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This paper aims to introduce a method to couple truss finite elements to the material point method (MPM). It presents modeling reinforced material using MPM and describes how to consider the bond behavior between the reinforcement and the continuum.

The embedded approach is used for coupling reinforcement bars with continuum elements. This description is achieved by coupling continuum elements in the background mesh to the reinforcement bars, which are described using truss- finite elements. The coupling is implemented between the truss elements and the continuum elements in the background mesh through bond elements that allow for freely distributed truss elements independent of the continuum element discretization. The bond elements allow for modeling the bond behavior between the reinforcement and the continuum.

The paper introduces a novel method to include the reinforcement bars in the MPM applications. The reinforcement bars can be modeled without any constraints with a bond-slip constitutive model being considered.

As modeling of reinforced materials is required in a wide range of applications, a method to include the reinforcement into the MPM framework is required. The proposed approach allows for modeling reinforced material within MPM applications.

This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It reviews the emerging technologies in PBF multimaterial printing and summarizes the latest simulation approaches for modeling them. The topic of “multimaterial PBF techniques” is still very new, undeveloped, and of interest to academia and industry on many levels.

This is a review paper. The study approach was to carefully search for and investigate notable works and peer-reviewed publications concerning multimaterial three-dimensional printing using PBF techniques. The current methodologies, as well as their advantages and disadvantages, are cross-compared through a systematic review.

The results show that the development of multimaterial PBF techniques is still in its infancy as many fundamental “research” questions have yet to be addressed before production. Experimentation has many limitations and is costly; therefore, modeling and simulation can be very helpful and is, of course, possible; however, it is heavily dependent on the material data and computational power, so it needs further development in future studies.

This work investigates the multimaterial PBF techniques and discusses the novel printing methods with practical examples. Our literature survey revealed that the number of accounts on the predictive modeling of stresses and optimizing laser scan strategies in multimaterial PBF is low with a (very) limited range of applications. To facilitate future developments in this direction, the key information of the simulation efforts and the state-of-the-art computational models of multimaterial PBF are provided.

Because of the anisotropy of the process and the variability in the quality of printed parts, finite element analysis is not directly applicable to recycled materials manufactured using fused filament fabrication. The purpose of this study is to investigate the numerical-experimental mechanical behavior modeling of the recycled polymer, that is, recyclable polyethylene terephthalate (rPET), manufactured by a deposition FFF process under compressive stresses for new sustainable designs.

In all, 42 test specimens were manufactured and analyzed according to the ASTM D695-15 standards. Eight numerical analyzes were performed on a real design manufactured with rPET using Young's compression modulus from the experimental tests. Finally, eight additional experimental tests under uniaxial compression loads were performed on the real sustainable design for validating its mechanical behavior versus computational numerical tests.

As a result of the experimental tests, rPET behaves linearly until it reaches the elastic limit, along each manufacturing axis. The results of this study confirmed the design's structural safety by the load scenario and operating boundary conditions. Experimental and numerical results show a difference of 0.001–0.024 mm, allowing for the rPET to be configured as isotropic in numerical simulation software without having to modify its material modeling equations.

The results obtained are of great help to industry, designers and researchers because they validate the use of recycled rPET for the ecological production of real-sustainable products using MEX technology under compressive stress and its configuration for numerical simulations. Major design companies are now using recycled plastic materials in their high-end designs.

Validation results have been presented on test specimens and real items, comparing experimental material configuration values with numerical results. Specifically, to the best of the authors’ knowledge, no industrial or scientific work has been conducted with rPET subjected to uniaxial compression loads for characterizing experimentally and numerically the material using these results for validating a real case of a sustainable industrial product.

This paper aims to report on the findings of an investigation to compare three different three-dimensional printing (3DP) or additive manufacturing technologies [i.e. fused deposition modeling (FDM), stereolithography (SLA) and material jetting (MJ)] and four different equipment (FDM, SLA, MJP 2600 and Object 260) in terms of their dimensional process capability (dimensional accuracy and surface roughness). It provides a comprehensive and comparative understanding about the level of attainable dimensional accuracy, repeatability and surface roughness of commonly used 3DP technologies. It is expected that these findings will help other researchers and industrialists in choosing the right technology and equipment for a given 3DP application.

A benchmark model of 5 × 5 cm with several common and challenging features, such as around protrusion and hole, flat surface, micro-scale ribs and micro-scale long channels was designed and printed repeatedly using four different equipment of three different 3DP technologies. The dimensional accuracy of the printed models was measured using non-contact digital measurement methods. The surface roughness was evaluated using a digital profilometer. Finally, the surface quality and edge sharpness were evaluated under a reflected light ZEISS microscope with a 50× magnification objective.

The results show that FDM technology with the used equipment results in a rough surface and loose dimensional accuracy. The SLA printer produced a smoother surface, but resulted in the distortion of thin features (<1 mm). MJ printers, on the other hand, produced comparable surface roughness and dimensional accuracy. However, ProJet MJP 3600 produced sharper edges when compared to the Objet 260 that produced round edges.

This paper, for the first time, provides a comprehensive comparison of three different commonly used 3DP technologies in terms of their dimensional capability and surface roughness without farther post-processing. Thus, it offers a reliable guideline for design consideration and printer selection based on the target application.

Digital twin (DT) is an emerging technology that enables sophisticated interaction between physical objects and their virtual replicas. Although DT has recently gained significant attraction in both industry and academia, there is no systematic understanding of DT from its development history to its different concepts and applications in disparate disciplines. The majority of DT literature focuses on the conceptual development of DT frameworks for a specific implementation area. Hence, this paper provides a state-of-the-art review of DT history, different definitions and models, and six types of key enabling technologies. The review also provides a comprehensive survey of DT applications from two perspectives: (1) applications in four product-lifecycle phases, i.e. product design, manufacturing, operation and maintenance, and recycling and (2) applications in four categorized engineering fields, including aerospace engineering, tunneling and underground engineering, wind engineering and Internet of things (IoT) applications. DT frameworks, characteristic components, key technologies and specific applications are extracted for each DT category in this paper. A comprehensive survey of the DT references reveals the following findings: (1) The majority of existing DT models only involve one-way data transfer from physical entities to virtual models and (2) There is a lack of consideration of the environmental coupling, which results in the inaccurate representation of the virtual components in existing DT models. Thus, this paper highlights the role of environmental factor in DT enabling technologies and in categorized engineering applications. In addition, the review discusses the key challenges and provides future work for constructing DTs of complex engineering systems.

The study aims to investigate the impact of additive manufacturing (AM) on the performance of a spare parts supply chain with a particular focus on underlying spare part demand patterns.

This work evaluates various AM-enabled supply chain configurations through Monte Carlo simulation. Historical demand simulation and intermittent demand forecasting are used in conjunction with a mixed integer linear program to determine optimal network nodal inventory policies. By varying demand characteristics and AM capacity this work assesses how to best employ AM capability within the network.

This research assesses the preferred AM-enabled supply chain configuration for varying levels of intermittent demand patterns and AM production capacity. The research shows that variation in demand patterns alone directly affects the preferred network configuration. The relationship between the demand volume and relative AM production capacity affects the regions of superior network configuration performance.

This research makes several simplifying assumptions regarding AM technical capabilities. AM production time is assumed to be deterministic and does not consider build failure probability, build chamber capacity, part size, part complexity and post-processing requirements.

This research is the first study to link realistic spare part demand characterization to AM supply chain design using quantitative modeling.

The main streams of the supply chain are defined as material, information and financial flow. There have been many studies and practical cases regarding the flow of material and information including information sharing. However, financial flow related studies have not been widely examined relatively, compared with their importance.

The information sharing is recognized as the method that can reduce the Bullwhip effect in supply chain management. The author intends to analyze the impact of financial information sharing on the results of the supply chain.

In the point of supply chain risk management view, the author examined the impact of financial flow among the various factors that can impede the stability of the supply chain.

In this study, the author embodied the simulation regarding the impact of financial information flow on supply chain performance and stability based on the system dynamics methodology and analyzed the performance.

Assuming the supply chain, composed of supplying company, manufacturing company and sales company , the author embodied the simulation model and assumed that working capital and cash information sharing were achieved. The author embodied the model to affect the settlement conditions according to the results of financial information sharing.

Currently on additive manufacturing, extensive research is directed toward mitigating the main challenges associated with multi-material in fused filament fabrication which has a weak bonding strength between dissimilar materials. Low interfacial bonding strength leads to defects, anisotropy and temperature gradient in materials which negatively impact the mechanical performance of the multi-material prints. The purpose of this study was to assess the performance of different interface geometry designs in terms of the mechanical properties of the specimens.

Tensile test specimens were printed using: mono-material without a boundary interface, mono-material with the interface geometries (Face-to-face; U-shape; T-shape; Dovetail; Encapsulation; Mechanical interlocking; and Overlap) and multi-material with the interface geometries. The materials chosen with high and low compatibility were Tough polylactic acid (PLA) and TPU.

The main results of this study indicate that the interface geometries with the mechanical constriction between materials provide better structural integrity to the specimens. Moreover, in the case of the mono-material parts, the most effective interface design was the mechanical interlocking for both Tough PLA and TPU. On the other hand, in the case of multi-material specimens, the encapsulation showed the highest ultimate tensile strength, whereas the overlap and T-shape presented more robust bonding.

This study examines the mechanical performance, particularly tensile strength, strain at break, Young’s modulus and yield strength of different interface designs which were not studied in the previous studies.

Internal gearings are commonly used in transmissions due to their advantages like high-power density. To ensure high efficiency, load-carrying capacity and good noise behavior, a profound knowledge of the local gear mesh is essential. The tooth contact of internal gears relates to a convex and concave surface that form a conformal contact. This is in contrast to external gears, where two convex surfaces form a contraformal contact. This paper aims at a better understanding of conformal contacts under elastohydrodynamic lubrication (EHL) to improve the design of internal gearings.

An existing numerical EHL model is used for studying the characteristic properties of a hard conformal EHL line contact. A hard contraformal EHL line contact is studied as reference. Non-Newtonian fluid behavior and thermal effects are considered. By taking into account the local contact conformity and kinematics, the effects and relevance of the curvature of the lubricant gap and micro-slip are analyzed. In a parameter study, scale effects of the contact radii on film thickness, temperature rise and friction are examined.

The curvature of the lubricant gap and effects of micro-slip are small in hard conformal EHL line contacts. For high micro-slip, it can be neglected. Hence, the modeling of conformal contacts using an equivalent geometry of the contact problem is reasonable. The parameter study shows beneficial tribological aspects of the conformal contact compared to the contraformal contact. Higher film thickness and lower fluid coefficient of friction are observed for conformal contacts, which can be attributed to lower pressures for the case of the same external normal force, or to a higher contact temperature rise for the case of equivalent contact pressure.

Despite its widespread existence, the local geometry and kinematics in hard conformal EHL line contacts like in internal gearings have been rarely studied. The findings help for a better understanding of local contact characteristics and its relevance. The quantified scale effects help to improve the efficiency and load-carrying capacity of machine elements with hard conformal EHL contacts, like internal gearings.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2022-0366/