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Additive manufacturing (AM) is an advanced manufacturing method that produces objects by sequential layering. Material extrusion AM (MEAM) with continuous-fibre reinforcement is becoming more widely used in naval structures, which are exposed to the marine environment. However, the water diffusion process and the effect of water ageing on the mechanical performance of AM materials are not yet well understood because of their complex internal structure, caused by defects generated during manufacturing. Current research on diffusion is mostly based on experimental methods for conventionally manufactured materials without considering AM-induced defects. The objective of this study is to explore how the defects inherent to MEAM affect water diffusion in a composite material by the capillary effect. Results from a numerical study of capillary flow in MEAM polymer are applied as a boundary condition in the subsequent finite-element analysis. The study illustrates that flow in the capillary reaches the steady state quicker compared to the saturation time in the matrix, predicted by Fick’s diffusion equation. It is demonstrated that the capillary effect can significantly affect the water diffusion in MEAM parts and reduce the saturation time to one-third compared to the case without accounting for this effect.

Compacted graphite iron (CGI) is an engineering material with the potential to fill the application gap between flake- and spheroidal-graphite irons thanks to its unique microstructure and competitive price. Despite its wide use and considerable past research, its complex microstructure often leads researchers to focus on models based on representative volume elements with multiple particles, frequently overlooking the impact of individual particle shapes and interactions between the neighbouring particles on crack initiation and propagation. This study focuses on the effects of graphite morphology and spacing between inclusions on the mechanical and fracture behaviours of CGI at the microscale. In this work, 2D cohesive-zone-element-based models with different graphite morphologies and spacings were developed to investigate the mechanical behaviour as well as crack initiation and propagation. ImageJ and scanning electron microscopy were used to characterise and analyse the microstructure of CGI. In simulations, both graphite particles and metallic matrix were assumed isotropic and ductile. Cohesive zone elements (CZEs) were employed in the whole domain studied. It was found that graphite morphology had a negligible effect on interface debonding but nodular inclusions can notably enhance the stiffness of the material and effectively impede the propagation of cracks within the matrix. Besides, a small distance between graphite particles accelerates the crack growth. These results can be used to design and manufacture better metal-matrix composites.

Achieving a comfortable socket residual limb interface is crucial for effective prosthetic rehabilitation, depending on the precise characterisation and fluctuations in the shape and volume of residual limbs. Clinicians rely on subjective and iterative methods for shaping sockets, often involving a trial-and-error approach. This study introduces a framework for measuring, analysing, and comparing residual limb shape and volume using scanned data to facilitate more informed clinical decision-making. Surface scans of 44 transtibial residual limb casts of various sizes and lengths were examined. All scans were spatially aligned to a mid-patella and subjected to analysis using a shape analysis toolbox. Geometric measurements were extracted, with particular attention to significant rectified regions during the cast rectification process. Following PTB guidelines, our analysis revealed substantial alterations, primarily in the mid-patella region, followed by the patellar tendon area. Notably, there was a significant volume change of 6.02% in the region spanning from mid-patella to 25% of the cast length. Beyond this point, linear cast modifications were observed for most amputees up to 60% of the cast length, followed by individual-specific deviations beyond this region. Regardless of residual limb size and length, the modifications applied to positive casts suggested categorising patients into five major groups. This study employs the AmpScan shape analysis tool, to comprehend the cast rectification process used for capturing and assessing the extent of rectification on patients’ residual limb casts. The clinical implications of our research are threefold: (a) the comparison data can serve as training resources for junior prosthetists; (b) this will aid prosthetists in identifying specific regions for rectification and assessing socket fit; (c) it will help in determining optimal timing for prosthetic fitting or replacement.

This study investigates the effect of void features in additively manufactured polymers on water diffusion, focusing on polyethylene terephthalate glycol (PETG) composites. The additive manufacturing (AM) of polymers, specifically, material extrusion AM (MEAM), results in manufacturing-induced voids, therefore affecting the water resistance of the printed parts. The research analyses the effects of size, shape, orientation and the hydrophilicity of voids on moisture diffusion in PETG composites employing numerical (finite-element) simulations. Two void types were examined: voids of Type I that retard the moisture propagation and voids of Type II that enhance it. Simulations demonstrate that a higher volume fraction of voids and their orientation with regard to the diffusion direction significantly hinder the moisture transport for Type I voids. Conversely, due to their high diffusivity, Type II voids serve as channels for rapid moisture transmission. Consequently, for such materials, the global diffusion rates mainly depend on the volume fraction of voids rather than their shape. These findings indicate the critical role of voids in the design of AM parts for environments exposed to moisture, such as marine and offshore applications. Understanding the void effects is critical for optimising the durability and performance of MEAM components underwater exposure.

Thanks to the distinctive morphology of graphite particles in its microstructure, compacted graphite iron (CGI) exhibits excellent thermal conductivity together with high strength and durability. CGI is extensively used in many applications, e.g., engine cylinder heads and brakes. The structural integrity of such metal-matrix materials is controlled by the generation and growth of microcracks. Although the effects of the volume fraction and morphology of graphite inclusions on the tensile response of CGI were investigated in recent years, their influence on crack initiation is still unknown. Experimental studies of crack initiation require a considerable amount of time and resources due to the highly complicated geometries of graphite inclusions scattered throughout the metallic matrix. Therefore, developing a 2D computational framework for CGI with a random microstructure capable of predicting the crack initiation and path is desirable. In this work, an integrated numerical model is developed for the analysis of the effects of volume fraction and nodularity on the mechanical properties of CGI as well as its damage and failure behaviours. Finite-element models of random microstructure are generated using an in-house Python script. The determination of spacings between a graphite inclusion and its four adjacent particles is performed with a plugin, written in Java and implemented in ImageJ. To analyse the orientation effect of inclusions, a statistical analysis is implemented for representative elements in this research. Further, Johnson–Cook damage criteria are used to predict crack initiation in the developed models. The numerical simulations are validated with conventional tensile-test data. The created models can support the understanding of the fracture behaviour of CGI under mechanical load, and the proposed approach can be utilised to design metal-matrix composites with optimised mechanical properties and performance.

Sandwich structures made with fibre-reinforced plastics are commonly used in maritime vessels thanks to their high strength-to-weight ratios, corrosion resistance, and buoyancy. Understanding their mechanical performance after moisture uptake and the implications of moisture uptake for their structural integrity and safety within out-of-plane loading regimes is vital for material optimisation. The use of modern methods such as acoustic emission (AE) and machine learning (ML) could provide effective techniques for the assessment of mechanical behaviour and structural health monitoring. In this study, the AE features obtained from quasi-static indentation tests on sandwich structures made from E-glass fibre face sheets with polyvinyl chloride foam cores were employed. Time- and frequency-domain features were then used to capture the relevant information and patterns within the AE data. A k-means++ algorithm was utilized for clustering analysis, providing insights into the principal damage modes of the studied structures. Three ensemble learning algorithms were employed to develop a damage-prediction model for samples exposed and unexposed to seawater and were loaded with indenters of different geometries. The developed models effectively identified all damage modes for the various indenter geometries under different loading conditions with accuracy scores between 86.4 and 95.9%. This illustrates the significant potential of ML for the prediction of damage evolution in composite structures for marine applications.

Due to unique patient characteristics, prosthetic sockets cannot be included in a standardised testing protocol as the rest major parts of the prosthesis. This makes the mechanical assessment of the socket a difficult process, which still remains crucial, especially nowadays, when new manufacturing technologies, such as additive manufacturing, are gaining ground in the field. In this study, a prototype testing rig was developed according to BS EN ISO 10328 standard, able to recreate the loading conditions of the early stance of the amputee gait on a paediatric transfemoral socket. The load requirements suggested in the standard were recalculated for the case of a 14-year-old male user with their weight in the 98th percentile. A variety of above-knee prosthetic sockets were produced with PLA and carbon-fibre reinforced nylon, using a commercial 3D printer. The sockets were tested under compressive load employing a plaster limb manikin. Video image processing was used to accurately capture the load-displacement relation of the sockets.

Understanding the mechanical behaviour of additively manufactured (AM) biomedical polymeric devices under various loading regimes is important for tailoring their design to specific applications. This paper presents the results of an experimental study of compressive mechanical properties of AM cubic samples of biocompatible polylactic acid (PLA) manufactured with fused filament fabrication. The measured elastic modulus and ultimate compression strength were compared and analysed for varying testing parameters, such as strain rate and contact friction, for samples with different characteristic sizes. The changes in density of the samples were also assessed for evaluation of the extent of material compaction after deformation. Surface morphology of specimens was examined before and after compression tests using scanning electron and optical microscopy. Different types of defects induced by the manufacturing process and caused by the subsequent compressive deformation were studied and compared. The obtained results are useful for design and optimization of small-size biomedical devices, which require precise control of their structural morphology and mechanical behaviour.

Abstract Bone drilling is a universal procedure in orthopaedics for fracture fixation, installing implants, or reconstructive surgery. Surgical drills are subjected to wear caused by their repeated use, thermal fatigue, irrigation with saline solution, and sterilization process. Wear of the cutting edges of a drill bit (worn drill) is detrimental for bone tissues and can seriously affect its performance. The aim of this study is to move closer to minimally invasive surgical procedures in bones by investigating the effect of wear of surgical drill bits on their performance. The surface quality of the drill was found to influence the bone temperature, the axial force, the torque and the extent of biological damage around the drilling region. Worn drill produced heat above the threshold level related to thermal necrosis at a depth equal to the wall thickness of an adult human bone. Statistical analysis showed that a sharp drill bit, in combination with a medium drilling speed and drilling at shallow depth, was favourable for safe drilling in bone. This study also suggests the further research on establishing a relationship between surface integrity of a surgical drill bit and irreversible damage that it can induce in delicate tissues of bone using different drill sizes as well as drilling parameters and conditions.

This study is focused on the deformation behaviour of composites formed by auxetic lattice structures acting as a matrix based on the re-entrant unit-cell geometry with a soft filler, motivated by biomedical applications. Three-dimensional models of two types of the auxetic-lattice structures were manufactured using filament deposition modelling. Numerical finite-element models were developed for computational analysis of the effect of the filler with different mechanical properties on the effective Poisson’s ratio and mechanical behaviour of such composites. Tensile tests of 3D-printed auxetic samples were performed with strain measurements using digital image correlation. The use of the filler phase with various elastic moduli resulted in positive, negative, and close-to-zero effective Poisson’s ratios. Two approaches for numerical measurement of the Poisson’s ratio were used. The failure probability of the two-phase composites with auxetic structure depending on the filler stiffness was investigated by assessing statistical distributions of stresses in the finite-elements models.

Adaptation is the process by which bone responds to changes in loading environment and modulates its properties and spatial organization to meet the mechanical demands. Adaptation in trabecular bone is achieved through increase in bone mass and alignment of trabecular-bone morphology along the loading direction. This transformation of internal microstructure is governed by mechanical stimuli sensed by mechanosensory cells in the bone matrix. Realisation of adaptation in the form of local bone-resorption and -formation activities as a function of mechanical stimuli is still debated. In silico modelling is a useful tool for simulation of various scenarios that cannot be investigated in vivo and particularly well suited for prediction of trabecular bone adaptation. This progress report presents the recent advances in in silico modelling of mechanoregulated adaptation at the scale of trabecular bone tissue. Four well-established bone-adaptation models are reviewed in terms of their recent improvements and validation. They consider various mechanical factors: (i) strain energy density, (ii) strain and damage, (iii) stress nonuniformity and (iv) daily stress. Contradictions of these models are discussed and their ability to describe adequately a real-life mechanoregulation process in bone is compared.

The use of fibre-reinforced plastics (FRPs) in various industrial applications continues to increase thanks to their good strength-to-weight ratio and impact resistance, as well as the high strength that provides engineers with advanced options for the design of modern structures subjected to a variety of out-of-plane impacts. An assessment of the damage morphology under such conditions using non-destructive techniques could provide useful data for material design and optimisation. This study investigated the damage mechanism and energy-absorption characteristics of E-glass laminates and sandwich structures with GFRP face sheets with PVC cores under quasi-static indentation with conical, square, and hemispherical indenters. An acoustic emission (AE) technique, coupled with a k-means++ pattern-recognition algorithm, was employed to identify the dominant microscopic and macroscopic damage mechanisms. Additionally, a post-mortem damage assessment was performed with X-ray micro computed tomography and scanning electron microscopy to validate the identified clusters. It was found that the specific energy absorption after impact with the square and hemispherical indenters of the GFRP sandwich and the plain laminate differed significantly, by 19.29% and 43.33%, respectively, while a minimal difference of 3.5% was recorded for the conical indenter. Additionally, the results obtained with the clustering technique applied to the acoustic emission signals detected the main damaged modes, such as matrix cracking, fibre/matrix debonding, delamination, the debonding of face sheets/core, and core failure. The results therefore could provide a methodology for the optimisation and prediction of damage for the health monitoring of composites.

A prosthesis is loaded by forces and torques exerted by its wearer, the amputee, and should withstand instances of peak loads without failure. Traditionally, strong prosthetic sockets were made using a composite with a variety of reinforcing fibres, such as glass, carbon, and Kevlar. Amputees in less-resourced nations can lack access to composite prosthetic sockets due to their unavailability or prohibitive cost. Therefore, this study investigates the feasibility of polyethylene terephthalate (PET) fibre-reinforced composites as a low-cost sustainable composite for producing functional lower-limb prosthetic sockets. Two types of these composites were manufactured using woven and knitted fabric with a vacuum-assisted resin transfer moulding (VARTM) process. For direct comparison purposes, traditional prosthetic-socket materials were also manufactured from laminated composite (glass-fibre-reinforced (GFRP)), monolithic thermoplastic (polypropylene (PP) and high-density polyethylene (HDPE)) were also manufactured. Dog-bone-shaped specimens were cut from flat laminates and monolithic thermoplastic to evaluate their mechanical properties following ASTM standards. The mechanical properties of PET-woven and PET-knitted composites were found to have demonstrated to be considerably superior to those of traditional socket materials, such as PP and HDPE. All the materials were also tested in the socket form using a bespoke test rig reproducing forefoot loading according to the ISO standard 10328. The static structural test of sockets revealed that all met the target load-bearing capacity of 125 kg. Like GFRP, the PETW and PETK sockets demonstrated higher deformation and stiffness resistance than their monolithic counterparts made from PP and HDPE. As a result, it was concluded that the PET-based composite could replace monolithic socket materials in producing durable and affordable prostheses.

Compacted graphite iron (CGI) has gained significant attention in automotive industry applications thanks to its superior thermomechanical properties and competitive price. Its main fracture mechanism at the microscale—interfacial damage and debonding between graphite inclusions and a metallic matrix—can happen under high-temperature service conditions as a result of a mismatch in the coefficients of thermal expansion between the two phases of CGI. Macroscopic fracture in cast iron components can be initiated by interfacial damage at the microscale under thermomechanical load. This phenomenon was investigated in various composites but still lacks information for CGI, with its complex morphology of graphite inclusions. This research focuses on the effect of this morphology on the thermomechanical performance of CGI under high temperatures. A set of three-dimensional finite-element models was created, with a unit cell containing a single graphite inclusion embedded in a cubic domain of the metallic matrix. Elastoplastic behaviour was assumed for both phases in numerical simulations. The effect of graphite morphology on the thermomechanical performance of CGI was investigated for pure thermal loading, focusing on a high-temperature response of its constituents. The results can provide a deeper understanding of the correlation between graphite morphology and CGI fracture mechanisms under high temperatures.

The nonlinear interaction of longitudinal vibration and ultrasound in beams with cracks is investigated. The central focus is on the localization effect of this interaction, i.e., the locally enhanced nonlinear vibro-acoustic modulation. Both numerical and experimental investigations are undertaken. The finite element (FE) method is used to investigate different crack models, including the bi-linear crack, open crack, and breathing crack. A parametric study is performed considering different crack depths, locations, and boundary conditions in a two-dimensional beam model. The study shows that observed nonlinearities (i.e., nonlinear crack–wave modulations) are particularly strong in the vicinity of the crack, allowing not only for crack localization but also for the separation of the crack-induced nonlinearity from other sources of nonlinearity.

The analysis of fibrous structures using micro-computer tomography (µCT) is becoming more important as it provides an opportunity to characterise the mechanical properties and performance of materials. This study is the first attempt to provide computations of fibre crimp for various random fibrous networks (RFNs) based on µCT data. A parametric algorithm was developed to compute fibre crimp in fibres in a virtual domain. It was successfully tested for six different X-ray µCT models of nonwoven fabrics. Computations showed that nonwoven fabrics with crimped fibres exhibited higher crimp levels than those with non-crimped fibres, as expected. However, with the increased fabric density of the non-crimped nonwovens, fibres tended to be more crimped. Additionally, the projected fibre crimp was computed for all three major 2D planes, and the obtained results were statistically analysed. Initially, the algorithm was tested for a small-size, nonwoven model containing only four fibres. The fraction of nearly straight fibres was computed for both crimped and non-crimped fabrics. The mean value of the fibre crimp demonstrated that fibre segments between intersections were almost straight. However, it was observed that there were no perfectly straight fibres in the analysed RFNs. This study is applicable to approach employing a finite-element analysis (FEA) and computational fluid dynamics (CFD) to model/analyse RFNs.

This work presents the results of an experimental investigation of the mechanical properties of polyetheretherketone (PEEK) specimens additively manufactured (AM) by using fused filament fabrication with different printing parameters and subjected to postprocessing heat treatment. Standard and compact tension samples were manufactured with a different infill angle using 0.4 mm and 0.6 mm nozzle diameters. Some of the samples were subjected to heat treatment at 220 °C after manufacturing. Tensile tests were conducted to determine the values of elastic modulus, tensile strength, as well as mode-I fracture toughness and critical strain energy release rate. Tensile properties of single-thread and as-delivered filaments were also studied. It was concluded that heat treatment significantly improved the elastic properties, tensile strength and fracture toughness of the AM PEEK samples: the fracture resistance increased by 33 to 45% depending on the stacking order, while the tensile strength increased by some 45–65%, with the elasticity modulus grown by up to 20%. Strain fields induced in specimens by crack propagation were captured with a digital image correlation technique and compared with results of numerical simulations implemented with the extended finite-element method (XFEM). Conclusions on the optimal parameters of 3D printing of PEEK were made.

This study describes the internal structure of materials used to produce medical stents. A two-level elastoviscoplastic mathematical model, which sets the parameters and describes the processes at the grain level, was developed and numerically implemented. A separate study was conducted to identify the most dangerous deformation modes in the balloon-expandable stent placement using the finite-element method in COMSOL Multiphysics. As a result, the challenging strain state type required for setting the kinematic loading on a representative macrovolume in the two-level model was obtained. A yield surface for different deformation paths in the principal deformation space for stainless steel AISI 316L was obtained and the effect of grain size on the deformation behavior of this material was explored using the developed model.

Samples in the form of cylindrical plates, additively manufactured using the fused deposition modelling (or filament freeform fabrication, FDM/FFF) technology from polylactide (PLA), polyethylene terephthalate glycol (PETG) and polyetheretherketone (PEEK), were studied in series of in-vitro experiments on the adhesion of rat bone-marrow cells and rat peritoneal cells. Methods of estimation of the absolute number of cells and polymer samples’ mass change were used for the evaluation of cells adhesion, followed by the evaluation of cell-culture supernatants. The results of experiments for both types of cells demonstrated a statistically significant change in the absolute number of cells (variation from 44 to 119%) and the weight of the polymer samples (variation from 0.61 to 2.18%), depending on roughness of sample surface, controlled by a nozzle diameter of a 3D printer as well as printing layer height. It was found that more cells adhere to PLA samples with a larger nozzle diameter and layer height. For PETG samples, the results did not show a clear relationship between cell adhesion and printing parameters. For PEEK samples, on the contrary, adhesion to samples printed with a lower nozzle diameter (higher resolution) is better than to samples printed with a larger nozzle diameter (lower resolution). The difference in results for various polymers can be explained by their chemical structure.

The dynamic mode-II energy release rate (ERR) of the end-loaded split (ELS) test with applied time-dependent displacement is derived for the first time with the effect of vibration included. Dynamic Euler-Bernoulli beams are used together with a deflection condition to simulate contact. To understand the dynamic effect and the relative dynamic contribution from each vibration mode, a ‘dynamic factor’ and a ‘spatial factor’ are defined. It is found that the contribution of the ith vibration mode is dependent on the spatial factor, which is a function of the delamination length and the total length of the ELS specimen. Certain vibration modes are dominant dependent on the spatial factor. In addition, for a given spatial factor, there may be a certain vibration mode, which makes approximately zero contribution to the ERR. The developed theory is verified against results from finite-element method (FEM) simulations and it is in excellent agreement. This work now allows the loading rate-dependent mode-II delamination toughness of materials to be determined by using ELS tests. In addition, it provides understanding of the structural dynamic response in the presence of mode-II delamination and can guide the design of structures to mitigate against vibration-driven delamination.

Collagen is the basic protein of animal tissues and has a complex hierarchical structure. It plays a crucial role in maintaining the mechanical and structural stability of biological tissues. Over the years, it has become a material of interest in the biomedical industries thanks to its excellent biocompatibility and biodegradability and low antigenicity. Despite its significance, the mechanical properties and performance of pure collagen have been never reviewed. In this work, the emphasis is on the mechanics of collagen at different hierarchical levels and its long-term mechanical performance. In addition, the effect of hydration, important for various applications, was considered throughout the study because of its dramatic influence on the mechanics of collagen. Furthermore, the discrepancies in reports of the mechanical properties of collagenous tissues (basically composed of 20–30% collagen fibres) and those of pure collagen are discussed.

This paper presents a finite-element (FE) model of a manipulator with a flexible link and flexible joint as well as embedded PZT actuators and proposes a corrected rebuilt reduced model (CRRM) to make its dynamic characteristics more consistent with reality and facilitate control design. The CRRM considers the holding torque of the manipulator driving motor and eliminates the response divergence induced by a fault of the mass matrix of the FE model. In order to reduce the dimensions and maintain the precision of the model, an iterated improved reduction system (IIRS) method is adopted. Additionally, a LQR controller is designed based on the output function of the improved model. The simulation results demonstrate that the CRRM is consistent with reality and the active controller has good performance in suppressing vibration of the manipulator with both the flexible link and the flexible joint.

In recent years carbon fibre reinforced polymers (CFRPs) have become some of the most important structural materials in the aerospace industry due to their excellent stiffness and strength to weight ratios. The real-life loading histories of aerospace composite components and structures involve the generation of transient loads that can propagate as cyclic impacts. This phenomenon is known as impact fatigue (IF). Such loads can cause various types of damage in composites, including fibre breakage, transverse matrix cracking, de-bonding between fibres and matrix and delamination, resulting in a reduction of residual stiffness and a loss of functionality.

Adhesives are being increasingly used in structural applications, especially in aerospace, automotive and naval structures, making their structural integrity an important issue. In-service loading histories of such structures usually contain low-energy impacts, repetition of which can significantly affect their performance. This paper deals with the behaviour of the toughened epoxy adhesive FM73 under repeated impacts, known as impact fatigue. Izod impact fatigue tests were performed on FM73 specimens in order to study the evolution of damage and to characterise this via measurable parameters, such as the maximum force and the contact time. A finite element model was developed to simulate the impact tests and this was used to calculate the dynamic strain energy release rate, which was compared with that determined using a simple analytical method. A relationship between the maximum dynamic strain energy release rate and impact fatigue crack growth rate was established that was used as the basis of an impact fatigue crack growth law.

The presence of a crack in a structure affects its dynamic behaviour under working conditions. Cracks introduce nonlinearities into the system; the use of such nonlinearities for damage detection should be investigated. A model of a one-dimensional cracked cantilever bar subjected to longitudinal harmonic excitation is used to analyse a vibro-impact response as a way to monitor structural health. The effect of contact nonlinearity due to crack's faces interaction is considered. This nonlinear information is obtained based on a combination of the analytical technique and the Matlab-Simulink computation. The procedure uses a numerical approximation for dynamic compliance operators and a nonlinear model of contact faces interaction implemented numerically as a nonlinear feedback. Nonlinear resonant phenomena due to vibro-impact interaction in the cracked bar are obtained and analysed. A distribution of the higher harmonics along the bar length, generated due to the nonlinear response of the crack, is revealed as a function of the distance from the crack. Recommendations on structural health monitoring of cracked bars due to contact nonlinearity are presented

Potential problems induced by the multilayered manufacturing process pose a serious threat to the long-term reliability of MEMSCAP® actuators under in-service thermal cycling. Damage would initiate and propagate in different material layers because of a large mismatch of their thermal expansions. In this research, residual stresses and variations of design parameters induced by metal multi-user micro electromechanical system processes (MetalMUMPs) were examined to evaluate their effects on the thermal fatigue lifetime of the multilayer structure and, thus, to improve MEMSCAP® design. Since testing in such micro internal structure is difficult to conduct and traditional testing schemes are destructive, a numerical subdomain method based on a finite element technique was employed. Thermomechanical deformation from metal to insulator layers under in-service temperature cycling (obtained from the multiphysics model of the entire actuator, which was validated by experimental and specified analytical solutions) was accurately estimated to define failures with a significant efficiency and feasibility. Simulation results showed that critical failure modes included interface delamination, plastic deformation, micro cracking, and thermal fatigue, similarly to what was concluded in the MEMSCAP® technical report.

A discontinuous and non-uniform microstructure of alow-density thermally bonded nonwoven materialdisplays in a complicated and unstable tensilebehavior. This paper reports uniaxial tensile tests of alow density thermally bonded nonwoven toinvestigate the effect of the specimen size and shapefactor, as well as the cyclic tensile loading conditionsemployed to investigate the deformational behaviorand performance of the nonwoven at differentloading stages. The experimental data are comparedwith results of microscopic image analysis and FEmodels.