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Measurement to mitigate automotive emission varies from energy content modification of fuel to waste energy recovery through energy system upgradation. The proposed energy-averaged emission mitigation technique involves interfacing piston design exchange and gasoline–methanol blend replacement with traditional gasoline for low carbon high energy content creation. Here, we interlinked the CO, CO2, NOx, O2, and HC to different design exchanges of coated pistons through the available brake power and speed of the engine. We assessed the relative effectiveness of various designs and coating thicknesses for different gasoline–methanol blends (0%,5%,10%, and 15%). The analysis shows the replacement of 5%, 10%, and 15% by volume of gasoline with methanol reduces the fuel carbon by 4.167%, 8.34%, and 12.5%, respectively. The fuel characteristics of blends are comparable to gasoline, hence there is no energy infrastructure modification required to develop the same amount of power. The CO and HC reduced significantly, while CO2 and NOx emissions are comparable. Increasing the coating thickness enhances the surface temperature retention and reduces heat transfer. The Type_C design of the steel piston and type_A design of the AlSi piston show temperature retention values of 582 °C and 598 °C, respectively. Type_A and type_B pistons are better compared to type_C and the type_D piston design for emission mitigation due to decarbonization of fuel through gasoline-methanol blend replacement. Surface response methodology predicts Delastic, σvon Mises, and Tsurface with percentage errors of 0.0042,0.35, and 0.9, respectively. [ABSTRACT FROM AUTHOR]

Conventional microfabrication processes have been well established, but their capabilities are generally limited simple and 2D extruded geometries. Additive manufacturing allows the ability to manufacture true 3D complex geometries, rapid design for manufacturing, mass customization, materials savings, and high precision, which have triggered the increased interest in manufacturing microelectromechanical systems (MEMS). Herein, MEMS manufacturing's recent advancements, including both conventional and additive manufacturing technologies, their working principles, and practical capabilities are consolidated. The use of additive manufacturing in several MEMS areas such as in microelectronics, circuitry, microfluidics, lab on a chip, packaging, and structural MEMS is also discussed in detail. Furthermore, the potentials and limitations of additive manufacturing are investigated with regard to the MEMS requirements. Finally, the technology outlook and improvements are discussed. This study shows that additive manufacturing offers a promising future for the fabrication of MEMS, especially using high‐resolution techniques such as microstereolithography, materials jetting, and materials extrusion. In contrast, current challenges such as materials requirements, equipment innovation, fabricating of in vivo devices for biomedical applications, inherited defects and poor surface finish, adhesion to substrates, and productivity are areas that require further study to increase the uptake by the MEMS community. [ABSTRACT FROM AUTHOR]