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This research paper focuses on the fabrication of a microstructure based on a natural structure pattern of hydrophobic properties using micro-milling technology, followed by an investigation of the dimensional accuracy, roughness, and replication of the fabricated microstructure. Design, modeling (CAD system), fabrication, and replication are the steps of this process. Knowledge of biomimetics was used to select the microstructure. The main research aim of the experiments is to verify and extend the applicability of conventional CNC manufacturing technologies to obtain a functional surface structure. The micro-milling was carried out on a conventional DMG MORI CNC machine, a CMX 600 V three-axis horizontal milling center, using an external high-frequency electric spindle clamped to the machine. The machined material was aluminum alloy EN AW 7075. The tool was a 0.1 mm diameter double-edged ball mill made of sintered carbide and coated with TiSiN. The cutting conditions were determined according to the tool manufacturer’s recommendations. To compare the achieved accuracies, the same microstructure was fabricated using PLA technology. For subsequent replication of the sample, the negative of the selected microstructure was created and machined. Subsequently, a positive microstructure was created using the silicone impression material by the replication process. This paper and the experiments performed extend the technical knowledge in the field of manufacturing surface functional structures and confirm the possibility of manufacturing the designed structures using chip and laser machining technology, with achieved discontinuities in the range of 3 to 50 μm. They also highlight the issues of replication of such structures with respect to critical manufacturing locations (geometrical parameters of the structures affecting the functional properties of the structure, venting, replica defects, etc.).

Plant and animal surfaces have become a model for preparing special synthetic surfaces with low wettability, reflectivity, or antibacterial properties. Processes that lead to the creation of replicas of natural character use two-step imprinting methods. This article describes a technique of synthetic polymer surface preparation by the process of two-stage imprinting. The laboratory-prepared structure copies the original natural pattern at the micrometer and sub-micrometer levels, supplemented by a new substructure. The new substructure identified by the scanning electron microscope is created at the nanometer level during the technological process. The nanostructure is formed only under the conditions that a hierarchical structure forms the surface of the natural replicated pattern, the replication mold is from a soft elastomeric material, and the material for producing the synthetic surface is a polymer capable of crystallizing. A new nanometer substructure formation occurs when the polymer cools to standard laboratory temperature and atmospheric pressure.

In this study, the effects of occupational exposure to nanoparticles (NPs) were studied by NMR metabolomics. Exhaled breath condensate (EBC) and blood plasma samples were obtained from a research nanoparticles-processing unit at a national research university. The samples were taken from three groups of subjects: samples from workers exposed to nanoparticles collected before and after shift, and from controls not exposed to NPs. Altogether, 60 1H NMR spectra of exhaled breath condensate (EBC) samples and 60 1H NMR spectra of blood plasma samples were analysed, 20 in each group. The metabolites identified together with binning data were subjected to multivariate statistical analysis, which provided clear discrimination of the groups studied. Statistically significant metabolites responsible for group separation served as a foundation for analysis of impaired metabolic pathways. It was found that the acute effect of NPs exposure is mainly reflected in the pathways related to the production of antioxidants and other protective species, while the chronic effect is manifested mainly in the alteration of glutamine and glutamate metabolism, and the purine metabolism pathway.

In this paper, a practical issue of the application of cubic boron nitride (CBN) cutting tools for the machining of steel 100Cr6 thin-walled bearing rings is addressed. Three geometries of the commercially available CBN cutting inserts were tested at different machining parameters. The effect of geometry was assessed in terms of surface integrity, considering 2D profile parameters, 3D topography of the surface, and residual stresses in the surface layer. The results were sometimes contradictory, since the same cutting inserts provided the largest and the lowest values of the topography parameters, dependent on different cutting conditions. In general, CBN cutting inserts with XCEL geometry ensured the smallest profile parameters Ra and Rz, and the spatial parameters of Smr1 exhibited the largest values among all tested tools, suggesting reduced wear resistance. Residual stresses analysis did not reveal any inacceptable or potentially dangerous surface layer state after machining.

Human data concerning exposure to nanoparticles are very limited, and biomarkers for monitoring exposure are urgently needed. In a follow-up of a 2016 study in a nanocomposites plant, in which only exhaled breath condensate (EBC) was examined, eight markers of oxidative stress were analyzed in three bodily fluids, i.e., EBC, plasma and urine, in both pre-shift and post-shift samples in 2017 and 2018. Aerosol exposures were monitored. Mass concentration in 2017 was 0.351 mg/m3 during machining, and 0.179 and 0.217 mg/m3 during machining and welding, respectively, in 2018. In number concentrations, nanoparticles formed 96%, 90% and 59%, respectively. In both years, pre-shift elevations of 50.0% in EBC, 37.5% in plasma and 6.25% in urine biomarkers were observed. Post-shift elevation reached 62.5% in EBC, 68.8% in plasma and 18.8% in urine samples. The same trend was observed in all biological fluids. Individual factors were responsible for the elevation of control subjects’ afternoon vs. morning markers in 2018; all were significantly lower compared to those of workers. Malondialdehyde levels were always acutely shifted, and 8-hydroxy-2-deoxyguanosine levels best showed chronic exposure effect. EBC and plasma analysis appear to be the ideal fluids for bio-monitoring of oxidative stress arising from engineered nanomaterials. Potential late effects need to be targeted and prevented, as there is a similarity of EBC findings in patients with silicosis and asbestosis.

Thousands of researchers and workers worldwide are employed in nanocomposites manufacturing, yet little is known about their respiratory health. Aerosol exposures were characterized using real time and integrated instruments. Aerosol mass concentration ranged from 0.120 mg/m3 to 1.840 mg/m3 during nanocomposite machining processes; median particle number concentration ranged from 4.8 × 104 to 5.4 × 105 particles/cm3. The proportion of nanoparticles varied by process from 40 to 95%. Twenty employees, working in nanocomposite materials research were examined pre-shift and post-shift using spirometry and fractional exhaled nitric oxide (FeNO) in parallel with 21 controls. Pro-inflammatory leukotrienes (LT) type B4, C4, D4, and E4; tumor necrosis factor (TNF); interleukins; and anti-inflammatory lipoxins (LXA4 and LXB4) were analyzed in their exhaled breath condensate (EBC). Chronic bronchitis was present in 20% of researchers, but not in controls. A significant decrease in forced expiratory volume in 1 s (FEV1) and FEV1/forced vital capacity (FVC) was found in researchers post-shift (p ˂ 0.05). Post-shift EBC samples were higher for TNF (p ˂ 0.001), LTB4 (p ˂ 0.001), and LTE4 (p ˂ 0.01) compared with controls. Nanocomposites production was associated with LTB4 (p ˂ 0.001), LTE4 (p ˂ 0.05), and TNF (p ˂ 0.001), in addition to pre-shift LTD4 and LXB4 (both p ˂ 0.05). Spirometry documented minor, but significant, post-shift lung impairment. TNF and LTB4 were the most robust markers of biological effects. Proper ventilation and respiratory protection are required during nanocomposites processing.

Researchers in nanocomposite processing may inhale a variety of chemical agents, including nanoparticles. This study investigated airway oxidative stress status in the exhaled breath condensate (EBC). Nineteen employees (42.4 ± 11.4 y/o), working in nanocomposites research for 18.0 ± 10.3 years were examined pre-shift and post-shift on a random workday, together with nineteen controls (45.5 ± 11.7 y/o). Panels of oxidative stress biomarkers derived from lipids, nucleic acids, and proteins were analyzed in the EBC. Aerosol exposures were monitored during three major nanoparticle generation operations: smelting and welding (workshop 1) and nanocomposite machining (workshop 2) using a suite of real-time and integrated instruments. Mass concentrations during these operations were 0.120, 1.840, and 0.804 mg/m3, respectively. Median particle number concentrations were 4.8 × 104, 1.3 × 105, and 5.4 × 105 particles/cm3, respectively. Nanoparticles accounted for 95, 40, and 61%, respectively, with prevailing Fe and Mn. All markers of nucleic acid and protein oxidation, malondialdehyde, and aldehydes C6–C13 were elevated, already in the pre-shift samples relative to controls in both workshops. Significant post-shift elevations were documented in lipid oxidation markers. Significant associations were found between working in nanocomposite synthesis and EBC biomarkers. More research is needed to understand the contribution of nanoparticles from nanocomposite processing in inducing oxidative stress, relative to other co-exposures generated during welding, smelting, and secondary oxidation processes, in these workshops.