Journals >International Journal of Extreme Manufacturing
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2025
Volume: 7 Issue 5
21 Article(s)
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[in Chinese]
International Journal of Extreme Manufacturing
- Publication Date: Oct. 27, 2025
- Vol. 7, Issue 5, 1 (2025)
Thermomorphic pneumatic metamaterials: numerous and robust shape-locking under temperature modulation through 4D printing
Wang Yafei, Cai Wei, Zhang Jingyi, Guo Weijia, Qi Biyun, Liu Yuheng, Huang Weimin, Lu Haibao, Wei Xueyong, Fu Richard, and Ding Zhen
Four-dimensional (4D) printing represents a groundbreaking advancement in manufacturing, yet a persistent challenge is the limited number of stable configurations achievable through spontaneous shape reconstruction. Herein, we present a novel 4D printing mechanism that utilizes self-adjustable gas pressure to facilitatFour-dimensional (4D) printing represents a groundbreaking advancement in manufacturing, yet a persistent challenge is the limited number of stable configurations achievable through spontaneous shape reconstruction. Herein, we present a novel 4D printing mechanism that utilizes self-adjustable gas pressure to facilitate a wide range of spontaneous and stable multi-shape transformations. The gas is precisely released at designated spatial locations through strategic temperature-controlled degradation of a solid material, which is printed and distributed as needed at the voxel level within a specially designed multi-material structure, consisting of a low degradation temperature material (LDTM), a high degradation temperature soft material (HDTSM), and a high degradation temperature hard material (HDTHM). Each shape configuration is determined and locked in by the maximum temperature experienced during its thermal history. Notably, this shape retains its form robustly, independently of subsequent temperature changes, until a higher temperature threshold is reached, at which point a new shape configuration is triggered. These shapes exhibit a remarkable temperature memory effect, permanently recording the peak temperature reached in their thermal history. Our study comprehensively investigates the underlying principles and key parameters that influence deformation. We present a series of examples demonstrating complex multi-shape transformations modulated by temperature, supported by finite element simulations. This advance in 4D printing has the potential to significantly enhance its functional capabilities, performance, and applicability, opening up new horizons in additive manufacturing and design..
International Journal of Extreme Manufacturing
- Publication Date: May. 12, 2025
- Vol. 7, Issue 5, 55001 (2025)
Low-temperature fabrication of high-specific strength SiC-based ceramics via photopolymerization 3D printing with controllable anisotropy
Qu Piao, Liang Guozhen, Hussain M Irfan, Hanif Muhammad, Hamza Muhammad, Huang Kaibin, Lou Yan, and Chen Zhangwei
The combination of silicon carbide (SiC) ceramics and stereolithography technology shows promise for manufacturing complex-shaped SiC components, expanding application possibilities. However, high sintering temperature and structural-performance anisotropy limit the practical use of 3D-printed SiC components. Herein, aThe combination of silicon carbide (SiC) ceramics and stereolithography technology shows promise for manufacturing complex-shaped SiC components, expanding application possibilities. However, high sintering temperature and structural-performance anisotropy limit the practical use of 3D-printed SiC components. Herein, a novel method is introduced to produce high-specific-strength SiC-based ceramics at a relatively low temperature of 1 100 °C. A mixed SiC/SiO2 slurry (30% SiO2 and 70% SiC by volume) with a solid loading of up to 40% was prepared to improve UV light penetration and printability. Additionally, incorporating a high content of methyl-phenyl-polysiloxane (PSO) solution (75% by weight) enabled low-temperature pyrolysis of SiC/SiO2/PSO ceramics. The SiC/SiO2/PSO ceramic lattices after pyrolysis achieved a specific strength as high as (1.03 × 105) N·m·kg–1 and a density of 1.75 g·cm–3, outperforming similar SiC-based lattices structures of similar porosities. The bending strength of (95.49 ± 8.79) MPa was comparable to that of ceramics sintered at 1 400 °C or higher. Notably, the addition of the silicon carbide oxide (SiOC) phase reduced anisotropy, lowering the transverse and longitudinal compression strength ratios from 1.87 to 1.08, and improving mechanical properties by 79%. This improvement is attributed to SiOC shrinkage, promoting a uniform distribution of sintered components, resulting in a more robust and balanced material structure. This method offers valuable insight into the additive manufacturing (AM) of SiC-based ceramics at lower temperatures and provides new guidance for controlling anisotropy in 3D-printed ceramic parts..
International Journal of Extreme Manufacturing
- Publication Date: May. 13, 2025
- Vol. 7, Issue 5, 55002 (2025)
3D bioprinted unidirectional neural network and its application for alcoholic neurodegeneration
Bae Mihyeon, Kim Joeng Ju, Jang Jinah, and Cho Dong-Woo
The brain exhibits complex physiology characterized by unique features such as a brain-specific extracellular matrix, compartmentalized structure (white and grey matter), and an aligned axonal network. These physiological characteristics underpin brain function and facilitate signal transduction similar to that in an eThe brain exhibits complex physiology characterized by unique features such as a brain-specific extracellular matrix, compartmentalized structure (white and grey matter), and an aligned axonal network. These physiological characteristics underpin brain function and facilitate signal transduction similar to that in an electrical circuit. Therefore, investigating these features in vitro is crucial for understanding the interactions between neuronal signal transduction processes and the pathology of neurological diseases. Compared to neurons on patterned substrates, three-dimensional (3D) bioprinting-based neural models provide significant advantages in replicating axonal kinetics without physical limitations. This study proposes the development of a 3D bioprinted engineered neural network (BENN) model to replicate the physiological features of the brain, suggesting its application as a tool for studying neurodegenerative diseases. We employed 3D bioprinting to reconstruct the compartmentalized structure of the brain, and controlled the directionality of axonal growth by applying electrical stimuli to the printed neural structure for overcoming spatial constraints. The reconstructed axonal network demonstrated reliability as a neural analog, including the visualization of mature neuronal features and spontaneous calcium reactions. Furthermore, these brain-like neural network models have demonstrated usefulness for studying neurodegeneration by enabling the visualization of degenerative pathophysiology in alcohol-exposed neurons. The BENN facilitates the visualization of region-specific pathological markers in soma or axon populations, including amyloid-beta formation and axonal deformation. Overall, the BENN closely mimics brain physiology, offers insights into the dynamics of axonal networks, and can be applied to studying neurological diseases..
International Journal of Extreme Manufacturing
- Publication Date: May. 20, 2025
- Vol. 7, Issue 5, 55003 (2025)
Achieving tip-based down-milling forming of nanograting structures with variable heights through precise control of nano revolving trajectories
Xue Bo, Yan Huilin, Liu Zhengchang, Yan Yongda, and Geng Yanquan
With the advantage of high light intensity due to low scatting, structural colors generated by metallic diffraction nanograting structures, used as a type of diffractive optical element, have shown great potential for application in industrial and scientific research fields such as optical anti-counterfeiting and sensoWith the advantage of high light intensity due to low scatting, structural colors generated by metallic diffraction nanograting structures, used as a type of diffractive optical element, have shown great potential for application in industrial and scientific research fields such as optical anti-counterfeiting and sensors. Within the visible light wavelength range, the diffraction performance is highly dependent on the height and shape consistencies of the nanograting. However, there is still room for the improvement in the flexible control over structure formation through mechanical nanomachining within this scale. The novelty of this paper lies in proposing a machining strategy for nanograting structures with variable heights through precise regulation of the revolving trajectory using tip-based nano down-milling. It explores how different geometric features of trajectories impact the amount of material deformed into a grating and its distribution shape, referred to as undeformed grating area. By analyzing the forming mechanisms of nanogratings under various trajectories with finite element simulation, the desired undeformed grating area is successfully achieved, which is mainly extruded by the tip flank face to form the right facet of the grating, resulting in a small deformation degree and a high deformation efficiency. Three distinct types of revolving trajectories are filtered out according to five quantitative evaluation indicators for machining performance, namely material plastic deformation, grating profile consistency, grating height consistency, machining forces, and area transforming height, and then are compared in processing nanogratings with different heights. It is obtained that only by regulating the vertical vibration amplitude of the revolving trajectory, the semicircle trajectory with the optimal geometric features has the ability to machine high-quality nanograting structures with a continuous height variation of up to 220 nm in a spacing of 400 nm..
International Journal of Extreme Manufacturing
- Publication Date: May. 13, 2025
- Vol. 7, Issue 5, 55101 (2025)
Physics-based modeling and mechanism of polycrystalline diamond tool wear in milling of 70 vol% Si/Al composite
Xin Lianjia, Zhao Guolong, Nian Zhiwen, Yang Haotian, Li Liang, and He Ning
High-volume fraction silicon particle-reinforced aluminium matrix composites (Si/Al) are increasingly applied in aerospace, radar communications, and large-scale integrated circuits because of their superior thermal conductivity, wear resistance, and low thermal expansion coefficient. However, the abrasive and adhesiveHigh-volume fraction silicon particle-reinforced aluminium matrix composites (Si/Al) are increasingly applied in aerospace, radar communications, and large-scale integrated circuits because of their superior thermal conductivity, wear resistance, and low thermal expansion coefficient. However, the abrasive and adhesive wear caused by the hard silicon reinforcement and the ductile aluminium matrix leads to significant tool wear, decreased machining efficiency, and compromised surface quality. This study combines theoretical analysis and cutting experiments to investigate polycrystalline diamond (PCD) tool wear during milling of 70 vol% Si/Al composite. A key contribution of this work is the development of a tool wear model that incorporates reinforcement particle characteristics, treating them as ellipsoidal structures, which enhances the accuracy of predicting abrasive and adhesive wear mechanisms. The model is based on abrasive and adhesive wear mechanisms, and can analyze the interaction between silicon particles, aluminium matrix, and tool components, thus providing deeper insights into PCD tool wear processes. Experimental validation of the model shows a good agreement with the results, with a mean deviation of approximately 10%. The findings on the tool wear mechanism reveal that, as tool wear progresses, the proportion of abrasive wear increases from 40% in the running-in stage to 75% in the rapid wear stage, while adhesive wear decreases. The optimal machining parameters of 120 m·min–1 cutting speed (vc) and 0.04 mm·z–1 feed rate (fz), result in tool life of 33 min and surface roughness (Sa) of 2.2μm. The study uncovers the variation patterns of abrasive and adhesive wear during the tool wear process, and the proposed model offers a robust framework for predicting tool wear during the machining of high-volume fraction Si/Al composites. The research findings also offer key insights for optimizing tool selection and machining parameters, advancing both the theoretical understanding and practical application of PCD tool wear..
International Journal of Extreme Manufacturing
- Publication Date: May. 13, 2025
- Vol. 7, Issue 5, 55102 (2025)
Electric field oriented deposition manufacturing of low loss, high gain flexible transparent antenna utilizing the skin effect
Zhang Houchao, Jin Maopeng, Zhu Xiaoyang, Zhang Youchao, Li Yansheng, Chen Shuo, Bai Yanjun, Li Hongke, Li Zhenghao, Wang Rui, Zhu Yuansheng, Wang Fei, and Lan Hongbo
Flexible transparent antennas (FTAs) are widely used in wireless transmission fields, and their technological iterations are accelerating. However, the high losses caused by materials and structures limit the development of FTAs with both high light transmission and high gain, and the rapid iteration rate demands greatFlexible transparent antennas (FTAs) are widely used in wireless transmission fields, and their technological iterations are accelerating. However, the high losses caused by materials and structures limit the development of FTAs with both high light transmission and high gain, and the rapid iteration rate demands greater process flexibility, which makes it difficult for existing technologies to achieve both demands. Here, we design a novel shell-core structure composite metal mesh (CMM) FTA to achieve extremely low skin depth loss and ohmic loss using skin effect and report a novel hybrid additive manufacturing method based on electric field oriented deposition to achieve efficient and flexible manufacturing of the unique Ag/Cu core-shell structure CMM FTA. The typical sample has a light transmittance of 80% (including substrate) when the sheet resistance is 0.29 Ω·sq–1, and has excellent bending and torsion resistance. The peak gain in the working band is as high as 5.22 dB, and the efficiency is 80%, which is close to the performance of the opaque Cu patch antenna. It also realizes smooth and stable real-time wireless transmission under bending and long-distance conditions. This method addresses the shortcomings of FTAs, namely their high cost, low manufacturing efficiency, and low performance, especially in the rapid iterative development of antennas..
International Journal of Extreme Manufacturing
- Publication Date: May. 29, 2025
- Vol. 7, Issue 5, 55103 (2025)
3D graphene paper-based tandem metal-free thin-film supercapacitors with integrated 200 V output
Liu Huilong, Gan Litian, Chen Renji, Xiao Zhiwen, Chen Yun, Yang Hongzuo, Liu Yahang, Wu Baisheng, Wong Ching-Ping, and Chen Xin
The development of high-voltage tandem thin-film supercapacitors (TFSCs) has been limited by the issues such as expensive electrode materials, indispensable commercial separators and metal current collectors, and complex manufacturing processes. Herein, we develop a potentially scalable approach to address all these isThe development of high-voltage tandem thin-film supercapacitors (TFSCs) has been limited by the issues such as expensive electrode materials, indispensable commercial separators and metal current collectors, and complex manufacturing processes. Herein, we develop a potentially scalable approach to address all these issues by using CO2 laser pyrolysis of polyimide (PI) paper into the three-dimensional (3D) morphology of graphene paper in air. The formation process and mechanism of PI to graphene were clarified by microstructure and chemical characterizations and reaction molecular dynamics. The influences of laser scan density, power, defocus, and scan speed on the sheet resistance, longitudinal resistance, Raman spectra, and electrochemical performance of graphene papers were systematically investigated. Results indicate that high-quality graphene papers with ultralow sheet resistance (4.88 Ω·square–1) and longitudinal resistance (3.46 Ω) and extra-large crystalline size (96.1 nm) were achieved under optimized process parameters. The graphene papers can simultaneously serve as active electrode materials, current collectors, and interconnectors. The active area of electrodes is defined by a PI mask, with the help of which a hydrogel electrolyte functions as a separator. The assembled graphene paper-based TFSCs demonstrate outstanding electrochemical performance and mechanical flexibility, with the areal capacitance of 54.5 mF·cm–2, energy density of 10.9 μWh·cm–2, and cycle stability retention of 86.9% over 15 000 cycles. Moreover, all the tandem metal-free TFSCs, ranging from 1 to 160 cells, show excellent performance uniformity. The output voltage increases linearly from 1.2 V to 200 V. Significantly, the 160-tandem TFSCs exhibit a high voltage density within a compact volume of ～3.8 cm3. This work provides an avenue for achieving tandem metal-free TFSCs in a simple and efficient manner..
International Journal of Extreme Manufacturing
- Publication Date: May. 13, 2025
- Vol. 7, Issue 5, 55501 (2025)
A magnetic patch robot with photothermal-activated multi-modality for targeted anti-postoperative adhesion
Wei Tanyong, Hu Yang, Yang Ming, Shi Chaoyang, and Hu Chengzhi
Adhesive patches offer an effective approach for wound closure, making them highly suitable for biomedical applications. However, conventional patches often face limitations such as dual-sided adhesion, lack of shape adaptability, and limited maneuverability, which restrict their applications in deeper tissues. In thisAdhesive patches offer an effective approach for wound closure, making them highly suitable for biomedical applications. However, conventional patches often face limitations such as dual-sided adhesion, lack of shape adaptability, and limited maneuverability, which restrict their applications in deeper tissues. In this paper, we develop a magnetic patch robot (PatchBot), for targeted Janus adhesion with tissues. The PatchBot features a unique triple-layer structure, with adhesive, shape-morphing, and anti-adhesive layers, each fulfilling roles to support targeted attachment, enable shape transformation, and prevent unwanted adhesion to surrounding tissues. The Janus adhesion of the PatchBot was extensively demonstrated across a variety of tissues. A localized near-infrared (NIR) laser irradiation was used to induce programmable shape transformations. Magnetic actuation of the PatchBot for targeted adhesion was successfully demonstrated in ex vivo porcine stomach tissue. NIR light-activated shape-morphing and multimodal magnetic actuation significantly enhance its maneuverability and adaptability in confined in vivo environments while ensuring the structural integrity of the adhesive surface during deployment. This proof-of-concept study demonstrates the feasibility of using PatchBot for targeted wound adhesion, showing its potential for minimally invasive, precision therapies in complex in vivo environments..
International Journal of Extreme Manufacturing
- Publication Date: May. 13, 2025
- Vol. 7, Issue 5, 55502 (2025)
Tailoring the number of lines for IGO-channel 2T0C DRAM comparable to conventional 2-line operation 1T1C structure for highly scaled cell volume
Kwag Jae-Hyeok, Choi Su-Hwan, Kim Daejung, Lee Jun-Yeoub, Hwang Taewon, Oh Hye-Jin, Park Chang-Kyun, and Park Jin-Seong
Capacitor-less 2T0C dynamic random-access memory (DRAM) employing oxide semiconductors (OSs) as a channel has great potential in the development of highly scaled three dimensional (3D)-structured devices. However, the use of OS and such device structures presents certain challenges, including the trade-off relationshipCapacitor-less 2T0C dynamic random-access memory (DRAM) employing oxide semiconductors (OSs) as a channel has great potential in the development of highly scaled three dimensional (3D)-structured devices. However, the use of OS and such device structures presents certain challenges, including the trade-off relationship between the field-effect mobility and stability of OSs. Conventional 4-line-based operation of the 2T0C enlarges the entire cell volume and complicates the peripheral circuit. Herein, we proposed an IGO (In-Ga-O) channel 2-line-based 2T0C cell design and operating sequences comparable to those of the conventional Si-channel 1 T1C DRAM. IGO was adopted to achieve high thermal stability above 800 °C, and the process conditions were optimized to simultaneously obtain a high μFE of 90.7 cm2·V–1·s–1, positive Vth of 0.34 V, superior reliability, and uniformity. The proposed 2-line-based 2T0C DRAM cell successfully exhibited multi-bit operation, with the stored voltage varying from 0 V to 1 V at 0.1 V intervals. Furthermore, for stored voltage intervals of 0.1 V and 0.5 V, the refresh time was 10 s and 1 000 s in multi-bit operation; these values were more than 150 and 15 000 times longer than those of the conventional Si channel 1T1C DRAM, respectively. A monolithic stacked 2-line-based 2T0C DRAM was fabricated, and a multi-bit operation was confirmed..
International Journal of Extreme Manufacturing
- Publication Date: May. 23, 2025
- Vol. 7, Issue 5, 55503 (2025)
Highly programmable 4D printed multi-shape gradient metamaterials and multifunctional devices
Yang Chunli, Xin Xiaozhou, Zhao Wenjun, Lin Cheng, Liu Liwu, Liu Yanju, and Leng Jinsong
Metamaterials, owing to their exceptional physical characteristics that are absent in natural materials, have emerged as a crucial constituent of intelligent devices and systems. However, there are still significant challenges that necessitate immediate attention, as they have considerably constrained the applicabilityMetamaterials, owing to their exceptional physical characteristics that are absent in natural materials, have emerged as a crucial constituent of intelligent devices and systems. However, there are still significant challenges that necessitate immediate attention, as they have considerably constrained the applicability of metamaterials, including fixed mechanical properties post-fabrication and restricted design freedom. Here, thermo-responsive, photo-responsive, electro-responsive, and magneto-responsive shape memory polymer nano-composites were developed, and shape memory gradient metamaterials were fabricated using multi-material 4D printing technology. The correlation mechanism between the design parameters and the mechanical properties of multi-responsive gradient metamaterials was systematically analyzed, and the highly designable and programmable configuration and mechanical properties of the gradient metamaterials were realized. More importantly, 4D printed multi-responsive shape memory polymer gradient metamaterials can be programmed in situ without additional infrastructure for multi-functional mechanical functions, paving the way for the realization of multiple functions of a single structure. Based on the multi-responsive gradient metamaterials, 4D printed digital pixel metamaterial intelligent information carriers were fabricated, featuring customizable encryption and decryption protocols, exceptional scalability, and reusability. Additionally, 4D printed gradient metamaterial logic gate electronic devices were developed, which were anticipated to contribute to the development of smart, adaptable robotic systems that combine sensing, actuation, and decision-making capabilities..
International Journal of Extreme Manufacturing
- Publication Date: May. 30, 2025
- Vol. 7, Issue 5, 55504 (2025)
ZnO-SnO2/WO3-x heterojunction artificial synapse for realization and integration of multiple biological cognitive functions
Sun Pengfei, Li Ruidong, Meng Haotian, Sun Tao, Gao Song, and Li Yang
In current memristor-based neuromorphic computing research, several studies face the challenge of realizing only a single function at a time or having isolated functions. This limitation is particularly evident when simulating biological cognition, as the overall synergy between multiple cognitive functions is difficulIn current memristor-based neuromorphic computing research, several studies face the challenge of realizing only a single function at a time or having isolated functions. This limitation is particularly evident when simulating biological cognition, as the overall synergy between multiple cognitive functions is difficult to represent. In this work, a high-performance heterojunction memristor is presented at first. The memristor-based neural network and functional circuit are further implemented to realize and integrate multiple cognitive functions. Specifically, the proposed photoelectric memristor has the structure of Ag/ZnO-SnO2/WO3-x/ITO, it exhibits various synaptic behaviors under external modulations, which are characterized by good stability and repeatability. Based on this device, a neural network is built to realize the basic recognition function in biological cognition. The recognition results are translated into different labelled voltage signals and subsequently fed into a memristor-based functional circuit. By leveraging memory characteristics and tunable conductance of the memristor, and controlling the specific circuit functionalities, the input signals are processed to produce different outputs representing various cognitive functions. This methodology allows the realization and integration of recognition, memory, learning, association, relearning, and forgetting into one single system, thereby enabling a more comprehensive and authentic simulation of biological cognition. This work presents a novel memristor and a method for achieving and integrating multiple neuromorphic computing functions within a single system, providing a successful example for achieving complete biological function..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 10, 2025
- Vol. 7, Issue 5, 55505 (2025)
Magneto-soft robots based on multi-materials optimizing and heat-assisted in-situ magnetic domains programming
Niu Fuzhou, Xue Quhao, Cao Qing, He Xinyang, Wang Taolei, Wang HaoChen, Hao Chonglei, Li Xiaojian, Li Ying, Yang Hao, Yang Huayong, and Han Dong
Soft robots, inspired by the flexibility and versatility of biological organisms, have potential in a variety of applications. Recent advancements in magneto-soft robots have demonstrated their abilities to achieve precise remote control through magnetic fields, enabling multi-modal locomotion and complex manipulation Soft robots, inspired by the flexibility and versatility of biological organisms, have potential in a variety of applications. Recent advancements in magneto-soft robots have demonstrated their abilities to achieve precise remote control through magnetic fields, enabling multi-modal locomotion and complex manipulation tasks. Nonetheless, two main hurdles must be overcome to advance the field: developing a multi-component substrate with embedded magnetic particles to ensure the requisite flexibility and responsiveness, and devising a cost-effective, straightforward method to program three-dimensional distributed magnetic domains without complex processing and expensive machinery. Here, we introduce a cost-effective and simple heat-assisted in-situ integrated molding fabrication method for creating magnetically driven soft robots with three-dimensional programmable magnetic domains. By synthesizing a composite material with neodymium-iron-boron (NdFeB) particles embedded in a polydimethylsiloxane (PDMS) and Ecoflex matrix (PDMS: Ecoflex = 1:2 mass ratio, 50% magnetic particle concentration), we achieved an optimized balance of flexibility, strength, and magnetic responsiveness. The proposed heat-assisted in-situ magnetic domains programming technique, performed at an experimentally optimized temperature of 120 °C, resulted in a 2 times magnetization strength (9.5 mT) compared to that at 20 °C (4.8 mT), reaching a saturation level comparable to a commercial magnetizer. We demonstrated the versatility of our approach through the fabrication of six kinds of robots, including two kinds of two-dimensional patterned soft robots (2D-PSR), a circular six-pole domain distribution magnetic robot (2D-CSPDMR), a quadrupedal walking magnetic soft robot (QWMSR), an object manipulation robot (OMR), and a hollow thin-walled spherical magneto-soft robot (HTWSMSR). The proposed method provides a practical solution to create highly responsive and adaptable magneto-soft robots..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 10, 2025
- Vol. 7, Issue 5, 55506 (2025)
3D printed organohydrogel-based strain sensors with enhanced sensitivity and stability via structural design
Guo Binbin, Lin Chengyu, Ye Haitao, Xue Yu, Mo Jiewen, Chen Jiawei, Cui Yangfeng, Fu Chenglong, Bai Jiaming, Ge Qi, and Yang Hui Ying
Organohydrogel-based strain sensors are gaining attention for real-time health services and human-machine interactions due to their flexibility, stretchability, and skin-like compliance. However, these sensors often have limited sensitivity and poor stability due to their bulk structure and strain concentration during Organohydrogel-based strain sensors are gaining attention for real-time health services and human-machine interactions due to their flexibility, stretchability, and skin-like compliance. However, these sensors often have limited sensitivity and poor stability due to their bulk structure and strain concentration during stretching. In this study, we designed and fabricated diamond-, grid-, and peanut-shaped organohydrogel based on positive, near-zero, and negative Poisson's ratios using digital light processing (DLP)-based 3D printing technology. Through structural design and optimization, the grid-shaped organohydrogel exhibited record sensitivity with gauge factors of 4.5 (0–200% strain, ionic mode) and 13.5/1.5 × 106 (0–2%/2%–100% strain, electronic mode), alongside full resistance recovery for enhanced stability. The 3D-printed grid structure enabled direct wearability and breathability, overcoming traditional sensor limitations. Integrated with a robotic hand system, this sensor demonstrated clinical potential through precise monitoring of paralyzed patients' grasping movements (with a minimum monitoring angle of 5°). This structural design paradigm advanced flexible electronics by synergizing high sensitivity, stability, wearability, and breathability for healthcare, and human-machine interfaces..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 23, 2025
- Vol. 7, Issue 5, 55507 (2025)
High-precision large-aperture single-frame interferometric surface profile measurement method based on deep learning
Tang Liang, Han Mingzhi, Yang Shuai, Sun Ye, Qiu Lirong, and Zhao Weiqian
Large-aperture optical components are of paramount importance in domains such as integrated circuits, photolithography, aerospace, and inertial confinement fusion. However, measuring their surface profiles relies predominantly on the phase-shifting approach, which involves collecting multiple interferograms and imposesLarge-aperture optical components are of paramount importance in domains such as integrated circuits, photolithography, aerospace, and inertial confinement fusion. However, measuring their surface profiles relies predominantly on the phase-shifting approach, which involves collecting multiple interferograms and imposes stringent demands on environmental stability. These issues significantly hinder its ability to achieve real-time and dynamic high-precision measurements. Therefore, this study proposes a high-precision large-aperture single-frame interferometric surface profile measurement (LA-SFISPM) method based on deep learning and explores its capability to realize dynamic measurements with high accuracy. The interferogram is matched to the phase by training the data measured using the small aperture. The consistency of the surface features of the small and large apertures is enhanced via contrast learning and feature-distribution alignment. Hence, high-precision phase reconstruction of large-aperture optical components can be achieved without using a phase shifter. The experimental results show that for the tested mirror with Φ = 820 mm, the surface profile obtained from LA-SFISPM is subtracted point-by-point from the ground truth, resulting in a maximum single-point error of 4.56 nm. Meanwhile, the peak-to-valley (PV) value is 0.075 8 λ, and the simple repeatability of root mean square (SR-RMS) value is 0.000 25 λ, which aligns well with the measured results obtained by ZYGO. In particular, a significant reduction in the measurement time (reduced by a factor of 48) is achieved compared with that of the traditional phase-shifting method. Our proposed method provides an efficient, rapid, and accurate method for obtaining the surface profiles of optical components with different diameters without employing a phase-shifting approach, which is highly desired in large-aperture interferometric measurement systems..
International Journal of Extreme Manufacturing
- Publication Date: May. 09, 2025
- Vol. 7, Issue 5, 55601 (2025)
Topical Review
Solution-based manufacturing of 2D materials for memristive device applications
Nam Kijeong, Kim Gwang Ya, Rhee Dongjoon, Park Hyesung, Jariwala Deep, and Kang Joohoon
Two-dimensional (2D) materials have attracted significant attention as resistive switching materials for two-terminal non-volatile memory devices, often referred to as memristors, due to their potential for achieving fast switching speeds and low power consumption. Their excellent gate tunability in electronic propertiTwo-dimensional (2D) materials have attracted significant attention as resistive switching materials for two-terminal non-volatile memory devices, often referred to as memristors, due to their potential for achieving fast switching speeds and low power consumption. Their excellent gate tunability in electronic properties also enables hybrid devices combining the functionality of memory devices and transistors, with the possibility of realizing large-scale memristive crossbar arrays with high integration density. To facilitate the use of 2D materials in practical memristor applications, scalable synthesis of 2D materials with high electronic quality is critical. In addition, low-temperature integration for complementary metal oxide semiconductor (CMOS) back-end-of-line (BEOL) integration is important for embedded memory applications. Solution-based exfoliation has been actively explored as a facile, cost-effective method for the mass production and low-temperature integration of 2D materials. However, the films produced from the resulting 2D nanosheet dispersions exhibited poor electrical properties in the early stages of research, thereby hindering their use in electronic devices. Recent progress in the exfoliation process and post-processing has led to significant improvements in the electronic performance of solution-processed 2D materials, driving increased adoption of these materials in memristor research. In this review article, we provide a thorough overview of the progress and current status of memristive devices utilizing solution-processed 2D resistive switching layers. We begin by introducing the electrical characteristics and resistive switching mechanisms of memristors fabricated with conventional materials to lay the groundwork for understanding memristive behavior in 2D materials. Representative solution-based exfoliation and film formation techniques are also introduced, emphasizing the benefits of these approaches for obtaining scalable 2D material films compared to conventional methods such as mechanical exfoliation and chemical vapor deposition. Finally, we explore the electrical characteristics, resistive switching mechanisms, and applications of solution-processed 2D memristive devices, discussing their advantages and remaining challenges..
International Journal of Extreme Manufacturing
- Publication Date: May. 23, 2025
- Vol. 7, Issue 5, 52001 (2025)
Additive manufacturing-by-design for support structures: a critical review
Su Jinlong, Mo Yang, Shangguan Peijie, Panwisawas Chinnapat, Jiang Fulin, and Sing Swee Leong
Support structure, a critical component in the design for additive manufacturing (DfAM), has been largely overlooked by additive manufacturing (AM) communities. The support structure stabilises overhanging sections, aids in heat dissipation, and reduces the risk of thermal warping, residual stress, and distortion, partSupport structure, a critical component in the design for additive manufacturing (DfAM), has been largely overlooked by additive manufacturing (AM) communities. The support structure stabilises overhanging sections, aids in heat dissipation, and reduces the risk of thermal warping, residual stress, and distortion, particularly in the fabrication of complex geometries that challenge traditional manufacturing methods. Despite the importance of support structures in AM, a systematic review covering all aspects of the design, optimisation, and removal of support structures remains lacking. This review provides an overview of various support structure types—contact and non-contact, as well as identical and dissimilar material configurations—and outlines optimisation methods, including geometric, topology, simulation-driven, data-driven, and multi-objective approaches. Additionally, the mechanisms of support removal, such as mechanical milling and chemical dissolution, and innovations like dissolvable supports and sensitised interfaces, are discussed. Future research directions are outlined, emphasising artificial intelligence (AI)-driven intelligent design, multi-material supports, sustainable support materials, support-free AM techniques, and innovative support removal methods, all of which are essential for advancing AM technology. Overall, this review aims to serve as a foundational reference for the design and optimisation of the support structure in AM..
International Journal of Extreme Manufacturing
- Publication Date: May. 27, 2025
- Vol. 7, Issue 5, 52002 (2025)
Biomass materials and their application in 4D printing
Yang Zhongda, Li Jian, Guo Yanling, Wang Yangwei, Zhao Wen, Zhao Wei, Liu Yanju, and Zhang Laichang
Four-dimensional (4D) printing technology is a revolutionary development that produces structures that can adapt in response to external stimuli. However, the responsiveness and printability of smart materials with shape memory properties, which are necessary for 4D printing, remain limited. Biomass materials derived fFour-dimensional (4D) printing technology is a revolutionary development that produces structures that can adapt in response to external stimuli. However, the responsiveness and printability of smart materials with shape memory properties, which are necessary for 4D printing, remain limited. Biomass materials derived from nature have offered an effective solution due to their various excellent and unique properties. Biomass materials have been abundant in resources and low in carbon content, contributing to the then-current global green energy-saving goals, including carbon peaking and carbon neutrality. This review focused on different sources of biomass materials used in 4D printing, including plant-based, animal-based, and microbial-based biomass materials. It systematically outlined the responsive deformation mechanisms of printed objects that contained biomass materials and delved into the roles and unique advantages of biomass materials in those printed objects. Leveraging these advantages, the review discussed the potential applications of biomass materials in biomedicine, food printing, and other fields to support ongoing development and application efforts. Additionally, it emphasized the crucial role played by bio-fabrication technologies utilizing biomass materials in the integration of biomass materials with 4D printing. Finally, this paper discussed the then-current challenges and potential future directions of biomass materials in 4D printing, aiming to promote the effective development of biomass materials in 4D printing applications..
International Journal of Extreme Manufacturing
- Publication Date: May. 27, 2025
- Vol. 7, Issue 5, 52003 (2025)
Advanced manufacturing techniques and applications of micro-/nanoscale helices
Ye Yanchen, Wu Hao, Wu Rongye, Xu Can, Dong Yue, Zhang Li, and Li Bing
Inspired by the ubiquitous helical structures in nature, research on artificial helices has attracted increasing attention. As a unique and complex three-dimensional (3D) geometry in the microscopic world, the micro-/nano helix has significant advantages in wide applications due to its distinctive properties at the micInspired by the ubiquitous helical structures in nature, research on artificial helices has attracted increasing attention. As a unique and complex three-dimensional (3D) geometry in the microscopic world, the micro-/nano helix has significant advantages in wide applications due to its distinctive properties at the micro-scale. Micro-/nanotechnology is advancing rapidly. The geometric complexity of helical structure poses technical challenges for the manufacturing at the micro-/nanoscale, requiring some emerging manufacturing techniques. In this review, we systematically classify and summarize existing manufacturing methods for micro/nano helical structures and their underlying mechanisms. Based on the unique physical properties of helical structures at the microscale, their latest applications are analyzed across different fields. Finally, we conclude the challenges and future research directions of micro-/nano helices in manufacturing methods and applications..
International Journal of Extreme Manufacturing
- Publication Date: May. 30, 2025
- Vol. 7, Issue 5, 52004 (2025)
Next generation High-Mobility 2D chalcogenides TFT for display backplane
Bisht Prashant, Shim Junoh, Oh Jooon, Lee Jieun, Shin Hoseong, Jeong Hyeonho, Kim Jimin, Lee Junho, Kwon Hyuk-Jun, and Kim Sunkook
The evolution of display backplane technologies has been driven by the relentless pursuit of higher form factor and superior performance coupled with lower power consumption. Current state-of-the-art backplane technologies based on amorphous Si, poly Si, and IGZO, face challenges in meeting the requirements of next-genThe evolution of display backplane technologies has been driven by the relentless pursuit of higher form factor and superior performance coupled with lower power consumption. Current state-of-the-art backplane technologies based on amorphous Si, poly Si, and IGZO, face challenges in meeting the requirements of next-generation displays, including larger dimensions, higher refresh rates, increased pixel density, greater brightness, and reduced power consumption. In this context, 2D chalcogenides have emerged as promising candidates for thin-film transistors (TFTs) in display backplanes, offering advantages such as high mobility, low leakage current, mechanical robustness, and transparency. This comprehensive review explores the significance of 2D chalcogenides as materials for TFTs in next-generation display backplanes. We delve into the structural characteristics, electronic properties, and synthesis methods of 2D chalcogenides, emphasizing scalable growth strategies that are relevant to large-area display backplanes. Additionally, we discuss mechanical flexibility and strain engineering, crucial for the development of flexible displays. Performance enhancement strategies for 2D chalcogenide TFTs have been explored encompassing techniques in device engineering and geometry optimization, while considering scaling over a large area. Active-matrix implementation of 2D TFTs in various applications is also explored, benchmarking device performance on a large scale which is a necessary aspect of TFTs used in display backplanes. Furthermore, the latest development on the integration of 2D chalcogenide TFTs with different display technologies, such as OLED, quantum dot, and MicroLED displays has been reviewed in detail. Finally, challenges and opportunities in the field are discussed with a brief insight into emerging trends and research directions..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 04, 2025
- Vol. 7, Issue 5, 52005 (2025)
Technical roadmap of ultra-thin crystalline silicon-based bioelectronics
Sang Mingyu, Kim Kyubeen, Lee Doohyun J, Cho Young Uk, Lee Jung Woo, and Yu Ki Jun
Ultra-thin crystalline silicon stands as a cornerstone material in the foundation of modern micro and nano electronics. Despite the proliferation of various materials including oxide-based, polymer-based, carbon-based, and two-dimensional (2D) materials, crystal silicon continues to maintain its stronghold, owing to itUltra-thin crystalline silicon stands as a cornerstone material in the foundation of modern micro and nano electronics. Despite the proliferation of various materials including oxide-based, polymer-based, carbon-based, and two-dimensional (2D) materials, crystal silicon continues to maintain its stronghold, owing to its superior functionality, scalability, stability, reliability, and uniformity. Nonetheless, the inherent rigidity of the bulk silicon leads to incompatibility with soft tissues, hindering the utilization amid biomedical applications. Because of such issues, decades of research have enabled successful utilization of various techniques to precisely control the thickness and morphology of silicon layers at the scale of several nanometres. This review provides a comprehensive exploration on the features of ultra-thin single crystalline silicon as a semiconducting material, and its role especially among the frontier of advanced bioelectronics. Key processes that enable the transition of rigid silicon to flexible form factors are exhibited, in accordance with their chronological sequence. The inspected stages span both prior and subsequent to transferring the silicon membrane, categorized respectively as on-wafer manufacturing and rigid-to-soft integration. Extensive guidelines to unlock the full potential of flexible electronics are provided through ordered analysis of each manufacturing procedure, the latest findings of biomedical applications, along with practical perspectives for researchers and manufacturers..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 13, 2025
- Vol. 7, Issue 5, 52006 (2025)
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