Microarchitected Stretching‐Dominated Mechanical Metamaterials with Minimal Surface Topologies

Historically, the creation of lightweight, yet mechanically robust, materials have been the most sought‐after engineering pursuit. For that purpose, research efforts are dedicated to finding pathways to emulate and mimic the resilience offered by natural biological systems (i.e., bone and wood). These natural systems evolved over time to provide the most attainable structural efficiency through their architectural characteristics that can span over multiple length scales. Nature‐inspired man‐made cellular metamaterials have effective properties that depend largely on their topology rather than composition and are hence remarkable candidates for a wide range of application. Despite their geometrical complexity, the fabrication of such metamaterials is made possible by the emergence of advanced fabrication techniques that permit the fabrication of complex architectures down to the nanometer scale. In this work, we report the fabrication and mechanical testing of nature‐inspired, mathematically created, micro‐architected, cellular metamaterials with topologies based on triply periodic minimal surfaces (TPMS) with cubic symmetries fabricated through direct laser writing two‐photon lithography. These TPMS‐based microlattices are sheet/shell‐ and strut‐based metamaterials with high geometrical complexity. Interestingly, results show that TPMS sheet‐based microlattices follow a stretching‐dominated mode of deformation, and further illustrate their mechanical superiority over the traditional and well‐known strut‐based microlattices and microlattice composites. The TPMS sheet‐based polymeric microlattices exhibited mechanical properties superior to other micrloattices comprising metal‐ and ceramic‐coated polymeric substrates and, interestingly, are less affected by the change in density, which opens the door for fabricating ultralightweight materials without much sacrificing mechanical properties.

     

Bio‐Mimicked Silica Architectures Capture Geometry,Microstructure, and Mechanical Properties of Marine Diatoms

The authors create life‐sized synthetic replicas of marine diatom coscinodiscus sp frustules out of cyclohexyl polyhedral oligomeric silsesquioxanes (POSS). The authors demonstrate that these synthetic structures have biosilica‐like amorphous atomic‐level microstructure and mechanical attributes similar to those of a natural diatom. In situ beam bending and fracture experiments on micron‐sized excised sections of natural and synthetic diatoms reveal similarities in their mechanical properties: a Young's modulus of GPa and a fracture toughness of 0.78 ± 0.10 MPa m^?1/2 for the synthetic materials; those of natural diatoms are GPa and MPa m^?1/2, respectively. In situ single edge notched beam (SENB) bending fracture experiments reveal that fracture behavior of the natural and synthetic specimens is virtually indistinguishable and is characterized by the same brittle failure and crack‐arresting behavior enabled by the double‐wall geometry. Their fracture toughness is comparable to that of fully dense silica, which suggests that the natural diatoms’ frustule maintains its mechanical resilience even at <50% of the weight attained through multi‐scale architecture. The demonstrated ability to fabricate a synthetic hard biomaterial that is virtually indistinguishable from its natural counterpart while capturing its complex architecture, microstructure, and mechanical properties provides a powerful platform for investigating the specific role of each geometrical feature at every relevant length scale in the often sophisticated, multi‐scale hierarchical construct of hard biomaterials, and provides a robust pathway for property optimization.

     

Nature‐Inspired Lightweight Cellular Co‐Continuous Composites with Architected Periodic Gyroidal Structures

Shell‐core cellular composites are a unique class of cellular materials, where the base constituent is made of a composite material such that the best distinctive physical and/or mechanical properties of each phase of the composite are employed. In this work, the authors demonstrate the additive manufacturing of a nature inspired cellular three‐dimensional (3D), periodic, co‐continuous, and complex composite materials made of a hard‐shell and soft‐core system. The architecture of these composites is based on the Schoen's single Gyroidal triply periodic minimal surface. Results of mechanical testing show the possibility of having a wide range of mechanical properties by tuning the composition, volume fraction of core, shell thickness, and internal architecture of the cellular composites. Moreover, a change in deformation and failure mechanism is observed when employing a shell‐core composite system, as compared to the pure stiff polymeric standalone cellular material. This shell‐core configuration and Gyroidal topology allowed for accessing toughness values that are not realized by the constituent materials independently, showing the suitability of this cellular composite for mechanical energy absorption applications.

     

Towards patient‐centered packaging design: An industry perspective on processes,functions, and constraints

Medication packaging is essential to provide patients with guidance and correct use of their medicines for effective treatment. This research aims to increase knowledge about the medication packaging innovation process and its uptake towards patient‐centered packaging design. The study applied a qualitative research approach based on data from 25 in‐depth interviews with stakeholders involved in medication packaging design. The empirical data analysis revealed four themes that can improve and advance user‐centered packaging design: medication packaging innovation process, medication packaging functions and features, medication packaging design constraints, and patient‐centered medication packaging design. The findings suggest that medication packaging design is strongly affected by an emphasis on protective and safety packaging functions rather than on patients' needs. Packaging innovation usually is constrained by rigid incremental development processes, where compliance with regulations, extensive documentation, avoidance of manufacturing complexity, and considerations on cost prevail. These findings are discussed in relation to the three most evident trade‐offs for patient‐centered design: protection versus openability, utility versus cost, and complexity of manufacturability versus complexity of use. This research contributes with valuable input and additional evidence about the necessary shift to a user‐centered approach in a field that has not been design driven. This input complements previous research and provides an opportunity for industry decision makers and policy makers to lead patient‐centered packaging design that can benefit patients and relieve overloaded health care systems.     

Template‐Assisted Electroforming of Fully Semi‐Hard‐Magnetic Helical Microactuators

The authors report on the fabrication of semi‐hard‐magnetic microhelices using template‐assisted electroforming. The method consists of electrodepositing a material on a sacrificial mandrel on which a pattern has been previously written. To electroform the helical microswimmers, a helical template on a polymer‐coated metallic mandrel is created using a laser, which precisely ablates the polymer coating and exposes the mandrel surface. Subsequently, the semi‐hard‐magnetic material is electrodeposited in the trenches produced by the laser. In this investigation, the helical structures are obtained from an electrolyte, which enables the production of hard‐magnetic CoPt alloys. The authors also show that electroformed semi‐hard‐magnetic helical microswimmers can propel in viscous environments such as silicon oil in three dimensions and against gravity. Their manufacturing approach can be used for the fabrication of more complex architectures for a wide range of applications and can be potentially extended to any electroplatable material.

     

A Hybrid SPC Method with the Chi‐Square Distance Monitoring Procedure for Large‐scale,Complex Process Data

Standard multivariate statistical process control (SPC) techniques, such as Hotelling's T², cannot easily handle large‐scale, complex process data and often fail to detect out‐of‐control anomalies for such data. We develop a computationally efficient and scalable Chi‐Square ( ) Distance Monitoring (CSDM) procedure for monitoring large‐scale, complex process data to detect out‐of‐control anomalies, and test the performance of the CSDM procedure using various kinds of process data involving uncorrelated, correlated, auto‐correlated, normally distributed, and non‐normally distributed data variables. Based on advantages and disadvantages of the CSDM procedure in comparison with Hotelling's T² for various kinds of process data, we design a hybrid SPC method with the CSDM procedure for monitoring large‐scale, complex process data. Copyright © 2005 John Wiley & Sons, Ltd.     

Ultra‐Light and Scalable Composite Lattice Materials

Architected lattice materials are some of the stiffest and strongest materials at ultra‐light density (<10 mg cm^?3), but scalable manufacturing with high‐performance constituent materials remains a challenge that limits their widespread adoption in load‐bearing applications. We show mesoscale, ultra‐light (5.8 mg cm^?3) fiber‐reinforced polymer composite lattice structures that are reversibly assembled from building blocks manufactured with a best‐practice high‐precision, high‐repeatability, and high‐throughput process: injection molding. Chopped glass fiber‐reinforced polymer (polyetherimide) lattice materials produced with this method display absolute stiffness (8.41 MPa) and strength (19 kPa) typically associated with metallic hollow strut microlattices at similar mass density. Additional benefits such as strain recovery, discrete damage repair with recovery of original stiffness and strength, and ease of modeling are demonstrated.

     

Construction of double sampling s‐control charts for agile manufacturing

Double sampling (DS) ‐control charts are designed to allow quick detection of a small shift of process mean and provides a quick response in an agile manufacturing environment. However, the DS ‐control charts assume that the process standard deviation remains unchanged throughout the entire course of the statistical process control. Therefore, a complementary DS chart that can be used to monitor the process variation caused by changes in process standard deviation should be developed. In this paper, the development of the DS s‐charts for quickly detecting small shift in process standard deviation for agile manufacturing is presented. The construction of the DS s‐charts is based on the same concepts in constructing the DS ‐charts and is formulated as an optimization problem and solved with a genetic algorithm. The efficiency of the DS s‐control chart is compared with that of the traditional s‐control chart. The results show that the DS s‐control charts can be a more economically preferable alternative in detecting small shifts than traditional s‐control charts. Copyright © 2002 John Wiley & Sons, Ltd.     

Nanomaterial‐Based Organelles Protect Normal Cells against Chemotherapy‐Induced Cytotoxicity

Chemotherapy‐induced cytotoxicity in normal cells and organs triggers undesired lesions. Although targeted delivery is used extensively, more than half of the chemotherapy dose still concentrates in normal tissues, especially in the liver. Enabling normal cells or organs to defend against cytotoxicity represents an alternative method for improving chemotherapy. Herein, rationally designed nanomaterials are used as artificial organelles to remove unexpected cytotoxicity in normal cells. Nanocomposites of gold‐oligonucleotides (Au‐ODN) can capture intracytoplasmic doxorubicin (DOX), a standard chemotherapy drug, blocking the drug's access into the cell nucleus. Cells with implanted Au‐ODN are more robust since their viability is maintained during DOX treatment. In vivo experiments confirm that the Au‐ODN nanomaterials selectively concentrate in hepatocytes and eliminate DOX‐induced hepatotoxicity, increasing the cell's capacity to resist the threatening chemotherapeutic milieu. The finding suggests that introducing functional materials as biological devices into living systems may be a new strategy for improving the regulation of cell fate in more complex conditions and for manufacturing super cells.     

Nano‐Scale Mechanics of Nanotubes,Nanowires, and Nanobelts

One‐dimensional (1D) nanostructures have numerous potential applications in science and engineering. Nanocomposites made of nanowires, such as carbon nanotubes, are likely to decrease material’s density and increase its strength,^[1] which are of critical importance to space technology. To investigate the uniqueness offered by these materials, new techniques must be developed to quantitatively measure the properties of individual wire‐like structures whose structures are well characterized by electron microscopy techniques, because their properties may sensitively depend on their geometrical shape/configurations and crystal as well as surface structures. Within the framework of in‐situ TEM we have recently developed a novel approach that relies on electric field induced mechanical resonance for measuring the properties of individual wire‐like structures, such as Young’s modulus, electron field emission, tip work function, and electrical quantum conductance. This is a new technique that provides the properties of a single nanowire with well characterized.     

A new multi‐scale dispersive gradient elasticity model with micro‐inertia: Formulation and ‐finite element implementation

Motivated by nano‐scale experimental evidence on the dispersion characteristics of materials with a lattice structure, a new multi‐scale gradient elasticity model is developed. In the framework of gradient elasticity, the simultaneous presence of acceleration and strain gradients has been denoted as dynamic consistency. This model represents an extension of an earlier dynamically consistent model with an additional micro‐inertia contribution to improve the dispersion behaviour. The model can therefore be seen as an enhanced dynamic extension of the Aifantis' 1992 strain‐gradient theory for statics obtained by including two acceleration gradients in addition to the strain gradient. Compared with the previous dynamically consistent model, the additional micro‐inertia term is found to improve the prediction of wave dispersion significantly and, more importantly, requires no extra computational cost. The fourth‐order equations are rewritten in two sets of symmetric second‐order equations so that ‐continuity is sufficient in the finite element implementation. Two sets of unknowns are identified as the microstructural and macrostructural displacements, thus highlighting the multi‐scale nature of the present formulation. The associated energy functionals and variationally consistent boundary conditions are presented, after which the finite element equations are derived. Considerable improvements over previous gradient models are observed as confirmed by two numerical examples. Copyright © 2016 John Wiley & Sons, Ltd.     

3‐D Printing and Development of Fluoropolymer Based Reactive Inks

Engineering reactive materials is an ever present goal in the energetics community. The desire is to have energetics configured in such a manner that performance is tailored and energy delivery can be targeted. Additive manufacturing (3‐D printing) is one area that could significantly improve our capabilities in this area, if adequate formulations are developed. In this paper, fluoropolymer based reactive inks are developed with micron (mAl) and nanoscale aluminum (nAl) serving, as the fuel at high solids loading (up to 67 wt%) and their viscosity required for 3‐D printing is detailed. For the pen‐type technique and valves used in this work, it is required to have viscosities on the order of 10⁴–10⁵ cP. For printed traces with apparent diameters under <500 μm, the combustion velocities for both micron and nano scale aluminum formulations, are approximately identical: 30 ± 3 versus 32 ± 2 mm s^?1, respectively. Further increasing the apparent diameter is shown to increase the combustion velocity in the case of the nanoscale aluminum formulation by four‐fold over that of the micron scale aluminum formulation, but it plateaus as it approaches an apparent diameter of 2 mm. The results suggest with proper architecture that tailorable combustion rates and energy delivery are feasible.

     

On the Performance of Shewhart‐type Synthetic and Runs‐rules Charts Combined with an Chart

A synthetic chart is a combination of a conforming run‐length chart and an chart, or equivalently, a 2‐of‐(H + 1) runs‐rules (RR) chart with a head‐start feature. However, a synthetic chart combined with an chart is called a Synthetic‐ chart. In this article, we build a framework for Shewhart Synthetic‐ and improved RR (i.e., 1‐of‐1 or 2‐of‐(H + 1) without head‐start) charts by conducting an in‐depth zero‐state and steady‐state study to gain insight into the design of different classes of these schemes and their average run‐length performance using the Markov chain imbedding technique. More importantly, we propose a modified side‐sensitive Synthetic‐ chart, and then using overall performance measures (i.e., the extra quadratic loss, average ratio of average run‐length, and performance comparison index), we show that this new chart has a uniformly better performance than its Shewhart competitors. We also provide easy‐to‐use tables for each of the chart's design parameters to aid practical implementation. Moreover, a performance comparison with their corresponding counterparts (i.e., synthetic and RR charts) is conducted. Copyright © 2015 John Wiley & Sons, Ltd.     

High‐Entropy Alloy (HEA)‐Coated Nanolattice Structures and Their Mechanical Properties

Nanolattice structure fabricated by two‐photon lithography (TPL) is a coupling of size‐dependent mechanical properties at micro/nano‐scale with structural geometry responses in wide applications of scalable micro/nano‐manufacturing. In this work, three‐dimensional (3D) polymeric nanolattices are initially fabricated using TPL, then conformably coated with an 80 nm thick high‐entropy alloy (HEA) thin film (CoCrFeNiAl_0.3) via physical vapor deposition (PVD). 3D atomic‐probe tomography (APT) reveals the homogeneous element distribution in the synthesized HEA film deposited on the substrate. Mechanical properties of the obtained composite architectures are investigated via in situ scanning electron microscope (SEM) compression test, as well as finite element method (FEM) at the relevant length scales. The presented HEA‐coated nanolattice encouragingly not only exhibits superior compressive specific strength of ≈0.032 MPa kg^?1 m³ with density well below 1000 kg m^?3, but also shows good compression ductility due to its composite nature. This concept of combining HEA with polymer lattice structures demonstrates the potential of fabricating novel architected metamaterials with tunable mechanical properties.

     

Phase‐Field Modeling of Microstructural Evolution by Freeze‐Casting

Freeze‐casting has attracted great attention as a potential method for manufacturing bioinspired materials with excellent flexibility in microstructure control. The solidification of ice crystals in ceramic colloidal suspensions plays an important role during the dynamic process of freeze‐casting. During solidification, the formation of a microstructure results in a dendritic pattern within the ice‐template crystals, which determines the macroscopic properties of materials. In this paper, the authors propose a phase‐field model that describes the crystallization in an ice template and the evolution of particles during anisotropic solidification. Under the assumption that ceramic particles represent mass flow, namely a concentration field, the authors derive a sharp‐interface model and then transform the model into a continuous initial boundary value problem via the phase‐field method. The adaptive finite‐element technique and generalized single‐step single‐solve (GSSSS) time‐integration method are employed to reduce computational cost and reconstruct microstructure details. The numerical results are compared with experimental results, which demonstrate good agreement. Finally, a microstructural morphology map is constructed to demonstrate the effect of different concentration fields and input cooling rates. The authors observe that at particle concentrations ranging between 25 and 30% and cooling rate lower than ?5° min^?1 generates the optimal dendrite structure in freeze casting process.

     

Manufacturing‐induced material properties of linear flow split and linear bend split profiles

In this work the two massive forming processes linear flow splitting and linear bend splitting, which generate profiles from sheet metal, are evaluated with respect to characteristic manufacturing‐induced material properties of the produced parts. Resulting microstructural features such as grain size and shape as well as crystallographic textures are linked to mechanical properties such as strength, ductility and anisotropic elasticity and general rules for their evolution are defined. Residual stress distributions are detailed and discussed with regard to the causing geometrical and forming process related aspects. The aim of this paper is to give a comprehensive overview of the properties of profiles produced by linear flow splitting and linear bend splitting and to illustrate general rules for their evolution in order to provide guidelines for an optimized product development process which allows a beneficial use of the manufacturing‐induced properties.     

Palm‐Sized Ag+ Ion Emission Gun Operated at Room Temperature in Non‐Vacuum Atmosphere

Ion implantation is an effective method for changing surface properties and inducing various functionalities. However, a high vacuum is generally necessary for ion implantation, which limits the range of applications. Here, we describe a palm‐sized Ag⁺ ion emission gun produced using a solid electrolyte. AgI–Ag₂O–B₂O₃ glass, known as a super‐ion‐conducting glass, has a Ag⁺ ion conductivity higher than 5 × 10^?3 S cm^?1 at room temperature. In addition, the melted glass has suitable viscous flow, and a sharp glass‐fiber emitter with a pyramid‐like apex can be obtained. Ag⁺ ion emission is observed from the tip of the glass fiber at accelerating voltages corresponding to electric fields above 20 kV cm^?1, even at room temperature in a non‐vacuum atmosphere. Ag nanoparticles of size 50–350 nm are precipitated on a Si target substrate. Other glass components such as boron and iodine are not detected. Electrochemical quartz crystal microbalance (EQCM) measurements show that the mass of Ag nanoparticles estimated from the emission current using Faraday's law of electrolysis is in good agreement with that estimated from the QCM frequency shift.

     

Scalable Chi‐Square Distance versus Conventional Statistical Distance for Process Monitoring with Uncorrelated Data Variables

Multivariate statistical process control charts are often used for process monitoring to detect out‐of‐control anomalies. However, multivariate control charts based on conventional statistical distance measures, such as the one used in the Hotelling's control chart, cannot scale up to large amounts of complex process data, e.g. data with a large number of variables and a high rate of data sampling. In our previous work we developed a multivariate statistical process monitoring procedure based on a more scalable chi‐square distance measure and tested this procedure for detecting out‐of control anomalies—intrusions—in a computer process using computer audit data. The testing results demonstrated the comparable performance of the scalable chi‐square procedure to that of Hotelling's control chart. To establish the chi‐square procedure as a generic, viable multivariate statistical processing monitoring procedure, we conduct a series of further studies to understand the detection power and limitations of the chi‐square procedure for processes with various kinds of data and various types of out‐of‐control anomalies in addition to the scalability and demonstrated performance of the chi‐square procedure for computer intrusion detection. This paper reports on one of these studies that investigates the effectiveness of the scalable chi‐square procedure in detecting out‐of‐control anomalies in processes with uncorrelated data variables, each of which has a normal probability distribution. The results of this study indicate that the chi‐square procedure is at least as effective as Hotelling's control chart for monitoring processes with uncorrelated data variables. Copyright © 2003 John Wiley & Sons, Ltd.     

Moulded pulp products manufacturing with thermoforming

Over the past years, eco‐friendly packaging solutions such as moulded pulp have resonated with a growing number of consumers. Among all of them, the thermoformed products make use of the most recent manufacturing approach that produces high‐quality, thin‐walled items. However, it remains an underresearched area, and the development of an efficient and precise manufacturing process is fundamental in order to increase the implementation of sustainable packaging. With the purpose of setting a step towards in the standardization of design and testing practices of eco‐friendly packaging, this work focused on the characterization of the thermoforming process of moulded pulp products and their characteristics. Three different analyses were carried out for this purpose, covering the dewatering efficiency of the process, a quantification of the moulding geometrical accuracy, and an analysis of the internal microstructure of the parts. Experimental results and statistical analysis show that the dewatering efficiency is mainly governed by the mould's temperature while the duration of the contact time is not influential. In the second investigation, the geometrical accuracy of the mouldability of microfeatures was assessed. The process appeared to be dependently related to the pulp type employed. Finally, the internal microstructure was documented using X‐ray computed tomography. The analysis shows an increase in the internal void fraction linked with an increase in the mould's temperature. The role of the water change of phase in the thermoforming process is also discussed by reference to the work conducted on impulse drying.     

Metal Alloys for Fusion‐Based Additive Manufacturing

Metal additive manufacturing (AM) is an innovative manufacturing technique, which builds parts incrementally layer by layer. Thus, metal AM has inherent advantages in part complexity, time, and waste saving. However, due to its complex thermal cycle and rapid solidification during processing, the alloys well suit and commercially used for metal AM today are limited. Therefore, it is important to understand the alloying strategy and current progress with materials performance to consider alloy development for metal AM. This review presents the current range of alloys available for metal AM, including titanium, steel, nickel, aluminum, less common alloys (including Mg alloys, metal matrix composites alloys, and low melting point alloys), and compositionally complex alloys (including bulk metallic glasses and high entropy alloys) with a focus on the relationship between compositions, processing, microstructures, and properties of each alloy system. In addition, some promising alloy systems for metal AM are highlighted. Approaches for designing and optimizing new materials for metal AM have been summarized.