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Although nano and macro manufacturing encompass two different scales of machining, investigating both is essential for understanding machining distortions and deformations. In both macro and nano fabrication, the fixture is the primary means of securing the workpiece in place while performing the manufacturing operations. Understanding the fixture design is a critical aspect relating the two different scales of manufacturing. This paper describes a method involving atomistic simulation for understanding machining distortions for the macro scale by investigation of nano machining and work holding devices. This research aims to help bridge the knowledge gap in manufacturing of macro and nano scale applications. The simulations performed showed that the fixture influences the machining distortions and the critical stress concentrations on the workpiece.

We discuss experimental, analytical, and numerical methods recently developed at the Advanced Light Source (ALS) X?Ray Optics Laboratory (XROL) for calibration and precision shaping of bendable x-ray mirrors. The methods are based on ex situ measurements with the mirrors using surface slope profilers available at the ALS XROL. The first realization of methods and dedicated software has allowed the optimization of the beamline performance of bendable mirrors by adjustment of the mirror shape to minimize the root-mean-square variation of residual (after subtraction of the ideal desired shape) slope deviations from ideal (specified) surface figure. Here, we further develop the methods that in application to elliptically bent mirrors adapt as a figure of merit the minimum of the rms size of the focused beam. The efficacy of the developed methods is demonstrated with examples of optimal tuning of an elliptically bendable cylindrical mirror designed for the ALS beamline 10.3.2.

Due to its high versatility and scalability, manual grinding is an important and widely used technology in production for rework, repair, deburring, and finishing of large or unique parts. To make the process more interactive and reliable, manual grinding needs to incorporate "skill-based design," which models a person-based system and can go significantly beyond the considerations of traditional human factors and ergonomics to encompass both processing parameters (e.g., feed rate, tool path, applied forces, material removal rate (MRR)), and machined surface quality (e.g., surface roughness). This study quantitatively analyzes the characteristics of complex techniques involved in manual operations. A series of experiments have been conducted using subjects of different levels of skill, while analyzing their visual gaze, cutting force, tool path, and workpiece quality. Analysis of variance (ANOVA) and multivariate regression analysis were performed and showed that the unique behavior of the operator affects the process performance measures of specific energy consumption and MRR. In the future, these findings can be used to predict product quality and instruct new practitioners.

A new design for a double-sided high-pressure diamond anvil cell laser heating set-up is described. The prototype is deployed at beamline 12.2.2 of the Advanced Light Source at Lawrence Berkeley National Lab. Our compact design features shortened mechanical lever arms, which results in more stable imaging optics, and thus more user friendly and more reliable temperature measurements based on pyrometry. A modification of the peak scaling method was implemented for pyrometry, including an iterative method to determine the absolute peak temperature, thus allowing for quasi-real time temperature mapping of the actual hotspot within a laser-heated diamond anvil cell without any assumptions on shape, size, and symmetry of the hotspot and without any assumptions to the relationship between fitted temperature and peak temperature. This is important since we show that the relationship between peak temperature and temperature obtained by fitting the Planck function against the thermal emission spectrum averaged over the entire hotspot is not constant but depends on variable fitting parameters (in particular, the size and position of the fitting window). The accuracy of the method is confirmed through measuring melting points of metal wires at ambient pressure. Having absolute temperature maps in real time allows for more differentiated analyses of laser heating experiments. We present such an example of the pressure variations within a heated hotspot of AgI at a loaded base pressure of 3.8 GPa.

Laser 3D printing is a promising technique to repair damaged Ni-based superalloy components. However, the occurrence of heat affected zone (HAZ) cracking severely limits its applicability. Here we unravel the cracking mechanism by studying the element, phase, defect, and strain distribution around an intergranular crack that initiated from the primary HAZ. Using synchrotron X-ray Laue microdiffraction, we measured high tensile strain/stress transverse to the building direction in both the primary HAZ and the cladding layers, as well as high-density dislocations, which resulted from the thermal contraction and rapid precipitation of γ′ phase. The crack initiated because the transverse tensile strain/stress tore up the liquid film formed by the low-melting point preexisting phases in the primary HAZ, such as γ/γ′ eutectics and coarse γ′ precipitates. The incoherent carbide particles were frequently observed near the crack root as local strain concentrators. In the cladding layers, micro-segregation could not be completely avoided, thus the hot crack continued to propagate over several layers with the assistance of the transverse tensile stress. Our investigations provide a useful guideline for the optimization of the 3D printing process to repair Ni-based superalloys with high susceptibility to hot cracking.

Laser 3D printing is a promising technique to repair damaged Ni-based superalloy components. However, the occurrence of heat affected zone (HAZ) cracking severely limits its applicability. Here we unravel the cracking mechanism by studying the element, phase, defect, and strain distribution around an intergranular crack that initiated from the primary HAZ. Using synchrotron X-ray Laue microdiffraction, we measured high tensile strain/stress transverse to the building direction in both the primary HAZ and the cladding layers, as well as high-density dislocations, which resulted from the thermal contraction and rapid precipitation of γ′ phase. The crack initiated because the transverse tensile strain/stress tore up the liquid film formed by the low-melting point preexisting phases in the primary HAZ, such as γ/γ′ eutectics and coarse γ′ precipitates. The incoherent carbide particles were frequently observed near the crack root as local strain concentrators. In the cladding layers, micro-segregation could not be completely avoided, thus the hot crack continued to propagate over several layers with the assistance of the transverse tensile stress. Our investigations provide a useful guideline for the optimization of the 3D printing process to repair Ni-based superalloys with high susceptibility to hot cracking.

We present a framework (TIT-4-TAT) that enables the study of manufacturing strategies by coupling a technoeconomic model with tariff and transportation algorithms to optimize supply chain layouts for PV manufacturing. We use this framework in a scenario where Mexico, China, USA, and Brazil interact under two tariffs scenarios. The optimal manufacturing locations due to tariff levels variations are highlighted through this approach.

China's energy consumption in the building sector (BEC) is not counted as a separate type of energy consumption, but divided and mixed in other sectors in China's statistical system. This led to the lack of historical data on China's BEC. Moreover, previous researches' shortages such as unsystematic research on BEC, various estimation methods with complex calculation process, and difficulties in data acquisition resulted in “heterogeneous” of current BEC in China. Aiming to these deficiencies, this study proposes a set of China building energy consumption calculation method (CBECM) by splitting out the building related energy consumption mixed in other sectors in the composition of China Statistical Yearbook-Energy Balance Sheet. Then, China's BEC from 2000 to 2014 are estimated using CBECM and compared with other studies. Results show that, from 2000 to 2014, China's BEC increased 1.7 times, rising from 301 to 814 million tons of standard coal consumed, with the BEC percentage of total energy consumption stayed relatively stable between 17.7% and 20.3%. By comparison, we find that our results are reliable and the CBECM has the following advantages over other methods: data source is authoritative, calculation process is concise, and it is easy to obtain time series data on BEC etc. The CBECM is particularly suitable for the provincial government to calculate the local BEC, even in the circumstance with statistical yearbook available only.

China's energy consumption in the building sector (BEC) is not counted as a separate type of energy consumption, but divided and mixed in other sectors in China's statistical system. This led to the lack of historical data on China's BEC. Moreover, previous researches' shortages such as unsystematic research on BEC, various estimation methods with complex calculation process, and difficulties in data acquisition resulted in “heterogeneous” of current BEC in China. Aiming to these deficiencies, this study proposes a set of China building energy consumption calculation method (CBECM) by splitting out the building related energy consumption mixed in other sectors in the composition of China Statistical Yearbook-Energy Balance Sheet. Then, China's BEC from 2000 to 2014 are estimated using CBECM and compared with other studies. Results show that, from 2000 to 2014, China's BEC increased 1.7 times, rising from 301 to 814 million tons of standard coal consumed, with the BEC percentage of total energy consumption stayed relatively stable between 17.7% and 20.3%. By comparison, we find that our results are reliable and the CBECM has the following advantages over other methods: data source is authoritative, calculation process is concise, and it is easy to obtain time series data on BEC etc. The CBECM is particularly suitable for the provincial government to calculate the local BEC, even in the circumstance with statistical yearbook available only.

Reducing food waste has many positive environmental and socio-economic ramifications. Even though many programs exist to reduce the amount of food waste, the attitudes and the behaviors driving food waste as well as the strategies to reduce it remain poorly understood. In this paper, we investigate how restaurateurs in Berkeley, California, USA perceive food waste given current financial incentives and policies. We found that 65% of the restaurants are measuring amounts of food waste and more than three-quarters of them (84%) use compost bins to dispose inedible food waste. Our survey results also show that the most common method employed to dispose of food waste (72%) was giving edible leftovers to restaurant's employees. However, three-quarters of restaurants avoided food donation because of unfounded fear of the legal liability. Finally, 14% of surveyed restaurants dumped their food waste into landfill bins. We suggest that further studies explore ways to target specific attitudes and behavioral changes, but also to quantify the impact of these changes.

Additive manufacturing, or 3D printing, has become significantly more commonplace in tissue engineering over the past decade, as a variety of new printing materials have been developed. In extrusion-based printing, materials are used for applications that range from cell free printing to cell-laden bioinks that mimic natural tissues. Beyond single tissue applications, multi-material extrusion based printing has recently been developed to manufacture scaffolds that mimic tissue interfaces. Despite these advances, some material limitations prevent wider adoption of the extrusion-based 3D printers currently available. This progress report provides an overview of this commonly used printing strategy, as well as insight into how this technique can be improved. As such, it is hoped that the prospective report guides the inclusion of more rigorous material characterization prior to printing, thereby facilitating cross-platform utilization and reproducibility.

Selective laser sintering (SLS) is an efficient process in additive manufacturing that enables rapid part production from computer-based designs. However, SLS is limited by its notable lack of in-situ process monitoring when compared to other manufacturing processes. We report the incorporation of optical coherence tomography into an SLS system in detail and demonstrate access to surface and sub-surface features. Video frame rate cross-sectional imaging reveals areas of sintering uniformity and areas of excessive heat error with high temporal resolution. We propose a set of image processing techniques for SLS process monitoring with OCT and report the limitations and obstacles for further OCT integration with SLS systems.

Reducing food waste has many positive environmental and socio-economic ramifications. Even though many programs exist to reduce the amount of food waste, the attitudes and the behaviors driving food waste as well as the strategies to reduce it remain poorly understood. In this paper, we investigate how restaurateurs in Berkeley, California, USA perceive food waste given current financial incentives and policies. We found that 65% of the restaurants are measuring amounts of food waste and more than three-quarters of them (84%) use compost bins to dispose inedible food waste. Our survey results also show that the most common method employed to dispose of food waste (72%) was giving edible leftovers to restaurant's employees. However, three-quarters of restaurants avoided food donation because of unfounded fear of the legal liability. Finally, 14% of surveyed restaurants dumped their food waste into landfill bins. We suggest that further studies explore ways to target specific attitudes and behavioral changes, but also to quantify the impact of these changes.

This paper reports an approach for co-fabrication of silicon-on-insulator (SOI) sensors with low-resistance vertical electrical interconnects in thick (up to 600μm ) wafers. The thru-wafer interconnects double-sided (TWIDS) process is based on bottom-up seedless copper electroplating, and allows for voids-free features and high aspect ratio (wafer thickness to copper diameter ratio of 10:1). This work describes the design trade-offs, process flow, and characterization of interconnects. TWIDS technology is compatible with a standard SOI micro-electro-mechanical systems (MEMS) fabrication process and is applicable for micro sensors, such as accelerometers, gyroscopes, resonators, and RF MEMS devices, as well as for the 3-D MEMS assemblies. As a demonstration of potential applications, miniature toroidal ring gyroscopes were fabricated using the TWIDS process. The experimental characterization showed that the low-resistance interconnects with low parasitic losses are suitable for integration with capacitive-detection sensors. In addition, the mechanical stability of the interconnects is discussed in this paper, and a method to enhance structural rigidity by means of filling the insulating gaps with Parylene C is demonstrated. [2017-0179]

Residential building heating plays a critical role in building energy conservation in China as it consumes a large proportion of the total primary energy use. Heating energy consumption in China is much larger than that in leading countries. This study investigated the energy saving potential from the building envelope design and actual operation optimization. Results showed that the heating energy consumption target specified in latest forth-step energy efficiency standard in Tianjin still leads to 30.9% higher energy consumption than German building energy efficiency standard EnEv'2009 and 49.7% higher than Passivhaus standard used in Germany. Via field measurement and questionnaire survey during operation, major findings are: (1) high indoor air temperature and window opening for ventilation are accountable for the high heating energy consumption during the operation; (2) radiator heating consumes less energy than radiant floor heating system; (3) temperature-type thermostatic valve and compartment automatic control mode have the best control performance; (4) ventilation device with purifying air unit helps to improve the indoor air quality in the terrible haze weather and to reduce the window opening demand of occupants; (5) heat metering and occupants' energy saving awareness should be encouraged.

Residential building heating plays a critical role in building energy conservation in China as it consumes a large proportion of the total primary energy use. Heating energy consumption in China is much larger than that in leading countries. This study investigated the energy saving potential from the building envelope design and actual operation optimization. Results showed that the heating energy consumption target specified in latest forth-step energy efficiency standard in Tianjin still leads to 30.9% higher energy consumption than German building energy efficiency standard EnEv'2009 and 49.7% higher than Passivhaus standard used in Germany. Via field measurement and questionnaire survey during operation, major findings are: (1) high indoor air temperature and window opening for ventilation are accountable for the high heating energy consumption during the operation; (2) radiator heating consumes less energy than radiant floor heating system; (3) temperature-type thermostatic valve and compartment automatic control mode have the best control performance; (4) ventilation device with purifying air unit helps to improve the indoor air quality in the terrible haze weather and to reduce the window opening demand of occupants; (5) heat metering and occupants' energy saving awareness should be encouraged.

The increasing global demand for natural rubber (100% increase in the last 15 years) is for most part met by Malaysia and Indonesia, and – to a lesser extent – other countries in South-East Asia and Africa. The consequent expansion of rubber plantation has often occurred at the expenses of agricultural land for staple crops, particularly in South-East Asia, where 90% of the land suitable for agriculture is already under cultivation. Here we investigate the extent to which the ongoing increase in rubber production is competing with the food system and affecting the livelihoods of rural communities living in the production areas and their appropriation of natural resources, such as water. We also investigate to what extent the expansion of rubber plantations is taking place through large scale land acquisitions (LSLAs) and evaluate the impacts on rural communities. Our results show how rubber production needs more than 10 million ha of fertile land and up to 136–149 × 109 m3 y−1 of freshwater (125 × 109 m3 y−1 of green water and 11–24 × 109 m3 y−1 of blue water). These resources would be sufficient to produce enough food to significantly reduce malnourishment in Indonesia, Thailand, and Vietnam if replaced by rice production. Overall, natural rubber production has important environmental, social, and economic impacts. Indeed, despite their ability to bring employment and increase the average income of economically disadvantaged areas, rubber plantations may threaten the local water and food security and induce a loss of rural livelihoods – particularly when the new plantations result from LSLAs that displace semi-subsistence forms of production – thereby forcing the local populations to depend on global food markets.

The development of fully coherent free electron lasers and diffraction limited storage ring x-ray sources has brought to focus the need for higher performing x-ray optics with unprecedented tolerances for surface slope and height errors and roughness. For example, the proposed beamlines for the future upgraded Advance Light Source, ALS-U, require optical elements characterized by a residual slope error of

The increasing global demand for natural rubber (100% increase in the last 15 years) is for most part met by Malaysia and Indonesia, and – to a lesser extent – other countries in South-East Asia and Africa. The consequent expansion of rubber plantation has often occurred at the expenses of agricultural land for staple crops, particularly in South-East Asia, where 90% of the land suitable for agriculture is already under cultivation. Here we investigate the extent to which the ongoing increase in rubber production is competing with the food system and affecting the livelihoods of rural communities living in the production areas and their appropriation of natural resources, such as water. We also investigate to what extent the expansion of rubber plantations is taking place through large scale land acquisitions (LSLAs) and evaluate the impacts on rural communities. Our results show how rubber production needs more than 10 million ha of fertile land and up to 136–149 × 109 m3 y−1 of freshwater (125 × 109 m3 y−1 of green water and 11–24 × 109 m3 y−1 of blue water). These resources would be sufficient to produce enough food to significantly reduce malnourishment in Indonesia, Thailand, and Vietnam if replaced by rice production. Overall, natural rubber production has important environmental, social, and economic impacts. Indeed, despite their ability to bring employment and increase the average income of economically disadvantaged areas, rubber plantations may threaten the local water and food security and induce a loss of rural livelihoods – particularly when the new plantations result from LSLAs that displace semi-subsistence forms of production – thereby forcing the local populations to depend on global food markets.

Wetting has been studied in various fields: chemical industry, automobile manufacturing, food companies, and even life sciences. In these studies, super-hydrophobic surfaces have been achieved through complex steps and processes. To realize super-hydrophobicity, however, we demonstrated a simple and single pass laser process for the fabrication of micro/nano hierarchical structures on the flexible polytetrafluoroethylene (PTFE, Teflon) surface. The fabricated hierarchical structures helped increase the hydrophobicity by augmenting the surface roughness and promoting air-trapping. In addition, we employed a low-cost and high-throughput replication process producing numerous polydimethylsiloxane (PDMS) replicas from the laser-processed PTFE film. Thanks to the anti-adhesive characteristics of PTFE and the elasticity of PDMS, the structure perfectly transferred to the replica without any mechanical failure. Moreover, our designed mesh patterns offered the possibility of large area applications through varying the process parameters (pitch, beam spot size, laser fluence, and scan speed). Even though mesh patterns had relatively large pitch (190 μm), we were able to achieve high contact angle (>150°). Through pneumatically deformed structure, we clearly showed that the shape of the droplets on our laser-processed super-hydrophobic surface was spherical. Based on these outcomes, we can expect our single laser pulse exposure process can overcome many drawbacks and offer opportunities for advancing applications of the wetting phenomena.

Architected materials can achieve impressive shape-changing capabilities according to how their microarchitecture is engineered. Here we introduce an approach for dramatically advancing such capabilities by utilizing wrapped flexure straps to guide the rolling motions of tightly packed micro-cams that constitute the material's microarchitecture. This approach enables high shape-morphing versatility and extreme ranges of deformation without accruing appreciable increases in strain energy or internal stress. Two-dimensional and three-dimensional macroscale prototypes are demonstrated, and the analytical theory necessary to design the proposed materials is provided and packaged as a software tool. An approach that combines two-photon stereolithography and scanning holographic optical tweezers is demonstrated to enable the fabrication of the proposed materials at their intended microscale.

Combination therapies mediate drug synergy to improve treatment efficacy and convenience, leading to higher levels of compliance. However, there are challenges with their manufacturing as well as reduced flexibility in dosing options. This study reports on the design and characterization of a polypill fabricated through the combination of material jetting and binder jetting for the treatment of hypertension. The drugs lisinopril and spironolactone were loaded into hydrophilic hyaluronic acid and hydrophobic poly(ethylene glycol) (PEG) photocurable bioinks, respectively, and dispensed through a piezoelectric nozzle onto a blank preform tablet composed of two attachable compartments fabricated via binder jetting 3D printing. The bioinks were photopolymerized and their mechanical properties were assessed via Instron testing. Scanning electron microscopy (SEM) was performed to indicate morphological analysis. The polypill was ensembled and drug release analysis was performed. Droplet formation of bioinks loaded with hydrophilic and hydrophobic active pharmaceutical ingredients (APIs) was achieved and subsequently polymerized after a controlled dosage was dispensed onto preform tablet compartments. High-performance liquid chromatography (HPLC) analysis showed sustained release profiles for each of the loaded compounds. This study confirms the potential of material jetting in conjunction with binder jetting techniques (powder-bed 3D printing), for the production of combination therapy oral dosage forms involving both hydrophilic and hydrophobic drugs.

This study sought to characterize aluminum nanocomposite wires that were fabricated through a cold-rolling process, having potential applications in TIG (tungsten inert gas) welding of aluminum. A206 (Al-4.5Cu-0.25Mg) master nanocomposites with 5 wt % γAl₂O₃ nanoparticles were first manufactured through a hybrid process combining semi-solid mixing and ultrasonic processing. A206/1 wt % γAl₂O₃ nanocomposites were fabricated by diluting the prepared master nanocomposites with a monolithic A206 alloy, which was then added to a pure aluminum melt. The fabricated Al-γAl₂O₃ nanocomposite billet was cold-rolled to produce an Al nanocomposite wire with a 1 mm diameter and a transverse area reduction of 96%. Containing different levels of nanocomposites, the fabricated samples were mechanically and electrically characterized. The results demonstrate a significantly higher strength of the aluminum wires with the nanocomposite addition. Further, the addition of alumina nanoparticles affected the wires' electrical conductivity compared with that of pure aluminum and aluminum-copper alloys. The overall properties of the new material demonstrate that these wires could be an appealing alternative for fillers intended for aluminum welding.

Two limitations of additive manufacturing methods that arise from layer-based fabrication are slow speed and geometric constraints (which include poor surface quality). Both limitations are overcome in the work reported here, introducing a new volumetric additive fabrication paradigm that produces photopolymer structures with complex nonperiodic three-dimensional geometries on a time scale of seconds. We implement this approach using holographic patterning of light fields, demonstrate the fabrication of a variety of structures, and study the properties of the light patterns and photosensitive resins required for this fabrication approach. The results indicate that low-absorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10 to 100 mW), may be successfully used to build full structures in ~1 to 10 s.

A Fresnel zoneplate is a diffractive optical element consisting of concentric rings (zones) for which the transmitted light produces a focal spot that is used in all wavelength regimes, including X-rays. The pattern of transmission openings determines the location of the spot and the sub-half wavelength size of the openings can adjust the intensity. Today, very general transmission zoneplate patterns are used for many special imaging and image compensation purposes. Manufacturing zoneplates require a zoneplate pattern file, which precisely describes the size, shape, and contour of the rings based on the desired optical properties of the lens. Generating such a pattern requires the delicate balance of achieving the required optical performance while maintaining manageable file sizes and computation times. Here we describe a new algorithm meeting these needs. By precisely controlling the number of shapes in each zone, the algorithm simultaneously optimizes the desired optical tolerances with the pattern file size.

Cold expansion (CX) is a material processing technique that has been widely used in the aircraft industry to enhance fatigue life of structural components containing holes. CX introduces compressive hoop residual stresses that slow crack growth near the hole edge. The objective of this paper is to predict residual stresses arising from cold expansion using two different finite element (FE) approaches, and compare the results to measurement data obtained by the contour method. The paper considers single-hole, double-hole, and triple-hole configurations with three different edge margins. The first FE approach considers process modeling, and includes elastic-plastic behavior, while the second approach is based on the eigenstrain method, and includes only elastic behavior. The results obtained from the FE models are in good agreement with one another, and with measurement data, especially close to the holes, and with respect to the effect of edge margin on the residual stress distributions. The distribution of the residual stress and equivalent plastic strain around the holes is also explored, and the results are discussed in detail. The eigenstrain method was found to be very useful, providing generally accurate predictions of residual stress.

This paper presents a miniature 50 mm3 inertial measurement unit (IMU) implemented using a folded microelectromechanical systems (MEMS) process. The approach is based on wafer-level fabrication of high aspect-ratio single-axis sensors interconnected by flexible hinges and folded into a 3-D configuration, like a silicon Origami [1]. Two different materials for flexible hinges have been explored, including photo-definable polyimide and parylene-C. We report, for the first time, an IMU prototype with seven operational sensors: three accelerometers, three gyroscopes, and a prototype of a reference clock. This paper concludes with the results of experimental characterization of inertial sensors demonstrating the feasibility of the proposed approach for a compact IMU.

This paper presents new techniques to analyze and understand the sensorimotor characteristics of manual operations such as grinding, and links their influence on process performance. A grinding task, though simple, requires the practitioner to combine elements from the large repertoire of his or her skillset. Based on the joint gaze, force, and velocity data collected from a series of manual grinding experiments, we have compared operators with different levels of experience and quantitatively described characteristics of human manual skill and their effects on manufacturing process parameters such as cutting energy, surface finish, and material removal rate (MRR). For instance, we find that an experienced subject performs the task in a precise manner by moving the tool in complex paths, with lower applied forces and velocities, and short fixations compared to a novice. A detailed understanding of gaze-motor behavior broadens our knowledge of how a manual task is executed. Our results help to provide this extra insight, and impact future efforts in workforce training as well as the digitalization of manual expertise, thereby facilitating the transformation of raw data into product-specific knowledge.

The development of deterministic polishing techniques has given rise to vendors that manufacture high quality threedimensional x-ray optics. The surface metrology on these optics remains a difficult task. For the fabrication, vendors usually use unique surface metrology tools, generally developed on site, that are not available in the optical metrology labs at x-ray facilities. At the Advanced Light Source X-Ray Optics Laboratory, we have developed a rather straightforward interferometric-microscopy-based procedure capable of sub microradian characterization of sagittal slope variation of x-ray optics for two-dimensionally focusing and collimating (such as ellipsoids, paraboloids, etc.). In the paper, we provide the mathematical foundation of the procedure and describe the related instrument calibration. We also present analytical expression describing the ideal surface shape in the sagittal direction of a spheroid specified by the conjugate parameters of the optic's beamline application. The expression is useful when analyzing data obtained with such optics. The high efficiency of the developed measurement and data analysis procedures is demonstrated in results of measurements with a number of x-ray optics with sagittal radius of curvature between 56 mm and 480 mm. We also discuss potential areas of further improvement.

The research and development work on the Advanced Light Source (ALS) upgrade to a diffraction limited storage ring light source, ALS-U, has brought to focus the need for near-perfect x-ray optics, capable of delivering light to experiments without significant degradation of brightness and coherence. The desired surface quality is characterized with residual (after subtraction of an ideal shape) surface slope and height errors of

The evaluation of multi-scale surface roughness parameters (SRPs) is important to solve many engineering problems (e.g. contact stress, sealing, friction) and is closely related to further fundamental problems (e.g. microbial contamination). Traditionally, surface roughness has been used as a standard for indicating process performance, such as tool wear, tool vibration etc. This paper also aims to find appropriate surface roughness parameters (SRPs) that can be used as process monitoring indices. Grade 304 stainless steel surfaces, generated by extrusion and grinding processes, were used in this study. The evaluation of different SRPs and their topography properties (such as fractal dimension) is discussed for extruded and ground surfaces. One problem with existing surface metrology is the availability of a multitude of disconnected roughness parameters. A statistical approach is presented in this paper that allows the most appropriate roughness parameters to monitor whether the intended surface quality converges to be found.

Osseointegrated implants transfer loads from native bone to a synthetic joint and can also function transdermally to provide a stable connection between the skeleton and the prostheses, eliminating many problems associated with socket prostheses. Additive manufacturing provides a cost-effective means to create patient-specific implants and allows for customized textures for integration with bone and other tissues. Our objective was to compare the osseointegration strength of two primary additive manufacturing methods of producing textured implants: electron beam melting (EBM) (mean Ra = 23 μm) and direct metal laser sintering (DMLS) (mean Ra = 10 μm). Due to spatial resolution, DMLS can produce surfaces with a roughness comparable to EBM. Two cohorts of Sprague-Dawley rats received bilateral, titanium implants in their distal femurs and were followed for 4 weeks. The first-cohort animals received EBM implants transcortically in one femur and a DMLS implant in the contralateral femur. The second cohort received DMLS implants (either fine textured or coarse textured to mimic EBM) in the intramedullary canal of each femur. Osseointegration was evaluated through mechanical testing and micro-computed tomography (bone volume fraction [BV/TV] and bone-implant contact [BIC]). The fixation strength of coarse textured implants provided superior interlocking relative to fine textured implants without affecting BV/TV or BIC in both cohorts. Coarse EBM implants in a transcortical model demonstrated an 85% increase in removal torque relative to the fine DMLS textured implants. The thrust load in the intramedullary model saw a 35% increase from fine to coarse DMLS implants.

The evaluation of multi-scale surface roughness parameters (SRPs) is important to solve many engineering problems (e.g. contact stress, sealing, friction) and is closely related to further fundamental problems (e.g. microbial contamination). Traditionally, surface roughness has been used as a standard for indicating process performance, such as tool wear, tool vibration etc. This paper also aims to find appropriate surface roughness parameters (SRPs) that can be used as process monitoring indices. Grade 304 stainless steel surfaces, generated by extrusion and grinding processes, were used in this study. The evaluation of different SRPs and their topography properties (such as fractal dimension) is discussed for extruded and ground surfaces. One problem with existing surface metrology is the availability of a multitude of disconnected roughness parameters. A statistical approach is presented in this paper that allows the most appropriate roughness parameters to monitor whether the intended surface quality converges to be found.

This paper describes a mechanism design methodology that draws plane curves which have finite Fourier series parameterizations, known as trigonometric curves. We present three ways to use the coefficients of this parameterization to construct a mechanical system that draws the curve. One uses Scotch yoke mechanisms for each of the terms in the coordinate trigonometric functions, which are then added using a belt or cable drive. The second approach uses two-coupled serial chains obtained from the coordinate trigonometric functions. The third approach combines the coordinate trigonometric functions to define a single-coupled serial chain that draws the plane curve. This work is a version of Kempe's universality theorem that demonstrates that every plane trigonometric curve has a linkage which draws the curve. Several examples illustrate the method including the use of boundary points and the discrete Fourier transform to define the trigonometric curve.

Technology learning rates can be dynamic quantities as a technology moves from early development to piloting and from low volume manufacturing to high volume manufacturing. This work describes a generalizable technology analysis approach for disaggregating observed technology cost reductions and presents results of this approach for one specific case study (micro-combined heat and power fuel cell systems in Japan). We build upon earlier reports that combine discussion of fuel cell experience curves and qualitative discussion of cost components by providing greater detail on the contributing mechanisms to observed cost reductions, which were not quantified in earlier reports. Greater standardization is added to the analysis approach, which can be applied to other technologies. This paper thus provides a key linkage that has been missing from earlier literature on energy-related technologies by integrating the output of earlier manufacturing cost studies with observed learning rates to quantitatively estimate the different components of cost reduction including economies of scale and cost reductions due to product performance and product design improvements. This work also provides updated fuel cell technology price versus volume trends from the California Self-Generation Incentive Program, including extensive data for solid-oxide fuel cells (SOFC) reported here for the first time. The Japanese micro-CHP market is found to have a learning rate of 18% from 2005 to 2015, while larger SOFC fuel cell systems (200 kW and above) in the California market are found to have a flat (near-zero) learning rate, and these are attributed to a combination of exogenous, market, and policy factors.

The ITER toroidal field (TF) strand procurement initiated the largest Nb3Sn superconducting strand production hitherto. The industrial-scale production started in Japan in 2008 and finished in summer 2015. Six ITER partners (so-called Domestic Agencies, or DAs) are in charge of the procurement and involved eight different strand suppliers all over the world, of which four are using the bronze route (BR) process and four the internal-tin (IT) process. In total more than 500 tons have been produced including excess material covering losses during the conductor manufacturing process, in particular the cabling. The procurement is based on a functional specification where the main strand requirements like critical current, hysteresis losses, Cu ratio and residual resistance ratio are specified but not the strand production process or layout. This paper presents the analysis on the data acquired during the quality control (QC) process that was carried out to ensure the same conductor performance requirements are met by the different strand suppliers regardless of strand design. The strand QC is based on 100% billet testing and on applying statistical process control (SPC) limits. Throughout the production, samples adjacent to the strand pieces tested by the suppliers are cross-checked ('verified') by their respective DAs reference labs. The level of verification was lowered from 100% at the beginning of the procurement progressively to approximately 25% during the final phase of production. Based on the complete dataset of the TF strand production, an analysis of the SPC limits of the critical strand parameters is made and the related process capability indices are calculated. In view of the large-scale production and costs, key manufacturing parameters such as billet yield, number of breakages and piece-length distribution are also discussed. The results are compared among all the strand suppliers, focusing on the difference between BR and IT processes. Following the completion of the largest Nb3Sn strand production, our experience gained from monitoring the execution of the QC activities and from auditing the results from the measurements is summarised for future superconducting strand material procurement activities.

BackgroundMedical 3D printing is expanding exponentially, with tremendous potential yet to be realized in nearly all facets of medicine. Unfortunately, multiple informal subdomain-specific isolated terminological 'silos' where disparate terminology is used for similar concepts are also arising as rapidly. It is imperative to formalize the foundational terminology at this early stage to facilitate future knowledge integration, collaborative research, and appropriate reimbursement. The purpose of this work is to develop objective, literature-based consensus-building methodology for the medical 3D printing domain to support expert consensus.ResultsWe first quantitatively survey the temporal, conceptual, and geographic diversity of all existing published applications within medical 3D printing literature and establish the existence of self-isolating research clusters. We then demonstrate an automated objective methodology to aid in establishing a terminological consensus for the field based on objective analysis of the existing literature. The resultant analysis provides a rich overview of the 3D printing literature, including publication statistics and trends globally, chronologically, technologically, and within each major medical discipline. The proposed methodology is used to objectively establish the dominance of the term "3D printing" to represent a collection of technologies that produce physical models in the medical setting. We demonstrate that specific domains do not use this term in line with objective consensus and call for its universal adoption.ConclusionOur methodology can be applied to the entirety of medical 3D printing literature to obtain a complete, validated, and objective set of recommended and synonymous definitions to aid expert bodies in building ontological consensus.

The present study focuses on the comparative analysis of superparamagnetic iron oxide nanoparticles (SPIONs) characteristics with the TOPSIS method. The prediction of the characteristics of SPIONs is required for better manufacturing of these nanoparticles. Although the characteristics of these nanoparticles have been investigated, no research has been done on their comparison in order to determine which one of their surface functionalities would be more appropriate for their diverse applications. The objective of this study was to analyze the characteristics of SPIONs without or with surface charge with a prediction model and TOPSIS in order to determine the best nanoparticles. Moreover, the effect of inappropriate consideration of their cost criterion on their ranks was explored with the modified TOPSIS. This analysis showed that the characteristics of SPIONs such as antibiofilm activity, hemocompatibility, activity with hydrogen peroxide, rheological properties, and the labour of their chemical synthesis could affect their ranking. Neutral SPIONs, negatively charged SPIONs, and positively charged SPIONs were ranked as the first, second, and third candidates, respectively. However, the improvement of the activity of positively charged SPIONs with hydrogen peroxide showed an increase to 0.3 instead of 0.2, which resulted in a better rank of these nanoparticles in comparison with that of the same nanoparticles in the first analysis series. One of the advantages of this study was to determine the impact of the characteristics of SPIONs on their ranking for their manufacturing. The other advantage was getting the information for further comparative study of these nanoparticles with the others. The results of this work can be used in manufacturing engineering and materials science.