Pub Date : 2025-01-01DOI: 10.1016/j.cirp.2025.04.075
Yu Gu , Runming Tao , Chris Yuan (2) , Hong C Zhang (1) , Michael Hauschild (1)
Maxwell-type dry processing has emerged as a promising manufacturing technology for high-areal-loading Li-ion battery electrodes, offering a significant advantage by eliminating the use of the toxic and costly NMP solvent. This study developed a cradle-to-grave life-cycle-assessment model to evaluate the environmental impacts of this innovative technology, benchmarking the results against the conventional NMP-based technique for a configured 42 kWh NMC622-graphite battery pack. The findings reveal that the dry-processing method merits a 4.8% lower energy consumption and achieves environmental impacts up to 47.5% lower in 12 out of 13 categories, highlighting its environmental benefits compared with the NMP-based manufacturing processes.
{"title":"A cradle-to-grave life-cycle-assessment of dry-processed Li-ion batteries for electric vehicles","authors":"Yu Gu , Runming Tao , Chris Yuan (2) , Hong C Zhang (1) , Michael Hauschild (1)","doi":"10.1016/j.cirp.2025.04.075","DOIUrl":"10.1016/j.cirp.2025.04.075","url":null,"abstract":"<div><div>Maxwell-type dry processing has emerged as a promising manufacturing technology for high-areal-loading Li-ion battery electrodes, offering a significant advantage by eliminating the use of the toxic and costly NMP solvent. This study developed a cradle-to-grave life-cycle-assessment model to evaluate the environmental impacts of this innovative technology, benchmarking the results against the conventional NMP-based technique for a configured 42 kWh NMC622-graphite battery pack. The findings reveal that the dry-processing method merits a 4.8% lower energy consumption and achieves environmental impacts up to 47.5% lower in 12 out of 13 categories, highlighting its environmental benefits compared with the NMP-based manufacturing processes.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 73-76"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611799","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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 : 2025-01-01DOI: 10.1016/j.cirp.2025.04.023
Amin Bagherzadeh , Ozkan Gokcekaya , Erhan Budak (1)
The anisotropic properties of additively manufactured materials cause variations in surface finish, cutting forces, and machinability due to directional differences in material properties. This creates challenges in tool path selection for five-axis machining to achieve optimal process conditions. Additionally, traditional models and methods for process modelling and simulation often fail, leading to significant errors, as they do not account for material anisotropy. This work investigates the material behaviour during machining of additively manufactured materials, proposes a directional-adaptive flow stress model for accurate process modelling and simulation, and introduces an adaptive tool path selection strategy tailored for milling of additively manufactured materials.
{"title":"Directional-adaptive approach in machining of additively manufactured Inconel 718","authors":"Amin Bagherzadeh , Ozkan Gokcekaya , Erhan Budak (1)","doi":"10.1016/j.cirp.2025.04.023","DOIUrl":"10.1016/j.cirp.2025.04.023","url":null,"abstract":"<div><div>The anisotropic properties of additively manufactured materials cause variations in surface finish, cutting forces, and machinability due to directional differences in material properties. This creates challenges in tool path selection for five-axis machining to achieve optimal process conditions. Additionally, traditional models and methods for process modelling and simulation often fail, leading to significant errors, as they do not account for material anisotropy. This work investigates the material behaviour during machining of additively manufactured materials, proposes a directional-adaptive flow stress model for accurate process modelling and simulation, and introduces an adaptive tool path selection strategy tailored for milling of additively manufactured materials.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 81-85"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611800","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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 : 2025-01-01DOI: 10.1016/j.cirp.2025.03.015
Peng Lyu, Jiyu Pan, Ze Liu, Fengzhou Fang (1)
Fused silica is widely used in optical systems such as imaging devices, spectrophotometers and telescopes, where surface quality and morphology play critical roles in product performance. To address these stringent requirements, this study proposes a novel laser-enhanced plasma method. This approach integrates a controlled laser beam into plasma processing, which locally activates the fused silica and increases the concentration of plasma active particles by ∼15 %. The technique facilitates both surface roughness and morphology, achieving a surface roughness of 0.28 nm in Sa and a shape error of 7.64 nm in RMS.
{"title":"Polishing of fused silica by laser-enhanced plasma at the atomic and close-to-atomic scale","authors":"Peng Lyu, Jiyu Pan, Ze Liu, Fengzhou Fang (1)","doi":"10.1016/j.cirp.2025.03.015","DOIUrl":"10.1016/j.cirp.2025.03.015","url":null,"abstract":"<div><div>Fused silica is widely used in optical systems such as imaging devices, spectrophotometers and telescopes, where surface quality and morphology play critical roles in product performance. To address these stringent requirements, this study proposes a novel laser-enhanced plasma method. This approach integrates a controlled laser beam into plasma processing, which locally activates the fused silica and increases the concentration of plasma active particles by ∼15 %. The technique facilitates both surface roughness and morphology, achieving a surface roughness of 0.28 nm in Sa and a shape error of 7.64 nm in RMS.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 281-285"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611849","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Jetting printing processes rely on 2D pixel data derived from decomposed 3D models, which are often unavailable in applications such as surface repair and 3D pattern printing. Reconstructing 3D models and decomposing them into 2D pixels is time-consuming, energy-intensive, and prone to accuracy loss. This paper introduces a novel 2D profile-based design and control method, using 2D contour curves to generate precise pixels for jetting 3D volumes. This approach enhances efficiency, accuracy, and agility while reducing costs. Case studies on surface repair and 3D pattern printing validate its feasibility, with potential applications in multi-axis robotic systems and functional surface formation.
{"title":"2D profile-based surface repair and 3D pattern generative design via material jetting","authors":"Pushkar Kamble , Hao Chen , Hanlin Liao , Yicha Zhang (2)","doi":"10.1016/j.cirp.2025.04.085","DOIUrl":"10.1016/j.cirp.2025.04.085","url":null,"abstract":"<div><div>Jetting printing processes rely on 2D pixel data derived from decomposed 3D models, which are often unavailable in applications such as surface repair and 3D pattern printing. Reconstructing 3D models and decomposing them into 2D pixels is time-consuming, energy-intensive, and prone to accuracy loss. This paper introduces a novel 2D profile-based design and control method, using 2D contour curves to generate precise pixels for jetting 3D volumes. This approach enhances efficiency, accuracy, and agility while reducing costs. Case studies on surface repair and 3D pattern printing validate its feasibility, with potential applications in multi-axis robotic systems and functional surface formation.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 167-171"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611833","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This study presents a model-based LCA framework for the ecodesign of battery, integrating performance and durability. Combining existing designer models (usage, electrothermal, aging) with LCA leveraging a Functional Unit grounded in the battery's State of Function, this framework simulates battery aging and predicts lifespan, enabling precise LCI modelling. Applied to ecodesign strategies, the framework uncovers ecodesign opportunities overlooked by classical LCAs. Results highlight trade-offs between extending lifespan and increased energy and resource consumption, the influence of use conditions, and the benefits of multifunctional casing with improved thermal insulation. This approach is implemented in dedicated software used by CEA battery designers.
{"title":"Ecodesign of lithium-ion battery systems for E-mobility: A model-based LCA approach","authors":"Teo Lavisse , Peggy Zwolinski , Daniel Brissaud (1) , Rémy Panariello , Fabien Perdu","doi":"10.1016/j.cirp.2025.03.046","DOIUrl":"10.1016/j.cirp.2025.03.046","url":null,"abstract":"<div><div>This study presents a model-based LCA framework for the ecodesign of battery, integrating performance and durability. Combining existing designer models (usage, electrothermal, aging) with LCA leveraging a Functional Unit grounded in the battery's State of Function, this framework simulates battery aging and predicts lifespan, enabling precise LCI modelling. Applied to ecodesign strategies, the framework uncovers ecodesign opportunities overlooked by classical LCAs. Results highlight trade-offs between extending lifespan and increased energy and resource consumption, the influence of use conditions, and the benefits of multifunctional casing with improved thermal insulation. This approach is implemented in dedicated software used by CEA battery designers.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 203-207"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611836","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Sustainability-by-Design requires information and communication technologies (ICTs) capable of integrating design engineering, manufacturing processes, materials, and sustainability considerations. Currently, methodologies for assessing environmental sustainability, such as product life cycle assessment, are often implemented too late in the design process, reducing opportunities for early intervention. Integrating environmental sustainability modeling in computer-aided systems (CAx) allows engineers to concurrently evaluate trade-offs between technical performance and environmental impact, facilitating informed decision-making during embodiment design stages. Using a prosthetic device produced via material jetting additive manufacturing as case study, we demonstrate the transformative role of advanced CAx tools capable of analyzing trade-offs among competing objectives.
{"title":"Enabling sustainability-by-design with multi-disciplinary computer aided systems","authors":"Iñigo Flores Ituarte , Emanuele Pagone , Amirmohammad Daareyni , Samniroshan Thayapararajah , Guido Tosello (2)","doi":"10.1016/j.cirp.2025.03.019","DOIUrl":"10.1016/j.cirp.2025.03.019","url":null,"abstract":"<div><div>Sustainability-by-Design requires information and communication technologies (ICTs) capable of integrating design engineering, manufacturing processes, materials, and sustainability considerations. Currently, methodologies for assessing environmental sustainability, such as product life cycle assessment, are often implemented too late in the design process, reducing opportunities for early intervention. Integrating environmental sustainability modeling in computer-aided systems (CAx) allows engineers to concurrently evaluate trade-offs between technical performance and environmental impact, facilitating informed decision-making during embodiment design stages. Using a prosthetic device produced via material jetting additive manufacturing as case study, we demonstrate the transformative role of advanced CAx tools capable of analyzing trade-offs among competing objectives.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 209-213"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611837","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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 : 2025-01-01DOI: 10.1016/j.cirp.2025.03.034
Yusuke Ito, Guoqi Ren, Naohiko Sugita (1)
Transient and selective laser (TSL) processing has attracted attention as an ultrafast, high-precision microfabrication method for glass. In TSL processing, the material is locally excited, and the excited region is selectively removed at ultra-high speed. However, its processing mechanism, dynamics, and applicability to other materials remain unclear. In this study, we visualized the processing phenomena using sub-microsecond-scale ultrafast imaging and nanosecond-scale precise timing control. We revealed that the process is triggered by bandgap shrinkage following electron–phonon relaxation. Furthermore, we demonstrated that this method enables the processing of sapphire—a large-bandgap material—at speeds 25,000 times faster than conventional methods.
{"title":"Mechanism and dynamics of transient and selective laser processing revealed through high-speed observation combined with precision timing control","authors":"Yusuke Ito, Guoqi Ren, Naohiko Sugita (1)","doi":"10.1016/j.cirp.2025.03.034","DOIUrl":"10.1016/j.cirp.2025.03.034","url":null,"abstract":"<div><div>Transient and selective laser (TSL) processing has attracted attention as an ultrafast, high-precision microfabrication method for glass. In TSL processing, the material is locally excited, and the excited region is selectively removed at ultra-high speed. However, its processing mechanism, dynamics, and applicability to other materials remain unclear. In this study, we visualized the processing phenomena using sub-microsecond-scale ultrafast imaging and nanosecond-scale precise timing control. We revealed that the process is triggered by bandgap shrinkage following electron–phonon relaxation. Furthermore, we demonstrated that this method enables the processing of sapphire—a large-bandgap material—at speeds 25,000 times faster than conventional methods.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 269-273"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611847","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This paper presents a novel digital twin framework employing batch incremental learning for geometry assurance. Addressing quality issues caused by part and process variation, the method evaluates three critical tasks: part matching, locator adjustments, and joining sequence. The proposed framework utilizes deep learning architectures, each trained on recursive simulation data. Employing incremental learning, the models adapt to new batch characteristics while maintaining predictive accuracy. A spot welded assembly demonstrated the proposed approach efficiency, achieving prediction accuracies with errors as low as 0.02 mm for part matching and 0.1 mm for locator adjustments.
{"title":"Augmented geometry assurance digital twin with physics-based incremental learning","authors":"Roham Sadeghi Tabar , Rikard Söderberg (1) , Dariusz Ceglarek (1) , Pasquale Franciosa , Lars Lindkvist","doi":"10.1016/j.cirp.2025.03.008","DOIUrl":"10.1016/j.cirp.2025.03.008","url":null,"abstract":"<div><div>This paper presents a novel digital twin framework employing batch incremental learning for geometry assurance. Addressing quality issues caused by part and process variation, the method evaluates three critical tasks: part matching, locator adjustments, and joining sequence. The proposed framework utilizes deep learning architectures, each trained on recursive simulation data. Employing incremental learning, the models adapt to new batch characteristics while maintaining predictive accuracy. A spot welded assembly demonstrated the proposed approach efficiency, achieving prediction accuracies with errors as low as 0.02 mm for part matching and 0.1 mm for locator adjustments.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 151-155"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611827","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The design of lightweight transmission units highlights the importance of additive manufacturing (AM) techniques in gear production; however, it suffers from a limited understanding of the cutting induced surface enhancement mechanism subjected to inevitable negative rake angle cutting (NRAc). This work applies the NRAc method to process hardened AM-produced 17-4PH stainless steel made with 0°, 67°, and 90° hatching strategies, elucidating subsurface alteration mechanisms in distinct crystallographic textures. In-depth microstructural analysis and machinability evaluation revealed that the compressive stress-induced material removal process promotes a refinement-dominated deformation mode, leading to surface strengthening via grain refinement and martensitic phase transition.
{"title":"Towards understanding the surface strengthening mechanism in negative rake angle cutting of additively manufactured stainless steel","authors":"Tingyue Bai , Chao Wang , Guangyuan Yu , Maxim Kolmanovskyi , Jannis Saelzer , Toru Kizaki (2) , Dirk Biermann (1) , Zhenglong Fang","doi":"10.1016/j.cirp.2025.04.071","DOIUrl":"10.1016/j.cirp.2025.04.071","url":null,"abstract":"<div><div>The design of lightweight transmission units highlights the importance of additive manufacturing (AM) techniques in gear production; however, it suffers from a limited understanding of the cutting induced surface enhancement mechanism subjected to inevitable negative rake angle cutting (NRAc). This work applies the NRAc method to process hardened AM-produced 17-4PH stainless steel made with 0°, 67°, and 90° hatching strategies, elucidating subsurface alteration mechanisms in distinct crystallographic textures. In-depth microstructural analysis and machinability evaluation revealed that the compressive stress-induced material removal process promotes a refinement-dominated deformation mode, leading to surface strengthening via grain refinement and martensitic phase transition.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 77-80"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611830","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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 : 2025-01-01DOI: 10.1016/j.cirp.2025.03.003
Wessel W. Wits (2) , Camill de Vos , Maria Montero-Sistiaga , Marc de Smit
Laser powder bed fusion of unsupported overhang structures, required for metamaterial lattices, are difficult to manufacture. In this study, process parameters are experimentally determined to successfully fabricate auxetic re-entrant metamaterial structures. Due to the support-less printing, higher linear energy densities compared to contour and hatch scanning are required to build continuously solidified overhang structures. Simulation results show that the melt pool width and in particular the length is enlarged, promoting loose powder attachment by denudation and balling. Auxetic re-entrant metamaterials are successfully fabricated. Impact tests show good mechanical performance and better energy absorption compared to previous studies.
{"title":"Laser powder bed fusion process parameters for the fabrication of unsupported overhang structures of metamaterial lattices","authors":"Wessel W. Wits (2) , Camill de Vos , Maria Montero-Sistiaga , Marc de Smit","doi":"10.1016/j.cirp.2025.03.003","DOIUrl":"10.1016/j.cirp.2025.03.003","url":null,"abstract":"<div><div>Laser powder bed fusion of unsupported overhang structures, required for metamaterial lattices, are difficult to manufacture. In this study, process parameters are experimentally determined to successfully fabricate auxetic re-entrant metamaterial structures. Due to the support-less printing, higher linear energy densities compared to contour and hatch scanning are required to build continuously solidified overhang structures. Simulation results show that the melt pool width and in particular the length is enlarged, promoting loose powder attachment by denudation and balling. Auxetic re-entrant metamaterials are successfully fabricated. Impact tests show good mechanical performance and better energy absorption compared to previous studies.</div></div>","PeriodicalId":55256,"journal":{"name":"Cirp Annals-Manufacturing Technology","volume":"74 1","pages":"Pages 309-313"},"PeriodicalIF":3.2,"publicationDate":"2025-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144611886","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"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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