Pub Date : 2023-07-06DOI: 10.1088/2631-7990/ace090
Zhiyang Lyu, Jinlan Wang, Y. Chen
Four-dimensional printing allows for the transformation capabilities of 3D-printed architectures over time, altering their shape, properties, or function when exposed to external stimuli. This interdisciplinary technology endows the 3D architectures with unique functionalities, which has generated excitement in diverse research fields, such as soft robotics, biomimetics, biomedical devices, and sensors. Understanding the selection of the material, architectural designs, and employed stimuli is crucial to unlocking the potential of smart customization with 4D printing. This review summarizes recent significant developments in 4D printing and establishes links between smart materials, 3D printing techniques, programmable structures, diversiform stimulus, and new functionalities for multidisciplinary applications. We start by introducing the advanced features of 4D printing and the key technological roadmap for its implementation. We then place considerable emphasis on printable smart materials and structural designs, as well as general approaches to designing programmable structures. We also review stimulus designs in smart materials and their associated stimulus-responsive mechanisms. Finally, we discuss new functionalities of 4D printing for potential applications and further development directions.
{"title":"4D printing: interdisciplinary integration of smart materials, structural design, and new functionality","authors":"Zhiyang Lyu, Jinlan Wang, Y. Chen","doi":"10.1088/2631-7990/ace090","DOIUrl":"https://doi.org/10.1088/2631-7990/ace090","url":null,"abstract":"Four-dimensional printing allows for the transformation capabilities of 3D-printed architectures over time, altering their shape, properties, or function when exposed to external stimuli. This interdisciplinary technology endows the 3D architectures with unique functionalities, which has generated excitement in diverse research fields, such as soft robotics, biomimetics, biomedical devices, and sensors. Understanding the selection of the material, architectural designs, and employed stimuli is crucial to unlocking the potential of smart customization with 4D printing. This review summarizes recent significant developments in 4D printing and establishes links between smart materials, 3D printing techniques, programmable structures, diversiform stimulus, and new functionalities for multidisciplinary applications. We start by introducing the advanced features of 4D printing and the key technological roadmap for its implementation. We then place considerable emphasis on printable smart materials and structural designs, as well as general approaches to designing programmable structures. We also review stimulus designs in smart materials and their associated stimulus-responsive mechanisms. Finally, we discuss new functionalities of 4D printing for potential applications and further development directions.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"82 5 1","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-07-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"80059052","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 : 2023-06-30DOI: 10.1088/2631-7990/acdf2d
Shiqi Hu, Xiao Huan, Yu Liu, Sixi Cao, Zhuoran Wang, Ji Tae Kim
The continual demand for modern optoelectronics with a high integration degree and customized functions has increased requirements for nanofabrication methods with high resolution, freeform, and mask-free. Meniscus-on-demand three-dimensional (3D) printing is a high-resolution additive manufacturing technique that exploits the ink meniscus formed on a printer nozzle and is suitable for the fabrication of micro/nanoscale 3D architectures. This method can be used for solution-processed 3D patterning of materials at a resolution of up to 100 nm, which provides an excellent platform for fundamental scientific studies and various practical applications. This review presents recent advances in meniscus-on-demand 3D printing, together with historical perspectives and theoretical background on meniscus formation and stability. Moreover, this review highlights the capabilities of meniscus-on-demand 3D printing in terms of printable materials and potential areas of application, such as electronics and photonics.
{"title":"Recent advances in meniscus-on-demand three-dimensional micro- and nano-printing for electronics and photonics","authors":"Shiqi Hu, Xiao Huan, Yu Liu, Sixi Cao, Zhuoran Wang, Ji Tae Kim","doi":"10.1088/2631-7990/acdf2d","DOIUrl":"https://doi.org/10.1088/2631-7990/acdf2d","url":null,"abstract":"The continual demand for modern optoelectronics with a high integration degree and customized functions has increased requirements for nanofabrication methods with high resolution, freeform, and mask-free. Meniscus-on-demand three-dimensional (3D) printing is a high-resolution additive manufacturing technique that exploits the ink meniscus formed on a printer nozzle and is suitable for the fabrication of micro/nanoscale 3D architectures. This method can be used for solution-processed 3D patterning of materials at a resolution of up to 100 nm, which provides an excellent platform for fundamental scientific studies and various practical applications. This review presents recent advances in meniscus-on-demand 3D printing, together with historical perspectives and theoretical background on meniscus formation and stability. Moreover, this review highlights the capabilities of meniscus-on-demand 3D printing in terms of printable materials and potential areas of application, such as electronics and photonics.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"86 1","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-06-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"89117269","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 : 2023-06-29DOI: 10.1088/2631-7990/acde21
Juqing Song, Baiheng Lv, Wen-Chien Chen, Peng Ding, Yong He
Because of the complex nerve anatomy and limited regeneration ability of natural tissue, the current treatment effect for long-distance peripheral nerve regeneration and spinal cord injury (SCI) repair is not satisfactory. As an alternative method, tissue engineering is a promising method to regenerate peripheral nerve and spinal cord, and can provide structures and functions similar to natural tissues through scaffold materials and seed cells. Recently, the rapid development of 3D printing technology enables researchers to create novel 3D constructs with sophisticated structures and diverse functions to achieve high bionics of structures and functions. In this review, we first outlined the anatomy of peripheral nerve and spinal cord, as well as the current treatment strategies for the peripheral nerve injury and SCI in clinical. After that, the design considerations of peripheral nerve and spinal cord tissue engineering were discussed, and various 3D printing technologies applicable to neural tissue engineering were elaborated, including inkjet, extrusion-based, stereolithography, projection-based, and emerging printing technologies. Finally, we focused on the application of 3D printing technology in peripheral nerve regeneration and spinal cord repair, as well as the challenges and prospects in this research field.
{"title":"Advances in 3D printing scaffolds for peripheral nerve and spinal cord injury repair","authors":"Juqing Song, Baiheng Lv, Wen-Chien Chen, Peng Ding, Yong He","doi":"10.1088/2631-7990/acde21","DOIUrl":"https://doi.org/10.1088/2631-7990/acde21","url":null,"abstract":"Because of the complex nerve anatomy and limited regeneration ability of natural tissue, the current treatment effect for long-distance peripheral nerve regeneration and spinal cord injury (SCI) repair is not satisfactory. As an alternative method, tissue engineering is a promising method to regenerate peripheral nerve and spinal cord, and can provide structures and functions similar to natural tissues through scaffold materials and seed cells. Recently, the rapid development of 3D printing technology enables researchers to create novel 3D constructs with sophisticated structures and diverse functions to achieve high bionics of structures and functions. In this review, we first outlined the anatomy of peripheral nerve and spinal cord, as well as the current treatment strategies for the peripheral nerve injury and SCI in clinical. After that, the design considerations of peripheral nerve and spinal cord tissue engineering were discussed, and various 3D printing technologies applicable to neural tissue engineering were elaborated, including inkjet, extrusion-based, stereolithography, projection-based, and emerging printing technologies. Finally, we focused on the application of 3D printing technology in peripheral nerve regeneration and spinal cord repair, as well as the challenges and prospects in this research field.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"134 1","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-06-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"78943143","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 : 2023-06-22DOI: 10.1088/2631-7990/acdc66
Houchao Zhang, Xiaoyan Zhu, Yuping Tai, Junyi Zhou, Hongke Li, Zhenghao Li, Rui Wang, Jinbao Zhang, Youchao Zhang, Wensong Ge, Fan Zhang, Luanfa Sun, Guangming Zhang, Hongbo Lan
Flexible and stretchable transparent electrodes are widely used in smart display, energy, wearable devices and other fields. Due to the limitations of flexibility and stretchability of indium tin oxide electrodes, alternative electrodes have appeared, such as metal films, metal nanowires, and conductive meshes. However, few of the above electrodes can simultaneously have excellent flexibility, stretchability, and optoelectronic properties. Nanofiber (NF), a continuous ultra-long one-dimensional conductive material, is considered to be one of the ideal materials for high-performance transparent electrodes with excellent properties due to its unique structure. This paper summarizes the important research progress of NF flexible transparent electrodes (FTEs) in recent years from the aspects of NF electrode materials, preparation technology and application. First, the unique advantages and limitations of various NF materials are systematically discussed. Then, we summarize the preparation technology of various advanced NF FTEs, and point out the future development trend. We also discuss the application of NFs in solar cells, supercapacitors, electric heating equipments, sensors, etc, and analyze its development potential in flexible electronic equipment, as well as problems that need to be solved. Finally, the challenges and future development trends are proposed in the wide application of NF FTEs in the field of flexible optoelectronics.
{"title":"Recent advances in nanofiber-based flexible transparent electrodes","authors":"Houchao Zhang, Xiaoyan Zhu, Yuping Tai, Junyi Zhou, Hongke Li, Zhenghao Li, Rui Wang, Jinbao Zhang, Youchao Zhang, Wensong Ge, Fan Zhang, Luanfa Sun, Guangming Zhang, Hongbo Lan","doi":"10.1088/2631-7990/acdc66","DOIUrl":"https://doi.org/10.1088/2631-7990/acdc66","url":null,"abstract":"Flexible and stretchable transparent electrodes are widely used in smart display, energy, wearable devices and other fields. Due to the limitations of flexibility and stretchability of indium tin oxide electrodes, alternative electrodes have appeared, such as metal films, metal nanowires, and conductive meshes. However, few of the above electrodes can simultaneously have excellent flexibility, stretchability, and optoelectronic properties. Nanofiber (NF), a continuous ultra-long one-dimensional conductive material, is considered to be one of the ideal materials for high-performance transparent electrodes with excellent properties due to its unique structure. This paper summarizes the important research progress of NF flexible transparent electrodes (FTEs) in recent years from the aspects of NF electrode materials, preparation technology and application. First, the unique advantages and limitations of various NF materials are systematically discussed. Then, we summarize the preparation technology of various advanced NF FTEs, and point out the future development trend. We also discuss the application of NFs in solar cells, supercapacitors, electric heating equipments, sensors, etc, and analyze its development potential in flexible electronic equipment, as well as problems that need to be solved. Finally, the challenges and future development trends are proposed in the wide application of NF FTEs in the field of flexible optoelectronics.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"17 1","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-06-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"78195681","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}
Nano-3D printing has obtained widespread attention owing to its capacity to manufacture end-use components with nano-scale features in recent years. Multiphoton lithography (MPL) is one of the most promising 3D nanomanufacturing technologies, which has been widely used in manufacturing micro-optics, photonic crystals, microfluidics, meta-surface, and mechanical metamaterials. Despite of tremendous potential of MPL in laboratorial and industrial applications, simultaneous achievement of high throughput, high accuracy, high design freedom, and a broad range of material structuring capabilities remains a long-pending challenge. To address the issue, we propose an acousto-optic scanning with spatial-switching multispots (AOSS) method. Inertia-free acousto-optic scanning and nonlinear swept techniques have been developed for achieving ultrahigh-speed and aberration-free scanning. Moreover, a spatial optical switch concept has been implemented to significantly boost the lithography throughput while maintaining high resolution and high design freedom. An eight-foci AOSS system has demonstrated a record-high 3D printing rate of 7.6 × 107 voxel s−1, which is nearly one order of magnitude higher than earlier scanning MPL, exhibiting its promise for future scalable 3D nanomanufacturing.
{"title":"Acousto-optic scanning spatial-switching multiphoton lithography","authors":"Binzhang Jiao, Fayu Chen, Yuncheng Liu, Xuhao Fan, Shaoqun Zeng, Qi Dong, Leimin Deng, Hui Gao, Wei Xiong","doi":"10.1088/2631-7990/ace0a7","DOIUrl":"https://doi.org/10.1088/2631-7990/ace0a7","url":null,"abstract":"Nano-3D printing has obtained widespread attention owing to its capacity to manufacture end-use components with nano-scale features in recent years. Multiphoton lithography (MPL) is one of the most promising 3D nanomanufacturing technologies, which has been widely used in manufacturing micro-optics, photonic crystals, microfluidics, meta-surface, and mechanical metamaterials. Despite of tremendous potential of MPL in laboratorial and industrial applications, simultaneous achievement of high throughput, high accuracy, high design freedom, and a broad range of material structuring capabilities remains a long-pending challenge. To address the issue, we propose an acousto-optic scanning with spatial-switching multispots (AOSS) method. Inertia-free acousto-optic scanning and nonlinear swept techniques have been developed for achieving ultrahigh-speed and aberration-free scanning. Moreover, a spatial optical switch concept has been implemented to significantly boost the lithography throughput while maintaining high resolution and high design freedom. An eight-foci AOSS system has demonstrated a record-high 3D printing rate of 7.6 × 107 voxel s−1, which is nearly one order of magnitude higher than earlier scanning MPL, exhibiting its promise for future scalable 3D nanomanufacturing.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"49 1","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-06-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"76215530","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}
Nanomaterial-based flexible sensors (NMFSs) can be tightly attached to the human skin or integrated with clothing to monitor human physiological information, provide medical data, or explore metaverse spaces. Nanomaterials have been widely incorporated into flexible sensors due to their facile processing, material compatibility, and unique properties. This review highlights the recent advancements in NMFSs involving various nanomaterial frameworks such as nanoparticles, nanowires, and nanofilms. Different triggering interaction interfaces between NMFSs and metaverse/virtual reality (VR) applications, e.g. skin-mechanics-triggered, temperature-triggered, magnetically triggered, and neural-triggered interfaces, are discussed. In the context of interfacing physical and virtual worlds, machine learning (ML) has emerged as a promising tool for processing sensor data for controlling avatars in metaverse/VR worlds, and many ML algorithms have been proposed for virtual interaction technologies. This paper discusses the advantages, disadvantages, and prospects of NMFSs in metaverse/VR applications.
{"title":"Nanomaterial-based flexible sensors for metaverse and virtual reality applications","authors":"Jianfei Wang, Jiao Suo, Zhengxun Song, Wen Jung Li, Zuobin Wang","doi":"10.1088/2631-7990/acded1","DOIUrl":"https://doi.org/10.1088/2631-7990/acded1","url":null,"abstract":"Nanomaterial-based flexible sensors (NMFSs) can be tightly attached to the human skin or integrated with clothing to monitor human physiological information, provide medical data, or explore metaverse spaces. Nanomaterials have been widely incorporated into flexible sensors due to their facile processing, material compatibility, and unique properties. This review highlights the recent advancements in NMFSs involving various nanomaterial frameworks such as nanoparticles, nanowires, and nanofilms. Different triggering interaction interfaces between NMFSs and metaverse/virtual reality (VR) applications, e.g. skin-mechanics-triggered, temperature-triggered, magnetically triggered, and neural-triggered interfaces, are discussed. In the context of interfacing physical and virtual worlds, machine learning (ML) has emerged as a promising tool for processing sensor data for controlling avatars in metaverse/VR worlds, and many ML algorithms have been proposed for virtual interaction technologies. This paper discusses the advantages, disadvantages, and prospects of NMFSs in metaverse/VR applications.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"1 1","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-06-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"79691261","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 : 2023-06-15DOI: 10.1088/2631-7990/acded2
C. Shuai, Desheng Li, Xiong Yao, xia Li, Chengde Gao
As a new generation of materials/structures, heterostructure is characterized by heterogeneous zones with dramatically different mechanical, physical or chemical properties. This endows heterostructure with unique interfaces, robust architectures, and synergistic effects, making it a promising option as advanced biomaterials for the highly variable anatomy and complex functionalities of individual patients. However, the main challenges of developing heterostructure lie in the control of crystal/phase evolution and the distribution/fraction of components and structures. In recent years, additive manufacturing techniques have attracted increasing attention in developing heterostructure due to the unique flexibility in tailored structures and synthetic multimaterials. This review focuses on the additive manufacturing of heterostructure for biomedical applications. The structural features and functional mechanisms of heterostructure are summarized. The typical material systems of heterostructure, mainly including metals, polymers, ceramics, and their composites, are presented. And the resulting synergistic effects on multiple properties are also systematically discussed in terms of mechanical, biocompatible, biodegradable, antibacterial, biosensitive and magnetostrictive properties. Next, this work outlines the research progress of additive manufacturing employed in developing heterostructure from the aspects of advantages, processes, properties, and applications. This review also highlights the prospective utilization of heterostructure in biomedical fields, with particular attention to bioscaffolds, vasculatures, biosensors and biodetections. Finally, future research directions and breakthroughs of heterostructure are prospected with focus on their more prospective applications in infection prevention and drug delivery.
{"title":"Additive manufacturing of promising heterostructure for biomedical applications","authors":"C. Shuai, Desheng Li, Xiong Yao, xia Li, Chengde Gao","doi":"10.1088/2631-7990/acded2","DOIUrl":"https://doi.org/10.1088/2631-7990/acded2","url":null,"abstract":"As a new generation of materials/structures, heterostructure is characterized by heterogeneous zones with dramatically different mechanical, physical or chemical properties. This endows heterostructure with unique interfaces, robust architectures, and synergistic effects, making it a promising option as advanced biomaterials for the highly variable anatomy and complex functionalities of individual patients. However, the main challenges of developing heterostructure lie in the control of crystal/phase evolution and the distribution/fraction of components and structures. In recent years, additive manufacturing techniques have attracted increasing attention in developing heterostructure due to the unique flexibility in tailored structures and synthetic multimaterials. This review focuses on the additive manufacturing of heterostructure for biomedical applications. The structural features and functional mechanisms of heterostructure are summarized. The typical material systems of heterostructure, mainly including metals, polymers, ceramics, and their composites, are presented. And the resulting synergistic effects on multiple properties are also systematically discussed in terms of mechanical, biocompatible, biodegradable, antibacterial, biosensitive and magnetostrictive properties. Next, this work outlines the research progress of additive manufacturing employed in developing heterostructure from the aspects of advantages, processes, properties, and applications. This review also highlights the prospective utilization of heterostructure in biomedical fields, with particular attention to bioscaffolds, vasculatures, biosensors and biodetections. Finally, future research directions and breakthroughs of heterostructure are prospected with focus on their more prospective applications in infection prevention and drug delivery.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"17 1","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-06-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"85144194","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 : 2023-06-02DOI: 10.1088/2631-7990/acdb0d
Shuai Peng, Jiawen Xu, Dongya Li, Jun Ren, Meng Zhang, Xiaolong Wang, Y. Liu
Complex-shaped optical lenses are of great interest in the areas of laser processing, machine vision, and optical communications. Traditionally, the processing of complex optical lenses is usually achieved by precision machining combined with post-grinding or polishing, which is expensive, labor-intensive and difficult in the processing of ultra-complex optical lenses. Additive manufacturing is an emerging technology that provides significant advantages in producing highly intricate optical devices. However, the layer-by-layer method employed in such manufacturing processes has resulted in low printing speeds, as well as limitations in surface quality. To address these challenges, we apply tomographic volumetric printing (TVP) in this work, which can realize the integrated printing of complex structural models without layering. By coordinating the TVP and the meniscus equilibrium post-curing methods, ultra-fast fabrication of complex-shaped lenses with sub-nanometric roughness has been achieved. A 2.5 mm high, outer diameter 9 mm spherical lens with a roughness value of RMS = 0.3340 nm is printed at a speed of 3.1 × 104 mm3 h−1. As a further demonstration, a complex-shaped fly-eye lens is fabricated without any part assembly. The designed spherical lens is mounted on a smartphone’s camera, and the precise alignments above the circuit board are captured. Upon further optimization, this new technology demonstrates the potential for rapid fabrication of ultra-smooth complex optical devices or systems.
{"title":"Ultra-fast 3D printing of assembly—free complex optics with sub-nanometer surface quality at mesoscale","authors":"Shuai Peng, Jiawen Xu, Dongya Li, Jun Ren, Meng Zhang, Xiaolong Wang, Y. Liu","doi":"10.1088/2631-7990/acdb0d","DOIUrl":"https://doi.org/10.1088/2631-7990/acdb0d","url":null,"abstract":"Complex-shaped optical lenses are of great interest in the areas of laser processing, machine vision, and optical communications. Traditionally, the processing of complex optical lenses is usually achieved by precision machining combined with post-grinding or polishing, which is expensive, labor-intensive and difficult in the processing of ultra-complex optical lenses. Additive manufacturing is an emerging technology that provides significant advantages in producing highly intricate optical devices. However, the layer-by-layer method employed in such manufacturing processes has resulted in low printing speeds, as well as limitations in surface quality. To address these challenges, we apply tomographic volumetric printing (TVP) in this work, which can realize the integrated printing of complex structural models without layering. By coordinating the TVP and the meniscus equilibrium post-curing methods, ultra-fast fabrication of complex-shaped lenses with sub-nanometric roughness has been achieved. A 2.5 mm high, outer diameter 9 mm spherical lens with a roughness value of RMS = 0.3340 nm is printed at a speed of 3.1 × 104 mm3 h−1. As a further demonstration, a complex-shaped fly-eye lens is fabricated without any part assembly. The designed spherical lens is mounted on a smartphone’s camera, and the precise alignments above the circuit board are captured. Upon further optimization, this new technology demonstrates the potential for rapid fabrication of ultra-smooth complex optical devices or systems.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"105 1","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-06-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"72751766","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 : 2023-06-02DOI: 10.1088/2631-7990/acdb0c
Yihe Huang, Yize Li, Kewen Pan, Yixian Fang, K. Chan, Xiaoyu Xiao, W. Chao, K. Novoselov, J. Gallop, L. Hao, Zhu Liu, Zhirun Hu, Lin Li
Microwave absorption in radar stealth technology is faced with challenges in terms of its effectiveness in low-frequency regions. Herein, we report a new laser-based method for producing an ultrawideband metamaterial-based microwave absorber with a highly uniform sheet resistance and negative magnetic permeability at resonant frequencies, which results in a wide bandwidth in the L- to S-band. Control of the electrical sheet resistance uniformity has been achieved with less than 5% deviation at 400 Ω sq−1 and 6% deviation at 120 Ω sq−1, resulting in a microwave absorption coefficient between 97.2% and 97.7% within a 1.56–18.3 GHz bandwidth for incident angles of 0°–40°, and there is no need for providing energy or an electrical power source during the operation. Porous N- and S-doped turbostratic graphene 2D patterns with embedded magnetic nanoparticles were produced simultaneously on a polyethylene terephthalate substrate via laser direct writing. The proposed low-frequency, wideband, wide-incident-angle, and high-electromagnetic-absorption microwave absorber can potentially be used in aviation, electromagnetic interference (EMI) suppression, and 5G applications.
{"title":"A direct laser-synthesized magnetic metamaterial for low-frequency wideband passive microwave absorption","authors":"Yihe Huang, Yize Li, Kewen Pan, Yixian Fang, K. Chan, Xiaoyu Xiao, W. Chao, K. Novoselov, J. Gallop, L. Hao, Zhu Liu, Zhirun Hu, Lin Li","doi":"10.1088/2631-7990/acdb0c","DOIUrl":"https://doi.org/10.1088/2631-7990/acdb0c","url":null,"abstract":"Microwave absorption in radar stealth technology is faced with challenges in terms of its effectiveness in low-frequency regions. Herein, we report a new laser-based method for producing an ultrawideband metamaterial-based microwave absorber with a highly uniform sheet resistance and negative magnetic permeability at resonant frequencies, which results in a wide bandwidth in the L- to S-band. Control of the electrical sheet resistance uniformity has been achieved with less than 5% deviation at 400 Ω sq−1 and 6% deviation at 120 Ω sq−1, resulting in a microwave absorption coefficient between 97.2% and 97.7% within a 1.56–18.3 GHz bandwidth for incident angles of 0°–40°, and there is no need for providing energy or an electrical power source during the operation. Porous N- and S-doped turbostratic graphene 2D patterns with embedded magnetic nanoparticles were produced simultaneously on a polyethylene terephthalate substrate via laser direct writing. The proposed low-frequency, wideband, wide-incident-angle, and high-electromagnetic-absorption microwave absorber can potentially be used in aviation, electromagnetic interference (EMI) suppression, and 5G applications.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"9 1","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-06-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"79597423","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}
Polycrystalline materials are extensively employed in industry. Its surface roughness significantly affects the working performance. Material defects, particularly grain boundaries, have a great impact on the achieved surface roughness of polycrystalline materials. However, it is difficult to establish a purely theoretical model for surface roughness with consideration of the grain boundary effect using conventional analytical methods. In this work, a theoretical and deep learning hybrid model for predicting the surface roughness of diamond-turned polycrystalline materials is proposed. The kinematic–dynamic roughness component in relation to the tool profile duplication effect, work material plastic side flow, relative vibration between the diamond tool and workpiece, etc, is theoretically calculated. The material-defect roughness component is modeled with a cascade forward neural network. In the neural network, the ratio of maximum undeformed chip thickness to cutting edge radius R TS, work material properties (misorientation angle θ g and grain size d g), and spindle rotation speed n s are configured as input variables. The material-defect roughness component is set as the output variable. To validate the developed model, polycrystalline copper with a gradient distribution of grains prepared by friction stir processing is machined with various processing parameters and different diamond tools. Compared with the previously developed model, obvious improvement in the prediction accuracy is observed with this hybrid prediction model. Based on this model, the influences of different factors on the surface roughness of polycrystalline materials are discussed. The influencing mechanism of the misorientation angle and grain size is quantitatively analyzed. Two fracture modes, including transcrystalline and intercrystalline fractures at different R TS values, are observed. Meanwhile, optimal processing parameters are obtained with a simulated annealing algorithm. Cutting experiments are performed with the optimal parameters, and a flat surface finish with Sa 1.314 nm is finally achieved. The developed model and corresponding new findings in this work are beneficial for accurately predicting the surface roughness of polycrystalline materials and understanding the impacting mechanism of material defects in diamond turning.
{"title":"A theoretical and deep learning hybrid model for predicting surface roughness of diamond-turned polycrystalline materials","authors":"Chunlei He, Jiwang Yan, Shuqi Wang, Shuo Zhang, Guangsi Chen, C. Ren","doi":"10.1088/2631-7990/acdb0a","DOIUrl":"https://doi.org/10.1088/2631-7990/acdb0a","url":null,"abstract":"Polycrystalline materials are extensively employed in industry. Its surface roughness significantly affects the working performance. Material defects, particularly grain boundaries, have a great impact on the achieved surface roughness of polycrystalline materials. However, it is difficult to establish a purely theoretical model for surface roughness with consideration of the grain boundary effect using conventional analytical methods. In this work, a theoretical and deep learning hybrid model for predicting the surface roughness of diamond-turned polycrystalline materials is proposed. The kinematic–dynamic roughness component in relation to the tool profile duplication effect, work material plastic side flow, relative vibration between the diamond tool and workpiece, etc, is theoretically calculated. The material-defect roughness component is modeled with a cascade forward neural network. In the neural network, the ratio of maximum undeformed chip thickness to cutting edge radius R TS, work material properties (misorientation angle θ g and grain size d g), and spindle rotation speed n s are configured as input variables. The material-defect roughness component is set as the output variable. To validate the developed model, polycrystalline copper with a gradient distribution of grains prepared by friction stir processing is machined with various processing parameters and different diamond tools. Compared with the previously developed model, obvious improvement in the prediction accuracy is observed with this hybrid prediction model. Based on this model, the influences of different factors on the surface roughness of polycrystalline materials are discussed. The influencing mechanism of the misorientation angle and grain size is quantitatively analyzed. Two fracture modes, including transcrystalline and intercrystalline fractures at different R TS values, are observed. Meanwhile, optimal processing parameters are obtained with a simulated annealing algorithm. Cutting experiments are performed with the optimal parameters, and a flat surface finish with Sa 1.314 nm is finally achieved. The developed model and corresponding new findings in this work are beneficial for accurately predicting the surface roughness of polycrystalline materials and understanding the impacting mechanism of material defects in diamond turning.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":"8 1","pages":""},"PeriodicalIF":14.7,"publicationDate":"2023-06-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"86022819","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}
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