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The mesoscale structure (MS) has a significant impact on the mechanical performance of parts made by additive manufacturing (AM). This paper aims to explore the design and fabrication of force-flow guided reinforcement mesoscale structure (FFRMS) compared with the homogeneous mesoscale structure (HMS), which is inconsistent with the stress field for a given load condition. Some cases were presented to demonstrate the mechanical properties of FFRMS in terms of MS combined with quasi-isotropy and anisotropy.

The paper consists of four main sections: the first developed the concept of FFRMS design based on HMS, the second explored volume fraction control for the proportion of force-flow lines in terms of mechanical property requirement, and the third presented a sequence stacking theory and practical manufacturing process framework and the final sections provided some application case studies.

The main contributions of this study were the definition and development of the FFRMS concept, the application framework and the original case studies. As an example, a typical lug designed with the proposed FFRMS method was fabricated by three different AM processes. The test results showed that both the strength and stiffness of the specimens are improved greatly by using the FFRMS design method.

The superposition of HMS as the basement and force-flow as an indication of the stiffener, leading to a heterogeneous structure, which exhibits more efficient and diversified means compared with the traditional way of increasing the HMS density merely.

This paper aims to provide a comprehensive review of the state-of–the-art design methods for additive manufacturing (AM) technologies to improve functional performance.

In this survey, design methods for AM to improve functional performance are divided into two main groups. They are design methods for a specific objective and general design methods. Design methods in the first group primarily focus on the improvement of functional performance, while the second group also takes other important factors such as manufacturability and cost into consideration with a more general framework. Design methods in each groups are carefully reviewed with discussion and comparison.

The advantages and disadvantages of different design methods for AM are discussed in this paper. Some general issues of existing methods are summarized below: most existing design methods only focus on a single design scale with a single function; few product-level design methods are available for both products’ functionality and assembly; and some existing design methods are hard to implement for the lack of suitable computer-aided design software.

This study is a useful source for designers to select an appropriate design method to take full advantage of AM.

In this survey, a novel classification method is used to categorize existing design methods for AM. Based on this classification method, a comprehensive review is provided in this paper as an informative source for designers and researchers working in this field.

Confronting the unveiled sophisticated structural and physical characteristics of permanent magnets, notably the samarium–cobalt (Sm-Co) alloy, This work aims to introduce a simulation scheme that can link physics-based micromagnetics on the nanostructures and magnetostatic homogenization on the mesoscale polycrystalline structures.

The simulation scheme is arranged in a multiscale fashion. The magnetization behaviors on the nanostructures examined with various orientations are surrogated as the micromagnetic-informed hysterons. The hysteresis behavior of the mesoscale polycrystalline structures with micromagnetic-informed hysterons is then evaluated by computational magnetostatic homogenization.

The micromagnetic-informed hysterons can emulate the magnetization reversal of the parameterized Sm-Co nanostructures as the local hysteresis behavior on the mesostructures. The simulation results of the mesoscale polycrystal demonstrate that the demagnetization process starts from the grain with the largest orientation angle (a) and then propagates to the surrounding grains.

The presented scheme depicts the demand for integrating data-driven methods, as the parameters of the surrogate hysteron intrinsically depend on the nanostructure and its orientation. Further hysteron parameters that help the surrogate hysteron emulate the micromagnetic-simulated magnetization reversal should be examined.

This work provides a novel multiscale scheme for simulating the polycrystalline permanent magnets’ hysteresis while recapitulating the nanoscale mechanisms, such as the nucleation of domains, and domain wall migration and pinning. This scheme can be further extended to simulate the part-level hysteresis considering the mesoscale features.

This paper aims to a novel fabricated resonator structure which consists of some single mechanical resonators as a mass sensor.

The structure is proposed to detect the target molecules and cells in a droplet. Also, at this design the mechanical coupling springs of the proposed structure are designed in such a way that it resonates in shear resonance mode which minimizes the damping effect.

This proposed design can be fabricated in different sizes due to the requirements of an application.

The proposed design is fabricated in mesoscale and its mass sensitivity is evaluated and reported in this paper.

This paper aims to establish a multiscale topology optimization method for the optimal design of non-periodic, self-supporting cellular structures subjected to thermo-mechanical loads. The result is a hierarchically complex design that is thermally efficient, mechanically stable and suitable for additive manufacturing (AM).

The proposed method seeks to maximize thermo-mechanical performance at the macroscale in a conceptual design while obtaining maximum shear modulus for each unit cell at the mesoscale. Then, the macroscale performance is re-estimated, and the mesoscale design is updated until the macroscale performance is satisfied.

A two-dimensional Messerschmitt Bolkow Bolhm (MBB) beam withstanding thermo-mechanical load is presented to illustrate the proposed design method. Furthermore, the method is implemented to optimize a three-dimensional injection mold, which is successfully prototyped using 420 stainless steel infiltrated with bronze.

By developing a computationally efficient and manufacturing friendly inverse homogenization approach, the novel multiscale design could generate porous molds which can save up to 30 per cent material compared to their solid counterpart without decreasing thermo-mechanical performance.

This study is a useful tool for the designer in molding industries to reduce the cost of the injection mold and take full advantage of AM.

The purpose of this paper is to develop an efficient numerical method to study the complex crack initiation and propagation in linear elastic multiphase composites.

A phase field method is developed to study the complex fracture behavior in multiphase composites. A damage threshold is introduced for referring crack initiation in the proposed method. The damage threshold is assigned as a material property so that different composite components possess different thresholds. In this manner, smooth transition from crack initiation to propagation is revealed.

The proposed method is used to investigate complex crack evolution in mesoscale cementitious composite, which consists of aggregates, matrix and void pores. From a mesoscale point of view, it is found that cracks prefer to evolve within the matrix phase. As a crack encounters an aggregate, it tends to bypass the aggregate and evolve along the interface. Cracks tend to avoid to penetrate through aggregates. Also, cracks tend to be attracted by void pores. From a mesoscale point of view, it is revealed that the elastic modulus and strength of concrete models are closely related to porosity.

A criterion with a damage threshold is introduced to the proposed method. The criterions with and without a damage threshold are compared with each other in details. The proposed method is proven to be a useful tool to study mechanical behavior and crack evolution of brittle multiphase composites.

Materials commonly involve microstructure. Clay is a microinhomogeneous material with nanoscale microstructure. Key issues to understand the behavior of such a finely microinhomogeneous material are as follows: the microstructure is characterized in detail, the local distribution of material properties is identified by experiment or simulation, and the microscale characteristics are related to the macroscale behavior by a seamless manner. For characterizing a microstructure of bentonite, we introduce a conforcal laser scanning microscope (CLSM) together with SEM. By CLSM we can specify a 3D configuration under atmospheric condition. Properties of water‐saturated bentonite are mainly controlled by hydrated montmorillonite, which is the major clay mineral of bentonite. Smectite minerals including montmorillonite are extremely fine and poorly crystallized, so it is difficult to determine the properties by experiment. We inquire into the physicochemical properties by a molecular dynamics simulation method. Then, we develop a multiscale homogenization method to extend the microscopic characteristics to the macroscopic behavior. We show numerical examples of a diffusion problem.

The novel structures and properties of nanostructure and nanomaterials give people perfect artistic expression of feeling and sense, then the nanoart discipline is developed and is closely related on the nanotechniques. The many achieved novel nanostructures with strong anti-corrosion prepared by the anodization have been reviewed. The paper would raise public awareness of nanotechnology, nanomaterial and their impact on our lives.

Anodization is a very effective and simple technique to form various nanostructures of metal oxide. It includes hard anodization, mild anodization and pulse anodization. Many measures have been introduced anodization process to improve the quality of formed nanostructure and enhance its properties, such as anti-corrosion.

The formation mechanism of anodic aluminum oxide (AAO) by using the mild, hard and pulse anodization has been discussed. The pretexture process and many other measures have been taken in mild and hard anodization to improve the regularity of pore array and greatly accelerate the formation rate of AAO. The pulse anodization has been used to prepare the multilayer Y-branched AAO film, which exhibits steady rich and vivid structure colors and gives a very good artistic expression. Furthermore, many other metal oxide nanostructures such as TiO₂ and CuO have also been fabricated using the anodization techniques.

Various nanostructures of metal oxide prepared by anodization have been reviewed and are itself a perfect artwork in mesoscale. Also, many nanostructures have exhibited steady, rich and vivid structure colors and give people a very good artistic expression.

Polymethyl methacrylate (PMMA) is a remarkable biocompatible material for bone cement and regeneration. It is also considered 3D printable but requires in-depth process–structure–properties studies. This study aims to elucidate the mechanistic effects of processing parameters and sterilization on PMMA-based implants.

The approach comprised manufacturing samples with different raster angle orientations to capitalize on the influence of the filament alignment with the loading direction. One sample set was sterilized using an autoclave, while another was kept as a reference. The samples underwent a comprehensive characterization regimen of mechanical tension, compression and flexural testing. Thermal and microscale mechanical properties were also analyzed to explore the extent of the appreciated modifications as a function of processing conditions.

Thermal and microscale mechanical properties remained almost unaltered, whereas the mesoscale mechanical behavior varied from the as-printed to the after-autoclaving specimens. Although the mechanical behavior reported a pronounced dependence on the printing orientation, sterilization had minimal effects on the properties of 3D printed PMMA structures. Nonetheless, notable changes in appearance were attributed, and heat reversed as a response to thermally driven conformational rearrangements of the molecules.

This research further deepens the viability of 3D printed PMMA for biomedical applications, contributing to the overall comprehension of the polymer and the thermal processes associated with its implementation in biomedical applications, including personalized implants.

There are many investigations in design methodologies, but there are also divergences and convergences as there are so many points of view. This study aims to evaluate to corroborate and deepen other researchers’ findings, dissipate divergences and provide directing to future work on the subject from a methodological and convergent perspective.

This study analyzes the previous reviews (about 15 reviews) and based on the consensus and the classifications provided by these authors, a significant sample of research is analyzed in the design for additive manufacturing (DFAM) theme (approximately 80 articles until June of 2017 and approximately 280–300 articles until February of 2019) through descriptive statistics, to corroborate and deepen the findings of other researchers.

Throughout this work, this paper found statistics indicating that the main areas studied are: multiple objective optimizations, execution of the design, general DFAM and DFAM for functional performance. Among the main conclusions: there is a lack of innovation in the products developed with the methodologies, there is a lack of exhaustivity in the methodologies, there are few efforts to include environmental aspects in the methodologies, many of the methods include economic and cost evaluation, but are not very explicit and broad (sustainability evaluation), it is necessary to consider a greater variety of functions, among other conclusions

The novelty in this study is the methodology. It is very objective, comprehensive and quantitative. The starting point is not the case studies nor the qualitative criteria, but the figures and quantities of methodologies. The main contribution of this review article is to guide future work on the subject from a methodological and convergent perspective and this article provides a broad database with articles containing information on many issues to make decisions: design methodology; optimization; processes, selection of parts and materials; cost and product management; mechanical, electrical and thermal properties; health and environmental impact, etc.