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Processes
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Innovations in Manufacturing Processes and Systems for Sustainable Practices
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Innovations in Manufacturing Processes and Systems for Sustainable Practices

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 30 December 2024 | Viewed by 17255

Special Issue Editor

Dr. Raul D. S. G. Campilho

E-Mail Website
Guest Editor
Departamento de Engenharia Mecânica, Instituto Superior de Engenharia do Porto, 4200-072 Porto, Portugal
Interests: advanced manufacturing systems; automation and robotics; industrial design
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

As a fundamental pillar of industrial progress, manufacturing continues to undergo significant changes driven by technological advancements, societal demands and a growing emphasis on sustainability. Manufacturing systems, the backbone of production frameworks, have evolved significantly in response to the integration of cutting-edge technologies. The advent of Industry 4.0 has guided a new era characterized by the seamless fusion of digitalization, automation and robotics, and data exchange. Simultaneously, advancements in manufacturing processes have been fundamental in enhancing efficiency, precision and sustainability. From micro-nano-manufacturing to additive technologies such as 3D printing, researchers and practitioners are exploring innovative methods that redefine conventional manufacturing paradigms. Sustainability, a key concern in the industry, is a recurring theme to associate all these concepts with the legislation and societal-driven green practices, made possible by the integration of sustainability metrics, green manufacturing practices and novel approaches to process design. This Special Issue of the journal Processes aims to explore and present the latest findings on modern manufacturing, highlighting key trends that are shaping the future of this critical industry. The Special Issue invites contributions that delve into the described subjects, offering a nuanced understanding of how they contribute to the evolution of manufacturing methodologies. The aim is to present a holistic view of how manufacturing processes and systems can align with environmental and societal goals, fostering a more responsible and eco-conscious industry. To advance the state of the art and disseminate the recent advances in all manufacturing-related matters, this Special Issue intends to collate a significant number of contributions in this area through high-quality original or review works, subsequently promoting the issue’s dissemination via the open access system.

Dr. Raul D. S. G. Campilho
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • manufacturing systems
  • manufacturing processes
  • manufacturing technologies
  • automation
  • robotics
  • micro-nano-manufacturing
  • green manufacturing
  • sustainability
  • process design
  • new sustainable processes and supply chains
  • Industry 4.0
  • digitalization
  • data exchange
  • additive technologies (3D printing)

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Published Papers (10 papers)

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Research

Jump to: Review

26 pages, 6021 KiB  
Article
Towards Sustainability in Hydraulic Machinery Manufacturing by 3D Printing
by Abel Remache, Modesto Pérez-Sánchez, Víctor Hugo Hidalgo, Helena M. Ramos and Francisco-Javier Sánchez-Romero
Processes 2024, 12(12), 2664; https://doi.org/10.3390/pr12122664 - 26 Nov 2024
Viewed by 185
Abstract
Material wear, maintenance costs, performance, efficiency, and corrosion are some of the issues that turbomachinery impellers may encounter. The optimization of impellers through additive manufacturing (AM) has been the focus of extensive research, aiming to address these challenges in turbine, pump, compressor, fan, [...] Read more.
Material wear, maintenance costs, performance, efficiency, and corrosion are some of the issues that turbomachinery impellers may encounter. The optimization of impellers through additive manufacturing (AM) has been the focus of extensive research, aiming to address these challenges in turbine, pump, compressor, fan, and mixer components. This research aims to identify and analyze the main techniques currently being developed to tackle several of these issues. Evaluating the published research, the methodology highlights various AM techniques applied to impellers and related components, as well as the diverse materials used in functional system elements. The analysis revealed that the most commonly used additive manufacturing technologies for the production of turbomachinery components are FDM, with a 22% application rate, and powder bed fusion technology, accounting for 35%, utilized for high-complexity parts and even superalloys. Although more expensive, these technologies employ materials with superior resistance capabilities, surpass the limitations of conventional machining, optimize manufacturing times, and allow for the fine-tuning of multiple parameters. In terms of wear and corrosion resistance, materials such as Inconel 718 exhibited a loss of less than 0.1 mpy (mils per year) in highly corrosive environments, representing a significant improvement over traditional materials. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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17 pages, 3236 KiB  
Article
Mathematical Model of the Electronic Cam in Terms of Application in a Dosing Machine
by Karol Wójkowski, Krzysztof Talaśka and Dominik Wilczyński
Processes 2024, 12(9), 1909; https://doi.org/10.3390/pr12091909 - 5 Sep 2024
Viewed by 548
Abstract
The article analyses the use of servomotors in the control systems of industrial equipment, focusing on the alternative offered by position and speed synchronization in relation to classical mechanical mechanisms. A complete methodology is presented to determine the dynamic parameters of the adopted [...] Read more.
The article analyses the use of servomotors in the control systems of industrial equipment, focusing on the alternative offered by position and speed synchronization in relation to classical mechanical mechanisms. A complete methodology is presented to determine the dynamic parameters of the adopted kinematic system using electronic motion profiles. The results obtained constitute a mathematical model of the execution chain and an analysis of the basic quantities for linear motion, supported by actual measurements of the drive parameters. The merit of the article is to show that the servomotors can significantly simplify the design of the device, make it more flexible in adaptation to different assortments, and allow integration with systems predicting the technical condition of the device. The analysis of the results revealed significant differences in the constant rotational speed of the servomotor, which do not align with previous findings. The results suggest that changing the angular working range of the assembly to the range (205°;270°) could significantly affect the generated linear acceleration, reducing the risk of stalling. The calculations and graphs conducted allowed for the accurate representation of the actual mechanical system, considering its dynamic characteristics. The key conclusion is that precise mathematical modelling is essential to ensure the stability and durability of engineering components. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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20 pages, 3109 KiB  
Article
Development of a Value Stream Map to Optimize the Production Process in a Luxury Metal Piece Manufacturing Company
by Beatriz Costa, José Varejão and Pedro Dinis Gaspar
Processes 2024, 12(8), 1612; https://doi.org/10.3390/pr12081612 - 31 Jul 2024
Viewed by 2060
Abstract
The current market is highly competitive, and customers are increasingly demanding. In this context, organizations need to adopt tools that enhance process efficiency to ensure competitiveness. This report aims to implement Lean tools, specifically Value Stream Mapping (VSM) and complementary tools, to optimize [...] Read more.
The current market is highly competitive, and customers are increasingly demanding. In this context, organizations need to adopt tools that enhance process efficiency to ensure competitiveness. This report aims to implement Lean tools, specifically Value Stream Mapping (VSM) and complementary tools, to optimize the production process in the metal treatment industry. A case study was conducted, beginning with a brief sector and process recognition, followed by an analysis of production stages using VSM. Value-added activities, non-value-added activities, and waste were identified. The current VSM revealed a Lead Time (LT) of approximately 336 h (14 days), value-added activities (VA) of 21 h, and a process cycle efficiency (PCE) of 6.29%. Improvement actions were proposed to reduce waste and increase competitiveness. After implementation, the LT decreased to approximately 318 h (13 days), VA increased to 23 h, and process efficiency improved to 7.15%. Despite the limitations of VSM in discontinuous flows, its use increased process efficiency, demonstrating its applicability in complex industrial contexts. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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21 pages, 2725 KiB  
Article
A Hierarchical Axiomatic Evaluation of Additive Manufacturing Equipment and the 3D Printing Process Based on Sustainability and Human Factors
by Ismael Mendoza-Muñoz, Mildrend Ivett Montoya-Reyes, Aidé Aracely Maldonado-Macías, Gabriela Jacobo-Galicia and Olivia Yessenia Vargas-Bernal
Processes 2024, 12(6), 1083; https://doi.org/10.3390/pr12061083 - 25 May 2024
Viewed by 1060
Abstract
As interest in additive manufacturing (AM) continues to increase, it has become more important to have a robust method to help potential users select the AM process that best suits their technological needs while providing the greatest potential benefits in terms of sustainability [...] Read more.
As interest in additive manufacturing (AM) continues to increase, it has become more important to have a robust method to help potential users select the AM process that best suits their technological needs while providing the greatest potential benefits in terms of sustainability and its effect on people. This paper presents the development of a framework for selecting the best AM process for a given application by considering both sustainability and human factors through the combination of axiomatic design and the analytic hierarchy process. Thirty-one participants with varying levels of expertise (novice and advanced users) were involved in the study, considering the frequency of 3D printer usage (novice users: never, rarely; expert users: sometimes, almost always, always) for prototyping parts. They employed fused deposition modeling (FDM) and stereolithography (SLA) (both 3D desktop printers) and collected data on five evaluation criteria. The participation of experts helped establish a novel methodology, with material cost deemed most important (49.8%), followed by cycle time (28%), energy consumption (11.7%), error rate (6.6%), and equipment noise (3.9%). The results showed that FDM was the optimal equipment option for advanced users. By examining the information content of the other options, it was found that FDM demanded less information than SLA, regardless of the user’s level of expertise. The proposed method is appropriate to assess the sustainability aspect of FDM and SLA; however, it can be further improved by adding indicators such as environmental impact, recyclability, and ergonomic and occupational health factors. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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39 pages, 42293 KiB  
Article
Biomimetic Approach for Enhanced Mechanical Properties and Stability of Self-Mineralized Calcium Phosphate Dibasic–Sodium Alginate–Gelatine Hydrogel as Bone Replacement and Structural Building Material
by Alberto T. Estevez and Yomna K. Abdallah
Processes 2024, 12(5), 944; https://doi.org/10.3390/pr12050944 - 7 May 2024
Cited by 1 | Viewed by 1604
Abstract
Mineralized materials are gaining increased interest recently in a number of fields, especially in bone tissue engineering as bone replacement materials as well as in the architecture-built environment as structural building materials. Until the moment, there has not been a unified sustainable approach [...] Read more.
Mineralized materials are gaining increased interest recently in a number of fields, especially in bone tissue engineering as bone replacement materials as well as in the architecture-built environment as structural building materials. Until the moment, there has not been a unified sustainable approach that addresses this multi-scale application objective by developing a self-mineralized material with minimum consumption of materials and processes. Thus, in the current study, a hydrogel developed from sodium alginate, gelatine, and calcium phosphate dibasic (CPDB) was optimized in terms of rheological properties and mineralization capacity through the formation of hydroxyapatite crystals. The hydrogel composition process adopted a three-stage, thermally induced chemical cross-linking to achieve a stable and enhanced hydrogel. The 6% CPDB-modified SA–gelatine hydrogel achieved the best rheological properties in terms of elasticity and hardness. Different concentrations of epigallocatechin gallate were tested as well as a rheological enhancer to optimize the hydrogel and to boost its anti-microbial properties. However, the results from the addition of EPGCG were not considered significant; thus, the 6% CPDB-modified SA–gelatine hydrogel was further tested for mineralization by incubation in various media, without and with cells, for 7 and 14 days, respectively, using scanning electron microscopy. The results revealed significantly enhanced mineralization of the hydrogel by forming hydroxyapatite platelets of the air-incubated hydrogel (without cells) in non-sterile conditions, exhibiting antimicrobial properties as well. Similarly, the air-incubated bioink with osteosarcoma SaOs-2 cells exhibited dense mineralized topology with hydroxyapatite crystals in the form of faceted spheres. Finally, the FBS-incubated hydrogel and FBS-incubated bioink, incubated for 7 and 14 days, respectively, exhibited less densely mineralized topology and less distribution of the hydroxyapatite crystals. The degradation rate of the hydrogel and bioink incubated in FBS after 14 days was determined by the increase in dimensions of the 3D-printed samples, which was between 5 to 20%, with increase in the bioink samples dimensions in comparison to their dimensions post cross-linking. Meanwhile, after 14 days, the hydrogel and bioink samples incubated in air exhibited shrinkage: a 2% decrease in the dimensions of the 3D-printed samples in comparison to their dimensions post cross-linking. The results prove the capacity of the developed hydrogel in achieving mineralized material with anti-microbial properties and a slow-to-moderate degradation rate for application in bone tissue engineering as well as in the built environment as a structural material using a sustainable approach. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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17 pages, 8324 KiB  
Article
A Fuzzy Decision-Making Method for Green Design for Remanufacturability
by Yu Cai, Chao Ke and Qunjing Ji
Processes 2024, 12(5), 911; https://doi.org/10.3390/pr12050911 - 29 Apr 2024
Viewed by 1021
Abstract
Designs for remanufacturing (DfRem) consider the remanufacturability of the product in the early stages of product design, which can greatly increase the reusability of the products. However, product design schemes lack reasonable evaluation indicators for remanufacturability, and the decision-makers of the design scheme [...] Read more.
Designs for remanufacturing (DfRem) consider the remanufacturability of the product in the early stages of product design, which can greatly increase the reusability of the products. However, product design schemes lack reasonable evaluation indicators for remanufacturability, and the decision-makers of the design scheme have subjective preferences and vague hesitation. These result in inaccurate decision making on DfRem schemes that will affect the successful implementation of product remanufacturing. In order to improve the accuracy of the DfRem scheme decision, a fuzzy decision-making method for green design for remanufacturability is proposed. Firstly, an evaluation indicator system for green design schemes was established that takes into account remanufacturability, reliability, cost, and the environment, and the entropy weighting method is used to quantify and weigh the design scheme evaluation indicators. Then, the hesitation fuzzy set is applied to construct the set of evaluations and the optimal design scheme is selected by applying the comprehensive evaluation method. Finally, the feasibility of the above method is verified by using the green design of an injection mold as an example, and the results show that the above method is able to make accurate and effective design scheme decisions. This method has been implemented in a prototype system using Visual Studio 2022 and Microsoft SQL Server 2022. The results show that the fuzzy decision-making system is accurate and effective for rapidly generating a rational green design scheme for remanufacturability. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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18 pages, 4734 KiB  
Article
Implementations of Digital Transformation and Digital Twins: Exploring the Factory of the Future
by Ramin Rahmani, Cristiano Jesus and Sérgio I. Lopes
Processes 2024, 12(4), 787; https://doi.org/10.3390/pr12040787 - 14 Apr 2024
Cited by 5 | Viewed by 2520
Abstract
In the era of rapid technological advancement and evolving industrial landscapes, embracing the concept of the factory of the future (FoF) is crucial for companies seeking to optimize efficiency, enhance productivity, and stay sustainable. This case study explores the concept of the FoF [...] Read more.
In the era of rapid technological advancement and evolving industrial landscapes, embracing the concept of the factory of the future (FoF) is crucial for companies seeking to optimize efficiency, enhance productivity, and stay sustainable. This case study explores the concept of the FoF and its role in driving the energy transition and digital transformation within the automotive sector. By embracing advancements in technology and innovation, these factories aim to establish a smart, sustainable, inclusive, and resilient growth framework. The shift towards hybrid and electric vehicles necessitates significant adjustments in vehicle components and production processes. To achieve this, the adoption of lighter materials becomes imperative, and new technologies such as additive manufacturing (AM) and artificial intelligence (AI) are being adopted, facilitating enhanced efficiency and innovation within the factory environment. An important aspect of this paradigm involves the development and utilization of a modular, affordable, safe human–robot interaction and highly performant intelligent robot. The introduction of this intelligent robot aims to foster a higher degree of automation and efficiency through collaborative human–robot environments on the factory floor and production lines, specifically tailored to the automotive sector. By combining the strengths of human and robotic capabilities, the future factory aims to revolutionize manufacturing processes, ultimately driving the automotive industry towards a more sustainable and technologically advanced future. This study explores the implementation of automation and the initial strides toward transitioning from Industry 4.0 to 5.0, focusing on three recognized, large, and automotive companies operating in the north of Portugal. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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30 pages, 12317 KiB  
Article
Fabrication and Characterisation of Sustainable 3D-Printed Parts Using Post-Consumer PLA Plastic and Virgin PLA Blends
by Mohammad Raquibul Hasan, Ian J. Davies, Alokesh Paramanik, Michele John and Wahidul K. Biswas
Processes 2024, 12(4), 760; https://doi.org/10.3390/pr12040760 - 9 Apr 2024
Viewed by 1892
Abstract
Sustainable manufacturing practices are becoming increasingly necessary due to the growing concerns regarding climate change and resource scarcity. Consequently, material recycling technologies have gradually become preferred over conventional processes. This study aimed to recycle waste polylactic acid (PLA) from household-disposed cups and lids [...] Read more.
Sustainable manufacturing practices are becoming increasingly necessary due to the growing concerns regarding climate change and resource scarcity. Consequently, material recycling technologies have gradually become preferred over conventional processes. This study aimed to recycle waste polylactic acid (PLA) from household-disposed cups and lids to create 3D-printed parts and promote sustainable manufacturing practices. To achieve this, the current study utilised virgin and post-consumer PLA (PC-PLA) (sourced from household waste) blends. The PC-PLA wastes were shredded and sorted by size with the aid of a washing step, resulting in a filament with a 1.70 ± 0.5 mm diameter without fragmentation or dissolution. A 50:50 wt.% blend of virgin PLA (vPLA) and PC-PLA was selected as the standard recycling percentage based on previous research and resource conservation goals. The study investigated the impact of three 3D printing parameters (layer height (LH), infill density (I), and nozzle temperature (NT)) on the quality of 3D-printed parts using a three-level L9 Taguchi orthogonal array. The findings revealed that blending PC-PLA with vPLA led to significant improvements in tensile, flexural, and impact strengths by 18.40%, 8%, and 9.15%, respectively, compared to those of recycled PLA (rPLA). This conclusion was supported by the investigation of the fracture surface area, which revealed fractographic features associated with printing parameters, such as plastic deformation and interfilament debonding. An ANOVA analysis revealed a positive influence of a greater layer height and high nozzle temperature on mechanical properties. Subsequently, the optimal printing parameters (LH: 0.3 mm, I: 100%, and NT: 215 °C) were determined using the S/N ratio, and a confirmation test using the optimum printing parameters exhibited a strong correlation with the statistically predicted outcomes. Finally, the study used optimum printing parameters to fabricate 100% PC-PLA 3D-printed parts, demonstrating their potential for low-strength applications. The findings suggest that employing vPLA and PC-PLA blended filaments for fabricating 3D-printed components presents an effective means of promoting plastic recycling within a closed-loop recycling system and achieving a circular economy. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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Review

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16 pages, 971 KiB  
Review
Sustainable Management of Manufacturing Processes: A Literature Review
by Lasma Tiuncika and Santa Bormane
Processes 2024, 12(6), 1222; https://doi.org/10.3390/pr12061222 - 14 Jun 2024
Viewed by 965
Abstract
Industrial economic activity is one of the primary causes of environmental degradation and a source of issues related to social inequality. Nevertheless, research has shown that the application of the sustainable entrepreneurship model can significantly improve environmental and social conditions while maintaining continuous [...] Read more.
Industrial economic activity is one of the primary causes of environmental degradation and a source of issues related to social inequality. Nevertheless, research has shown that the application of the sustainable entrepreneurship model can significantly improve environmental and social conditions while maintaining continuous and sustainable economic growth. Despite that, statistics show relatively low engagement in sustainable entrepreneurship, potentially due to a lack of expertise among entrepreneurs. Due to the low engagement, available sustainability performance metrics are not a relevant measurement tool. Thus, the purpose of this study is to identify a set of criteria that evaluate expertise levels in sustainable entrepreneurship within the manufacturing industry. Through the application of monographic and secondary data analysis methods, the authors carried out a literature review. The findings indicated that sustainable management is a key component to the triple-bottom-line (TBL) framework that is used as a conceptual basis for sustainable entrepreneurship. Additionally, the authors identified 19 criteria of sustainable entrepreneurship within four dimensions of sustainability (environmental, social, economic, and management). Despite the limitations, with a more refined literature review, the criteria could be applied as a comprehensive resource to estimate expertise in sustainable entrepreneurship in future studies on small and medium enterprises (SMEs). Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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28 pages, 7430 KiB  
Review
Dry Machining Techniques for Sustainability in Metal Cutting: A Review
by Shailendra Pawanr and Kapil Gupta
Processes 2024, 12(2), 417; https://doi.org/10.3390/pr12020417 - 19 Feb 2024
Cited by 4 | Viewed by 2275
Abstract
Dry machining has gained significant importance in the last few years due to its promising contribution towards sustainability. This review study introduces dry machining, presents its benefits, and summarizes the recent technological developments that can facilitate dry machining. It aims to provide a [...] Read more.
Dry machining has gained significant importance in the last few years due to its promising contribution towards sustainability. This review study introduces dry machining, presents its benefits, and summarizes the recent technological developments that can facilitate dry machining. It aims to provide a concise overview of the current state of the art in dry machining to promote sustainability. This article synthesizes and emphasizes the useful information from the existing literature, and summarizes the methods and tools used to implement it. It also identifies some of the major problems and challenges and their potential solutions to make dry machining more viable and efficient. It concludes with some future research directions important for the scholars and researchers to establish the field further. From this review study, the major findings are: (1) tools with textures or patterns can enhance the cutting performance of dry machining for various materials, (2) tool coating is an effective way to lower the tool cost in dry machining and can achieve the required functionality for the cutting tool without affecting its core properties, (3) Alumina-based mixed ceramic tools with SiC whiskers have better fracture toughness, thermal shock resistance, and self-crack healing properties, (4) one effective method to improve the dry cutting of engineering materials is to apply external energy sources to assist the dry machining process, (5) by using microwave sintering, cutting tools with finer microstructures and higher densities can be produced, which improve their hardness, wear resistance, and thermal stability to perform well in dry machining conditions. Full article
(This article belongs to the Special Issue Innovations in Manufacturing Processes and Systems for Sustainable Practices)
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