Abstract Highly programmable shape morphing of 4D-printed micro/nanostructures is urgently desired for applications in robotics and intelligent systems. However, due to the lack of autonomous holistic strategies throughout the target shape input, optimal material distribution generation, and fabrication program output, 4D nanoprinting that permits arbitrary shape morphing remains a challenging task for manual design. In this study, we report an autonomous inverse encoding strategy to decipher the genetic code for material property distributions that can guide the encoded modeling toward arbitrarily pre-programmed 4D shape morphing. By tuning the laser power of each voxel at the nanoscale, the genetic code can be spatially programmed and controllable shape morphing can be realized through the inverse encoding process. Using this strategy, the 4D-printed structures can be designed and accurately shift to the target morphing of arbitrarily hand-drawn lines under stimulation. Furthermore, as a proof-of-concept, a flexible fiber micromanipulator that can approach the target region through pre-programmed shape morphing is autonomously inversely encoded according to the localized spatial environment. This strategy may contribute to the modeling and arbitrary shape morphing of micro/nanostructures fabricated via 4D nanoprinting, leading to cutting-edge applications in microfluidics, micro-robotics, minimally invasive robotic surgery, and tissue engineering.
{"title":"Autonomous inverse encoding guides 4D nanoprinting for highly programmable shape morphing","authors":"Shuaiqi Ren, Zhiang Zhang, Ruokun He, Jiahao Fan, Guangming Wang, Hesheng Wang, Bing Han, Yong‐Lai Zhang, Zhuo‐Chen Ma","doi":"10.1088/2631-7990/ada839","DOIUrl":"https://doi.org/10.1088/2631-7990/ada839","url":null,"abstract":"Abstract Highly programmable shape morphing of 4D-printed micro/nanostructures is urgently desired for applications in robotics and intelligent systems. However, due to the lack of autonomous holistic strategies throughout the target shape input, optimal material distribution generation, and fabrication program output, 4D nanoprinting that permits arbitrary shape morphing remains a challenging task for manual design. In this study, we report an autonomous inverse encoding strategy to decipher the genetic code for material property distributions that can guide the encoded modeling toward arbitrarily pre-programmed 4D shape morphing. By tuning the laser power of each voxel at the nanoscale, the genetic code can be spatially programmed and controllable shape morphing can be realized through the inverse encoding process. Using this strategy, the 4D-printed structures can be designed and accurately shift to the target morphing of arbitrarily hand-drawn lines under stimulation. Furthermore, as a proof-of-concept, a flexible fiber micromanipulator that can approach the target region through pre-programmed shape morphing is autonomously inversely encoded according to the localized spatial environment. This strategy may contribute to the modeling and arbitrary shape morphing of micro/nanostructures fabricated via 4D nanoprinting, leading to cutting-edge applications in microfluidics, micro-robotics, minimally invasive robotic surgery, and tissue engineering.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"7 3","pages":"035502-035502"},"PeriodicalIF":0.0,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://iopscience.iop.org/article/10.1088/2631-7990/ada839/pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147331953","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-09DOI: 10.1088/2631-7990/ada83a
Fan‐Chun Bin, Xiao‐Qin Wu, Jie Liu, Xian-Zi Dong, Teng Li, Q.Q. Duan, Jiayuan Alex Zhang, Katsumasa Fujita, Mei‐Ling Zheng
Abstract Chitosan (CS)-based nanocomposites have been studied in various fields, requiring a more facile and efficient technique to fabricate nanoparticles with customized structures. In this study, Ag@methacrylamide CS/poly(ethylene glycol) diacrylate (Ag@MP) micropatterns are successfully fabricated by femtosecond laser maskless optical projection lithography (Fs-MOPL) for the first time. The formation mechanism of core-shell nanomaterial is demonstrated by the local surface plasmon resonances and the nucleation and growth theory. Amino and hydroxyl groups greatly affect the number of Ag@MP nanocomposites, which is further verified by replacing MCS with methacrylated bovine serum albumin and hyaluronic acid methacryloyl, respectively. Besides, the performance of the surface-enhanced Raman scattering, cytotoxicity, cell proliferation, and antibacterial was investigated on Ag@MP micropatterns. Therefore, the proposed protocol to prepare hydrogel core-shell micropattern by the home-built Fs-MOPL technique is prospective for potential applications in the biomedical and biotechnological fields, such as biosensors, cell imaging, and antimicrobial.
{"title":"Micropattern of core-shell Ag@MCS/PEGDA nanoparticles fabricated by femtosecond laser maskless optical projection lithography","authors":"Fan‐Chun Bin, Xiao‐Qin Wu, Jie Liu, Xian-Zi Dong, Teng Li, Q.Q. Duan, Jiayuan Alex Zhang, Katsumasa Fujita, Mei‐Ling Zheng","doi":"10.1088/2631-7990/ada83a","DOIUrl":"https://doi.org/10.1088/2631-7990/ada83a","url":null,"abstract":"Abstract Chitosan (CS)-based nanocomposites have been studied in various fields, requiring a more facile and efficient technique to fabricate nanoparticles with customized structures. In this study, Ag@methacrylamide CS/poly(ethylene glycol) diacrylate (Ag@MP) micropatterns are successfully fabricated by femtosecond laser maskless optical projection lithography (Fs-MOPL) for the first time. The formation mechanism of core-shell nanomaterial is demonstrated by the local surface plasmon resonances and the nucleation and growth theory. Amino and hydroxyl groups greatly affect the number of Ag@MP nanocomposites, which is further verified by replacing MCS with methacrylated bovine serum albumin and hyaluronic acid methacryloyl, respectively. Besides, the performance of the surface-enhanced Raman scattering, cytotoxicity, cell proliferation, and antibacterial was investigated on Ag@MP micropatterns. Therefore, the proposed protocol to prepare hydrogel core-shell micropattern by the home-built Fs-MOPL technique is prospective for potential applications in the biomedical and biotechnological fields, such as biosensors, cell imaging, and antimicrobial.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"7 3","pages":"035001-035001"},"PeriodicalIF":0.0,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147332464","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-09DOI: 10.1088/2631-7990/ada838
Wenxin Xu, Hao Tian, Yanzhen Song, Hanfeng Qin, J. R. Gao, Yichi Chen, Wei‐Chang Huang, Lin Lin, Haixin Tan, Yicheng Ye, Xiaoting Zhang, Daniela A. Wilson, Guang Yang, Fei Peng, Yingfeng Tu
Abstract Ferroptosis is a newly proposed type of programmed cell death, which has been associated with a variety of diseases including tumors. Researchers have thereby presented nanoplatforms to mediate ferroptosis for anti-cancer therapy. However, the development of ferroptosis-based nanotherapeutics is generally hindered by the limited penetration depth in tumors, poor active pharmaceutical ingredient (API) loading content and the systemic toxicity. Herein, self-propelled ferroptosis nanoinducers composed of two endogenous proteins, glucose oxidase and ferritin, are presented to show enhanced tumor inhibition via ferroptosis while maintaining high API and biocompatibility. The accumulation of our proteomotors at tumor regions is facilitated by the active tumor-targeting effect of ferritin. The enhanced diffusion of proteomotors is then actuated by efficiently decomposing glucose into gluconic acid and H 2 O 2 , leading to deeper penetration and enhanced uptake into tumors. Under the synergistic effect of glucose oxidase and ferritin, the equilibrium between reactive oxygen species and GSH is damaged, leading to lipid peroxidation. As a result, by inducing ferroptosis, our self-propelled ferroptosis nanoinducers exhibit enhanced tumor inhibitory effects. This work paves a way for the construction of a biocompatible anticancer platform with enhanced diffusion utilizing only two endogenous proteins, centered around the concept of ferroptosis.
{"title":"Self-propelled ferroptosis nanoinducer for enhanced cancer therapy","authors":"Wenxin Xu, Hao Tian, Yanzhen Song, Hanfeng Qin, J. R. Gao, Yichi Chen, Wei‐Chang Huang, Lin Lin, Haixin Tan, Yicheng Ye, Xiaoting Zhang, Daniela A. Wilson, Guang Yang, Fei Peng, Yingfeng Tu","doi":"10.1088/2631-7990/ada838","DOIUrl":"https://doi.org/10.1088/2631-7990/ada838","url":null,"abstract":"Abstract Ferroptosis is a newly proposed type of programmed cell death, which has been associated with a variety of diseases including tumors. Researchers have thereby presented nanoplatforms to mediate ferroptosis for anti-cancer therapy. However, the development of ferroptosis-based nanotherapeutics is generally hindered by the limited penetration depth in tumors, poor active pharmaceutical ingredient (API) loading content and the systemic toxicity. Herein, self-propelled ferroptosis nanoinducers composed of two endogenous proteins, glucose oxidase and ferritin, are presented to show enhanced tumor inhibition via ferroptosis while maintaining high API and biocompatibility. The accumulation of our proteomotors at tumor regions is facilitated by the active tumor-targeting effect of ferritin. The enhanced diffusion of proteomotors is then actuated by efficiently decomposing glucose into gluconic acid and H 2 O 2 , leading to deeper penetration and enhanced uptake into tumors. Under the synergistic effect of glucose oxidase and ferritin, the equilibrium between reactive oxygen species and GSH is damaged, leading to lipid peroxidation. As a result, by inducing ferroptosis, our self-propelled ferroptosis nanoinducers exhibit enhanced tumor inhibitory effects. This work paves a way for the construction of a biocompatible anticancer platform with enhanced diffusion utilizing only two endogenous proteins, centered around the concept of ferroptosis.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"7 3","pages":"035501-035501"},"PeriodicalIF":0.0,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147330553","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-01-09DOI: 10.1088/2631-7990/ada834
Xiaoyun Qi, Shicheng Zhou, Yan Ma, Tadatomo Suga, Chenxi Wang
Abstract Due to its superior nanoscale properties, cobalt (Co) is highly desirable for ultrahigh-density 3D integration into materials through metal/dielectric hybrid bonding. However, this process is very challenging through Co/SiO 2 hybrid bonding, as very hydrophilic SiO 2 surfaces are needed for bonding during dehydration reactions and oxidation of the Co surfaces must be avoided. Additionally, the substantial coefficient of thermal expansion mismatch between the robust capping layers (Co and SiO 2 layers) necessitates hybrid bonding with minimal thermal input and compression. In this study, we introduce a ternary plasma activation strategy employing an Ar/NH 3 /H 2 O gas mixture to facilitate Co/SiO 2 hybrid bonding at temperatures as low as ∼200 °C, which is markedly lower than the melting point of Co (∼1500 °C). Intriguingly, non-oxide metallization at the Co–Co interface can be realized without the hindrance of a bonding barrier, thereby reducing the electrical resistance by over 40% and compression force requirements. Moreover, the enhancement in the SiO 2 surface energy through active group terminations fosters extensive interfacial hydration and strengthens the mechanical properties. This research paves the way for fine-tuning bonding surfaces using a material-selective strategy, which should advance metal/dielectric hybrid bonding for future integration applications.
{"title":"Boosting non-oxide interfacial Co/SiO<sub>2</sub> hybrid bonding by selective surface activation","authors":"Xiaoyun Qi, Shicheng Zhou, Yan Ma, Tadatomo Suga, Chenxi Wang","doi":"10.1088/2631-7990/ada834","DOIUrl":"https://doi.org/10.1088/2631-7990/ada834","url":null,"abstract":"Abstract Due to its superior nanoscale properties, cobalt (Co) is highly desirable for ultrahigh-density 3D integration into materials through metal/dielectric hybrid bonding. However, this process is very challenging through Co/SiO 2 hybrid bonding, as very hydrophilic SiO 2 surfaces are needed for bonding during dehydration reactions and oxidation of the Co surfaces must be avoided. Additionally, the substantial coefficient of thermal expansion mismatch between the robust capping layers (Co and SiO 2 layers) necessitates hybrid bonding with minimal thermal input and compression. In this study, we introduce a ternary plasma activation strategy employing an Ar/NH 3 /H 2 O gas mixture to facilitate Co/SiO 2 hybrid bonding at temperatures as low as ∼200 °C, which is markedly lower than the melting point of Co (∼1500 °C). Intriguingly, non-oxide metallization at the Co–Co interface can be realized without the hindrance of a bonding barrier, thereby reducing the electrical resistance by over 40% and compression force requirements. Moreover, the enhancement in the SiO 2 surface energy through active group terminations fosters extensive interfacial hydration and strengthens the mechanical properties. This research paves the way for fine-tuning bonding surfaces using a material-selective strategy, which should advance metal/dielectric hybrid bonding for future integration applications.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"7 3","pages":"035101-035101"},"PeriodicalIF":0.0,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://iopscience.iop.org/article/10.1088/2631-7990/ada834/pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147330445","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-02-01Epub Date: 2023-11-17DOI: 10.1088/2631-7990/ad07e7
Amit Bandyopadhyay, Indranath Mitra, Sushant Ciliveri, Jose D Avila, William Dernell, Stuart B Goodman, Susmita Bose
Bacterial colonization of orthopedic implants is one of the leading causes of failure and clinical complexities for load-bearing metallic implants. Topical or systemic administration of antibiotics may not offer the most efficient defense against colonization, especially in the case of secondary infection, leading to surgical removal of implants and in some cases even limbs. In this study, laser powder bed fusion was implemented to fabricate Ti3Al2V alloy by a 1:1 weight mixture of CpTi and Ti6Al4V powders. Ti-Tantalum (Ta)-Copper (Cu) alloys were further analyzed by the addition of Ta and Cu into the Ti3Al2V custom alloy. The biological, mechanical, and tribo-biocorrosion properties of Ti3Al2V alloy were evaluated. A 10 wt.% Ta (10Ta) and 3 wt.% Cu (3Cu) were added to the Ti3Al2V alloy to enhance biocompatibility and impart inherent bacterial resistance. Additively manufactured implants were investigated for resistance against Pseudomonas aeruginosa and Staphylococcus aureus strains of bacteria for up to 48 h. A 3 wt.% Cu addition to Ti3Al2V displayed improved antibacterial efficacy, i.e. 78%-86% with respect to CpTi. Mechanical properties for Ti3Al2V-10Ta-3Cu alloy were evaluated, demonstrating excellent fatigue resistance, exceptional shear strength, and improved tribological and tribo-biocorrosion characteristics when compared to Ti6Al4V. In vivo studies using a rat distal femur model revealed improved early-stage osseointegration for alloys with 10 wt.% Ta addition compared to CpTi and Ti6Al4V. The 3 wt.% Cu-added compositions displayed biocompatibility and no adverse inflammatory response in vivo. Our results establish the Ti3Al2V-10Ta-3Cu alloy's synergistic effect on improving both in vivo biocompatibility and microbial resistance for the next generation of load-bearing metallic implants.
{"title":"Additively manufactured Ti-Ta-Cu alloys for the next-generation load-bearing implants.","authors":"Amit Bandyopadhyay, Indranath Mitra, Sushant Ciliveri, Jose D Avila, William Dernell, Stuart B Goodman, Susmita Bose","doi":"10.1088/2631-7990/ad07e7","DOIUrl":"10.1088/2631-7990/ad07e7","url":null,"abstract":"<p><p>Bacterial colonization of orthopedic implants is one of the leading causes of failure and clinical complexities for load-bearing metallic implants. Topical or systemic administration of antibiotics may not offer the most efficient defense against colonization, especially in the case of secondary infection, leading to surgical removal of implants and in some cases even limbs. In this study, laser powder bed fusion was implemented to fabricate Ti3Al2V alloy by a 1:1 weight mixture of CpTi and Ti6Al4V powders. Ti-Tantalum (Ta)-Copper (Cu) alloys were further analyzed by the addition of Ta and Cu into the Ti3Al2V custom alloy. The biological, mechanical, and tribo-biocorrosion properties of Ti3Al2V alloy were evaluated. A 10 wt.% Ta (10Ta) and 3 wt.% Cu (3Cu) were added to the Ti3Al2V alloy to enhance biocompatibility and impart inherent bacterial resistance. Additively manufactured implants were investigated for resistance against <i>Pseudomonas aeruginosa</i> and <i>Staphylococcus aureus</i> strains of bacteria for up to 48 h. A 3 wt.% Cu addition to Ti3Al2V displayed improved antibacterial efficacy, i.e. 78%-86% with respect to CpTi. Mechanical properties for Ti3Al2V-10Ta-3Cu alloy were evaluated, demonstrating excellent fatigue resistance, exceptional shear strength, and improved tribological and tribo-biocorrosion characteristics when compared to Ti6Al4V. <i>In vivo</i> studies using a rat distal femur model revealed improved early-stage osseointegration for alloys with 10 wt.% Ta addition compared to CpTi and Ti6Al4V. The 3 wt.% Cu-added compositions displayed biocompatibility and no adverse inflammatory response <i>in vivo</i>. Our results establish the Ti3Al2V-10Ta-3Cu alloy's synergistic effect on improving both <i>in vivo</i> biocompatibility and microbial resistance for the next generation of load-bearing metallic implants.</p>","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"6 1","pages":"015503"},"PeriodicalIF":16.1,"publicationDate":"2024-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10654690/pdf/","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138464304","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
It is a challenge to polish the interior surface of an additively manufactured component with complex structures and groove sizes less than 1 mm. Traditional polishing methods are disabled to polish the component, meanwhile keeping the structure intact. To overcome this challenge, small grooved components made of aluminum alloy with sizes less than 1 mm were fabricated by a custom-made printer. A novel approach of multi-phase jet polishing is proposed using a developed polisher, consisting of solid, liquid and gas phases. In comparison, an abrasive air jet polishing is suggested through a customized polisher, including solid and gas phases. After jet polishing, surface roughness (Sa) on the interior surface of grooves decreases from pristine 8.596 to 0.701 and 0.336 μm by abrasive air jet polishing and multi-phase jet polishing, respectively, and Sa reduces 92% and 96%, correspondingly. A formula is given out for the relationship between linear energy density and unit defect volume. The optimized parameters in additive manufacturing are that linear energy density varies from 0.135 to 0.22 J∙mm-1. Defect volume of unit area achieved by optimized parameters lessens 1/12 that of non-optimized ones. Computational fluid dynamics simulation reveals that material is removed by shear stress, and the alumina abrasives experience multiple collisions with the defects on the heat pipe groove, resulting in uniform material removal. This is in good agreement with the experimental results. The novel proposed setups, approach and findings provide new insights to manufacture complex-structured components, polish the small grooved structure, and keep it unbroken.
{"title":"A novel approach of jet polishing for interior surface of small grooved components using three developed setups","authors":"Qinming Gu, Zhenyu Zhang, Hongxiu Zhou, Jiaxin Yu, Dong Wang, Junyuan Feng, C. Shi, Jianjun Yang, Junfeng Qi","doi":"10.1088/2631-7990/ad1bba","DOIUrl":"https://doi.org/10.1088/2631-7990/ad1bba","url":null,"abstract":"\u0000 It is a challenge to polish the interior surface of an additively manufactured component with complex structures and groove sizes less than 1 mm. Traditional polishing methods are disabled to polish the component, meanwhile keeping the structure intact. To overcome this challenge, small grooved components made of aluminum alloy with sizes less than 1 mm were fabricated by a custom-made printer. A novel approach of multi-phase jet polishing is proposed using a developed polisher, consisting of solid, liquid and gas phases. In comparison, an abrasive air jet polishing is suggested through a customized polisher, including solid and gas phases. After jet polishing, surface roughness (Sa) on the interior surface of grooves decreases from pristine 8.596 to 0.701 and 0.336 μm by abrasive air jet polishing and multi-phase jet polishing, respectively, and Sa reduces 92% and 96%, correspondingly. A formula is given out for the relationship between linear energy density and unit defect volume. The optimized parameters in additive manufacturing are that linear energy density varies from 0.135 to 0.22 J∙mm-1. Defect volume of unit area achieved by optimized parameters lessens 1/12 that of non-optimized ones. Computational fluid dynamics simulation reveals that material is removed by shear stress, and the alumina abrasives experience multiple collisions with the defects on the heat pipe groove, resulting in uniform material removal. This is in good agreement with the experimental results. The novel proposed setups, approach and findings provide new insights to manufacture complex-structured components, polish the small grooved structure, and keep it unbroken.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"9 4","pages":""},"PeriodicalIF":14.7,"publicationDate":"2024-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139381055","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-01-05DOI: 10.1088/2631-7990/ad1bbb
Zhiwei Li, Jianfu Zhang, Zhongpeng Zheng, P. Feng, D. Yu, Jianjian Wang
High-aspect-ratio metallic surface microstructures are increasingly demanded in breakthrough applications, such as high-performance heat transfer enhancement and surface plasmon devices. However, the fast and cost-effective fabrication of high-aspect-ratio microstructures on metallic surfaces remains challenging for existing techniques. This study proposes a novel cutting-based process, namely elliptical vibration chiseling (EV-chiseling), for the high-efficiency texturing of surface microstructures with an ultrahigh aspect ratio. Unlike conventional cutting, EV-chiseling superimposes a microscale elliptical vibration on a backward-moving tool. The tool chisels into the material in each vibration cycle to generate an upright chip with a high aspect ratio through material deformation. Thanks to the tool’s backward movement, the chip is left on the material surface to form a microstructure rather than falling off. Since one microstructure is generated in one vibration cycle, the process can be highly efficient using ultrafast (>1 kHz) tool vibration. A finite element analysis model is established to explore the process mechanics of EV-chiseling. Next, a mechanistic model of the microstructured surface generation is developed to describe the microstructures’ aspect ratio dependency on the process parameters. Then, surface texturing tests are performed on copper to verify the efficacy of EV-chiseling. Uniformed micro ribs with a spacing of 1~10 μm and an aspect ratio of 2~5 have been successfully textured on copper. Compared with the conventional EV-cutting that uses a forward-moving tool, EV-chiseling can improve the aspect ratio of textured microstructure by up to 40 times. The experimental results also verify the accuracy of the developed surface generation model of microstructures. Finally, the effects of elliptical trajectory, depth of cut (DoC), tool shape, and tool edge radius on the surface generation of micro ribs have been discussed.
高宽比金属表面微结构在高性能传热增强和表面等离子体器件等突破性应用中的需求日益增长。然而，对于现有技术而言，在金属表面快速、低成本地制造高宽比微结构仍具有挑战性。本研究提出了一种基于切割的新型工艺，即椭圆振动凿刻（EV-chiseling），用于高效制备具有超高纵横比的表面微结构。与传统切割工艺不同，EV-凿刻工艺是在向后移动的工具上叠加微尺度椭圆振动。在每个振动周期中，刀具凿入材料，通过材料变形产生具有高纵横比的直立切屑。由于工具向后运动，切屑留在材料表面形成微结构，而不是脱落。由于一个振动周期可产生一个微结构，因此使用超快（>1 kHz）工具振动可实现高效工艺。我们建立了一个有限元分析模型来探索电动车凿毛的工艺力学。接着，建立了微结构表面生成的力学模型，以描述微结构的高宽比与工艺参数的关系。然后，对铜进行了表面纹理测试，以验证 EV 凿刻的功效。在铜上成功制备出了间距为 1~10 μm、纵横比为 2~5 的均匀微肋。与使用前移工具的传统 EV 切割相比，EV-凿刻可将纹理微结构的纵横比提高 40 倍。实验结果还验证了所开发的微结构表面生成模型的准确性。最后，还讨论了椭圆轨迹、切削深度（DoC）、刀具形状和刀具边缘半径对微肋表面生成的影响。
{"title":"Elliptical vibration chiseling: a novel process for texturing ultra-high-aspect-ratio microstructures on the metallic surface","authors":"Zhiwei Li, Jianfu Zhang, Zhongpeng Zheng, P. Feng, D. Yu, Jianjian Wang","doi":"10.1088/2631-7990/ad1bbb","DOIUrl":"https://doi.org/10.1088/2631-7990/ad1bbb","url":null,"abstract":"\u0000 High-aspect-ratio metallic surface microstructures are increasingly demanded in breakthrough applications, such as high-performance heat transfer enhancement and surface plasmon devices. However, the fast and cost-effective fabrication of high-aspect-ratio microstructures on metallic surfaces remains challenging for existing techniques. This study proposes a novel cutting-based process, namely elliptical vibration chiseling (EV-chiseling), for the high-efficiency texturing of surface microstructures with an ultrahigh aspect ratio. Unlike conventional cutting, EV-chiseling superimposes a microscale elliptical vibration on a backward-moving tool. The tool chisels into the material in each vibration cycle to generate an upright chip with a high aspect ratio through material deformation. Thanks to the tool’s backward movement, the chip is left on the material surface to form a microstructure rather than falling off. Since one microstructure is generated in one vibration cycle, the process can be highly efficient using ultrafast (>1 kHz) tool vibration. A finite element analysis model is established to explore the process mechanics of EV-chiseling. Next, a mechanistic model of the microstructured surface generation is developed to describe the microstructures’ aspect ratio dependency on the process parameters. Then, surface texturing tests are performed on copper to verify the efficacy of EV-chiseling. Uniformed micro ribs with a spacing of 1~10 μm and an aspect ratio of 2~5 have been successfully textured on copper. Compared with the conventional EV-cutting that uses a forward-moving tool, EV-chiseling can improve the aspect ratio of textured microstructure by up to 40 times. The experimental results also verify the accuracy of the developed surface generation model of microstructures. Finally, the effects of elliptical trajectory, depth of cut (DoC), tool shape, and tool edge radius on the surface generation of micro ribs have been discussed.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"4 5","pages":""},"PeriodicalIF":14.7,"publicationDate":"2024-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139381229","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Additive manufacturing provides achievability for the fabrication of bimetallic and multi-material structures; however, the material compatibility and bondability directly affect the parts’ formability and final quality. It is essential to understand the underlying printability of different material combinations based on an adapted process. Here, the printability disparities of two common and attractive material combinations (nickel- and iron-based alloys) are evaluated at the macro and micro levels via laser directed energy deposition (DED). The deposition processes were captured using in situ high-speed imaging, and the dissimilarities in melt pool features and track morphology were quantitatively investigated within specific process windows. Moreover, the microstructure diversity of the tracks and blocks processed with varied material pairs was comparatively elaborated and, complemented with the informative multi-physics modeling, the presented non-uniformity in mechanical properties (microhardness) among the heterogeneous material pairs was rationalized. The differences in melt flow induced by the unlike thermophysical properties of the material pairs and the resulting element intermixing and localized re-alloying during solidification dominate the presented dissimilarity in printability among the material combinations. This work provides an in-depth understanding of the phenomenological differences in the deposition of dissimilar materials and aims to guide more reliable DED forming of bimetallic parts.
{"title":"Printability disparities in heterogeneous material combinations via laser directed energy deposition: a comparative study","authors":"Jinsheng Ning, Lida Zhu, Shuhao Wang, Zhichao Yang, Peihua Xu, Pengsheng Xue, Hao Lu, Miao Yu, Yunha Zhao, Jiachen Li, S. Bose, Amit Bandyopadhyay","doi":"10.1088/2631-7990/ad172f","DOIUrl":"https://doi.org/10.1088/2631-7990/ad172f","url":null,"abstract":"Additive manufacturing provides achievability for the fabrication of bimetallic and multi-material structures; however, the material compatibility and bondability directly affect the parts’ formability and final quality. It is essential to understand the underlying printability of different material combinations based on an adapted process. Here, the printability disparities of two common and attractive material combinations (nickel- and iron-based alloys) are evaluated at the macro and micro levels via laser directed energy deposition (DED). The deposition processes were captured using in situ high-speed imaging, and the dissimilarities in melt pool features and track morphology were quantitatively investigated within specific process windows. Moreover, the microstructure diversity of the tracks and blocks processed with varied material pairs was comparatively elaborated and, complemented with the informative multi-physics modeling, the presented non-uniformity in mechanical properties (microhardness) among the heterogeneous material pairs was rationalized. The differences in melt flow induced by the unlike thermophysical properties of the material pairs and the resulting element intermixing and localized re-alloying during solidification dominate the presented dissimilarity in printability among the material combinations. This work provides an in-depth understanding of the phenomenological differences in the deposition of dissimilar materials and aims to guide more reliable DED forming of bimetallic parts.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"58 17","pages":""},"PeriodicalIF":14.7,"publicationDate":"2024-01-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"139385765","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-12-22DOI: 10.1088/2631-7990/ad1825
Guohua Zhang, Ming Huang, Gangli Chen, Jiasheng Li, Yang Liu, Jianguo He, Yueqing Zheng, Siwei Tang, Hailong Cui
Fluid lubricated bearings have been widely adopted for supporting components of high-end equipments in the field of metrology, semi-conductor, aviation, strategic defense, ultra-precision manufacturing, medical treatment and power generations. These fields all involve extreme working conditions such as ultra-high moving precision, ultra-high rotation speed, ultra-heavy bearing load, ultra-high environmental temperature, high radiation and high vacuum, which present challenges for the design and optimization of reliable fluid lubricated bearings. Breakthrough of any related bottlenecks will promote the development course of high-end equipments. To further promote the advancement of high-end equipments, this paper reviews the design and optimization of fluid lubricated bearings operated with typical extreme working performances. Targeting on the realization of extreme working perfor mances, the current challenges, the current solutions, the underlying deficiencies and the promising developing directions regarding to the design and optimization of fluid lubricat ed bearings are systematically pointed out. This paper can provide guidance for choosing suitable fluid lubricated bearings and optimizing their structures based on required extreme working performances.
{"title":"Design and optimization of fluid lubricated bearings operated with extreme working performances-A comprehensive review","authors":"Guohua Zhang, Ming Huang, Gangli Chen, Jiasheng Li, Yang Liu, Jianguo He, Yueqing Zheng, Siwei Tang, Hailong Cui","doi":"10.1088/2631-7990/ad1825","DOIUrl":"https://doi.org/10.1088/2631-7990/ad1825","url":null,"abstract":"\u0000 Fluid lubricated bearings have been widely adopted for supporting components of high-end equipments in the field of metrology, semi-conductor, aviation, strategic defense, ultra-precision manufacturing, medical treatment and power generations. These fields all involve extreme working conditions such as ultra-high moving precision, ultra-high rotation speed, ultra-heavy bearing load, ultra-high environmental temperature, high radiation and high vacuum, which present challenges for the design and optimization of reliable fluid lubricated bearings. Breakthrough of any related bottlenecks will promote the development course of high-end equipments. To further promote the advancement of high-end equipments, this paper reviews the design and optimization of fluid lubricated bearings operated with typical extreme working performances. Targeting on the realization of extreme working perfor mances, the current challenges, the current solutions, the underlying deficiencies and the promising developing directions regarding to the design and optimization of fluid lubricat ed bearings are systematically pointed out. This paper can provide guidance for choosing suitable fluid lubricated bearings and optimizing their structures based on required extreme working performances.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"24 6","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-12-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138947028","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-12-19DOI: 10.1088/2631-7990/ad1730
Desheng Liu, Pan Jiang, Yue Hu, Yaozhong Lu, Yixian Wang, Jiayu Wu, Danli Hu, Tao Wu, Xiaolong Wang
Hydrogels inevitably undergo dehydration, structural collapse, and shrinkage deformation due to the uninterrupted evaporation in the atmosphere, thereby losing their flexibility, slippery, and manufacturing precision. Here, we propose a novel bioinspired strategy to construct a spontaneously formed “skin” on the slippery hydrogels by incorporating biological stress metabolites trehalose into the hydrogel network, which can generate robust hydrogen bonding interactions to restrain water evaporation. The contents of trehalose in hydrogel matrix can also regulate the desiccation-tolerance, mechanical properties, and lubricating performance of slippery hydrogels in a wide range. Combining vat photopolymerization 3D printing and trehalose-modified slippery hydrogels enables to achieve the structural hydrogels with high resolution, shape fidelity, and sophisticated architectures, instead of structural collapse and shrinkage deformation caused by dehydration. And thus, this proposed functional hydrogel adapts to manufacture large-scale hydrogels with sophisticated architectures in a long-term process. As a proof-of-concept demonstration, a high-precision and sophisticated slippery hydrogel vascular phantom was easily fabricated to imitate guidewire intervention. Additionally, the proposed protocol is universally applicable to diverse types of hydrogel systems. This strategy opens up a versatile methodology to fabricate dry-resistant slippery hydrogel for functional structures and devices, expanding their high-precision processing and broad applications in the atmosphere.
{"title":"Slippery Hydrogel with Desiccation-Tolerant \"Skin\" for High-Precision Additive Manufacturing","authors":"Desheng Liu, Pan Jiang, Yue Hu, Yaozhong Lu, Yixian Wang, Jiayu Wu, Danli Hu, Tao Wu, Xiaolong Wang","doi":"10.1088/2631-7990/ad1730","DOIUrl":"https://doi.org/10.1088/2631-7990/ad1730","url":null,"abstract":"\u0000 Hydrogels inevitably undergo dehydration, structural collapse, and shrinkage deformation due to the uninterrupted evaporation in the atmosphere, thereby losing their flexibility, slippery, and manufacturing precision. Here, we propose a novel bioinspired strategy to construct a spontaneously formed “skin” on the slippery hydrogels by incorporating biological stress metabolites trehalose into the hydrogel network, which can generate robust hydrogen bonding interactions to restrain water evaporation. The contents of trehalose in hydrogel matrix can also regulate the desiccation-tolerance, mechanical properties, and lubricating performance of slippery hydrogels in a wide range. Combining vat photopolymerization 3D printing and trehalose-modified slippery hydrogels enables to achieve the structural hydrogels with high resolution, shape fidelity, and sophisticated architectures, instead of structural collapse and shrinkage deformation caused by dehydration. And thus, this proposed functional hydrogel adapts to manufacture large-scale hydrogels with sophisticated architectures in a long-term process. As a proof-of-concept demonstration, a high-precision and sophisticated slippery hydrogel vascular phantom was easily fabricated to imitate guidewire intervention. Additionally, the proposed protocol is universally applicable to diverse types of hydrogel systems. This strategy opens up a versatile methodology to fabricate dry-resistant slippery hydrogel for functional structures and devices, expanding their high-precision processing and broad applications in the atmosphere.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":" 14","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-12-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"138962534","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
京公网安备 11010802042870号
京ICP备2023020795号-1
扫码关注我们
求助内容：
应助结果提醒方式：