Computational Fluid Dynamics as a Digital Tool for Enhancing Safety Uptake in Advanced Manufacturing Environments Within a Safe-by-Design Strategy.

In modern manufacturing environments, pollution management is critical as exposure to harmful substances can cause serious health issues. This study presents a two-stage computational fluid dynamic (CFD) model to estimate the distribution of pollutants in indoor production spaces. In the first stage, the Reynolds-averaged Navier-Stokes (RANS) method was used to simulate airflow and temperature.

Integrating Exposure Assessment and Process Hazard Analysis: The Nano-Enabled 3D Printing Filament Extrusion Case.

Nanoparticles are being used in novel applications of the thermoplastics industry, including automotive parts, the sports industry and leisure and consumer goods, which can be produced nowadays through additive manufacturing. However, there is limited information on the health and safety aspects during the production of these new materials, mainly from recycled sources. This study covers the exposure assessment to nano- and micro-size particles emitted from the nanocomposites during the production of filaments for 3D printing through a compounding and extrusion pilot line using recycled (post-industrial) thermoplastic polyurethane (TPU) and recycled polyamide 12 (PA12), which have been also upcycled through reinforcement with iron oxide nanoparticles (FeO NPs), introducing matrix healing properties triggered by induction heating.

Employment of 3D-Printed Bilayer Structures with Embedded Continuous Fibers for Thermal Management Applications: An Axial Cooling 4D-Printed Fan Application Case Study.

Bi-material composite structures with continuous fibers embedded on polymer substrates exhibit self-morphing under thermal stimulus induced by the different coefficients of thermal expansion (CTE) between the two constituent materials. In this study, a series of such structures are investigated in terms of fiber patterns and materials to achieve programmable and reversible transformations that can be exploited for thermal management applications. Stemming from this investigation's results, an axial cooling fan prototype is designed and fabricated with composite blades that passively alter their shape, specifically their curvature and twist angle, under different operating temperatures.

Digital Innovation Enabled Nanomaterial Manufacturing; Machine Learning Strategies and Green Perspectives.

Machine learning has been an emerging scientific field serving the modern multidisciplinary needs in the Materials Science and Manufacturing sector. The taxonomy and mapping of nanomaterial properties based on data analytics is going to ensure safe and green manufacturing with consciousness raised on effective resource management. The utilization of predictive modelling tools empowered with artificial intelligence (AI) has proposed novel paths in materials discovery and optimization, while it can further stimulate the cutting-edge and data-driven design of a tailored behavioral profile of nanomaterials to serve the special needs of application environments.

Occupational Safety Analysis for COVID-Instigated Repurposed Manufacturing Lines: Use of Nanomaterials in Injection Moulding.

The COVID-19 pandemic instigated massive production of critical medical supplies and personal protective equipment. Injection moulding (IM) is considered the most prominent thermoplastic part manufacturing technique, offering the use of a large variety of feedstocks and rapid production capacity. Within the context of the European Commission-funded imPURE project, the benefits of IM have been exploited in repurposed IM lines to accommodate the use of nanocomposites and introduce the unique properties of nanomaterials.

Mechanical Properties, Surface Assessment, and Structural Analysis of Functionalized CFRPs after Accelerated Weathering.

The present study focuses on the effect of two novel carbon fibre surface treatments, electropolymerisation of methacrylic acid and air pressure plasma, on the mechanical properties and structural integrity of carbon-fibre-reinforced composites under operational conditions. Extensive mechanical testing was applied, both in nano- and macro-scale, to assess the performance of the composites and the interphase properties after ultraviolet/humidity weathering. The results of the mechanical assessment are supported by structure, surface, and chemistry examination in order to reveal the failure mechanism of the composites.

Carbon Fiber Reinforced Composites: Study of Modification Effect on Weathering-Induced Ageing via Nanoindentation and Deep Learning.

The exposure of carbon-fiber-reinforced polymers (CFRPs) to open-field conditions was investigated. Establishment of structure-property relations with nanoindentation enabled the observation of modification effects on carbon-fiber interfaces, and impact resistance. Mapping of nanomechanical properties was performed using expectation-maximization optimization of Gaussian fitting for each CFRPs microstructure (matrix, interface, carbon fiber), while Weibull analysis connected the weathering effect to the statistically representative behavior of the produced composites.

Additive manufacturing of hydroxyapatite-chitosan-genipin composite scaffolds for bone tissue engineering applications.

Additive manufacturing holds promise for the fabrication of three-dimensional scaffolds with precise geometry, to serve as substrates for the guided regeneration of natural tissue. In this work, a bioinspired approach is adopted for the synthesis of hybrid hydroxyapatite hydrogels, which were subsequently printed to form 3D scaffolds for bone tissue engineering applications. These hydrogels consist of hydroxyapatite nanocrystals, biomimetically synthesized in the presence of both chitosan and l-arginine.

End-of-Life Recycling Options of (Nano)Enhanced CFRP Composite Prototypes Waste-A Life Cycle Perspective.

Life cycle assessment is a methodology to assess environmental impacts associated with a product or system/process by accounting resource requirements and emissions over its life cycle. The life cycle consists of four stages: material production, manufacturing, use, and end-of-life. This study highlights the need to conduct life cycle assessment (LCA) early in the new product development process, as a means to assess and evaluate the environmental impacts of (nano)enhanced carbon fibre-reinforced polymer (CFRP) prototypes over their entire life cycle.

Mechanical Enhancement of Cytocompatible 3D Scaffolds, Consisting of Hydroxyapatite Nanocrystals and Natural Biomolecules, Through Physical Cross-Linking.

Bioinspired scaffolds mimicking natural bone-tissue properties holds great promise in tissue engineering applications towards bone regeneration. Within this work, a way to reinforce mechanical behavior of bioinspired bone scaffolds was examined by applying a physical crosslinking method. Scaffolds consisted of hydroxyapatite nanocrystals, biomimetically synthesized in the presence of collagen and l-arginine.

Testing Novel Portland Cement Formulations with Carbon Nanotubes and Intrinsic Properties Revelation: Nanoindentation Analysis with Machine Learning on Microstructure Identification.

Nanoindentation was utilized as a non-destructive technique to identify Portland Cement hydration phases. Artificial Intelligence (AI) and semi-supervised Machine Learning (ML) were used for knowledge gain on the effect of carbon nanotubes to nanomechanics in novel cement formulations. Data labelling is performed with unsupervised ML with k-means clustering.

3D-Printed Lab-on-a-Chip Diagnostic Systems-Developing a Safe-by-Design Manufacturing Approach.

The aim of this study is to provide a detailed strategy for Safe-by-Design (SbD) 3D-printed lab-on-a-chip (LOC) device manufacturing, using Fused Filament Fabrication (FFF) technology. First, the applicability of FFF in lab-on-a-chip device development is briefly discussed. Subsequently, a methodology to categorize, identify and implement SbD measures for FFF is suggested.