Pub Date : 2025-09-01Epub Date: 2025-06-13DOI: 10.1016/j.mfglet.2025.06.198
Mohammad Mohammadzadeh Sanandaji, Rahat Mollick, Albert Ratner, Hongtao Ding
This study presents a laser-enabled organic coating (LASEO) approach that integrates laser texturing with gel-like carbon dot (G-CD) treatment to develop a PFAS-free alternative for metal surfaces. In this method, nanosecond laser-induced micro/nanostructures enhance coating adhesion, while the G-CD coating provides durable superhydrophilicity and even superwicking behavior. Experimental results show that LASEO-treated surfaces maintain a water contact angle below 10° for over 30 days, outperforming conventional hydrophilic coatings. This scalable technique holds promise for applications in fluid transport and thermal management, offering a sustainable alternative to PFAS-based coatings.
{"title":"Laser-enabled organic coating for sustainable PFAS-free metal surfaces","authors":"Mohammad Mohammadzadeh Sanandaji, Rahat Mollick, Albert Ratner, Hongtao Ding","doi":"10.1016/j.mfglet.2025.06.198","DOIUrl":"10.1016/j.mfglet.2025.06.198","url":null,"abstract":"<div><div>This study presents a laser-enabled organic coating (LASEO) approach that integrates laser texturing with gel-like carbon dot (G-CD) treatment to develop a PFAS-free alternative for metal surfaces. In this method, nanosecond laser-induced micro/nanostructures enhance coating adhesion, while the G-CD coating provides durable superhydrophilicity and even superwicking behavior. Experimental results show that LASEO-treated surfaces maintain a water contact angle below 10° for over 30 days, outperforming conventional hydrophilic coatings. This scalable technique holds promise for applications in fluid transport and thermal management, offering a sustainable alternative to PFAS-based coatings.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 8-12"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144366061","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}
Artificial intelligence (AI) offers promise for advancing composite manufacturing by enhancing process monitoring, efficiency, and quality while mitigating defects. Nevertheless, AI application for anomaly detection is constrained by limited real-world data and reliance on labeled datasets, necessitating frequent retraining. We propose a novel three-stage anomaly detection framework for composite curing. First, an autoencoder is trained on normal data to extract features. Next, K-means clustering groups similar patterns. Finally, a model combining Mahalanobis distance with an elliptic envelope quantifies deviations using cluster-specific thresholds. Evaluation on autoclave data with a Digital Image Correlation setup yielded an impressive detection accuracy of 99.69% overall.
{"title":"Unsupervised anomaly detection in composite manufacturing using autoencoders and cluster-specific thresholding","authors":"Deepak Kumar, Pragathi Chan Agraharam, Sirish Namilae","doi":"10.1016/j.mfglet.2025.08.001","DOIUrl":"10.1016/j.mfglet.2025.08.001","url":null,"abstract":"<div><div>Artificial intelligence (AI) offers promise for advancing composite manufacturing by enhancing process monitoring, efficiency, and quality while mitigating defects. Nevertheless, AI application for anomaly detection is constrained by limited real-world data and reliance on labeled datasets, necessitating frequent retraining. We propose a novel three-stage anomaly detection framework for composite curing. First, an autoencoder is trained on normal data to extract features. Next, K-means clustering groups similar patterns. Finally, a model combining Mahalanobis distance with an elliptic envelope quantifies deviations using cluster-specific thresholds. Evaluation on autoclave data with a Digital Image Correlation setup yielded an impressive detection accuracy of 99.69% overall.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 101-106"},"PeriodicalIF":2.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144902875","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}
Pub Date : 2025-09-01Epub Date: 2025-06-21DOI: 10.1016/j.mfglet.2025.06.200
Hrishikesh Das, Shivakant Shukla, Piyush Upadhyay
We present the first experimental demonstration of high-speed (1 m/min) robotic friction stir lap welding for three-sheet (3T) stack-ups of both similar and dissimilar aluminum alloys, including wrought and cast forms. The mechanical performance of the joints under lap shear, T-peel, and U-peel/KSII loading were evaluated. A novel U-peel/KSII configuration, applied for the first time for linear joints demonstrates the role of stitch welds in arresting crack growth. These results establish the feasibility of using robotic FSLW for complex, high-volume automotive structures while maintaining high weld quality at industrially relevant speeds.
{"title":"High-speed robotic friction stir lap welding of three stack aluminum alloy assembly for automotive applications","authors":"Hrishikesh Das, Shivakant Shukla, Piyush Upadhyay","doi":"10.1016/j.mfglet.2025.06.200","DOIUrl":"10.1016/j.mfglet.2025.06.200","url":null,"abstract":"<div><div>We present the first experimental demonstration of high-speed (1 m/min) robotic friction stir lap welding for three-sheet (3T) stack-ups of both similar and dissimilar aluminum alloys, including wrought and cast forms. The mechanical performance of the joints under lap shear, T-peel, and U-peel/KSII loading were evaluated. A novel U-peel/KSII configuration, applied for the first time for linear joints demonstrates the role of stitch welds in arresting crack growth. These results establish the feasibility of using robotic FSLW for complex, high-volume automotive structures while maintaining high weld quality at industrially relevant speeds.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 36-40"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144563557","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}
Pub Date : 2025-09-01Epub Date: 2025-06-15DOI: 10.1016/j.mfglet.2025.06.199
Ethan York , Xijia Zhao , Hassan Ghessemi-Armaki , Blair Carlson , Peng Wang
Resistance Spot Welding (RSW) is a crucial manufacturing process, especially in automotive manufacturing. However, quality assurance in RSW remains a challenge, due to the lack of low-cost, non-invasive process sensing techniques. This paper investigates Transformer for generating virtual electrode force and displacement signals from physically measurable DR signals. Furthermore, to enhance the generalizability, the transformer has been enhanced by transfer learning to adapt to dynamic welding scenarios, by pre-training the transformer model with data from diverse welding conditions and fine-tuning using minimal experimental data from novel conditions. Experimental results validate the effectiveness of virtual sensing technology for RSW process monitoring.
{"title":"Transfer learning-enhanced transformer for virtual process sensing in resistance spot welding","authors":"Ethan York , Xijia Zhao , Hassan Ghessemi-Armaki , Blair Carlson , Peng Wang","doi":"10.1016/j.mfglet.2025.06.199","DOIUrl":"10.1016/j.mfglet.2025.06.199","url":null,"abstract":"<div><div>Resistance Spot Welding (RSW) is a crucial manufacturing process, especially in automotive manufacturing. However, quality assurance in RSW remains a challenge, due to the lack of low-cost, non-invasive process sensing techniques. This paper investigates Transformer for generating virtual electrode force and displacement signals from physically measurable DR signals. Furthermore, to enhance the generalizability, the transformer has been enhanced by transfer learning to adapt to dynamic welding scenarios, by pre-training the transformer model with data from diverse welding conditions and fine-tuning using minimal experimental data from novel conditions. Experimental results validate the effectiveness of virtual sensing technology for RSW process monitoring.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 13-16"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144338296","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}
Pub Date : 2025-09-01Epub Date: 2025-05-28DOI: 10.1016/j.mfglet.2025.05.002
Sergei Ivanov, Artur Vildanov, Konstantin Babkin, Evgeniy Zemlyakov
In this work the influence of the heat transfer coefficient on the accuracy of the numerical prediction of the macroscopic temperature field in direct laser deposition of large-scale thin-walled structures is investigated in detail. It is shown that a temperature-independent constant heat transfer coefficient results in a considerable discrepancy in the prediction of the interpass temperature and the temperature distribution in the whole buildup. The numerical simulation revealed that the macroscopic temperature field in the buildup exhibits a pronounced sensitivity to the temperature dependence of the heat transfer coefficient. The film coefficient of the bottom surface of the substrate, which contacts the massive turntable of the direct laser deposition machine, has a negligible effect on the interpass temperature and mainly influences the temperature distribution near the substrate.
{"title":"Influence of convection heat transfer coefficient on the predicted macroscopic temperature field in direct laser deposition of large-scale parts","authors":"Sergei Ivanov, Artur Vildanov, Konstantin Babkin, Evgeniy Zemlyakov","doi":"10.1016/j.mfglet.2025.05.002","DOIUrl":"10.1016/j.mfglet.2025.05.002","url":null,"abstract":"<div><div>In this work the influence of the heat transfer coefficient on the accuracy of the numerical prediction of the macroscopic temperature field in direct laser deposition of large-scale thin-walled structures is investigated in detail. It is shown that a temperature-independent constant heat transfer coefficient results in a considerable discrepancy in the prediction of the interpass temperature and the temperature distribution in the whole buildup. The numerical simulation revealed that the macroscopic temperature field in the buildup exhibits a pronounced sensitivity to the temperature dependence of the heat transfer coefficient. The film coefficient of the bottom surface of the substrate, which contacts the massive turntable of the direct laser deposition machine, has a negligible effect on the interpass temperature and mainly influences the temperature distribution near the substrate.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 1-7"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144212459","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}
Pub Date : 2025-09-01Epub Date: 2025-07-30DOI: 10.1016/j.mfglet.2025.07.005
Salman Murad , Marvin Heyer , Fabian Lickert , Judith Schlanderer , Daniel Kainz , Markus Rombach , Christoph Stöver , Thomas Ruhl , Benedikt Bläsi , Julian Menges , Tobias Hutzenlaub , Nils Paust , Peter Juelg
Developing scalable and cost-effective fabrication methods for microfluidic lab-on-a-chip devices is critical to bridging the gap between rapid prototyping and mass production. We present a rapid and affordable prototyping method for lab-on-a-foil devices with multi-scale fluidic features ranging from picoliters (features size: 20 µm) to microliters (feature size: 100–1500 µm). Our three-step approach — thermoforming, hot embossing, and thermal sealing — enables the co-integration of picoliter wells with nano- to microliter channels and chambers using cyclic olefin copolymer (COC), a thermoplastic polymer suitable for scalable manufacturing without requiring additional surface treatments. This method overcomes the limitations of non-scalable polydimethylsiloxane (PDMS) prototyping and the high initial cost of thermoplastic injection molding. With low tooling costs, rapid turnaround times, and material compatibility with high-precision mass production, this technique offers an efficient pathway for the development of multi-scale lab-on-a-chip devices for applications such as digital PCR and solid phase extraction.
{"title":"Rapid prototyping of microfluidic multi-scale lab-on-a-foil devices in COC","authors":"Salman Murad , Marvin Heyer , Fabian Lickert , Judith Schlanderer , Daniel Kainz , Markus Rombach , Christoph Stöver , Thomas Ruhl , Benedikt Bläsi , Julian Menges , Tobias Hutzenlaub , Nils Paust , Peter Juelg","doi":"10.1016/j.mfglet.2025.07.005","DOIUrl":"10.1016/j.mfglet.2025.07.005","url":null,"abstract":"<div><div>Developing scalable and cost-effective fabrication methods for microfluidic lab-on-a-chip devices is critical to bridging the gap between rapid prototyping and mass production. We present a rapid and affordable prototyping method for lab-on-a-foil devices with multi-scale fluidic features ranging from picoliters (features size: 20 µm) to microliters (feature size: 100–1500 µm). Our three-step approach — thermoforming, hot embossing, and thermal sealing — enables the co-integration of picoliter wells with nano- to microliter channels and chambers using cyclic olefin copolymer (COC), a thermoplastic polymer suitable for scalable manufacturing without requiring additional surface treatments. This method overcomes the limitations of non-scalable polydimethylsiloxane (PDMS) prototyping and the high initial cost of thermoplastic injection molding. With low tooling costs, rapid turnaround times, and material compatibility with high-precision mass production, this technique offers an efficient pathway for the development of multi-scale lab-on-a-chip devices for applications such as digital PCR and solid phase extraction.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 88-92"},"PeriodicalIF":2.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144813856","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}
Pub Date : 2025-09-01Epub Date: 2025-06-21DOI: 10.1016/j.mfglet.2025.06.202
Damian Gogolewski
This paper describes a new method, based on wavelet transformation, for evaluation repeatability during optical measurements of surface topography. Repeated measurements are made with the same parameters without repositioning the measuring object. The analysis carried out proved differences in the variability of surface irregularities with respect to scale. On the surface it is possible to distinguish a number of morphological features which, during the realization of subsequent measurements, were defined by a different distribution of irregularity height, resulting in highlighting measurement errors. The analysis showed that these changes are particularly visible for scales up to 13 μm, nevertheless for larger scales the differences occur only in selected sections of the profile and not along the entire length, which has a direct correlation with the occurrence of peak or valley. For small scales, slight shifts of certain morphological features in corresponding profiles were noted, as highlighted by the varying orientation of the arrows. The study has the potential for practical use in both the research field and industrial applications, and can contribute to supplementing the current standards.
{"title":"Evaluation of repeatability of topographic measurements based on multiscale analysis","authors":"Damian Gogolewski","doi":"10.1016/j.mfglet.2025.06.202","DOIUrl":"10.1016/j.mfglet.2025.06.202","url":null,"abstract":"<div><div>This paper describes a new method, based on wavelet transformation, for evaluation repeatability during optical measurements of surface topography. Repeated measurements are made with the same parameters without repositioning the measuring object. The analysis carried out proved differences in the variability of surface irregularities with respect to scale. On the surface it is possible to distinguish a number of morphological features which, during the realization of subsequent measurements, were defined by a different distribution of irregularity height, resulting in highlighting measurement errors. The analysis showed that these changes are particularly visible for scales up to 13 μm, nevertheless for larger scales the differences occur only in selected sections of the profile and not along the entire length, which has a direct correlation with the occurrence of peak or valley. For small scales, slight shifts of certain morphological features in corresponding profiles were noted, as highlighted by the varying orientation of the arrows. The study has the potential for practical use in both the research field and industrial applications, and can contribute to supplementing the current standards.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 17-20"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144502336","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}
Pub Date : 2025-09-01Epub Date: 2025-08-22DOI: 10.1016/j.mfglet.2025.08.002
Rafael Guerra Silva , Gustavo Morales Pavez , Luis F. Caminos
Additive manufacturing of continuous fiber-reinforced polymer composites faces challenges in achieving consistent flexural strength and stiffness. Additively manufactured sandwich structures with continuous fiber reinforcement were produced in different batches and subjected to flexural tests. The production replicated real-world conditions, including filament spool changes, fiber aging, and time gaps between batches. The mechanical properties were consistent in early batches, but variability in flexural strength and stiffness increased from one batch to the next, reaching deviations up to 60% for glass fiber and 70% for carbon fiber in later batches. Although the dual-head additive manufacturing system protects the polymer filament from humidity during the sequential fiber deposition process and waiting periods, similar provisions are also necessary for the reinforcement filament to minimize or eliminate polymer-fiber interlayer debonding.
{"title":"Reliability challenges in additive manufacturing of continuous fiber-reinforced sandwich structures","authors":"Rafael Guerra Silva , Gustavo Morales Pavez , Luis F. Caminos","doi":"10.1016/j.mfglet.2025.08.002","DOIUrl":"10.1016/j.mfglet.2025.08.002","url":null,"abstract":"<div><div>Additive manufacturing of continuous fiber-reinforced polymer composites faces challenges in achieving consistent flexural strength and stiffness. Additively manufactured sandwich structures with continuous fiber reinforcement were produced in different batches and subjected to flexural tests. The production replicated real-world conditions, including filament spool changes, fiber aging, and time gaps between batches. The mechanical properties were consistent in early batches, but variability in flexural strength and stiffness increased from one batch to the next, reaching deviations up to 60% for glass fiber and 70% for carbon fiber in later batches. Although the dual-head additive manufacturing system protects the polymer filament from humidity during the sequential fiber deposition process and waiting periods, similar provisions are also necessary for the reinforcement filament to minimize or eliminate polymer-fiber interlayer debonding.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 112-115"},"PeriodicalIF":2.0,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144902889","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}
Pub Date : 2025-09-01Epub Date: 2025-06-25DOI: 10.1016/j.mfglet.2025.06.205
Hatem A. Soliman, Mohamed Elbestawi
The processing of Titanium Aluminides (TiAls) and Ti64 significantly benefits aerospace applications due to their excellent strength-to-weight ratio. Ti64 is commonly used for turbine disks, while TiAl is utilized for low-pressure blades. Laser Powder Bed Fusion (L-PBF) can facilitate the seamless integration of these materials, where reducing connections is essential for weight savings. However, challenges remain, such as variations in thermal expansion coefficients and the potential for crack formation during L-PBF. This study develops a functional graded material from Ti64 to TNM-B1 in 20 % increments, for the first time using L-PBF without cracks, followed by post-processing to enhance the microstructure.
{"title":"Development of crack-free functionally graded Ti64/TNM-B1 material using laser powder bed fusion","authors":"Hatem A. Soliman, Mohamed Elbestawi","doi":"10.1016/j.mfglet.2025.06.205","DOIUrl":"10.1016/j.mfglet.2025.06.205","url":null,"abstract":"<div><div>The processing of Titanium Aluminides (TiAls) and Ti64 significantly benefits aerospace applications due to their excellent strength-to-weight ratio. Ti64 is commonly used for turbine disks, while TiAl is utilized for low-pressure blades. Laser Powder Bed Fusion (L-PBF) can facilitate the seamless integration of these materials, where reducing connections is essential for weight savings. However, challenges remain, such as variations in thermal expansion coefficients and the potential for crack formation during L-PBF. This study develops a functional graded material from Ti64 to TNM-B1 in 20 % increments, for the first time using L-PBF without cracks, followed by post-processing to enhance the microstructure.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 26-30"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144502312","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}
Pub Date : 2025-09-01Epub Date: 2025-06-21DOI: 10.1016/j.mfglet.2025.06.204
Mert Gülçür, Adam Rich, Olivia Griffiths, Paul Wilson, Mark Williams, Gregory Gibbons
Rapid tooling enables the fabrication of polymer mould inserts, reducing reliance on subtractive manufacturing and mould heating. This study compares rapid polymer and metal tooling in micro-injection moulding, focusing on mechanical properties and energy efficiency. A micro-tensile bar design was used polymer mould and an aluminium counterpart. Both moulds were tested on a μ-IM machine, monitoring energy consumption during cycles. The study showed: (i) Polymer tooling achieves tensile properties within 6.4% of metal, (ii) up to 17.6% energy savings per moulding, (iii) rapid tools can replace metal for micro-products, offering energy efficiency, reduced lead times for product iterations.
{"title":"Rapid tooling: comparative analysis of mechanical properties and energy efficiency in micro-injection mouldings using polymer and metal moulds","authors":"Mert Gülçür, Adam Rich, Olivia Griffiths, Paul Wilson, Mark Williams, Gregory Gibbons","doi":"10.1016/j.mfglet.2025.06.204","DOIUrl":"10.1016/j.mfglet.2025.06.204","url":null,"abstract":"<div><div>Rapid tooling enables the fabrication of<!--> <!-->polymer mould inserts, reducing reliance on subtractive manufacturing and mould heating. This study compares rapid polymer and metal tooling in micro-injection moulding, focusing on mechanical properties and energy efficiency. A micro-tensile bar design was used polymer mould and an aluminium counterpart. Both moulds were tested on a μ-IM machine, monitoring energy consumption during cycles. The study<!--> <!-->showed: (i) Polymer tooling achieves tensile properties within 6.4% of metal, (ii) up to 17.6% energy savings per moulding, (iii) rapid tools can replace metal for micro-products, offering energy efficiency, reduced lead times for product iterations.</div></div>","PeriodicalId":38186,"journal":{"name":"Manufacturing Letters","volume":"45 ","pages":"Pages 31-35"},"PeriodicalIF":1.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144502313","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}
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