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The purpose of this study to investigate the organized porous network zinc (OPNZ) scaffolds. Their mechanical characteristics, surface roughness and fracture mechanism were assessed in relation to their structural properties. The prospects of fused deposition modeling (FDM) for printing metal scaffolds via rapid tooling have also been studied.

Zn scaffolds with different pore and strut sizes were manufactured via the rapid tooling method. This method is a multistep process that begins with the 3D printing of a polymer template. Later, a paraffin template was obtained from the prepared polymer template. Finally, this paraffin template was used to fabricate the Zn scaffold using microwave sintering. The characterization of prepared Zn samples involved structural characterization, microstructural study, surface roughness testing and compression testing. Moreover, based on the Gibson–Ashby model analysis, the model equations’ constant values were evaluated, which can help in predicting the mechanical properties of Zn scaffolds.

The scanning electron microscopy study confirmed that the fabricated sample pores were open and interconnected. The X-ray diffraction analysis revealed that the Zn scaffold contained hexagonal closed-packed Zn peaks related to the a-Zn phase, validating that scaffolds were free from contamination and impurity. The range for ultimate compressive strength, compressive modulus and plateau stresses for Zn samples were found to be 6.75–39 MPa, 0.14–3.51 GPa and 1.85–12.6 MPa by adjusting their porosity, which are comparable with the cancellous bones. The average roughness value for the Zn scaffolds was found to be 1.86 µm.

This research work can widen the scope for extrusion-based FDM printers for fabricating biocompatible and biodegradable metal Zn scaffolds. This study also revealed the effects of scaffold structural properties like porosity, pore and strut size effect on their mechanical characteristics in view of tissue engineering applications.

While additive manufacturing via melt-extrusion of plastics has been around for more than several decades, its application to complex geometries has been hampered by the discretization of parts into planar layers. This requires wasted support material and introduces anisotropic weaknesses due to poor layer-to-layer adhesion. Curved-layer manufacturing has been gaining attention recently, with increasing potential to fabricate complex, low-weight structures, such as mechanical metamaterials. This paper aims to study the fabrication and mechanical characterization of non-planar lattice structures under cyclic loading.

A mathematical approach to parametrize lattices onto Bèzier surfaces is validated and applied here to fabricate non-planar lattice samples via curved-layer fused deposition modeling. The lattice chirality, amplitude and unit cell size were varied, and the properties of the samples under cyclic-loading were studied experimentally.

Overall, lattices with higher auxeticity showed less energy dissipation, attributed to their bending-deformation mechanism. Additionally, bistability was eliminated with increasing auxeticity, reinforcing the conclusion of bending-dominated behavior. The analysis presented here demonstrates that mechanical metamaterial lattices such as auxetics can be explored experimentally for complex geometries where traditional methods of comparing simple geometry to end-use designs are not applicable.

The mechanics of non-planar lattice structures fabricated using curved-layer additive manufacturing have not been studied thoroughly. Furthermore, traditional approaches do not apply due to parameterization deformations, requiring novel approaches to their study. Here the properties of such structures under cyclic-loading are studied experimentally for the first time. Applications for this type of structures can be found in areas like biomedical scaffolds and stents, sandwich-panel packaging, aerospace structures and architecture of lattice domes.

This work presents an experimental approach to study the mechanical properties of non-planar lattice structures via quasi-static cyclic loading, comparing variations across several lattice patterns including auxetic sinusoids, disrupted sinusoids and their equivalent-density quadratic patterns.

This study aims to present a direct repurposing activity of consumed high-speed steel (HSS) hacksaw blade into fine-looking handmade knives to increase the awareness about sustainability by evaluating the relationship between the quality of material alloys and heat treatment as well as cultural aspects such as the treatment on the HSS hacksaw blade that will affect the material hardness.

The quality of HSS hacksaw blade samples was analyzed by using scanning electron microscope/energy dispersive X-Ray spectroscopy (SEM/EDX) through the identification of material element’s properties. Besides, finite element structural analysis was performed by using SolidWorks Simulation to evaluate the material performance by determining the Von Mises stress to find the factor of safety of the knife designs. Then, the effect of tribology implementation toward mechanical properties of the handmade knives was determined by using a Rockwell C hardness test.

It is found that the material composition of carbon plays a vital role in increasing and improving the hardness and wear resistance of the HSS hacksaw blade. The Von Mises stress obtained is lower than the yield strength of 3,250 MPa by 71.44 per cent with the safety factor of 3.58,which means the design will not be subjected to failure. The mechanical properties of the HSS hacksaw blade such as hardness were determined averagely by 5 per cent of hardness increase.

It has been validated that the tribological effect toward the material characteristic leads to hardness changes which contributed to the enhancement of tool life of the HSS hacksaw blade, thus producing better quality knives.

Encapsulant materials for flip‐chip‐on‐board (FCOB) were developed to address issues that have been observed during assembly of consumer electronic products on a high volume manufacturing FCOB/SMT line. The viscosity, surface tension, and filler particle sizes of several encapsulants were studied in an attempt to correlate these properties to their recorded underfill times and to observe their flow properties under the gap. Materials characterization studies were performed to determine their glass transition temperatures (Tg), tensile elastic and loss moduli (E′ and E′′), coefficients of thermal expansion (CTE), and apparent strengths of adhesion (ASA). In addition, reliability tests were conducted, and several promising materials were identified. The ASA of the encapsulant to the die passivation and the printed circuit board (PCB) is critical to the robustness of the assembly. Studies were conducted to observe the ASA as a function of FCOB assembly conditioning prior to underfilling and the degradation of the ASA as a function of humidity exposure. The ASA of the FCOB encapsulants was highest when the assembly was “baked‐out” prior to underfilling. Conditioning the assemblies for 24 hours at 23°C/85 per cent RH, to simulate the “worse case” factory environment, reduced the ASA. The ASA was also reduced when the “baked‐out” assemblies were placed in the 85°C/85 per cent RH chamber after underfilling. Although the ASA was decreased when the boards were not “baked‐out”, the reliability performance was not affected during air to air temperature cycling (AATC). A new class of low stress encapsulant materials systems were developed to reduce the stress state of the backside of the die. Studies showed that for specific materials compositions, the stress was proportional to the glass transition temperature of the encapsulant. In addition, it was observed that the stress state was a function of humidity, temperature, and time. FCOB assemblies were built with several low stress encapsulants and placed in reliability testing and they performed as well as assemblies underfilled with the qualified encapsulant.

The purpose of this paper is to present a novel computational framework capable of simulating the block cave phenomenon of fines migration in two dimensions. Fines migration is characterised by the faster movement of fine and often low‐grade material towards the draw point in comparison to larger, blocky material. A greater understanding of the kinematic behaviour of fines and ore within the cave during draw is integral to the solution of this problem.

The lattice Boltzmann method (LBM) is employed in a nonlinear form to represent the fines as a continuum, and it is coupled to the discrete element method (DEM) which is used to represent large blocks. The issues relevant to this approach, such as fluid‐solid interaction, the synchronisation of explicit schemes, and the characterisation of a bulk material as a non‐Newtonian fluid are discussed.

Results of the 2D simulations reveal migration trends for the geometries, material properties and operational sequences analysed. By executing an extensive programme of numerical experiments the influence of these and other relevant block cave factors on the migration of fines could be isolated.

To the authors' knowledge, this is the first time the LBM has been used to simulate the flow of bulk materials. The non‐Newtonian LBM‐DEM framework is also a novel approach to the investigation of fines migration, which until now has been limited to scale models, cellular automata or pure DEM simulations. The results of the 2D migration analyses highlight the potential for this novel approach to be applied in an industrial context and also encourage the extension of the framework to 3D.

The purpose of this paper is to outline some key aspects such as material systems used, phenomenological and statistical process modeling, techniques applied to monitor the process and optimization approaches reported. All these need to be taken into account for the ongoing development of the SLM technique, particularly in health care applications. The outcomes from this review allow not only to summarize the main features of the process but also to collect a considerable amount of investigation effort so far achieved by the researcher community.

This paper reviews four significant areas of the selective laser melting (SLM) process of metallic systems within the scope of medical devices as follows: established and novel materials used, process modeling, process tracking and quality evaluation, and finally, the attempts for optimizing some process features such as surface roughness, porosity and mechanical properties. All the consulted literature has been highly detailed and discussed to understand the current and existing research gaps.

With this review, there is a prevailing need for further investigation on copper alloys, particularly when conformal cooling, antibacterial and antiviral properties are sought after. Moreover, artificial intelligence techniques for modeling and optimizing the SLM process parameters are still at a poor application level in this field. Furthermore, plenty of research work needs to be done to improve the existent online monitoring techniques.

This review is limited only to the materials, models, monitoring methods, and optimization approaches reported on the SLM process for metallic systems, particularly those found in the health care arena.

SLM is a widely used metal additive manufacturing process due to the possibility of elaborating complex and customized tridimensional parts or components. It is corroborated that SLM produces minimal amounts of waste and enables optimal designs that allow considerable environmental advantages and promotes sustainability.

The key perspectives about the applications of novel materials in the field of medicine are proposed.

The investigations about SLM contain an increasing amount of knowledge, motivated by the growing interest of the scientific community in this relatively young manufacturing process. This study can be seen as a compilation of relevant researches and findings in the field of the metal printing process.

The purpose of this study is to undertake surface graft copolymerization of viscose fabric via altering its fibrous properties by using acrylic acid (AA) as a carboxyl-containing monomer and peroxydisulfate (PDS) in presence of ferrous sulfate as a novel redox pair for initiating grafting. The latter process acted as an energy-saving process with respect to the reduction in polymerization temperature and maximizing the graft yield %, in addition to rendering the grafted viscose fabrics dye-able with cationic dye (crystal violet), which has frequently no direct affinity to fix on fabric.

To make graft copolymerization more efficient and economic, the optimum conditions for graft copolymerization were established. The graft yield % was determined as a function of initiator, catalyst and monomer concentrations and the material to liquor ratio, in addition to polymerization time and temperatures. Metrological characterizations via Fourier transform infrared spectroscopy and scanning electron microscopy of topographic morphological surface change have also been established in comparison with the ungrafted samples.

The maximum graft yield of 70.6% is obtained at the following optimum conditions: monomer (150 % based on the weight of fabric), PDS (50 m mole), ferrous sulfate (80 m mole) and sulfuric acid (30 m mole) at 40° C for 1.5 h using a liquor ratio of 30. Remarkably, grafting with AA enabled a multifold upsurge in color strength, with improvements in the fastness properties of cationically dyed grafted viscose fabric measured on the blue scale in comparison with untreated viscose fabric.

The novelty addressed here is undertaken with studying the effect of altering the extent of grafting of poly (AA)-viscose graft copolymers expressed as graft yield % in addition to carboxyl contents on cationic dyeing of viscose fabric for the first time in the literature. Moreover, rendering the viscose fabrics after grafting is dye-able with cationic dye with high brilliance of shades, which has regularly no direct affinity to fix on this type of fabrics.

Surface heat treatment by induction heating (10-100 kHz) requires precise prediction and control of the depth of the induced phase transformation. This paper aims at identifying common issues with the measurement and modeling of magnetic properties used in induction heating simulations, and it proposes ways to improve the situation.

In particular, it is demonstrated how intrinsic magnetic properties (i.e. the B-H curve) of a sample can change during the magnetic characterization process itself, due to involuntary annealing of the sample. Then, for a B-H curve that is supposed perfectly known, a comparison is performed between multiple models, each one representing the magnetic properties of steel in time-harmonic (TH) finite element method simulations. Finally, a new model called “power-equivalent model” is proposed. This model provides the best possible accuracy for a known nonlinear and hysteretic B-H curve used in TH simulations.

By carefully following the guidelines identified in this paper, reduction of errors in the range of 5-10 per cent can be achieved, both at the experimental and modeling levels. The new “power-equivalent model” proposed is also expected to be more generic than existing models.

This paper highlights common pitfalls in the measurement and modeling of magnetic properties, and suggests ways to improve the situation.

Material jetting approximates composite material properties through deposition of base materials in a dithered pattern. This microscale, voxel-based patterning leads to macroscale property changes, which must be understood to appropriately design for this additive manufacturing (AM) process. This paper aims to identify impacts on these composites’ viscoelastic properties due to changes in base material composition and distribution caused by incomplete dithering in small features.

Dynamic mechanical analysis (DMA) is used to measure viscoelastic properties of two base PolyJet materials and seven “digital materials”. This establishes the material design space enabled by voxel-by-voxel control. Specimens of decreasing width are tested to explore effects of feature width on dithering’s ability to approximate macroscale material properties; observed changes are correlated to multi-material distribution via an analysis of ingoing layers.

DMA shows storage and loss moduli of preset composites trending toward the iso-strain boundary as composition changes. An added iso-stress boundary defines the property space achievable with voxel-by-voxel control. Digital materials exhibit statistically significant changes in material properties when specimen width is under 2 mm. A quantified change in same-material droplet groupings in each composite’s voxel pattern shows that dithering requires a certain geometric size to accurately approximate macroscale properties.

This paper offers the first quantification of viscoelastic properties for digital materials with respect to material composition and identification of the composite design space enabled through voxel-by-voxel control. Additionally, it identifies a significant shift in material properties with respect to feature width due to dithering pattern changes. This establishes critical design for AM guidelines for engineers designing with digital materials.

The benefits of the thin film multichip module (MCM‐D) approach to high density packaging for VLSI devices have now been amply demonstrated by a number of research groups. The successful emergence of a viable multichip module industry from this research base will, however, depend upon the installation of an industry‐wide manufacturing infrastructure. This will have to provide the necessary range of concurrent design capabilities, make pretested bare die available, and include multichip module vendors who can offer an integrated capability in module design, substrate layout and manufacture, advanced module assembly, packaging and test. Each of these areas of MCM‐D technology merits detailed attention in its own right, sufficient to justify many individual papers and presentations. This present paper focuses on just one of these topics and addresses the approach taken by GEC Plessey Semiconductors (GPS) to the development and control of a highly manufacturable MCM‐D silicon substrate process. The GPS ‘Process I’ four‐layer metal, aluminium‐polyimide substrate technology is described, the technology development and process control test structures are detailed and process characterisation data presented.