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The building and construction industry faces mounting pressure to adopt sustainable practices and materials due to its significant environmental impacts. Corncob (CC), a by-product of the corn industry, has shown great potential as a sustainable and versatile building material as contained in literature. Although no study has categorised the different repurposing applications of CC in building and construction. This systematic review investigates the potential of corncob, an abundant agricultural by-product, as a sustainable building material. Through analysis of 33 peer-reviewed studies from 2000 to 2023, it examined the diverse applications and evolving research trends of corncob in the building and construction industry. Key findings highlight corncob's global availability, low carbon footprint, and favourable properties for building applications. The review reveals nine distinct uses, including thermal/acoustic insulation, soil stabilization, fillers, cement replacement, aggregates, composite materials, particleboard production, and alkali-activated binders. Emerging research focuses on corncob ash as a supplementary cementitious material, with optimal cement replacement levels of 5–30 % by weight identified. Corncob-based materials demonstrate enhanced fire resistance, chemical durability, thermal insulation, and long-term strength development, though compressive strength remains a limitation for structural applications. The study concludes that corncob shows significant promise for advancing environmental sustainability in construction, particularly for non-structural and insulation applications. However, further research is needed to optimize material properties, standardize production methods, and evaluate full lifecycle impacts to enable widespread commercial adoption. This review provides a foundation for future investigations into innovative, low-carbon building materials derived from agricultural residues.

Auxetic lattice structures are three-dimensionally designed intricately repeating units with multifunctionality in three-dimensional space, especially with the emergence of additive manufacturing (AM) technologies. In aerospace applications, these structures have potential for use in high-performance lightweight components, contributing to enhanced efficiency. This paper investigates the design, numerical simulation, manufacturing, and testing of three-dimensional (3D) star-shaped lattice structures with tailored mechanical properties. Finite element analysis (FEA) was employed to examine the effect of a lattice unit’s vertex angle and strut diameter on the lattice structure’s Poisson’s ratio and effective elastic modulus. The strut diameter was altered from 0.2 to 1 mm, while the star-shaped vertex angle was adjusted from 15 to 90 degrees. Laser powder bed fusion (LPBF), an AM technique, was employed to experimentally fabricate 3D star-shaped honeycomb structures made of Ti6Al4V alloy, which were then subjected to compression testing to verify the modelling results. The effective elastic modulus was shown to decrease when increasing the vertex angle or decreasing the strut diameter, while the Poisson’s ratio had a complex behaviour depending on the geometrical characteristics of the structure. By tailoring the unit vertex angle and strut diameter, the printed structures exhibited negative, zero, and positive Poisson’s ratios, making them applicable across a wide range of aerospace components such as impact absorption systems, aircraft wings, fuselage sections, landing gear, and engine mounts. This optimization will support the growing demand for lightweight structures across the aerospace sector.

Recent progress in additive manufacturing, also known as 3D printing, has offered several benefits, including high geometrical freedom and the ability to create bioinspired structures with intricate details. Mantis shrimp can scrape the shells of prey molluscs with its hammer-shaped stick, while beetles have highly adapted forewings that are lightweight, tough, and strong. This paper introduces a design approach for bioinspired lattice structures by mimicking the internal microstructures of a beetle’s forewing, a mantis shrimp’s shell, and a mantis shrimp’s dactyl club, with improved mechanical properties. Finite element analysis (FEA) and experimental characterisation of 3D printed polylactic acid (PLA) samples with bioinspired structures were performed to determine their compression and impact properties. The results showed that designing a bioinspired lattice with unit cells parallel to the load direction improved quasi-static compressive performance, among other lattice structures. The gyroid honeycomb lattice design of the insect forewings and mantis shrimp dactyl clubs outperformed the gyroid honeycomb design of the mantis shrimp shell, with improvements in ultimate mechanical strength, Young’s modulus, and drop weight impact. On the other hand, hybrid designs created by merging two different designs reduced bending deformation to control collapse during drop weight impact. This work holds promise for the development of bioinspired lattices employing designs with improved properties, which can have potential implications for lightweight high-performance applications.

Single-point incremental forming (SPIF) has emerged as a time-efficient approach that offers increased material formability compared to conventional sheet-metal forming techniques. However, the physical interaction between the forming tool and the sheet poses challenges, such as tool wear and formability limits. This study introduces a novel sheet-forming technique called contactless single-point incremental forming (CSPIF), which uses hot compressed air as a deformation tool, eliminating the requirement for physical interaction between the sheet and a rigid forming tool. In this study, a polycarbonate sheet was chosen as the case-study material and subjected to the developed CSPIF. The experiments were carried out at an air temperature of 160 °C, air pressure of 1 bar, a nozzle speed of 750 mm/min, and a step-down thickness of 0.75 mm. A Schlieren setup and a thermal camera were used to visualize the motion of the compressed hot air as it traveled from the nozzle to the sheet. The results showed that the CSPIF technique allowed for the precise shaping of the polycarbonate sheet with minimal springback. However, minor deviations from the designed profile were observed, primarily at the starting point of the nozzle, which can be attributed to the bending effects of the sample. In addition, the occurrence of sheet thinning and material buildup on the deformed workpiece was also observed. The average surface roughness (Ra) of the deformed workpiece was measured to be 0.2871 microns.

The Ti6Al4V alloy has many advantages, such as being lightweight, formal, and resistant to corrosion. This makes it highly desirable for various applications, especially in the aerospace industry. Laser Powder Bed Fusion (LPBF) is a technique that allows for the production of detailed and unique parts with great flexibility in design. However, there are challenges when it comes to achieving high-quality surfaces and porosity formation in the material, which limits the wider use of LPBF. To tackle these challenges, this study uses statistical techniques called Design of Experiments (DoE) and Analysis of Variance (ANOVA) to investigate and optimise the process parameters of LPBF for making Ti6Al4V components with improved density and surface finish. The parameters examined in this study are laser power, laser scan speed, and hatch space. The optimisation study results show that using specific laser settings, like a laser power of 175 W, a laser scan speed of 1914 mm/s, and a hatch space of 53 µm, produces Ti6Al4V parts with a high relative density of 99.54% and low top and side surface roughness of 2.6 µm and 4.3 µm, respectively. This promising outcome demonstrates the practicality of optimising Ti6Al4V and other metal materials for a wide range of applications, thereby overcoming existing limitations and further expanding the potential of LPBF while minimising inherent process issues.

Carbon-fibre-reinforced plastic (CFRP) is increasingly being used in various applications including aerospace, automotive, wind energy, sports, and robotics, which makes the precision modelling of its machining operations a critical research area. However, the classic finite element modelling (FEM) approach has limitations in capturing the complexity of machining, particularly with regard to the interaction between the fibre–matrix interface and the cutting edge. To overcome this limitation, a hybrid approach that integrates smoothed particle hydrodynamics (SPHs) with FEM was developed and tested in this study. The hybrid FEM-SPH approach was compared with the classic FEM approach and validated with experimental measurements that took into account the cutting tool’s round edge. The results showed that the hybrid FEM-SPH approach outperformed the classic FEM approach in predicting the thrust force and bounce back of CFRP machining due to the integrated cohesive model and the element conversion after failure in the developed approach. The accurate representation of the fibre–matrix interface in the FEM-SPH approach resulted in predicting precise chip formation in terms of direction and morphology. Nonetheless, the computing time of the FEM-SPH approach is higher than the classic FEM. The developed hybrid FEM-SPH model is promising for improving the accuracy of simulation in machining processes, combining the benefits of both techniques.

Remanufacturing has been gaining increasing attention in the last few years as a part of green engineering. It is the process of restoring the original specifications of a given product utilizing a combination of new, repaired, and old parts. The present study investigates non-destructive disassembly of an interference fit pin-hub joint to enable the reuse of worn parts with the same loading capacity. The aim is to reduce the disassembly force while preventing plastic deformation and frictional damage on the contact surface to avoid fretting failure and enable further coating. A finite element model of a shaft/hub interference fit was developed, taking into account two cases of damage to the mating parts: deformation and corrosion. The results indicate that thermal disassembly is effective in reducing breaking force by 50% in deformed joints, whereas vibration waves are more suitable for corroded parts with increased friction. In addition, applying a low-frequency oscillation force to the axis of disassembly reduces the pulling out force by 5% and plastic deformation by 99% due to acoustic softening effects. Furthermore, using a heat flux simultaneously with vibration decreases the breaking force by 85%, indicating the higher effectiveness of thermal-aided disassembly and vibration-assisted disassembly in reducing the breaking force of corroded parts with increased friction. This study provides remanufacturing designers with efficient tools to weaken the interference fit and decrease the disconnecting force, ultimately reducing the cost and time required for the disassembly process.

Fused Deposition Modelling (FDM) 3D printers have gained significant popularity in the pharmaceutical and biomedical industries. In this study, a new biomaterial filament was developed by preparing a polylactic acid (PLA)/calcium peroxide (CPO) composite using wet solution mixing and extrusion. The content of CPO varied from 3% to 24% wt., and hot-melt extruder parameters were optimised to fabricate 3D printable composite filaments. The filaments were characterised using an X-ray diffraction analysis, surface morphology assessment, evaluation of filament extrudability, microstructural analysis, and examination of their rheological and mechanical properties. Our findings indicate that increasing the CPO content resulted in increased viscosity at 200 °C, while the PLA/CPO samples showed microstructural changes from crystalline to amorphous. The mechanical strength and ductility of the composite filaments decreased except for in the 6% CPO filament. Due to its acceptable surface morphology and strength, the PLA/CPO filament with 6% CPO was selected for printability testing. The 3D-printed sample of a bone scaffold exhibited good printing quality, demonstrating the potential of the PLA/CPO filament as an improved biocompatible filament for FDM 3D printing.

The latest advancements in bone scaffold technology have introduced novel biomaterials that have the ability to generate oxygen when implanted, improving cell viability and tissue maturation. In this paper, we present a new oxygen-generating polylactic acid (PLA)/calcium peroxide (CPO) composite filament that can be used in 3D printing scaffolds. The composite material was prepared using a wet solution mixing method, followed by drying and hot melting extrusion. The concentration of calcium peroxide in the composite varied from 0% to 9%. The prepared filaments were characterized in terms of the presence of calcium peroxide, the generated oxygen release, porosity, and antibacterial activities. Data obtained from scanning electron microscopy and X-ray diffraction showed that the calcium peroxide remained stable in the composite. The maximum calcium and oxygen release was observed in filaments with a 6% calcium peroxide content. In addition, bacterial inhibition was achieved in samples with a calcium peroxide content of 6% or higher. These results indicate that an optimized PLA filament with a 6% calcium peroxide content holds great promise for improving bone generation through bone cell oxygenation and resistance to bacterial infections.

This study presents a thorough experimental investigation utilising the design of experiments and analysis of variance (ANOVA) to examine the impact of machining process parameters on chip formation mechanisms, machining forces, workpiece surface integrity, and damage resulting from the orthogonal cutting of unidirectional CFRP. The study identified the mechanisms behind chip formation and found it to significantly impact the workpiece orientation of fibre and the tool’s cutting angle, resulting in increased fibre bounceback at larger fibre orientation angles and when using smaller rake angle tools. Increasing the depth of cut and fibre orientation angle results in an increased damage depth, while using higher rake angles reduces it. An analytical model based on response surface analysis for predicting machining forces, damage, surface roughness, and bounceback was also developed. The ANOVA results indicate that fibre orientation is the most significant factor in machining CFRP, while cutting speed is insignificant. Increasing fibre orientation angle and depth leads to deeper damage, while larger tool rake angles reduce damage. Machining workpieces with 0° fibre orientation angle results in the least subsurface damage, and surface roughness is unaffected by the tool rake angle for fibre orientations between 0° to 90° but worsens for angles greater than 90°. Optimisation of cutting parameters was subsequently carried out to improve machined workpiece surface quality and reduce forces. The experimental results showed that negative rake angle and cutting at moderately low speeds (366 mm/min) are the optimal conditions for machining laminates with a fibre angle of θ = 45°. On the other hand, for composite materials with fibre angles of θ = 90° and θ = 135°, it is recommended to use a high positive rake angle and cutting speeds.

Abstract Ceramic materials are increasingly used in micro-electro-mechanical systems (MEMS) as they offer many advantages such as high-temperature resistance, high wear resistance, low density, and favourable mechanical and chemical properties at elevated temperature. However, with the emerging of additive manufacturing, the use of ceramics for functional and structural MEMS raises new opportunities and challenges. This paper provides an extensive review of the manufacturing processes used for ceramic-based MEMS, including additive and conventional manufacturing technologies. The review covers the micro-fabrication techniques of ceramics with the focus on their operating principles, main features, and processed materials. Challenges that need to be addressed in applying additive technologies in MEMS include ceramic printing on wafers, post-processing at the micro-level, resolution, and quality control. The paper also sheds light on the new possibilities of ceramic additive micro-fabrication and their potential applications, which indicates a promising future.

Modern aircrafts require the assembly of thousands of components with high accuracy and reliability. The normality of drilled holes is a critical geometrical tolerance that is required to be achieved in order to realize an efficient assembly process. Failure to achieve the required tolerance leads to structures prone to fatigue problems and assembly errors. Elastomer-based tactile sensors have been used to support robots in acquiring useful physical interaction information with the environments. However, current tactile sensors have not yet been developed to support robotic machining in achieving the tight tolerances of aerospace structures. In this paper, a novel elastomer-based tactile sensor was developed for cobot machining. Three commercial silicon-based elastomer materials were characterised using mechanical testing in order to select a material with the best deformability. A Finite element model was developed to simulate the deformation of the tactile sensor upon interacting with surfaces with different normalities. Additive manufacturing was employed to fabricate the tactile sensor mould, which was chemically etched to improve the surface quality. The tactile sensor was obtained by directly casting and curing the optimum elastomer material onto the additively manufactured mould. A machine learning approach was used to train the simulated and experimental data obtained from the sensor. The capability of the developed vision tactile sensor was evaluated using real-world experiments with various inclination angles, and achieved a mean perpendicularity tolerance of 0.34°. The developed sensor opens a new perspective on low-cost precision cobot machining.

The power systems of today seem inseparable from clean energy sources such as wind turbines (WTs) and photovoltaics (PVs). However, due to their uncertain nature, operational challenges are expected when WT and PV energy is added to the electricity network. It is necessary to introduce new technologies to compensate for the intermittent nature of renewable energy sources (RESs). Therefore, rationally implementing a demand response (DR) program with energy storage systems (ESSs) in a virtual power plant (VPP) environment is recommended as a way forward to minimize the volatile nature of RESs and improve power system reliability. Our proposed approach aims to maximize social welfare (SW) (i.e., maximization of consumer benefits while minimizing energy costs). Our method assesses the impact of the DR program on SW maximization. Two scenarios are examined, one with and one without a DR program. Stochastic programming theory is used to address the optimization problem. The uncertain behavior of WTs, PVs, and load demand is modeled using a scenario-based approach. The correctness of the proposed approach is demonstrated on a 16-bus UK generic distribution system. Our results show that SW and active power dispatch capacity of WT, PV, and ESS are fairly increased using the proposed approach.

The penetration of renewable energy sources (RESs) in the electrical power system has increased significantly over the past years due to increasing global concern about climate change. However, integrating RESs into the power market is highly problematic. The output of RESs such as wind turbines (WTs) and photovoltaics (PVs) is highly uncertain. Their correlation with load demand is not always guaranteed, which compromises system reliability. Distributed energy resources (DERs), especially demand response (DR) programs and energy storage systems (ESSs), are possible options to overcome these operational challenges under the virtual power plant (VPP) setting. This study investigates the impact of using a DR program and battery energy storage system (BESS) on the VPP’s internal electricity market, and also cost-minimization analysis from a utility viewpoint. Three different constrained optimal power flow (OPF) problems are solved such as base case, DR case, and BESS case to determine total incurred costs, locational marginal prices (LMPs), and generator commitments. A scenario tree approach is used to model the uncertainties associated with WTs, PVs, and load demand. The proposed model is investigated on a 14-bus distribution system. The simulation results obtained demonstrate a favorable impact of DR and a BESS on renewable operational challenges.

This work aimed to study one of the most important challenges in orthopaedic implantations, known as stress shielding of total shoulder implants. This problem arises from the elastic modulus mismatch between the implant and the surrounding tissue, and can result in bone resorption and implant loosening. This objective was addressed by designing and optimising a cellular-based lattice-structured implant to control the stiffness of a humeral implant stem used in shoulder implant applications. This study used a topology lattice-optimisation tool to create different cellular designs that filled the original design of a shoulder implant, and were further analysed using finite element analysis (FEA). A laser powder bed fusion technique was used to fabricate the Ti-6Al-4V test samples, and the obtained material properties were fed to the FEA model. The optimised cellular design was further fabricated using powder bed fusion, and a compression test was carried out to validate the FEA model. The yield strength, elastic modulus, and surface area/volume ratio of the optimised lattice structure, with a strut diameter of 1 mm, length of 5 mm, and 100% lattice percentage in the design space of the implant model were found to be 200 MPa, 5 GPa, and 3.71 mm−1, respectively. The obtained properties indicated that the proposed cellular structure can be effectively applied in total shoulder-replacement surgeries. Ultimately, this approach should lead to improvements in patient mobility, as well as to reducing the need for revision surgeries due to implant loosening.

Reconfigurable multipoint forming is a flexible sheet forming technique aimed at customised sheet metal products. However, one drawback of multipoint forming is the cost and time needed to set up and align the upper and lower pin matrices. This study introduces an optimisation study of a novel hole-type rubber punch replacing the top pin matrix of multipoint incremental forming, aiming to reduce pins setting up and alignment complexity and time. Finite element modelling and design of experiments were used to investigate the effect of hole-type rubber punch configuration such as hole size, hole type, and the compression ratio on the wrinkling, thickness variation, and shape deviation. This research shows that the most significant process parameter in all responses was the hole size. The compression ratio of the material was found to be insignificant in wrinkling and shape deviation. The hole-type rubber punch parameters were found to be a hole size of 9 mm, circular hole type, and a compression ratio of 75%. This experimentally resulted in an improved parts wrinkling of 80%, when compared to using solid rubber punch, with the added benefits of reduction of the cost and time needed to set up and align the pin matrices.

Entrapped double oxide film defects are known to be the most detrimental defects during the casting of aluminium alloys. In addition, hydrogen dissolved in the aluminium melt was suggested to pass into the defects to expand them and cause hydrogen porosity. In this work, the effect of two important casting parameters (the filtration and hydrogen content) on the properties of Al–7 Si–0.3 Mg alloy castings was studied using a full factorial design of experiments approach. Casting properties such as the Weibull modulus and position parameter of the elongation and the tensile strength were considered as response parameters. The results suggested that adopting 10 PPI filters in the gating system resulted in a considerable boost of the Weibull moduli of the tensile strength and elongation due to the enhanced mould filling conditions that minimised the possibility of oxide film entrainment. In addition, the results showed that reducing the hydrogen content in the castings samples from 0.257 to 0.132 cm3/100 g Al was associated with a noticeable decrease in the size of bifilm defects with a corresponding improvement in the mechanical properties. Such significant effect of the process parameters studied on the casting properties suggests that the more careful and quiescent mould filling practice and the lower the hydrogen level of the casting, the higher the quality and reliability of the castings produced.

Single-point incremental forming (SPIF) is a flexible technology that can form a wide range of sheet metal products without the need for using punch and die sets. As a relatively cheap and die-less process, this technology is preferable for small and medium customised production. However, the SPIF technology has drawbacks, such as the geometrical inaccuracy and the thickness uniformity of the shaped part. This research aims to optimise the formed part geometric accuracy and reduce the processing time of a two-stage forming strategy of SPIF. Finite element analysis (FEA) was initially used and validated using experimental literature data. Furthermore, the design of experiments (DoE) statistical approach was used to optimise the proposed two-stage SPIF technique. The mass scaling technique was applied during the finite element analysis to minimise the computational time. The results showed that the step size during forming stage two significantly affected the geometrical accuracy of the part, whereas the forming depth during stage one was insignificant to the part quality. It was also revealed that the geometrical improvement had taken place along the base and the wall regions. However, the areas near the clamp system showed minor improvements. The optimised two-stage strategy successfully decreased both the geometrical inaccuracy and processing time. After optimisation, the average values of the geometrical deviation and forming time were reduced by 25% and 55.56%, respectively.

Ti-6Al-2Sn-4Zr-6Mo is one of the most important titanium alloys characterised by its high strength, fatigue, and toughness properties, making it a popular material for aerospace and biomedical applications. However, no studies have been reported on processing this alloy using laser powder bed fusion. In this paper, a deep learning neural network (DLNN) was introduced to rationalise and predict the densification and hardness due to Laser Powder Bed Fusion of Ti-6Al-2Sn-4Zr-6Mo alloy. The process optimisation results showed that near-full densification is achieved in Ti-6Al-2Sn-4Zr-6Mo alloy samples fabricated using an energy density of 77–113 J/mm3. Furthermore, the hardness of the builds was found to increase with increasing the laser energy density. Porosity and the hardness measurements were found to be sensitive to the island size, especially at high energy density. Hot isostatic pressing (HIP) was able to eliminate the porosity, increase the hardness, and achieve the desirable α and β phases. The developed model was validated and used to produce process maps. The trained deep learning neural network model showed the highest accuracy with a mean percentage error of 3% and 0.2% for the porosity and hardness. The results showed that deep learning neural networks could be an efficient tool for predicting materials properties using small data.

Three-dimensional (3D) printing is a recent technology, which gives the possibility to manufacture personalised dosage forms and it has a broad range of applications. One of the most developed, it is the manufacture of oral solid dosage and the four 3DP techniques which have been more used for their manufacture are FDM, inkjet 3DP, SLA and SLS. This systematic review is carried out to statistically analyze the current 3DP techniques employed in manufacturing oral solid formulations and assess the recent trends of this new technology. The work has been organised into four steps, (1) screening of the articles, definition of the inclusion and exclusion criteria and classification of the articles in the two main groups (included/excluded); (2) quantification and characterisation of the included articles; (3) evaluation of the validity of data and data extraction process; (4) data analysis, discussion, and conclusion to define which technique offers the best properties to be applied in the manufacture of oral solid formulations. It has been observed that with SLS 3DP technique, all the characterisation tests required by the BP (drug content, drug dissolution profile, hardness, friability, disintegration time and uniformity of weight) have been performed in the majority of articles, except for the friability test. However, it is not possible to define which of the four 3DP techniques is the most suitable for the manufacture of oral solid formulations, because the selection is affected by different parameters, such as the type of formulation, the physical-mechanical properties to achieve. Moreover, each technique has its specific advantages and disadvantages, such as for FDM the biggest challenge is the degradation of the drug, due to high printing temperature process or for SLA is the toxicity of the carcinogenic risk of the photopolymerising material.

Origami structures have attracted attention in biomedical applications due to their ability to develop surgical tools that can be expanded from a minimal volume to a larger and functional device. On the other hand, four-dimensional (4D) printing is an emerging technology, which involves 3D printing of smart materials that can respond to external stimuli such as heat. This short communication introduces the proof of concept of merging origami and 4D printing technologies to develop minimally invasive delivery of functional biomedical scaffolds with high shape recovery. The shape-memory effect (SME) of the PLA filament and the origami designs were also assessed in terms of deformability and recovery rate. The results showed that herringbone tessellation origami structure combined with internal natural cancellous bone core satisfies the design requirement of foldable scaffolds. The substantial and consistent SME of the 4D printed herringbone tessellation origami, which exhibited 96% recovery compared to 61% for PLA filament, was the most significant discovery of this paper. The experiments demonstrated how the use of 4D printing in situ with origami structures could achieve reliable and repeatable results, therefore conclusively proving how 4D printing of origami structures can be applied to biomedical scaffolds.

There is an increasing demand for flexible, relatively inexpensive manufacturing techniques that can accommodate frequent changes to part design and production technologies, especially when limited batch sizes are required. Reconfigurable multi-point forming (MPF) is an advanced manufacturing technique which uses a reconfigurable die consisting of a set of moveable pins to shape sheet metal parts easily. This study investigates the use of a novel variable thickness waffle-type elastic cushion and a variable punch-loading profile to either eliminate or minimise defects associated with MPF, namely wrinkling, thickness variation, shape deviation, and dimpling. Finite element modelling (FEM), analysis of variance (ANOVA), and the response surface methodology (RSM) were used to investigate the effect of process parameters pertaining to the cushion dimensions and type of loading profile on the aforementioned defects. The results of this study indicate that the most significant process parameters were maximum cushion thickness, cushion cut-out base radius, and cushion cut-out profile radius. The type of loading profile was found to be insignificant in all responses, but further investigation is required as the rate, and the thermal effects were not considered in the material modelling. Optimal process parameters were found to be a maximum cushion thickness of 3.01 mm, cushion cut-out base radius of 2.37 mm, cushion cut-out profile radius of 10 mm, and a “linear” loading profile. This yielded 0.50 mm, 0.00515 mm, 0.425 mm for peak shape deviation, thickness variation, and wrinkling, respectively.

Auxetic structures have attracted attention in energy absorption applications owing to their improved shear modulus and enhanced resistance to indentation. On the other hand, four-dimensional (4D) printing is an emerging technology that is capable of 3D printing smart materials with additional functionality. This paper introduces the development of a NiTi negative-Poisson’s-ratio structure with superelasticity/shape memory capabilities for improved ballistic applications. An analytical model was initially used to optimize the geometrical parameters of a re-entrant auxetic structure. It was found that the re-entrant auxetic structure with a cell angle of −30° produced the highest Poisson’s ratio of −2.089. The 4D printing process using a powder bed fusion system was used to fabricate the optimized NiTi auxetic structure. The measured negative Poisson’s ratio of the fabricated auxetic structure was found in agreement with both the analytical model and the finite element simulation. A finite element model was developed to simulate the dynamic response of the optimized auxetic NiTi structure subjected to different projectile speeds. Three stages of the impact process describing the penetration of the top plate, auxetic structure, and bottom plate have been identified. The results show that the optimized auxetic structures affect the dynamic response of the projectile by getting denser toward the impact location. This helped to improve the energy absorbed per unit mass of the NiTi auxetic structure to about two times higher than that of the solid NiTi plate and five times higher than that of the solid conventional steel plate.

Fused deposition modelling (FDM) is one of most popular 3D printing techniques of thermoplastic polymers. Nonetheless, the poor mechanical strength of FDM parts restricts the use of this technology in functional parts of many applications such as unmanned aerial vehicles (UAVs) where lightweight, high strength, and stiffness are required. In the present paper, the fabrication process of low-density acrylonitrile butadiene styrenecarbon (ABS) with carbon fibre reinforced polymer (CFRP) sandwich layers for UAV structure is proposed to improve the poor mechanical strength and elastic modulus of printed ABS. The composite sandwich structures retains FDM advantages for rapid making of complex geometries, while only requires simple post-processing steps to improve the mechanical properties. Artificial neural network (ANN) was used to investigate the influence of the core density and number of CFRP layers on the mechanical properties. The results showed an improvement of specific strength and elastic modulus with increasing the number of CFRP. The specific strength of the samples improved from 20 to 145 KN·m/kg while the Young’s modulus increased from 0.63 to 10.1 GPa when laminating the samples with CFRP layers. On the other hand, the core density had no significant effect on both specific strength and elastic modulus. A case study was undertaken by applying the CFRP/ABS/CFRP sandwich structure using the proposed method to manufacture improved dual-tilting clamps of a quadcopter UAV.

Oral modified-release multiparticulate dosage forms, which are also referred to as oral multiple-unit particulate systems, are becoming increasingly popular for oral drug delivery applications. The compaction of polymer-coated multiparticulates into tablets to produce a sustained-release dosage form is preferred over hard gelatin capsules. Moreover, multiparticulate tablets are a promising solution to chronic conditions, patients’ adherence, and swallowing difficulties if incorporated into orodispersible matrices. Nonetheless, the compaction of multiparticulates often damages the functional polymer coat, which results in a rapid release of the drug substance and the subsequent loss of sustained-release properties. This review brings to the forefront key formulation variables that are likely to influence the compaction of coated multiparticulates into sustained-release tablets. It focusses on the tabletting of coated drug-loaded pellets, microparticles, and nanoparticles with a designated section on each. Furthermore, it explores the various approaches that are used to evaluate the compaction behaviour of particulate systems.

Recently, there are growing demands in manufacturing of net shape micro parts for wide range of applications due to the increasing interest in miniaturization. In this paper, the fabrication of tetragonal phase zirconia/alumina (YSZ/Al2O3) nanocomposite micro-parts with high quality is presented. The fabrication process is based on soft lithography and colloidal powder dispersion. Experimental results showed that by optimizing the soft lithography and the dispersion process, it was possible to produce high-resolution micro-parts with well dispersed alumina. The X-ray diffraction results had confirmed the important role of the alumina particles in eliminating the emergence of monoclinic phase while the microstructures reveal a pure tetragonal phase. In addition, the sintered YSZ/Al2O3 micro parts achieved micro hardness with 20% superior to the pure YSZ sintered micro-parts with the addition of 5% alumina.