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Industry 4.0 conceptualizes the automation of processes through the introduction of technologies such as artificial intelligence and advanced robotics, resulting in a significant production improvement. Detecting defects in the production process, predicting mechanical malfunctions in the assembly line, and identifying defects of the final product are just a few examples of applications of these technologies. In this context, this work focuses on the detection of ultrasound probes' surface defects, with a focus on Esaote S.p.A.'s production line probes. To date, this control is performed manually and therefore biased by many factors such as surface morphology, color, size of the defect, and by lighting conditions (which can cause reflections preventing detection). To overcome these shortfalls, this work proposes a fully automatic machine vision system for surface acquisition of ultrasound probes coupled with an automated defect detection system that leverage artificial intelligence. The paper addresses two crucial steps: (i) the development of the acquisition system (i.e., selection of the acquisition device, analysis of the illumination system, and design of the camera handling system); (ii) the analysis of neural network models for defect detection and classification by comparing three possible solutions (i.e., MMSD-Net, ResNet, EfficientNet). The results suggest that the developed system has the potential to be used as a defect detection tool in the production line (full image acquisition cycle takes ~ 200 s), with the best detection accuracy obtained with the EfficientNet model being 98.63% and a classification accuracy of 81.90%. [ABSTRACT FROM AUTHOR]

Featured Application: A developed large-scale axial-flux generator is used for electricity generation at a run-of-river hydrokinetic power system. The system is to be used in a river with a high volumetric flow rate in Asia. The study demonstrates an application of actual technologies and tools for the development of an axial-flux electricity generator. The specifics of its application—a run-of-river sited power station—predefine some of the design parameters that are close to a wind turbine generator. An extensive study of available solutions is used as a starting point for further concept development. The study aims to provide a viable solution for a large-scale electrical machine. A step-based methodology is defined for concept parameters' assessment and a feasibility study. It demonstrates the advantages of virtual prototyping when assessing various design parameters such as air gaps, coil thickness, and the number of rotor disks. Several simulations over different virtual prototypes provide sufficient information to elaborate an improved design concept. The major result is a ready-for-detailed design concept, with defined major parameters and studied work behavior for a specific, large structure of an electrical machine. Another important result is the presentation of the application of virtual prototyping in the assessment of large structures, for which physical prototyping is an expensive and time-consuming approach. The application of virtual prototyping at a very early product development stage is an effective way to undertake efficient solutions involving the concept of the product. [ABSTRACT FROM AUTHOR]

Virtual reality (VR) applications for surgical planning and mentoring are currently becoming more widespread. Within these fields of applications, haptic systems are crucial to help the understanding of the feedback provided by the tissue during the interaction with the surgical tool. The accuracy of the VR scenario is related to many aspects, among them the ability of the haptic device to provide the force feedback and thus the adoption of proper characterization and modeling of the soft tissue behavior during deformation. This paper presents the current development concerning a VR environment to be equipped with a force feedback haptic device to simulate and experience clamping in colorectal surgery. The reaction at the clamp handle is provided starting from a FEA of the contact between the surgical tool and the tissue, coupled with the kinematic analysis of the mechanism. Connecting the virtual scenario to a microcontroller board, the reaction force is applied to the the haptic device, shaped as a clamping tool handle, so that the user may experience the tissue impedence during clamping. By simulations made through Simscape, a concept is evaluated according to some simulation paths that involve common scenarios of the virtual reality experience (such as collision, partial or total clamping operation). The novelty of the research regards the system design oriented to increase the accuracy of the soft tissue material behaviour through a preliminary off-line dedicated FEA investigation. Through Simulink simulations, the system design is verified so that the VR system set-up may be carried out. The results highlighted: (a) a good correspondence among the theoretical study of the reference kinematism that the haptic device must reproduce; (b) the implementation of a bilinear material model, derived off-line from FEA, is suitable to capture hyperelastic and geometric non-linearities of the soft tissue; (c) the feasibility of the open loop haptic control in accordance to the explored kinematism. The final goal of the research is to propose a system design approach able to tune the VR experince for teaching and mentoring through a in-house set-up easy to be tailored. [ABSTRACT FROM AUTHOR]

Abstract When considering the vibroacoustical behavior of the family of violin instruments, especially related to their construction, numerous beliefs and theories coexist that are not necessarily compatibles between each other. More specifically, the resulting sound or dynamics of the instrument are associated to tonewood properties and geometry, but with ranking and weights that vary according to beliefs and testimony of makers. This study presents an approach to understanding the relative influence of both geometrical and material properties on the vibrational dynamics of the violin. By conducting a screening analysis, using finite element method based computations of a complete violin, we explore impact of maker’s choices during the construction process. The results highlight that the dynamical behavior of the violin is mainly depending on geometrical choices, such as thickness of back and top plate or f-holes shapes, rather than the complete variability of properties of tonewoods. Therefore, the wood selection appears to be a second order effect compared to other luthier’s choices, supporting a craftsmanship practice and can pave the way to the use of lower grade woods, which are more in adequacy with what the resource can offer. This work offers new insights that can assist violin makers in optimizing their design choices and adapting to sustainable material use without compromising subsequent behavior.

Nowadays, robots hold crucial roles in an increasing number of different fields, highlighting an ongoing transition to ever-closer collaboration between humans and machines. In this context, this new technological era has brought out safety issues and, consequently, robots need to be monitored with an appropriate control architecture and human–machine interaction forces should be correctly estimated. For this purpose, friction, inertia, external perturbation, and the intrinsic dynamic of the robots should be monitored. This specific work starts from the need to monitor human–robot interaction forces to ensure safety for users. A successful case study concerning the integration of additional sensors on a wrist robot that directly interacts with humans is shown. Its limits have been the inability to directly measure forces applied by users and the impossibility to know accurately the end-effector position. Firstly, introducing a force/torque sensor, the detection of the forces applied by the user to the robot has been enabled. The user's force data have been used to measure force dissipation and, together with the smoothness of operation, to compare three different embeddable mechanisms. Moreover, the integration of a linear encoder allowed measuring the instantaneous end-effector position on a non-actuated linear guideway, consequently knowing the motor torque value and the force applied by the robot to the user. This has been compared to the interaction force estimated from the motor torques without the linear sensor. The error assessed between the force measured with the encoder and estimated without it is about 12.9%. These results demonstrate the importance of this new embedded system to detect human–machine interaction forces in an accurate way and prevent safety issues. [ABSTRACT FROM AUTHOR]

Featured Application: Prediction and selection of the clamping conditions of large-size workpieces for the purpose of milling, based on modal tests and milling simulations. Vibrations occurring during milling operations are one of the main issues disturbing the pursuit of better efficiency of milling operations and product quality. Even in the case of a stable cutting process, vibration reduction is still an important goal. One of the possible solutions to obtain it is selection of the favorable conditions for clamping the workpiece to the machine table. In this paper, a method for predicting and selecting the clamping condition of a large-size workpiece for the reduction in vibrations during milling is presented. A modal test of the workpiece is performed first for a selected set of tightening screw settings. Next, one milling pass is performed to obtain reference data which are then used to tune the hybrid computational model. In the subsequent step, milling simulations are performed for a set of tightening variants, and the best one is selected, providing the lowest vibrations, assessed as the root mean square (RMS) of vibration displacements. In this paper, the description of the clamping selection procedure, key elements of the simulation model, and simulation and experimental results obtained for the milling of the test workpiece performed for a set of different clamping conditions are provided. The proposed method accurately predicts not only the best but also the worst clamping conditions. [ABSTRACT FROM AUTHOR]

Over the last years, many progresses have been made in the field of virtual prototyping, pushed by the interest of industries and artisans. Especially in the context of the textile industry, the digitizing of the prototyping stage offers the possibility to validate the product design choices before committing to the market. This paper presents a framework for the virtual prototyping of crocheted objects. The core of the framework is an algorithm that is capable of generating the crocheting patterns for a given object and the corresponding instructions. The instructions are leveraged by the framework to visualize the 3D geometry of the object, and can be also used to craft it. Compared to previous works, the proposed algorithm combines a number of features (primarily, the use of parametric surfaces and the support for short rows) that can reduce the distortions in crafted object shape while also lowering computational cost; the algorithm is also able to consider material- and style-related information. The results of a comparison between the proposed algorithm and state-of-the-art approaches showed improved performance in terms of similarity of the generated shape with the target one, computation time, and appearance of the crafted object. [ABSTRACT FROM AUTHOR]

Wearable robots are emerging as a viable and effective solution for assisting and enabling people who suffer from balance and mobility disorders. Virtual prototyping is a powerful tool to design robots, preventing the costly iterative physical prototyping and testing. Design of wearable robots through modelling, however, often involves computationally expensive and error-prone multi-body simulations wrapped in an optimization framework to simulate human–robot–environment interactions. This paper proposes a framework to make the human–robot link segment system statically determinate, allowing for the closed-form inverse dynamics formulation of the link–segment model to be solved directly in order to simulate human–robot dynamic interactions. The paper also uses a technique developed by the authors to estimate the walking ground reactions from reference kinematic data, avoiding the need to measure them. The proposed framework is (a) computationally efficient and (b) transparent and easy to interpret, and (c) eliminates the need for optimization, detailed musculoskeletal modelling and measuring ground reaction forces for normal walking simulations. It is used to optimise the position of hip and ankle joints and the actuator torque–velocity requirements for a seven segments of a lower-limb wearable robot that is attached to the user at the shoes and pelvis. Gait measurements were carried out on six healthy subjects, and the data were used for design optimization and validation. The new technique promises to offer a significant advance in the way in which wearable robots can be designed. [ABSTRACT FROM AUTHOR]

Nuclear microreactors (MRs) have attracted significant attention for their versatility in installation locations, especially with the growing demand for sustainable green energy in large data processing facilities. However, ensuring their safe operation necessitates frequent inspections, which can be challenging for practical efficient management. This study proposes a novel approach using direct energy deposition to incorporate an optical fiber sensor into MR components, enabling real-time monitoring with artificial intelligence. The embedded optical fiber generates real-time data that allows for AI-driven in-vivo thermal deformation analysis. Our smart MR component can detect structural anomalies, identify abnormal operations, and assess operational conditions through augmented reality interfaces and AI technology.

Virtual prototyping combined with additive manufacturing technologies are opening new horizons in healthcare and biomimetic medical device personalisation is becoming feasible and competitive. Finite element-based optimisation combined with metallic additive manufacturing has already demonstrated the physical prototyping of interesting topologies for innovative articular prostheses. However, metallic implants are biomechanically and biologically suboptimal and a shift to ceramic materials, for bone replacement and articular implants, could result interesting. To this end, challenges liked to the engineering design of large-sized topology optimised ceramic implants and their additive manufacture still need to be overcome and exemplified. Accordingly, the whole engineering design of innovative short stem hip prostheses is presented here. Different approaches to the virtual prototyping of massive ceramic implants, involving strategies for their topology optimisation, are tested and systematically compared from biomechanical and mechanobiological perspectives. After virtual validation, the selected alternatives are successfully prototyped employing lithography-based ceramic manufacturing of alumina-toughened zirconia, which constitutes a design-enabled manufacturing breakthrough considering the massive implants achieved. Non-destructive evaluation using X-ray computed tomography allows for quantitative quality control and defect detection. Summarising, the study provides a systematic knowledge-based methodology for the engineering of topology optimised ceramic implants for critically sized defects with remarkable biomechanical and mechanobiological performance.

The main challenge to face in the development of energy-related products is represented by the adoption of effective design for sustainability strategies that encompasses the adoption of engineering design tools, knowledge collection, and reuse/sharing in technical departments. This present paper proposes an engineering design for sustainability methodology that assists engineers in developing energy-related products in compliance with ecodesign standards. The methodology uses virtual prototyping tools to assess energy consumption in compliance with energy labeling directives and analyze different use scenarios. The results obtained by numerical simulations (e.g., Finite Element Method—FEM, Computational Fluid Dynamics—CFD) are used to create specific design eco-knowledge in the field of energy-related products. Numerical results are linked with design configurations to understand the benefits introduced by engineering design choices. This knowledge is stored in a structured database with the aim of being reused when a new product is developed or improved/upgraded. The case study of an induction hob, belonging to the household appliance product family, is investigated to understand the potential and drawbacks of the presented approach in a real application. The results show that potential energy and environmental performance benefits are achieved (e.g., reduction of energy losses, achievement of A+ energy class, and overall life cycle environmental impact reduction). Additionally, a new set of ecodesign guidelines are defined for this product family and employed in developing new compliant products belonging to the same family. [ABSTRACT FROM AUTHOR]

Over the last years 3D garment simulations have improved the workflow of garment production in the clothing industry. While some brands have established themselves as pioneers in this area, planning collections only digitally, other brands are still considering how to start with 3D. 3D clothing simulation enable a clear reduction in product development times from the design idea to the point of sale . To be able to reduce the number of prototypes, it is crucial to create virtual prototypes, that are as close as possible to the final product. To reduce the differences between the physical and virtual garment, production guidelines are needed to establish rules regarding the workmanship of virtual prototypes. A step-by-step description of the processing of virtual garments was made using the simulation system CLO 3D. Different variations of virtual workmanships were shown, with their advantages, disadvantages, optical differences, and applicability. The production guidelines were created for basic garments and then for more challenging products such as winter jackets and bras. It is time consuming to create production guidelines, but the effort is worth it. It enables users and companies to achieve reliable and consistent simulation results.

Abstract Background Virtual Reality (VR) has already emerged as an effective instrument for simulating realistic interactions, across various domains. In the field of User Experience (UX), VR has been used to create prototypes of real-world products. Here, the question is to what extent the users’ experience of a virtual prototype can be equivalent to that of its real counterpart (the real product). This issue particularly concerns the perceptual, cognitive and affective dimensions of users’ experiences. Methods This exploratory study aims to address this issue by comparing the users’ experience of a well-known product, i.e., the Graziella bicycle, presented either in Sumerian or Sansar VR platform, or in a physical setting. Participants’ Emotional Engagement, Sense of Presence, Immersion, and Perceived Product Quality were evaluated after being exposed to the product in all conditions (i.e., Sumerian, Sansar and Physical). Results The findings indicated significantly higher levels of Engagement and Positive Affect in the virtual experiences when compared to their real-world counterparts. Additionally, the sole notable distinction among the VR platforms was observed in terms of Realism. Conclusions This study suggests the feasibility and potential of immersive VR environments as UX evaluation tools and underscores their effectiveness in replicating genuine real-world experiences.

The study demonstrates an application of actual technologies and tools for the development of an axial-flux electricity generator. The specifics of its application—a run-of-river sited power station—predefine some of the design parameters that are close to a wind turbine generator. An extensive study of available solutions is used as a starting point for further concept development. The study aims to provide a viable solution for a large-scale electrical machine. A step-based methodology is defined for concept parameters’ assessment and a feasibility study. It demonstrates the advantages of virtual prototyping when assessing various design parameters such as air gaps, coil thickness, and the number of rotor disks. Several simulations over different virtual prototypes provide sufficient information to elaborate an improved design concept. The major result is a ready-for-detailed design concept, with defined major parameters and studied work behavior for a specific, large structure of an electrical machine. Another important result is the presentation of the application of virtual prototyping in the assessment of large structures, for which physical prototyping is an expensive and time-consuming approach. The application of virtual prototyping at a very early product development stage is an effective way to undertake efficient solutions involving the concept of the product.

This research investigated the potential of a short industry-facilitated masterclass in virtual product development to inform future curriculum development and teaching and learning approaches within the context of Higher Education. An action research approach was adopted with fashion business student participants (n = 22). A pre-class survey, field notes, discussions, and reflections during the four-day masterclass provided data for the study. This study actively engaged student participants to inform curriculum development to advance the digital transformation of the industry. The fashion business students reported the experience as helpful to understand the potential of 3D or 'virtual' technologies within more sustainable product development processes, and to understand their roles as fashion marketing and/or management professionals within the emerging Design/Present/Sell/Produce-model. This study contributes to the literature on how to advance digital skills in higher education. [ABSTRACT FROM AUTHOR]

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In Industry 4.0, companies must focus on human-centred design for a competitive edge. The 4USER project aims to establish a user-centred design method using an interactive Photorealistic Virtual Prototype (PVP) based on Extended Reality (XR) technology, objectifying customer requirements into technical specifications. The PVP overcomes limitations associated with traditional physical prototypes, serving as a quality benchmark for final products. The research focuses on a case study involving the development of sports rifles, emphasising the importance of aesthetic quality. The proposed semi-automatic process in Blender enables the generation of low-poly PVPs, incorporating hyper-realistic textures and high-frequency details. In particular, the overall process is composed of the following steps: i) wooden texture generation via the Wasserstein Generative Adversarial Network (WGAN); ii) model creation based on a low poly "Shrinkwrap Cage"; iii) integration of generated textures into the UV-mapped model. This approach accelerates the product development cycle, reduces costs, and facilitates efficient quality control. [ABSTRACT FROM AUTHOR]

Vibrations occurring during milling operations are one of the main issues disturbing the pursuit of better efficiency of milling operations and product quality. Even in the case of a stable cutting process, vibration reduction is still an important goal. One of the possible solutions to obtain it is selection of the favorable conditions for clamping the workpiece to the machine table. In this paper, a method for predicting and selecting the clamping condition of a large-size workpiece for the reduction in vibrations during milling is presented. A modal test of the workpiece is performed first for a selected set of tightening screw settings. Next, one milling pass is performed to obtain reference data which are then used to tune the hybrid computational model. In the subsequent step, milling simulations are performed for a set of tightening variants, and the best one is selected, providing the lowest vibrations, assessed as the root mean square (RMS) of vibration displacements. In this paper, the description of the clamping selection procedure, key elements of the simulation model, and simulation and experimental results obtained for the milling of the test workpiece performed for a set of different clamping conditions are provided. The proposed method accurately predicts not only the best but also the worst clamping conditions.

This study evaluates the applicability of rapid life prediction methods of integrated circuit packages. Although computing power is becoming less of an issue, the complexity and inputs required for finite element analysis of electronics still need to be improved. We analyze the life estimation of ball grid array components using the Engelmaier model, compared to the closed-form Ansys Sherlock computer-aided engineering tool. The latter addresses some of the caveats of the analytical Engelmaier model. The study shows that the main advantage of the discussed analytical approaches is the fast assessment of parameter influence. However, validation is challenging due to the simplifications assumed in analytical life prediction models. Researchers and engineers should consider both the applicability and limitations of the approaches in the decision-making process. [ABSTRACT FROM AUTHOR]

Among the leading immersive technologies, augmented reality is one of the most promising and empowering for supporting designers in production environments. This research investigates the application of mobile augmented reality, based on the Web, as a mediation tool focused on cognitive activities of reading and understanding of technical drawings in the production and assembly of tailor-made projects of the scenographic industry. In this context, the research presents a method to use WebAR to improve the reading of technical drawings, seeking efficiency in the visualization of models and the exchange of information between professionals involved in the processes of design, production, and assembly of products, in the scope of scenography. This mediation tool was developed using Web AR platforms, compatible with native libraries (ARCore and ARKit) to ensure, first, compatibility with commonly used devices that workers or businesses can access, and second, to leverage hybrid tracking techniques that combine vision and sensors to improve the reliability of augmented reality viewing. The proposed solution adopts multiple tracking and navigation techniques in order to expand Space Skills components to provide greater exploratory freedom to users. The research process took place in light of the Design Science Research Methodology and the DSR-Model, since it aimed to develop a solution to a practical problem, as well as to produce knowledge from this process. Field experiments were conducted in two real companies, with end users on their respective mobile devices, in order to evaluate usability and behavioral intent, through the Acceptance, Intent, and Use of Technology questionnaires and perceived mental workload, NASA-TLX. The experimental results show that the adoption of this tool reduces the cognitive load in the process of reading technical drawings and project understanding. In general, its usability and intent to use provided significant levels of satisfaction, being positively accepted by all participants involved in the study. [ABSTRACT FROM AUTHOR]

Graduated compression is widely used for medical application to prevent perioperative venous thromboembolism, but other applications such as sportswear can potentially also benefit from it. A tight-fit cycling shirt meant to ensure the correct position during cycling and prevent injuries was designed. The aim of this study was to improve garment pattern design from the aspect of clothing pressure for providing support and enhancing comfort to the user. This paper investigates the suitability of pressure maps from 3D fashion design software CLO 3D for design and in particular its capability to discriminate between various materials and cycling postures. Moreover, the impact of the mechanical properties of fabric was analyzed. In particular, virtual prototyping tool CLO 3D and pressure mapping were employed to achieve the required graduated compression while ensuring fit and comfort. Pattern adjustments were iteratively performed until stress, strain, and pressure maps showed adequate fit and pressure of the cycling garment on the virtual cyclist in static and dynamic cycling positions. The impact of fabric types on garment fit has been shown by generating the stress, strain, and pressure maps with a virtual simulation. It was found that the visualized pressure on the human body model shows distributions that are related to contact between body and garment, and large compression stresses occur in the lower parts of the two shirts. Evident garment deformation was shown at hip level, upper arm, lower front side seam, and front neck, which can reduce garment wear comfort and freedom of movement. The output was found to be sufficiently accurate to optimize the garments based on material and cycling posture.

Wearable robots are emerging as a viable and effective solution for assisting and enabling people who suffer from balance and mobility disorders. Virtual prototyping is a powerful tool to design robots, preventing the costly iterative physical prototyping and testing. Design of wearable robots through modelling, however, often involves computationally expensive and error-prone multi-body simulations wrapped in an optimization framework to simulate human–robot–environment interactions. This paper proposes a framework to make the human–robot link segment system statically determinate, allowing for the closed-form inverse dynamics formulation of the link–segment model to be solved directly in order to simulate human–robot dynamic interactions. The paper also uses a technique developed by the authors to estimate the walking ground reactions from reference kinematic data, avoiding the need to measure them. The proposed framework is (a) computationally efficient and (b) transparent and easy to interpret, and (c) eliminates the need for optimization, detailed musculoskeletal modelling and measuring ground reaction forces for normal walking simulations. It is used to optimise the position of hip and ankle joints and the actuator torque–velocity requirements for a seven segments of a lower-limb wearable robot that is attached to the user at the shoes and pelvis. Gait measurements were carried out on six healthy subjects, and the data were used for design optimization and validation. The new technique promises to offer a significant advance in the way in which wearable robots can be designed.

The White Rabbit protocol allows synchronization and communication via an optical link in an integrated, modular, and scalable manner. It provides a solution to those applications that have very demanding requirements in terms of synchronization. Field-programmable gate arrays are used to implement the protocol; additionally, special hardware is needed to provide the necessary clock signals used by the dual-mixer time difference for precise phase measurement. In the present work, an expansion board that allows for White Rabbit functionality is presented. The expansion board contains the oscillators required by the White Rabbit protocol, one running at 125 MHz and another at 124.922 MHZ. The architecture of this board includes two oscillator systems for tests and comparison. One is based on VCOs and another on crystal oscillators running at the desired frequencies. In addition, it incorporates a temperature sensor, from where the medium access control address is extracted, an electrically erasable programmable read-only memory, a pulse-per-second output, and a USB UART to access the White Rabbit IP core at the field-programmable gate array. Finally, to ensure the quality of the layout design and guarantee the level of synchronization desired, the results of the power and signal integrity simulations are also presented. [ABSTRACT FROM AUTHOR]

Lower limb-powered exoskeletons can help rehabilitate patients with lower limb disabilities. However, the changes in the biomechanical load on the human body when exoskeletons are used are still poorly understood. The goal of this study was to investigate the changes in kinematic and biomechanical parameters of the lower extremity exoskeleton when worn by normal subjects and patients with unilateral motor impairment using a virtual prototype. The effect of wearing the exoskeleton on gait was derived, and the basis for exoskeleton optimization was given. Virtual prototyping is a cost-effective method to validate the performance of exoskeleton robots. Therefore, two models, a human-exoskeleton model and an asymmetric movement disorder (SSP) subject-exoskeleton model, were developed in AnyBody software for this study. The human-exoskeleton model was driven by the kinematic data of 20 healthy participants walking in an exoskeleton at normal speed (3.6 km/h). As a comparison, the SSP subject-exoskeleton model was driven by data from five SSP subjects walking in an exoskeleton. The experimental results show that after wearing the lower limb exoskeleton, the walking gait satisfies the normal human gait characteristics, but some of the muscle forces suddenly increase. The maximum activation level does not exceed 1, which means that the exoskeleton does not cause muscle damage or fatigue in a short period of time. In both models, the vertical ground reaction force (GRF) Z correlation was the strongest (R > 0.90). The center of pressure (COP) X trajectory correlation was the weakest (R < 0.35). These findings will support the study of the effects of exoskeletal optimization. Also, some gait characteristics of exoskeletons worn by patients with unilateral dyskinesia can be initially explored. [ABSTRACT FROM AUTHOR]