cost option for educators and students to access milling technology. The intent of the machine and, later, the supporting curriculum is to introduce machining and machining science to the next generation of manufacturers using a desktop format. Results are provided for the machine design and testing, including error motions, dynamics, and machining performance.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"46 ","pages":"Pages 72-76"},"PeriodicalIF":2.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145416610","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}
Manufacturing LettersPub Date : 2025-12-01Epub Date: 2025-10-13DOI: 10.1016/j.mfglet.2025.10.004
Zhen Zhao, John Liu
{"title":"Improving employer engagement in manufacturing workforce development programs","authors":"Zhen Zhao, John Liu","doi":"10.1016/j.mfglet.2025.10.004","DOIUrl":"10.1016/j.mfglet.2025.10.004","url":null,"abstract":"<div><div>U.S. manufacturers face significant recruitment and retention challenges, compelling them to seek support from workforce development (WD) programs. Effective WD programs actively incorporate employer input in program design, development, and implementation to ensure relevance and meet the specific hiring needs of the manufacturing industry. Using a multi-method approach, this study examined manufacturers' preferences for engagement across areas in oversight, design, delivery, recruitment, and resource support. The results show that employers seek greater involvement in strategic oversight, curriculum design, and program delivery. Structured strategies for employer participation are recommended to ensure that WD programs align closely with industry needs.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"46 ","pages":"Pages 83-87"},"PeriodicalIF":2.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145416716","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}
Manufacturing LettersPub Date : 2025-12-01Epub Date: 2025-11-27DOI: 10.1016/j.mfglet.2025.11.010
M.C.A. van der Pas , A.E. Akçay , R.M. Dijkman , I.J.B.F. Adan
{"title":"Combining case-based reasoning and process mining for root cause analysis in complex manufacturing environments","authors":"M.C.A. van der Pas , A.E. Akçay , R.M. Dijkman , I.J.B.F. Adan","doi":"10.1016/j.mfglet.2025.11.010","DOIUrl":"10.1016/j.mfglet.2025.11.010","url":null,"abstract":"<div><div>Root Cause Analysis (RCA) of problems in a manufacturing process is becoming increasingly complex due to the growing complexity of products and processes. On the other hand, due to digitalisation and Industry 4.0, various systems collect an increasing volume of data about the processes. These data can be used to improve the RCA, but it can be challenging because the data is scattered across different systems. Therefore, this paper presents a framework to assist engineers with location-time RCA. The proposed framework is based on the Case-Based Reasoning cycle. It includes four steps: collect production trace data, enrich the collected data, identify the production trace, and finally compare traces to identify the location of the root cause. Techniques from the Semantic Web and Process Mining communities are combined in the framework to offer an integrated solution from data collection to root cause localisation.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"46 ","pages":"Pages 156-160"},"PeriodicalIF":2.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145684483","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}