This study investigated the efficacy of a novel correlation of power input, energy dissipation rate and mixing time as a potential route to identify the orbitally shaken bioreactor (OSB) system. The Buckingham’s π-theorem was used to designate and transform dimensionless Newton numbers with five relevant power input variables. These variables were empirically varied to evaluate the correlation among the dimensionless numbers. The Newton number decreases with the increased shaking frequency and filling volume. Previous work has focused on optimizing the mixing process by evaluating different shaking and agitation mixing methods. We establish a new mixing process and assessable measurement of the mixing time in the OSB. An innovative explanation of mixing time for the thermal method is proposed. The optimal mixing time is independent of the temperature of filled liquid. The dimensionless mixing number remained constant in the turbulent regime and increasing with the increased liquid viscosity and filling volume. Our findings revealed that the observed correlation is a practical tool to figure the power consumption and mixing efficiency as cell cultivation in all OSB scales and is fully validated when scaling–up system.

Stereolithography-based additive manufacturing of ceramics has received tremendous attention in academic and industrial communities. In order to fabricate silicon carbide (SiC) components with complex shapes by stereolithography, a high SiC loaded ceramic slurry with low viscosity and excellent curing ability is required. However, it is challenging to meet these slurry requirements. In this work, the effects of resin formulation, dispersant, particle size, solid content and ball milling time on the properties of SiC ceramic slurry were systematically studied. The SiC slurries were prepared by using four precursor SiC powders having different particle sizes and modified by high temperature oxidation to reduce its UV absorbance. Additionally, the suitable SiC slurries for stereolithography were prepared by ball milling under appropriate processing parameters, and the geometrically complex SiC green bodies were subsequently fabricated.

When using foil queue microelectrodes (FQ-microelectrodes) for micro electrical discharge machining (micro-EDM), the processed results of each foil microelectrode (F-microelectrode) can be stacked to construct three-dimensional (3D) microstructures. However, the surface of the 3D microstructure obtained from this process will have a step effect, which has an adverse effect on the surface quality and shape accuracy of the 3D microstructures. To focus on this problem, this paper proposes to use FQ-microelectrodes with tapered structures for micro-EDM, thereby eliminating the step effect on the 3D microstructure’s surface. By using a low-speed wire EDM machine, a copper foil with thickness of 300 μm was processed to obtain a FQ-microelectrode in which each of the F-microelectrodes has a tapered structure along its thickness direction. These tapered structures could effectively improve the construction precision of the 3D microstructure and effectively eliminate the step effect. In this paper, the effects of the taper angle and the number of microelectrodes on the step effect were investigated. The experimental results show that the step effect on the 3D microstructure’s surface became less evident with the taper angle and the number of F-microelectrodes increased. Finally, under the processing voltage of 120 V, pulse width of 1 μs and pulse interval of 10 μs, a FQ-microelectrode (including 40 F-microelectrodes) with 10° taper angle was used for micro-EDM. The obtained 3D microstructure has good surface quality and the step effect was essentially eliminated.

An ultrasonic plasticizing and pressing method (UPP) that fully utilizes ultrasonic vibration is proposed for fabricating thermoplastic polymer surface microstructures with high aspect ratios (ARs). The characteristics of UPP are elucidated based on the plasticization of the raw material, the melt flow, and the stress on the template microstructure during the forming process. Initially, the micronscale single-stage micropillar arrays (the highest AR of 4.1) were fabricated by using 304 stainless steel thin sheets with micronscale pore (through-hole) arrays as primary templates. Subsequently, anodic aluminum oxides (AAOs) with ordered nanoscale pore arrays were added as secondary templates, and the micro/nanoscale hierarchical micropillar arrays (the highest AR up to 24.1) were successfully fabricated, which verifies the feasibility and forming capability of UPP. The superiority and achievements of UPP are illustrated by comparing the prepared hierarchical micropillar arrays with those prepared in the previous work in four indexes: microstructure scale, aspect ratio, forming time, and preheating temperature of the raw material. Finally, the water contact angle (WCA) and oil droplet complete immersion time of the surface microstructures were measured by a droplet shape analyzer, and the results indicate that the prepared micropillar arrays are superhydrophobic and superoleophilic.

Carbon/glass fiber-reinforced polymer hybrid composite (HFRP) has the advantages of a light weight and high strength. For the lightweight design of automobile parts, composite parts made of HFRP and polymer materials are increasingly in demand. The method of the injection molding is usually adopted to fabricate composite part with HFRP and polymer materials. The connecting strength between the two materials has an important influence on the service life of the composite part. In this paper, HFRP and polyamide-6 (PA6) were used to fabricate a composite part by the injection molding method. In order to improve the connecting strength between HFRP and PA6, a kind of micro-grooves was fabricated on the HFRP surface. The micro-grooves on the surface of the HFRP provided sufficient adhesion and infiltrating space of molten PA6 material into the mold. In addition, the glass fiber in HFRP can also be used as nucleating agent to facilitate the rapid crystallization of PA6. The micro-grooves on the surface of HFRP were embedded into PA6 like nails, which could improve the connecting strength at the interface effectively. The paper investigated the effects of mold temperature, injection pressure, holding pressure and holding time on the injection quality and connecting strength of composite parts in detail. With a mold temperature of 240 °C, an injection pressure of 8 MPa, a holding pressure of 8 MPa and a holding time of 3 s, the maximum tensile strength of 10.68 MPa was obtained for the composite part. At the effect of micro-grooves, the tensile strength of the composite part could be increased by 126.27%.