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Selective laser sintering (SLS) is an essential technology in the field of additive manufacturing. However, SLS technology is limited by the traditional point-laser sintering method and has reached the bottleneck of efficiency improvement. This study aims to develop an image-shaped laser sintering (ISLS) system based on a digital micromirror device (DMD) to address this problem. The ISLS system uses an image-shaped laser light source with a size of 16 mm × 25.6 mm instead of the traditional SLS point-laser light source.

The ISLS system achieves large-area image-shaped sintering of polymer powder materials by moving the laser light source continuously in the x-direction and updating the sintering pattern synchronously, as well as by overlapping the splicing of adjacent sintering areas in the y-direction. A low-cost composite powder suitable for the ISLS system was prepared using polyether sulfone (PES), pinewood and carbon black (CB) powders as raw materials. Large-sized samples were fabricated using composite powder, and the microstructure, dimensional accuracy, geometric deviation, density, mechanical properties and feasible feature sizes were evaluated.

The experimental results demonstrate that the ISLS system is feasible and can print large-sized parts with good dimensional accuracy, acceptable geometric deviations, specific small-scale features and certain density and mechanical properties.

This study has achieved the transition from traditional point sintering mode to image-shaped surface sintering mode. It has provided a new approach to enhance the system performance of traditional SLS.

The purpose of this paper is to improve the productivity and quality of the wire arc additive manufacturing process by benchmarking the strategies from the selected six strategies, namely, heat treatment process, inter pass cooling process, inter pass cold rolling process, peening process, friction stir processing and oscillation process.

To overcome the lack of certainty associated with correlations and relationships in quality functional deployment, fuzzy numbers have been integrated with the quality functional deployment framework. Twenty performance measures have been identified from the literature under five groups, namely, mechanical properties, physical properties, geometrical properties, cost and material properties. Using house of quality weights are allocated to performance measures and groups, relationships are established between performance measures and strategies, and correlations are assigned between strategies. Finally, for each strategy, relative importance, score and crisp values are calculated.

Inter pass cold rolling process strategy is computed with the highest crisp value of 15.80 which is followed by peening process, heat treatment process, friction stir processing, inter pass cooling process,] and oscillation process strategy.

To the best of the authors’ knowledge, there has been no research in the literature that analyzes the strategies to improve the quality and productivity of the wire arc additive manufacturing process.

Polymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing the fabrication of gears without the aid of support structures and subsequent assembly. However, there are constraints in the process that negatively affect its adoption compared to other additive technologies such as material extrusion to produce gears. This study aims to demonstrate that it is possible to overcome the problems due to the physics of the process to produce accurate mechanism.

Technological aspects such as orientation, wheel-shaft thicknesses and degree of powder recycling were examined. Furthermore, the evolving tooth profile was considered as a design parameter to provide a manufacturability map of gear-based mechanisms.

Results show that there are some differences in the functioning of the gear depending on the type of powder used, 100% virgin or 50% virgin and 50% recycled for five cycles. The application of a groove on a gear produced with 100% virgin powder allows the mechanism to be easily unlocked regardless of the orientation and wheel-shaft thicknesses. The application of a specific evolutionary profile independent of the diameter of the reference circle on vertically oriented gears guarantees rotation continuity while preserving the functionality of the assembled mechanism.

In the literature, there are various studies on material aging and reuse in the PBF-LB/P process, mainly focused on the powder deterioration mechanism, powder fluidity, microstructure and mechanical properties of the parts and process parameters. This study, instead, was focused on the functioning of gears, which represent one of the applications in which this technology can have great success, by analyzing the two main effects that can compromise it: recycled powder and vertical orientation during construction.

This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS).

PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools.

Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route.

This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.

The purpose of this paper is to investigate how different manufacturing technologies are bundled together and how these bundles influence operations performance and, indirectly, business performance. With the emergence of Industry 4.0 (I4.0) technologies, manufacturing companies can use a wide variety of advanced manufacturing technologies (AMT) to build an efficient and effective production system. Nevertheless, the literature offers little guidance on how these technologies, including novel I4.0 technologies, should be combined in practice and how these combinations might have a different impact on performance.

Using a survey study of 165 manufacturing plants from 11 different countries, we use factor analysis to empirically derive three distinct manufacturing technology bundles and structural equation modeling to quantify their relationship with operations and business performance.

Our findings support an evolutionary rather than a revolutionary perspective. I4.0 technologies build on traditional manufacturing technologies and do not constitute a separate direction that would point towards a fundamental digital transformation of companies within our sample. Performance effects are rather weak: out of the three technology bundles identified, only “automation and robotization” have a positive influence on cost efficiency, while “base technologies” and “data-enabled technologies” do not offer a competitive advantage, neither in terms of cost nor in terms of differentiation. Furthermore, while the business performance impact is positive, it is quite weak, suggesting that financial returns on technology investments might require longer time periods.

Relying on a complementarity approach, our research offers a novel perspective on technology implementation in the I4.0 era by investigating novel and traditional manufacturing technologies together.

The purpose of this study, most recent advancements in threedimensional (3D) printing have focused on the fabrication of components. It is typical to use different print settings, such as raster angle, infill and orientation to improve the 3D component qualities while fabricating the sample using a 3D printer. However, the influence of these factors on the characteristics of the 3D parts has not been well explored. Owing to the effect of the different print parameters in fused deposition modeling (FDM) technology, it is necessary to evaluate the strength of the parts manufactured using 3D printing technology.

In this study, the effect of three print parameters − raster angle, build orientation and infill − on the tensile characteristics of 3D-printed components made of three distinct materials − acrylonitrile styrene acrylate (ASA), polycarbonate ABS (PC-ABS) and ULTEM-9085 − was investigated. A variety of test items were created using a commercially accessible 3D printer in various configurations, including raster angle (0°, 45°), (0°, 90°), (45°, −45°), (45°, 90°), infill density (solid, sparse, sparse double dense) and orientation (flat, on-edge).

The outcome shows that variations in tensile strength and force are brought on by the effects of various printing conditions. In all possible combinations of the print settings, ULTEM 9085 material has a higher tensile strength than ASA and PC-ABS materials. ULTEM 9085 material’s on-edge orientation, sparse infill, and raster angle of (0°, −45°) resulted in the greatest overall tensile strength of 73.72 MPa. The highest load-bearing strength of ULTEM material was attained with the same procedure, measuring at 2,932 N. The tensile strength of the materials is higher in the on-edge orientation than in the flat orientation. The tensile strength of all three materials is highest for solid infill with a flat orientation and a raster angle of (45°, −45°). All three materials show higher tensile strength with a raster angle of (45°, −45°) compared to other angles. The sparse double-dense material promotes stronger tensile properties than sparse infill. Thus, the strength of additive components is influenced by the combination of selected print parameters. As a result, these factors interact with one another to produce a high-quality product.

The outcomes of this study can serve as a reference point for researchers, manufacturers and users of 3D-printed polymer material (PC-ABS, ASA, ULTEM 9085) components seeking to optimize FDM printing parameters for tensile strength and/or identify materials suitable for intended tensile characteristics.

This papers aims to study lattice structures in terms of geometric variables, manufacturing variables and material-based variants and their correlation with compressive behaviour for their application in a methodology for the design and development of personalized elastic therapeutic products.

Lattice samples were designed and manufactured using extrusion-based additive manufacturing technologies. Mechanical tests were carried out on lattice samples for elasticity characterization purposes. The relationships between sample stiffness and key geometric and manufacturing variables were subsequently used in the case study on the design of a pressure cushion model for validation purposes. Differentiated areas were established according to patient’s pressure map to subsequently make a correlation between the patient’s pressure needs and lattice samples stiffness.

A substantial and wide variation in lattice compressive behaviour was found depending on the key study variables. The proposed methodology made it possible to efficiently identify and adjust the pressure of the different areas of the product to adapt them to the elastic needs of the patient. In this sense, the characterization lattice samples turned out to provide an effective and flexible response to the pressure requirements.

This study provides a generalized foundation of lattice structural design and adjustable stiffness in application of pressure cushions, which can be equally applied to other designs with similar purposes. The relevance and contribution of this work lie in the proposed methodology for the design of personalized therapeutic products based on the use of individual lattice structures that function as independent customizable cells.

This study aims to investigate the fabrication of solid ankle foot orthoses (SAFOs) using fused deposition modeling (FDM) printing technology. It emphasizes cost-effective 3D scanning with the Kinect sensor and conducts a comparative analysis of SAFO durability with varying thicknesses and materials, including polylactic acid (PLA) and carbon fiber-reinforced (PLA-C), to address research gaps from prior studies.

In this study, the methodology comprises key components: data capture using a cost-effective Microsoft Kinect® Xbox 360 scanner to obtain precise leg dimensions for SAFOs. SAFOs are designed using CAD tools with varying thicknesses (3, 4, and 5 mm) while maintaining consistent geometry, allowing controlled thickness impact investigation. Fabrication uses PLA and PLA-C materials via FDM 3D printing, providing insights into material suitability. Mechanical analysis uses dual finite element analysis to assess force–displacement curves and fracture behavior, which were validated through experimental testing.

The results indicate that the precision of the scanned leg dimensions, compared to actual anthropometric data, exhibits a deviation of less than 5%, confirming the accuracy of the cost-effective scanning approach. Additionally, the research identifies optimal thicknesses for SAFOs, recommending a 4 and 5 mm thickness for PLA-C-based SAFOs and an only 5 mm thickness for PLA-based SAFOs. This optimization enhances the overall performance and effectiveness of these orthotic solutions.

This study’s innovation lies in its holistic approach, combining low-cost 3D scanning, 3D printing and computational simulations to optimize SAFO materials and thickness. These findings advance the creation of cost-effective and efficient orthotic solutions.

This paper aims to solve the problems molybdenum disulfide (MoS₂) nanosheets suffer from inadequate dispersion stability and form a weak lubricating film on the friction surface, which severely limits their application as lubricant additives.

MoS₂/C₆₀ nanocomposites were prepared by synthesizing molybdenum disulfide (MoS₂) nanosheets on the surface of hydrochloric acid-activated fullerenes (C₆₀) by in situ hydrothermal method. The composition, structure and morphology of MoS₂/C₆₀ nanocomposites were characterized. Through the high-frequency reciprocating tribology test, its potential as a lubricant additive was evaluated.

MoS₂/C₆₀ nanocomposites that were prepared showed good dispersion in dioctyl sebacate (DOS). When 0.5 Wt.% MoS₂/C₆₀ was added, the friction reduction performance and wear resistance improved by 54.5% and 62.7%, respectively.

MoS₂/C₆₀ composite nanoparticles were prepared by in-situ formation of MoS₂ nanosheets on the surface of C₆₀ activated by HCl through hydrothermal method and were used as potential lubricating oil additives.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2023-0321/

Industry 4.0 has an inimitable potential to create competitive advantages for the apparel industry by enhancing productivity, production, profitability, efficiency and effectiveness. This study, thus, aims to assess the digitalisation level of the Tanzanian apparel industry through the Industry 4.0 perspectives.

A mixed-methods-based approach was deployed. This study deployed semi-structured interviews, document review and observation methods for the qualitative approach. For the quantitative approach, closed-ended questionnaires were used to ascertain the digitalisation levels and maturity level of the textiles and apparel (T&A) factories and small and medium-sized textile enterprises in Tanzania. The sample size was 110, with participants engaged through the purposive sampling technique.

Industry 4.0 frameworks evolved into practices mainly since 2011 in several service and manufacturing industries globally. For Tanzania, the findings indicate that the overall maturity level of the T&A industries is 2.5 out of 5.0, demonstrating a medium level of adoption. Thus, the apparel industries are not operating under the industry 4.0 framework; they are operating within the third industrial revolution – Industry 3.0 – framework. For such industries to operate within the fourth industrial revolution – Industry 4.0 – that is only possible if there is significantly well-developed industrial infrastructure, availability of engineering talent, stable commercial partnerships, demand from the marketplace and transactional relationship with customers.

This study’s limitations include: firstly, Industry 4.0 is an emerging area; this resulted in limited theoretical underpinnings in the Tanzanian perspectives. Secondly, the studied industries may not suffice the need to generalise the findings for the entire country, thus needing another study.

Although Industry 4.0 conceptual frameworks have been on trial in several industries since 2011, this is amongst the first empirical research on Industry 4.0 in the Tanzanian apparel industry that assesses the digitalisation levels.