Anand Krishnan, Xingjian Yang, Utsav Seth, Jonathan M Jeyachandran, Jonathan Y Ahn, Richard Gardner, Samuel F Pedigo, Adriana W Blom-Schieber, Ashis G Banerjee, Krithika Manohar
{"title":"Data-driven ergonomic risk assessment of complex hand-intensive manufacturing processes.","authors":"Anand Krishnan, Xingjian Yang, Utsav Seth, Jonathan M Jeyachandran, Jonathan Y Ahn, Richard Gardner, Samuel F Pedigo, Adriana W Blom-Schieber, Ashis G Banerjee, Krithika Manohar","doi":"10.1038/s44172-025-00382-w","DOIUrl":"10.1038/s44172-025-00382-w","url":null,"abstract":"<p><p>Hand-intensive manufacturing processes, such as composite layup and textile draping, require significant human dexterity to accommodate task complexity. These strenuous hand motions often lead to musculoskeletal disorders and rehabilitation surgeries. Here we develop a data-driven ergonomic risk assessment system focused on hand and finger activity to better identify and address these risks in manufacturing. This system integrates a multi-modal sensor testbed that captures operator upper body pose, hand pose, and applied force data during hand-intensive composite layup tasks. We introduce the Biometric Assessment of Complete Hand (BACH) ergonomic score, which measures hand and finger risks with greater granularity than existing risk scores for upper body posture (Rapid Upper Limb Assessment, or RULA) and hand activity level (HAL). Additionally, we train machine learning models that effectively predict RULA and HAL metrics for new participants, using data collected at the University of Washington in 2023. Our assessment system, therefore, provides ergonomic interpretability of manufacturing processes, enabling targeted workplace optimizations and posture corrections to improve safety.</p>","PeriodicalId":72644,"journal":{"name":"Communications engineering","volume":"4 1","pages":"45"},"PeriodicalIF":0.0,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11903948/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143617862","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}
Karan P Patel, Andrew Maicke, Jared Arzate, Jaesuk Kwon, J Darby Smith, James B Aimone, Jean Anne C Incorvia, Suma G Cardwell, Catherine D Schuman
{"title":"AI-guided framework for the design of materials and devices for magnetic-tunnel-junction-based true random number generators.","authors":"Karan P Patel, Andrew Maicke, Jared Arzate, Jaesuk Kwon, J Darby Smith, James B Aimone, Jean Anne C Incorvia, Suma G Cardwell, Catherine D Schuman","doi":"10.1038/s44172-025-00376-8","DOIUrl":"10.1038/s44172-025-00376-8","url":null,"abstract":"<p><p>Emerging devices, such as magnetic tunnel junctions, are key for energy-efficient, performant future computing systems. However, designing devices with the desirable specification and performance for these applications is often found to be time-consuming and non-trivial. Here, we investigate the design and optimization of spin-orbit torque and spin transfer torque magnetic tunnel junction models as the probabilistic devices for true random number generation. We leverage reinforcement learning and evolutionary optimization to vary key device and material properties of the various device models for stochastic operation. Our artificial-intelligence-guided codesign methods generated different candidate devices capable of generating stochastic samples for a desired probability distribution, while also minimizing energy usage for the devices. This framework can also be applied to other devices and applications.</p>","PeriodicalId":72644,"journal":{"name":"Communications engineering","volume":"4 1","pages":"43"},"PeriodicalIF":0.0,"publicationDate":"2025-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11897232/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143607386","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}
{"title":"Emerging sensor technologies and physics-guided methods for monitoring automotive lithium-based batteries.","authors":"Xia Zeng, Maitane Berecibar","doi":"10.1038/s44172-025-00383-9","DOIUrl":"10.1038/s44172-025-00383-9","url":null,"abstract":"<p><p>As the automotive industry undergoes a major shift to electric propulsion, reliable assessment of battery health and potential safety issues is critical. This review covers advances in sensor technology, from mechanical and gas sensors to ultrasonic imaging techniques that provide insight into the complex structures and dynamics of lithium-ion batteries. In addition, we explore the integration of physics-guided machine learning methods with multi-sensor systems to improve the accuracy of battery modeling and monitoring. Challenges and opportunities in prototyping and scaling these multi-sensor systems are discussed, highlighting both current limitations and future potential. The purpose of this study is to provide a comprehensive overview of the current status, challenges, and future directions of combining sensors with physically guided methods for future vehicle battery management systems.</p>","PeriodicalId":72644,"journal":{"name":"Communications engineering","volume":"4 1","pages":"44"},"PeriodicalIF":0.0,"publicationDate":"2025-03-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11897319/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143607369","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}
Haoran Wang, Peter T Brown, Jessica Ullom, Douglas P Shepherd, Rainer Heintzmann, Benedict Diederich
{"title":"Fully automated multicolour structured illumination module for super-resolution microscopy with two excitation colours.","authors":"Haoran Wang, Peter T Brown, Jessica Ullom, Douglas P Shepherd, Rainer Heintzmann, Benedict Diederich","doi":"10.1038/s44172-025-00365-x","DOIUrl":"10.1038/s44172-025-00365-x","url":null,"abstract":"<p><p>In biological imaging, there is a demand for cost-effective, high-resolution techniques to study dynamic intracellular processes. Structured illumination microscopy (SIM) is ideal for achieving high axial and lateral resolution in live samples due to its optical sectioning and low phototoxicity. However, conventional SIM systems remain expensive and complex. We introduce openSIMMO, an open-source, fully-automated SIM module compatible with commercial microscopes, supporting dual-color excitation. Our design uses affordable single-mode fiber-coupled lasers and a digital micromirror device (DMD), integrated with the open-source ImSwitch software for real-time super-resolution imaging. This setup offers up to 1.55-fold improvement in lateral resolution over wide-field microscopy. To optimize DMD diffraction, we developed a model for tilt and roll pixel configurations, enabling use with various low-cost projectors in SIM setups. Our goal is to democratize SIM-based super-resolution microscopy by providing open-source documentation and a flexible software framework adaptable to various hardware (e.g., cameras, stages) and reconstruction algorithms, enabling more widespread super-resolution upgrades across devices.</p>","PeriodicalId":72644,"journal":{"name":"Communications engineering","volume":"4 1","pages":"42"},"PeriodicalIF":0.0,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11894046/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143598409","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}
Tim Weber, Andrey Boyarintsev, Umut Kose, Botao Li, Davide Sgalaberna, Tetiana Sibilieva, Johannes Wüthrich, Siddartha Berns, Eric Boillat, Albert De Roeck, Till Dieminger, Matthew Franks, Boris Grynyov, Sylvain Hugon, Carsten Jaeschke, André Rubbia
{"title":"Additive manufacturing of a 3D-segmented plastic scintillator detector for tracking and calorimetry of elementary particles.","authors":"Tim Weber, Andrey Boyarintsev, Umut Kose, Botao Li, Davide Sgalaberna, Tetiana Sibilieva, Johannes Wüthrich, Siddartha Berns, Eric Boillat, Albert De Roeck, Till Dieminger, Matthew Franks, Boris Grynyov, Sylvain Hugon, Carsten Jaeschke, André Rubbia","doi":"10.1038/s44172-025-00371-z","DOIUrl":"10.1038/s44172-025-00371-z","url":null,"abstract":"<p><p>Plastic scintillators, segmented into small, optically isolated voxels, are used for detecting elementary particles and provide reliable particle identification with nanosecond time resolution. Building large detectors requires the production and precise alignment of millions of individual units, a process that is time-consuming, cost-intensive, and difficult to scale. Here, we introduce an additive manufacturing process chain capable of producing plastic-based scintillator detectors as a single, monolithic structure. Unlike previous manufacturing methods, this approach consolidates all production steps within one machine, creating a detector that integrates and precisely aligns its voxels into a unified structure. By combining fused deposition modeling with an injection process optimized for fabricating scintillation geometries, we produced an additively manufactured fine-granularity plastic scintillator detector with performance comparable to the state of the art, and demonstrated its capabilities for 3D tracking of elementary particles and energy-loss measurement. This work presents an efficient and economical production process for manufacturing plastic-based scintillator detectors, adaptable to various sizes and geometries.</p>","PeriodicalId":72644,"journal":{"name":"Communications engineering","volume":"4 1","pages":"41"},"PeriodicalIF":0.0,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11882974/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143568933","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}
Dmitry Dobrykh, Konstantin Grotov, Anna Mikhailovskaya, Dmytro Vovchuk, Vladyslav Tkach, Mykola Khobzei, Anton Kharchevskii, Aviel Glam, Pavel Ginzburg
{"title":"3D evolutionarily designed metamaterials for scattering maximization.","authors":"Dmitry Dobrykh, Konstantin Grotov, Anna Mikhailovskaya, Dmytro Vovchuk, Vladyslav Tkach, Mykola Khobzei, Anton Kharchevskii, Aviel Glam, Pavel Ginzburg","doi":"10.1038/s44172-025-00349-x","DOIUrl":"10.1038/s44172-025-00349-x","url":null,"abstract":"<p><p>The rapid growth in drone air traffic calls for enhanced radar surveillance systems to ensure reliable detection in challenging conditions. Increasing radar scattering cross-section can greatly improve detection reliability in civilian applications. Here, we introduce a concept of evolutionarily designed metamaterials in the form of multilayer stacks of arrays, featuring strongly coupled electric and magnetic resonators. These structures demonstrate a broadband end-fire scattering cross-section exceeding 1 m² at 10 GHz and, despite their compact footprint, achieve over 10% fractional bandwidth, meeting essential radar requirements for high-range resolution. While scattering cross-section and bandwidth are typically contradictory in resonant structures, this trend is circumvented by applying the resonance cascading principle, wherein a series of closely spaced, spectrally aligned resonant multipoles create a coherent response. The resonance cascading is engineered with the aid of multi-objective optimization, implemented on top of a genetic algorithm, operating in a large search space, encompassing over 100 independent variables. Experimentally realized parameters match typical scattering cross-sections of large airborne targets. Consequently, these performance characteristics enable the exploration of highly scattering structures as identifiers for small airborne targets, supporting effective radar-based air traffic monitoring in civilian applications, which we demonstrate through outdoor experiments using the DJI Mini 2 drone.</p>","PeriodicalId":72644,"journal":{"name":"Communications engineering","volume":"4 1","pages":"40"},"PeriodicalIF":0.0,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11882990/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143568839","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}
{"title":"Revealing the mechanism of cold metal transfer.","authors":"J Karimi, C Zhao","doi":"10.1038/s44172-025-00378-6","DOIUrl":"10.1038/s44172-025-00378-6","url":null,"abstract":"<p><p>Cold metal transfer (CMT) is a pioneering feeding system widely used in wire-arc additive manufacturing (WAAM) and welding. However, process optimisation remains challenging. Although CMT has been extensively applied in various industrial sectors, its underlying mechanism is poorly understood because of the complex physics of the interactions between the wire and molten material and the wire's highly dynamic motion. To elucidate the complexity and features of CMT, we explore the dynamic behaviour and anatomy of molten materials during wire motions (withdrawal and dipping cycles) using high-speed photography at a timescale of microseconds. We reveal a crucial driving force in the melt pool and the frequent ejection of streams or particles during CMT. This study contributes to WAAM and welding by presenting the influential features of ultra-high-dynamics CMT and facilitating the progression of process optimisation.</p>","PeriodicalId":72644,"journal":{"name":"Communications engineering","volume":"4 1","pages":"39"},"PeriodicalIF":0.0,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11882817/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143568887","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}
{"title":"Anthrone/XLPE: an adaptive charge capture intelligent insulation material for advanced electric power transmission.","authors":"Ke Li, Lu-Ming Zhou, Xiao-Qian Zhu, Zheng Bai, Gui-Min Jiang, Yuan-Xiang Zhou, Yun-Xiao Zhang","doi":"10.1038/s44172-025-00361-1","DOIUrl":"10.1038/s44172-025-00361-1","url":null,"abstract":"<p><p>The degradation of electrical insulation is mainly attributed to local defects. Although incorporating organic small molecules into dielectric polymers promotes the insulation strength, accurate suppression of defect development is a long-term and formidable challenge. Here we utilize the adaptive charge capture methodology to achieve precise defect suppression, leading to a 123% increase in the initiation voltage of electrical trees in anthrone/cross-linked polyethylene, significantly outperforming existing dielectric polymers and polymer composites. A significant observation is the confinement of charge at the interface between the anode and cross-linked polyethylene in anthrone/cross-linked polyethylene, generating a reverse inherent electric field near the interface and reducing the internal electric field strength of cross-linked polyethylene by up to 18%. These findings not only open avenues for further exploration of materials for ultra-high voltage cables but also play a crucial role in the commercialization and practical application of organic semiconductors in insulation dielectrics.</p>","PeriodicalId":72644,"journal":{"name":"Communications engineering","volume":"4 1","pages":"38"},"PeriodicalIF":0.0,"publicationDate":"2025-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11876605/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143544748","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}
{"title":"A computational spectrometer for the visible, near, and mid-infrared enabled by a single-spinning film encoder.","authors":"Junren Wen, Weiming Shi, Cheng Gao, Yujie Liu, Shuaibo Feng, Yu Shao, Haiqi Gao, Yuchuan Shao, Yueguang Zhang, Weidong Shen, Chenying Yang","doi":"10.1038/s44172-025-00379-5","DOIUrl":"10.1038/s44172-025-00379-5","url":null,"abstract":"<p><p>Computational spectrometers enable low-cost, in-situ, and rapid spectral analysis, with applications in chemistry, biology, and environmental science. Traditional filter-based spectral encoding approaches typically use filter arrays, complicating the manufacturing process and hindering device consistency. Here we propose a computational spectrometer spanning visible to mid-infrared by combining the Single-Spinning Film Encoder (SSFE) with a deep learning-based reconstruction algorithm. Optimization through particle swarm optimization (PSO) allows for low-correlation and high-complexity spectral responses under different polarizations and spinning angles. The spectrometer demonstrates single-peak resolutions of 0.5 nm, 2 nm, 10 nm, and dual-peak resolutions of 3 nm, 6 nm, 20 nm for the visible, near, and mid-infrared wavelength ranges. Experimentally, it shows an average MSE of 1.05 × 10⁻³ for narrowband spectral reconstruction in the visible wavelength range, with average center-wavelength and linewidth errors of 0.61 nm and 0.56 nm. Additionally, it achieves an overall 81.38% precision for the classification of 220 chemical compounds, showcasing its potential for compact, cost-effective spectroscopic solutions.</p>","PeriodicalId":72644,"journal":{"name":"Communications engineering","volume":"4 1","pages":"37"},"PeriodicalIF":0.0,"publicationDate":"2025-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11871129/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143532111","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}
Yunlong Su, Xiyao Li, Jiao Wang, Rui Du, Xiaofei Xue, Yongzhen Peng
{"title":"Pilot-scale partial nitrification and anaerobic ammonium oxidation system for nitrogen removal from municipal wastewater.","authors":"Yunlong Su, Xiyao Li, Jiao Wang, Rui Du, Xiaofei Xue, Yongzhen Peng","doi":"10.1038/s44172-025-00362-0","DOIUrl":"10.1038/s44172-025-00362-0","url":null,"abstract":"<p><p>Partial nitrification has the advantages of saving energy and reducing the need for carbon sources in municipal wastewater treatment. However, for municipal wastewater with low ammonia, start-up and maintenance of partial nitrification is a worldwide challenge. Here we developed a pilot-scale double sludge system consisting of two sequencing batch reactors for partial nitrification (12 m<sup>2</sup>) and denitrification/anaerobic ammonium oxidation (denitrification/anammox, 8.4 m<sup>2</sup>) to treat municipal wastewater. Partial nitrification was maintained at no ammonium remaining with a nitrite accumulation rate of 87.7%. This study found that partial nitrification system effluent chemical oxygen demand increased from 24.8 mg L<sup>-1</sup> to 64.9 mg L<sup>-1</sup> accompanied by transformation from complete nitrification to partial nitrification. In the denitrification/anammox system, the reduction of nitrite to nitrogen required about 40% less carbon consumption than nitrate. High nitrogen removal was achieved with effluent total inorganic nitrogen of 2.7 mg L<sup>-1</sup> without carbon addition. This work provided a pilot-scale demonstration of low-carbon high-nitrogen removal.</p>","PeriodicalId":72644,"journal":{"name":"Communications engineering","volume":"4 1","pages":"36"},"PeriodicalIF":0.0,"publicationDate":"2025-02-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC11868482/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143525222","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}