Journals >International Journal of Extreme Manufacturing
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2025
Volume: 7 Issue 3
25 Article(s)
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International Journal of Extreme Manufacturing
- Publication Date: Sep. 29, 2025
- Vol. 7, Issue 3, 1 (2025)
Ultrafast laser welding of transparent materials: from principles to applications
Jia Xianshi, Luo Jinlin, Li Kai, Wang Cong, Li Zhou, Wang Mengmeng, Jiang Zhengyi, Veiko Vadim P, and Duan Ji'an
The ultrafast laser-matter interaction is explored to induce new pioneering principles and technologies into the realms of fundamental science and industrial production. The local thermal melting and connection properties of the ultrafast laser welding technology offer a novel method for welding of diverse transparent The ultrafast laser-matter interaction is explored to induce new pioneering principles and technologies into the realms of fundamental science and industrial production. The local thermal melting and connection properties of the ultrafast laser welding technology offer a novel method for welding of diverse transparent materials, thus having wide range of potential applications in aerospace, opto-mechanical systems, sensors, micro fluidic, optics, etc. In this comprehensive review, tuning the transient electron activation processes, high-rate laser energy deposition, and dynamic evolution of plasma morphology by the temporal/spatial shaping methods have been demonstrated to facilitate the transition from conventional homogeneous transparent material welding to the more intricate realm of transparent/metal heterogeneous material welding. The welding strength and stability are also improvable through the implementation of real-time, in-situ monitoring techniques and the prompt diagnosis of welding defects. The principles of ultrafast laser welding, bottleneck problems in the welding, novel welding methods, advances in welding performance, in-situ monitoring and diagnosis, and various applications are reviewed. Finally, we offer a forward-looking perspective on the fundamental challenges within the field of ultrafast laser welding and identify key areas for future research, underscoring the imperative need for ongoing innovation and exploration..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 23, 2025
- Vol. 7, Issue 3, 32001 (2025)
Ink-jetting-based conformal additive manufacturing: advantages, opportunities, and challenges
Yi Hao, Guo Xiaoqi, Chang Fangle, Cao Huajun, An Jia, and Chua Chee Kai
Ink-jetting printing stands out among various conformal additive manufacturing techniques for its multi-material, digital control, and process flexibility. Ink-jetting-based conformal additive manufacturing is renowned for its adaptability to complex topological surfaces and is emerging as a critical technology for futInk-jetting printing stands out among various conformal additive manufacturing techniques for its multi-material, digital control, and process flexibility. Ink-jetting-based conformal additive manufacturing is renowned for its adaptability to complex topological surfaces and is emerging as a critical technology for future comprehensive conformal printing systems. This review highlights the distinctiveness of four primary ink-jetting printing techniques in conformal additive manufacturing—piezoelectric jetting, thermal bubble jetting, aerosol jetting, and electrohydrodynamic jetting—and delves into how these attributes endow ink-jetting printing with unique advantages in conformal processes. Furthermore, leveraging these advantages, the review discusses potential applications in conformal electronics, energy devices, biology, and electromagnetics to bolster the ongoing development and application. Considering the current state of this technology, the review identifies critical challenges for future advancements, such as dynamic surface printing, integrated fabrication of multifunctional conformal structures, and the balance between resolution and throughput. This review summarizes the latest research and technological advancements in ink-jetting-based conformal additive manufacturing, aiding in its innovative applications and enhanced manufacturing capabilities in the future..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 27, 2025
- Vol. 7, Issue 3, 32002 (2025)
Manufacturing high-performance flexible sensors via advanced patterning techniques
Qin Xiaokun, Zhong Bowen, Xu Hao, Jackman Joshua A, Xu Kaichen, Cho Nam-Joon, Lou Zheng, and Wang Lili
Sensors play an important role in information perception during the age of intelligence, particularly in areas such as environmental monitoring and human perception. To meet the huge demands for information acquisition in the whole society, the development of elaborated sensor structures using patterned manufacturing tSensors play an important role in information perception during the age of intelligence, particularly in areas such as environmental monitoring and human perception. To meet the huge demands for information acquisition in the whole society, the development of elaborated sensor structures using patterned manufacturing technology is important to improve the performance of sensors. Creating patterned structures can enhance the interaction between the sensitive material and target matter, increase the contact area between the sensor and the target matter, amplify the effect of target matter on the sensor structure, and enhance the density of information sensing by building arrays. This review presents a comprehensive overview of patterned micro-nanostructure manufacturing techniques for performance enhancement of flexible sensors, including printing, exposure lithography, mould method, soft lithography, nanoimprinting lithography, and laser direct writing technology. Meanwhile, it introduces the evaluation methods of flexible sensor performance and discusses how patterned structures influence this performance. Finally, some practical application examples of patterned manufacturing techniques are introduced according to different types of flexible sensors. This review also summarises and provides an outlook on the role of these techniques in enhancing sensor performance offering valuable insights for future developments in the patterned manufacturing of flexible sensors..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 27, 2025
- Vol. 7, Issue 3, 32003 (2025)
Advances of wearable silicone rubber-based triboelectric nanogenerators: from manufacturing to application
Shen Dianlong, Du Taili, Dong Fangyang, Cai Hu, Noor Aziz, Du Xiannan, Zou Yongjiu, Lee Chengkuo, and Xu Minyi
Wearable bioelectronic devices are rapidly evolving towards miniaturization and multifunctionality, with remarkable features such as flexibility and comfort. However, achieving a sustainable power supply for wearable bioelectronic devices is still a great challenge. Triboelectric nanogenerators (TENGs) provide an efficWearable bioelectronic devices are rapidly evolving towards miniaturization and multifunctionality, with remarkable features such as flexibility and comfort. However, achieving a sustainable power supply for wearable bioelectronic devices is still a great challenge. Triboelectric nanogenerators (TENGs) provide an efficient solution by converting irregular, low-frequency bioenergy from the human body into electrical energy. Beyond sustainably powering wearable bioelectronics, the harvested electrical energy also carries rich information for human body sensing. In this conversion process, the choice of material plays a crucial role in affecting the output performance of the TENGs. Among various materials, silicone rubber (SR) stands out due to its exceptional plasticity, flexibility, comfortability and other favorable properties. Moreover, with appropriate treatment, SR can achieve extreme functionalities such as high robustness, good stability, self-healing capabilities, rapid response, and more. In this review, recent advances in wearable SR-based TENGs (SR-TENGs) are systematically reviewed with a focus on their application in different parts of the human body. Given that the manufacturing method of SR-TENGs largely determines its output performance and sensitivity, this paper introduces the design of SR-TENGs, including material selection, process modulation, and structure optimization. Additionally, this article discusses the current challenges in the SR-TENG fabrication technology and potential future directions, aiming to promote the effective development of SR-TENGs in biomechanical energy harvesting and self-powered sensing applications..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 27, 2025
- Vol. 7, Issue 3, 32004 (2025)
Biofabrication of brain-like living tissue: structure to intelligence
Wang Ling, Wang Sen, Liu Yingjie, Zhang Bowen, Pan Zhaoyu, Bai Luge, Yao Siqi, Zhang Chenrui, Xie Huangfan, He Jiankang, and Li Dichen
Brain, the material foundation of human intelligence, is the most complex tissue in the human body. Brain diseases are among the leading threats to human life, yet our understanding of their pathogenic mechanisms and drug development remains limited, largely due to the lack of accurate brain-like tissue models that repBrain, the material foundation of human intelligence, is the most complex tissue in the human body. Brain diseases are among the leading threats to human life, yet our understanding of their pathogenic mechanisms and drug development remains limited, largely due to the lack of accurate brain-like tissue models that replicate its complex structure and functions. Therefore, constructing brain-like models—both in morphology and function—possesses significant scientific value for advancing brain science and pathological pharmacology research, representing the frontiers in the biomanufacturing field. This review outlines the primary requirements and challenges in biomanufacturing brain-like tissue, addressing its complex structures, functions, and environments. Also, the existing biomanufacturing technologies, strategies, and characteristics for brain-like models are depicted, and cutting-edge developments in biomanufacturing central neural repair prosthetics, brain development models, brain disease models, and brain-inspired biocomputing models are systematically reviewed. Finally, the paper concludes with future perspectives on the biomanufacturing of brain-like tissue transitioning from structural manufacturing to intelligent functioning..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 30, 2025
- Vol. 7, Issue 3, 32005 (2025)
New era towards autonomous additive manufacturing: a review of recent trends and future perspectives
Fan Haolin, Liu Chenshu, Bian Shijie, Ma Changyu, Huang Junlin, Liu Xuan, Doyle Marshall, Lu Thomas, Chow Edward, Chen Lianyi, Fuh Jerry Ying Hsi, Lu Wen Feng, and Li Bingbing
The additive manufacturing (AM) landscape has significantly transformed in alignment with Industry 4.0 principles, primarily driven by the integration of artificial intelligence (AI) and digital twins (DT). However, current intelligent AM (IAM) systems face limitations such as fragmented AI tool usage and suboptimal huThe additive manufacturing (AM) landscape has significantly transformed in alignment with Industry 4.0 principles, primarily driven by the integration of artificial intelligence (AI) and digital twins (DT). However, current intelligent AM (IAM) systems face limitations such as fragmented AI tool usage and suboptimal human-machine interaction. This paper reviews existing IAM solutions, emphasizing control, monitoring, process autonomy, and end-to-end integration, and identifies key limitations, such as the absence of a high-level controller for global decision-making. To address these gaps, we propose a transition from IAM to autonomous AM, featuring a hierarchical framework with four integrated layers: knowledge, generative solution, operational, and cognitive. In the cognitive layer, AI agents notably enable machines to independently observe, analyze, plan, and execute operations that traditionally require human intervention. These capabilities streamline production processes and expand the possibilities for innovation, particularly in sectors like in-space manufacturing. Additionally, this paper discusses the role of AI in self-optimization and lifelong learning, positing that the future of AM will be characterized by a symbiotic relationship between human expertise and advanced autonomy, fostering a more adaptive, resilient manufacturing ecosystem..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 31, 2025
- Vol. 7, Issue 3, 32006 (2025)
Recent progress in triboelectric platforms: engineering materials to industrial applications from the perspective of manufacturing
Ra Yoonsang, Song Minjun, Lee Donghan, Jang Sunmin, Kim Yu-seop, Chae Joonmin, Cho Sumin, Kam Dongik, Lee Donghyun, Lee Gibeom, Lee Younghoon, and Choi Dongwhi
With the growing importance of wearable and portable electronics in modern society and industry, researchers from all over the world have reported on advances in energy harvesting and self-powered sensing technologies. The current review discusses recent developments in triboelectric platforms from a manufacturing persWith the growing importance of wearable and portable electronics in modern society and industry, researchers from all over the world have reported on advances in energy harvesting and self-powered sensing technologies. The current review discusses recent developments in triboelectric platforms from a manufacturing perspective, including material, design, application, and industrialization. Manufacturing is an essential component of both industry and technology. The use of a proper manufacturing process enables cutting-edge technology in a lab-scale stage to progress to commercialization and popularization with scalability, availability, commercial advantage, and consistent quality. Furthermore, much literature has emphasized that the most powerful advantage of the triboelectric platform is its wide range of available materials and simple working mechanism, both of which are important characteristics in manufacturing engineering. As a result, different manufacturing processes can be implemented as needed. Because the practical process can have a synergetic effect on the fundamental development, resulting in the growth of both, the development of the triboelectric platform from the standpoint of manufacturing engineering can be further advanced. However, research into the development of a productive manufacturing process is still in its early stages in the field of triboelectric platforms. This review looks at the various manufacturing technologies used in previous studies and discusses the potential benefits of the appropriate process for triboelectric platforms. Given its unique strength, which includes a diverse material selection and a simple working mechanism, the triboelectric platform can use a variety of manufacturing technologies and the process can be optimized as needed. Numerous research groups have clearly demonstrated the triboelectric platform's advantages. As a result, using appropriate manufacturing processes can accelerate the technological advancement of triboelectric platforms in a variety of research and industrial fields by allowing them to move beyond the lab-scale fabrication stage..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 06, 2025
- Vol. 7, Issue 3, 32007 (2025)
Optimizing electrical output performance of triboelectric nanogenerators by micro-/nano-morphology design and fabrication
Han Jiaxin, Dai Xingyi, Huang Long-Biao, and Hao Jianhua
Fueled by the increasing imperative for sustainable energy solutions and the burgeoning emphasis on health awareness, self-powered techniques have undergone notable strides in advancement. Triboelectric nanogenerators (TENGs) stand out as a prominent device capitalizing on the principles of triboelectrification and eleFueled by the increasing imperative for sustainable energy solutions and the burgeoning emphasis on health awareness, self-powered techniques have undergone notable strides in advancement. Triboelectric nanogenerators (TENGs) stand out as a prominent device capitalizing on the principles of triboelectrification and electrostatic induction to generate electricity or electrical signals. In efforts to augment the electrical output performance of TENGs and broaden their range of applications, researchers have endeavored to refine materials, surface morphology, and structural design. Among them, physical morphological modifications play a pivotal role in enhancing the electrical properties of TENGs by increasing the contact surface area, which can be achieved by building micro-/nano-structures on the surface or inside the friction material. In this review, we summarize the common morphologies of TENGs, categorize the morphologies into surface and internal structures, and elucidate their roles in enhancing the electric output performance of devices. Moreover, we systematically classify the methodologies employed for morphological preparation into physical and chemical approaches, thereby furnishing a comprehensive survey of the diverse techniques. Subsequently, typical applications of TENGs with special morphology divided by energy harvesting and self-powered sensors are presented. Finally, an overview of the challenges and future trajectories pertinent to TENGs is conducted. Through this endeavor, the aim of this article is to catalyze the evolution of further strategies for enhancing performance of TENGs..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 11, 2025
- Vol. 7, Issue 3, 32008 (2025)
Micropattern of core-shell Ag@MCS/PEGDA nanoparticles fabricated by femtosecond laser maskless optical projection lithography
Bin Fan-Chun, Wu Xin-Yi, Liu Jie, Dong Xian-Zi, Li Teng, Duan Qi, Zhang Jian-Miao, Fujita Katsumasa, and Zheng Mei-Ling
Chitosan (CS)-based nanocomposites have been studied in various fields, requiring a more facile and efficient technique to fabricate nanoparticles with customized structures. In this study, Ag@methacrylamide CS/poly(ethylene glycol) diacrylate (Ag@MP) micropatterns are successfully fabricated by femtosecond laser masklChitosan (CS)-based nanocomposites have been studied in various fields, requiring a more facile and efficient technique to fabricate nanoparticles with customized structures. In this study, Ag@methacrylamide CS/poly(ethylene glycol) diacrylate (Ag@MP) micropatterns are successfully fabricated by femtosecond laser maskless optical projection lithography (Fs-MOPL) for the first time. The formation mechanism of core-shell nanomaterial is demonstrated by the local surface plasmon resonances and the nucleation and growth theory. Amino and hydroxyl groups greatly affect the number of Ag@MP nanocomposites, which is further verified by replacing MCS with methacrylated bovine serum albumin and hyaluronic acid methacryloyl, respectively. Besides, the performance of the surface-enhanced Raman scattering, cytotoxicity, cell proliferation, and antibacterial was investigated on Ag@MP micropatterns. Therefore, the proposed protocol to prepare hydrogel core-shell micropattern by the home-built Fs-MOPL technique is prospective for potential applications in the biomedical and biotechnological fields, such as biosensors, cell imaging, and antimicrobial..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 23, 2025
- Vol. 7, Issue 3, 35001 (2025)
Construction of complex three-dimensional vascularized liver tissue model in vitro based on a biphasic cell-laden embedding medium
Lv Weikang, Yu Haoran, Aazmi Abdellah, Naren Tuya, Cheng Wanli, Yu Mengfei, Wang Zhen, Xu Xiaobin, Yang Huayong, and Ma Liang
Constructing an in vitro vascularized liver tissue model that closely simulates the human liver is crucial for promoting cell proliferation, mimicking physiological heterogeneous structures, and recreating the cellular microenvironment. However, the layer-by-layer printing method is significantly constrained by the rheConstructing an in vitro vascularized liver tissue model that closely simulates the human liver is crucial for promoting cell proliferation, mimicking physiological heterogeneous structures, and recreating the cellular microenvironment. However, the layer-by-layer printing method is significantly constrained by the rheological properties of the bioink, making it challenging to form complex three-dimensional vascular structures in low-viscosity soft materials. To overcome this limitation, we developed a cross-linkable biphasic embedding medium by mixing low-viscosity biomaterials with gelatin microgel. This medium possesses yield stress and self-healing properties, facilitating efficient and continuous three-dimensional shaping of sacrificial ink within it. By adjusting the printing speed, we controlled the filament diameter, achieving a range from 250 μm to 1000 μm, and ensuring precise control over ink deposition locations and filament shapes. Using the in situ endothelialization method, we constructed complex vascular structures and ensured close adhesion between hepatocytes and endothelial cells. In vitro experiments demonstrated that the vascularized liver tissue model exhibited enhanced protein synthesis and metabolic function compared to mixed liver tissue. We also investigated the impact of varying vascular densities on liver tissue function. Transcriptome sequencing revealed that liver tissues with higher vascular density exhibited upregulated gene expression in metabolic and angiogenesis-related pathways. In summary, this method is adaptable to various materials, allowing the rheological properties of the supporting bath and the tissue's porosity to be modified using microgels, thus enabling precise regulation of the liver tissue microenvironment. Additionally, it facilitates the rapid construction of three-dimensional vascular structures within liver tissue. The resulting vascularized liver tissue model exhibits enhanced biological functionality, opening new opportunities for biomedical applications..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 28, 2025
- Vol. 7, Issue 3, 35002 (2025)
Digital light processing three-dimensional printing with acrylic–titanium composite powders for multiscale porous scaffolds
Zhao Guangbin, Wu Yanlong, Li Bochen, Tian Hang, Li Bo, Li Xiao, Chen Xu, Zhou Tao, Wang Yaning, Gong Yichao, Hou Dingchang, Liu Yaxiong, Zong Xuewen, and Lu Bingheng
Porous metals fabricated via three-dimensional (3D) printing have attracted extensive attention in many fields owing to their open pores and customization potential. However, dense internal structures produced by the powder bed fusion technique fails to meet the feature of porous materials in scenarios that demand largPorous metals fabricated via three-dimensional (3D) printing have attracted extensive attention in many fields owing to their open pores and customization potential. However, dense internal structures produced by the powder bed fusion technique fails to meet the feature of porous materials in scenarios that demand large specific surface areas. Herein, we propose a strategy for 3D printing of titanium scaffolds featuring multiscale porous internal structures via powder modification and digital light processing (DLP). After modification, the titanium powders were composited with acrylic resin and maintained spherical shapes. Compared with the raw powder slurries, the modified powder slurries exhibited higher stability and preferable curing characteristics, and the depth sensitivity of the modified powder slurries with 45 vol% solid loading increased by approximately 72%. Green scaffolds were subsequently printed from the slurries with a solid loading reaching 45 vol% via DLP 3D printing. The scaffolds had macropores (pore diameters of approximately 1 mm) and internal open micropores (pore diameters of approximately 5.7–13.0 μm) after sintering. Additionally, these small-featured (approximately 320 μm) scaffolds retained sufficient compressive strength ((70.01±3.53) MPa) even with high porosity (approximately 73.95%). This work can facilitate the fabrication of multiscale porous metal scaffolds with high solid loading slurries, offering potential for applications requiring high specific surface area ratios..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 05, 2025
- Vol. 7, Issue 3, 35003 (2025)
3D laser structuring of supermetalphobic microstructures inside elastomer for multilayer high-density interconnect soft electronics
Zhang Chengjun, Yang Qing, Li Haoyu, Luo Zexiang, Lu Yu, Zhang Jialiang, Li Cheng, and Chen Feng
High-density interconnect (HDI) soft electronics that can integrate multiple individual functions into one miniaturized monolithic system is promising for applications related to smart healthcare, soft robotics, and human-machine interactions. However, despite the recent advances, the development of three-dimensional (High-density interconnect (HDI) soft electronics that can integrate multiple individual functions into one miniaturized monolithic system is promising for applications related to smart healthcare, soft robotics, and human-machine interactions. However, despite the recent advances, the development of three-dimensional (3D) soft electronics with both high resolution and high integration is still challenging because of the lack of efficient manufacturing methods to guarantee interlayer alignment of the high-density vias and reliable interlayer electrical conductivity. Here, an advanced 3D laser printing pathway, based on femtosecond laser direct writing (FLDW), is demonstrated for preparing liquid metal (LM)-based any layer HDI soft electronics. FLDW technology, with the characteristics of high spatial resolution and high precision, allows the maskless fabrication of high-resolution embedded LM microchannels and high-density vertical interconnect accesses for 3D integrated circuits. High-aspect-ratio blind/through LM microstructures are formed inside the elastomer due to the supermetalphobicity induced during laser ablation. The LM-based HDI circuit featuring high resolution (~1.5 μm) and high integration (10-layer electrical interconnection) is achieved for customized soft electronics, including various customized multilayer passive electric components, soft multilayer circuit, and cross-scale multimode sensors. The 3D laser printing method provides a versatile approach for developing chip-level soft electronics..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 05, 2025
- Vol. 7, Issue 3, 35004 (2025)
Osteomimetic bioceramic scaffolds with high-fidelity human-bone features produced by rotational printing
Pang Shumin, Wu Dongwei, Hanaor Dorian A H, Haibel Astrid, Kurreck Jens, and Gurlo Aleksander
Scaffolds that emulate the architecture of human bone, combined with strong mechanical stability and biocompatibility, are vital for promoting effective bone tissue regeneration. However, most existing bone-mimetic scaffolds fall short in reproducing the intricate hierarchical structure of human bone, which restricts tScaffolds that emulate the architecture of human bone, combined with strong mechanical stability and biocompatibility, are vital for promoting effective bone tissue regeneration. However, most existing bone-mimetic scaffolds fall short in reproducing the intricate hierarchical structure of human bone, which restricts their practical application. This study introduces a novel strategy that combines rotational three-dimensional (3D) printing technology and sponge replication technique to fabricate bone-mimetic scaffolds based on composite materials comprising copper-substituted diopside and biphasic calcium phosphate. The scaffolds closely mimic the structure of human bone, featuring both cancellous and cortical bone with Haversian canals. Additionally, the scaffolds exhibit high porosity and transport capacity, while exhibiting compressive strength that is on par with human bone under both axial and lateral loads. Moreover, they demonstrate good biocompatibility and the potential to induce and support osteogenesis and angiogenesis. The scaffolds produced here present a pathway to remediating particularly large bone defects. Given their close resemblance to human bone structure and function, these scaffolds may be well-suited for developing in vitro bone disease models for pharmaceutical testing and various biomedical applications..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 06, 2025
- Vol. 7, Issue 3, 35005 (2025)
4D printing of direct-driven deformable wheel with multiple programmable configurations
Tian Huichun, Chu Guanghao, Zhou Bin, Zhou Dekai, Qiao Jing, and Li Longqiu
Conventional deformable wheel systems in robots and other mechatronic systems face significant challenges in achieving miniaturization, intelligence, and integration. To address these issues, we propose a novel integrated structural design method and four-dimensional printing strategy for deformable wheels capable of sConventional deformable wheel systems in robots and other mechatronic systems face significant challenges in achieving miniaturization, intelligence, and integration. To address these issues, we propose a novel integrated structural design method and four-dimensional printing strategy for deformable wheels capable of shaping among multiple programmable direct-driven deformation configurations. The load-bearing capacity of the printed wheel is strengthened by employing deformed components in various locations and actuated states. Additionally, a novel analytical design method is presented to determine the structure, actuation, and deformation parameters of each component under complex coupled deformation. Our findings reveal that the designed wheel can transform into three different configurations, exhibiting desired deformations of 12.5% in the radial direction and 19.6% in the axial direction. It also demonstrates robust deformation behavior and structural stability under multi-directional loads. By integrating a terrain sensing system, the designed wheel exhibits highly adaptive deformation capabilities on various terrains, showing great potential for exploring complex environments..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 13, 2025
- Vol. 7, Issue 3, 35006 (2025)
Boosting non-oxide interfacial Co/SiO2 hybrid bonding by selective surface activation
Qi Xiaoyun, Zhou Shicheng, Ma Yan, Suga Tadatomo, and Wang Chenxi
Due to its superior nanoscale properties, cobalt (Co) is highly desirable for ultrahigh-density 3D integration into materials through metal/dielectric hybrid bonding. However, this process is very challenging through Co/SiO2 hybrid bonding, as very hydrophilic SiO2 surfaces are needed for bonding during dehydration reaDue to its superior nanoscale properties, cobalt (Co) is highly desirable for ultrahigh-density 3D integration into materials through metal/dielectric hybrid bonding. However, this process is very challenging through Co/SiO2 hybrid bonding, as very hydrophilic SiO2 surfaces are needed for bonding during dehydration reactions and oxidation of the Co surfaces must be avoided. Additionally, the substantial coefficient of thermal expansion mismatch between the robust capping layers (Co and SiO2 layers) necessitates hybrid bonding with minimal thermal input and compression. In this study, we introduce a ternary plasma activation strategy employing an Ar/NH3/H2O gas mixture to facilitate Co/SiO2 hybrid bonding at temperatures as low as~200 °C, which is markedly lower than the melting point of Co (~1500 °C). Intriguingly, non-oxide metallization at the Co–Co interface can be realized without the hindrance of a bonding barrier, thereby reducing the electrical resistance by over 40% and compression force requirements. Moreover, the enhancement in the SiO2 surface energy through active group terminations fosters extensive interfacial hydration and strengthens the mechanical properties. This research paves the way for fine-tuning bonding surfaces using a material-selective strategy, which should advance metal/dielectric hybrid bonding for future integration applications..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 23, 2025
- Vol. 7, Issue 3, 35101 (2025)
Micro-amplitude vibration-assisted scratching: a new method for one step and controllable fabrication of the microscale V-groove and nanoscale ripples
Wu Haoxiang, Huang Hu, Zhang Zhiyu, and Yan Jiwang
Micro/nano hierarchical structures could endow materials with various surface functions. However, the multilayer and multiscale characteristics of micro/nano hierarchical structures bring difficulties for their one step and controllable fabrication. Accordingly, based on tip-based fabrication techniques, this study proMicro/nano hierarchical structures could endow materials with various surface functions. However, the multilayer and multiscale characteristics of micro/nano hierarchical structures bring difficulties for their one step and controllable fabrication. Accordingly, based on tip-based fabrication techniques, this study proposed a micro-amplitude vibration-assisted scratching method by introducing a periodic backward displacement into the conventional scratching process, which enabled the synchronous creation of the microscale V-groove and nanoscale ripples, i.e. a typical micro/nano hierarchical structure. The experiments and finite element modeling were employed to explore the formation process and mechanism of the micro/nano hierarchical structures. Being different from conventional cutting, this method was mainly based on the plow mechanism, and it could accurately replicate the shape of the indenter on the material surface. The microscale V-groove was formed due to the scratching action, and the nanoscale ripple was formed due to the extrusion action of the indenter on the microscale V-groove's surface. Furthermore, the relationships between the processing parameters and the dimensions of the micro/nano hierarchical structures were established through experiments, and optimized processing parameters were determined to achieve regular micro/nano hierarchical structures. By this method, complex patterns constructed by various micro/nano hierarchical structures were fabricated on both flat and curved surfaces, achieving diverse surface structural colors..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 06, 2025
- Vol. 7, Issue 3, 35102 (2025)
Predictive models for the surface roughness and subsurface damage depth of semiconductor materials in precision grinding
Gao Shang, Wang Haoxiang, Huang Han, Dong Zhigang, and Kang Renke
Workpiece rotational grinding is widely used in the ultra-precision machining of hard and brittle semiconductor materials, including single-crystal silicon, silicon carbide, and gallium arsenide. Surface roughness and subsurface damage depth (SDD) are crucial indicators for evaluating the surface quality of these materWorkpiece rotational grinding is widely used in the ultra-precision machining of hard and brittle semiconductor materials, including single-crystal silicon, silicon carbide, and gallium arsenide. Surface roughness and subsurface damage depth (SDD) are crucial indicators for evaluating the surface quality of these materials after grinding. Existing prediction models lack general applicability and do not accurately account for the complex material behavior under grinding conditions. This paper introduces novel models for predicting both surface roughness and SDD in hard and brittle semiconductor materials. The surface roughness model uniquely incorporates the material's elastic recovery properties, revealing the significant impact of these properties on prediction accuracy. The SDD model is distinguished by its analysis of the interactions between abrasive grits and the workpiece, as well as the mechanisms governing stress-induced damage evolution. The surface roughness model and SDD model both establish a stable relationship with the grit depth of cut (GDC). Additionally, we have developed an analytical relationship between the GDC and grinding process parameters. This, in turn, enables the establishment of an analytical framework for predicting surface roughness and SDD based on grinding process parameters, which cannot be achieved by previous models. The models were validated through systematic experiments on three different semiconductor materials, demonstrating excellent agreement with experimental data, with prediction errors of 6.3% for surface roughness and 6.9% for SDD. Additionally, this study identifies variations in elastic recovery and material plasticity as critical factors influencing surface roughness and SDD across different materials. These findings significantly advance the accuracy of predictive models and broaden their applicability for grinding hard and brittle semiconductor materials..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 06, 2025
- Vol. 7, Issue 3, 35103 (2025)
Self-propelled ferroptosis nanoinducer for enhanced cancer therapy
Xu Wenxin, Tian Hao, Song Yanzhen, Qin Hanfeng, Gao Junbin, Chen Yichi, Huang Weichang, Lin Lin, Tan Haixin, Ye Yicheng, Zhang Xiaoting, Wilson Daniela A, Yang Guang, Peng Fei, and Tu Yingfeng
Ferroptosis is a newly proposed type of programmed cell death, which has been associated with a variety of diseases including tumors. Researchers have thereby presented nanoplatforms to mediate ferroptosis for anti-cancer therapy. However, the development of ferroptosis-based nanotherapeutics is generally hindered by tFerroptosis is a newly proposed type of programmed cell death, which has been associated with a variety of diseases including tumors. Researchers have thereby presented nanoplatforms to mediate ferroptosis for anti-cancer therapy. However, the development of ferroptosis-based nanotherapeutics is generally hindered by the limited penetration depth in tumors, poor active pharmaceutical ingredient (API) loading content and the systemic toxicity. Herein, self-propelled ferroptosis nanoinducers composed of two endogenous proteins, glucose oxidase and ferritin, are presented to show enhanced tumor inhibition via ferroptosis while maintaining high API and biocompatibility. The accumulation of our proteomotors at tumor regions is facilitated by the active tumor-targeting effect of ferritin. The enhanced diffusion of proteomotors is then actuated by efficiently decomposing glucose into gluconic acid and H2O2, leading to deeper penetration and enhanced uptake into tumors. Under the synergistic effect of glucose oxidase and ferritin, the equilibrium between reactive oxygen species and GSH is damaged, leading to lipid peroxidation. As a result, by inducing ferroptosis, our self-propelled ferroptosis nanoinducers exhibit enhanced tumor inhibitory effects. This work paves a way for the construction of a biocompatible anticancer platform with enhanced diffusion utilizing only two endogenous proteins, centered around the concept of ferroptosis..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 24, 2025
- Vol. 7, Issue 3, 35501 (2025)
Autonomous inverse encoding guides 4D nanoprinting for highly programmable shape morphing
Ren Shuaiqi, Zhang Zhiang, He Ruokun, Fan Jiahao, Wang Guangming, Wang Hesheng, Han Bing, Zhang Yong-Lai, and Ma Zhuo-Chen
Highly programmable shape morphing of 4D-printed micro/nanostructures is urgently desired for applications in robotics and intelligent systems. However, due to the lack of autonomous holistic strategies throughout the target shape input, optimal material distribution generation, and fabrication program output, 4D nanopHighly programmable shape morphing of 4D-printed micro/nanostructures is urgently desired for applications in robotics and intelligent systems. However, due to the lack of autonomous holistic strategies throughout the target shape input, optimal material distribution generation, and fabrication program output, 4D nanoprinting that permits arbitrary shape morphing remains a challenging task for manual design. In this study, we report an autonomous inverse encoding strategy to decipher the genetic code for material property distributions that can guide the encoded modeling toward arbitrarily pre-programmed 4D shape morphing. By tuning the laser power of each voxel at the nanoscale, the genetic code can be spatially programmed and controllable shape morphing can be realized through the inverse encoding process. Using this strategy, the 4D-printed structures can be designed and accurately shift to the target morphing of arbitrarily hand-drawn lines under stimulation. Furthermore, as a proof-of-concept, a flexible fiber micromanipulator that can approach the target region through pre-programmed shape morphing is autonomously inversely encoded according to the localized spatial environment. This strategy may contribute to the modeling and arbitrary shape morphing of micro/nanostructures fabricated via 4D nanoprinting, leading to cutting-edge applications in micro fluidics, micro-robotics, minimally invasive robotic surgery, and tissue engineering..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 28, 2025
- Vol. 7, Issue 3, 35502 (2025)
Three-dimensional direct lithography of stable quantum dots in hybrid glass
Zhu Dezhi, Jiang Shangben, Wang Ying, Liu Dejun, Bao Weijia, Liu Liwei, Qu Junle, Wang Yiping, and Liao Changrui
Semiconductor quantum dots (QDs), as high-performance materials, play an essential role in contemporary industry, mainly due to their high photoluminescent quantum yield, wide absorption characteristics, and size-dependent light emission. It is essential to construct well-defined micro-/nano-structures using QDs as buiSemiconductor quantum dots (QDs), as high-performance materials, play an essential role in contemporary industry, mainly due to their high photoluminescent quantum yield, wide absorption characteristics, and size-dependent light emission. It is essential to construct well-defined micro-/nano-structures using QDs as building blocks for micro-optic applications. However, the fabrication of stable QDs with designed functional structures has long been challenging. Here, we propose a strategy for three-dimensional direct lithography of desired QDs within a hybrid medium with specific protection properties. The acrylate-functionalized hybrid precursors enable local crosslinking through ultrafast laser-induced multiphoton absorption, achieving sub-100 nm resolution surpassing the diffraction limit. The printed micro-/nano-structures possess thermal stability up to 600 °C, which can be transformed to inorganic architectures with a volume shrinkage. Due to the encapsulated QDs within the densely silicon-oxygen molecular networks, the functional structures demonstrate good stability against ultraviolet irradiation, corrosive solutions, and elevated temperatures. Based on hybrid 3D nanolithography, bicolor multilayer micro-/nano-structures are manufactured for applications in 3D data storage and optical information encryption. This research presents an effective strategy for the fabrication of desired QD micro-/nano-structures, supporting the development of stable functional device applications..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 29, 2025
- Vol. 7, Issue 3, 35503 (2025)
Electrically reconfigurable surface acoustic wave phase shifters based on ZnO TFTs on LiNbO3 substrate
Zhang Yi, Xiong Zilong, He Lewei, Jiang Yang, Deng Chenkai, Du Fangzhou, Wen Kangyao, Tang Chuying, Hu Qiaoyu, Li Mujun, Wang Xiaohui, Wang Wenhui, Wang Han, Wang Qing, Yu Hongyu, and Wang Zhongrui
Reconfigurable surface acoustic wave (SAW) phase shifters have garnered significant attention owing to their potential applications in emerging fields such as secure wireless communication, adaptable signal processing, and intelligent sensing systems. Among various modulation methods, employing gate voltage-controlled Reconfigurable surface acoustic wave (SAW) phase shifters have garnered significant attention owing to their potential applications in emerging fields such as secure wireless communication, adaptable signal processing, and intelligent sensing systems. Among various modulation methods, employing gate voltage-controlled tuning methodologies that leverage acoustoelectric interactions has proven to be an efficient modulation approach that requires a low bias voltage. However, current acoustoelectric devices suffer from limited tunability, intricate heterogeneous structures, and complex manufacturing processes, all of which impede their practical applications. In this study, we present a novel material system for voltage-tunable SAW phase shifters. This system incorporates an atomic layer deposition ZnO thin-film transistors on LiNbO3 structure. This structure combines the benefits of LiNbO3's high electromechanical coupling coefficient (K2) and ZnO's superior conductivity adjustability. Besides, the device possesses a simplified structural configuration, which is easy to fabricate. Devices with different mesa lengths were fabricated and measured, and two of the different modes were compared. The results indicate that both the maximum phase shift and attenuation of the Rayleigh mode and longitudinal leaky SAW (LLSAW) increase proportionally with mesa length. Furthermore, LLSAW with larger effective electromechanical coupling coefficients () values exhibits greater phase velocity shifts and attenuation coefficients, with a maximum phase velocity tuning of 1.22% achieved. It is anticipated that the proposed devices will find utility in a variety of applications necessitating tunable acoustic components..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 06, 2025
- Vol. 7, Issue 3, 35504 (2025)
Fully integrated wearable control system for micro/nanorobot navigation
Zhang Zhanxiang, Wang Lin, Jiang Fengqi, Yu Shimin, Ji Fengtong, Sun Tianhao, Zhang He, Zhu Yanhe, Chang Hao, Li Tianlong, and Zhao Jie
Micro/nanorobots have exhibited excellent application potential in the biomedical field, such as drug delivery, minimally invasive surgery, and bio-sensing. Furthermore, in order to achieve practical application, it is essential for swimming micro/nanorobots to navigate towards specific targets or adjust their speed anMicro/nanorobots have exhibited excellent application potential in the biomedical field, such as drug delivery, minimally invasive surgery, and bio-sensing. Furthermore, in order to achieve practical application, it is essential for swimming micro/nanorobots to navigate towards specific targets or adjust their speed and morphology in complete environments. The navigation of swimming micro/nanorobots with temporal and spatial precision is critical for fulfilling the demand of applications. Here, we introduced a fully integrated wearable control system for micro/nanorobots navigation and manipulation, which is composed of a multifunctional sensor array, an artificial intelligence (AI) planner, and a magnetic field generator. The sensor array could perceive real-time changes in gestures, wrist rotation, and acoustic signals. AI planner based on machine learning offers adaptive path planning in response to dynamically changing signals to generate magnetic fields for the on-demand manipulation of micro/nanorobots. Such a novel, feasible control strategy was validated in the biological experiment in which cancer cells were targeted and killed by photothermal therapy using micro/nanorobots and integrated control platform. This wearable control system could play a crucial role in future intelligent medical applications and could be easily reconfigured toward other medical robots' control..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 10, 2025
- Vol. 7, Issue 3, 35505 (2025)
Textile hybrid electronics for monolithically multimodal wearable monitoring and therapy
Luo Huayu, Yang Geng, Jin Ziguan, Cai Zimo, Li Yibo, Lu Yuyao, Wang Jian, Yang Huayong, Zheng Yinfei, and Xu Kaichen
Textiles with electronic components offer a portable and personalized approach for health monitoring and therapy. However, there is a lack of reliable strategy to integrate layered circuits and high-density chips on or inside textiles, which hinders system-level functionality and untethered user experiences. Herein, weTextiles with electronic components offer a portable and personalized approach for health monitoring and therapy. However, there is a lack of reliable strategy to integrate layered circuits and high-density chips on or inside textiles, which hinders system-level functionality and untethered user experiences. Herein, we propose monolithically integrated textile hybrid electronics (THE) on a textile platform, with multimodal functions and reliable performances. The textile system encompasses flexible electrodes, laser-induced sensors, and surface-mount devices, along with double-layer circuits interconnecting all of them. Vertical conductive paths are rendered by liquid metal composites infiltrated into textiles, which allows resistances less than 0.1 Ω while reserving intact textile structures. The assembled THE exhibits endurance to handwashing and crumpling, as well as bendability. We customize a wireless textile patch for synchronously tracking multiple physiological indicators during exercise. Furthermore, a textile band is elaborated for monitoring and alleviating muscular fatigue, demonstrating potential in closed-loop diagnosis and treatment..
International Journal of Extreme Manufacturing
- Publication Date: Feb. 25, 2025
- Vol. 7, Issue 3, 35506 (2025)
Frequency multiplexed photothermal correlation tomography for non-destructive evaluation of manufactured materials
Zhu Pengfei, Wang Rongbang, Sivagurunathan Koneswaran, Sfarra Stefano, Sarasini Fabrizio, Ibarra-Castanedo Clemente, Maldague Xavier, Zhang Hai, and Mandelis Andreas
Infrared thermography has been widely applied in real industrial inspection of aerospace, energy management systems, engines, and electric systems. However, two-dimensional imaging modality limits its development. Here, a technique named frequency multiplexed photothermal correlation tomography (FM-PCT) was developed tInfrared thermography has been widely applied in real industrial inspection of aerospace, energy management systems, engines, and electric systems. However, two-dimensional imaging modality limits its development. Here, a technique named frequency multiplexed photothermal correlation tomography (FM-PCT) was developed to enable non-destructive and contactless cross-sectional imaging for manufactured material evaluation and characterization. By combining advantages of photothermal tomography and pulsed thermography, FM-PCT facilitates the generation of three-dimensional thermal images through temporal superposition (stacking) of two-dimensional images from sequential subsurface depths. FM-PCT image processing involves pulsed excitation signals to which frequency delay and matched filtering techniques are applied. Major features of FM-PCT are high-resolution three-dimensional tomographic imaging under low camera frame-rate conditions with self-correcting capability for diffusion (blurring) correction of subsurface images due to cross-correlation processing of individual frequencies in the Fourier decomposition spectrum of the excitation pulse. Furthermore, FM-PCT extends truncated-correlation photothermal coherence tomography from chirp and pulsed signals to more general linear heating sources. Lock-in thermography and x-ray computed tomography validation demonstrate that 3D FM-PCT imaging accurately reveals subsurface discontinuities/defects in solids despite the diffusive nature of thermal-wave imaging..
International Journal of Extreme Manufacturing
- Publication Date: Jan. 28, 2025
- Vol. 7, Issue 3, 35601 (2025)
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