Over the last few years, fused filament fabrication (FFF) has become one of the most promising and widely used techniques for the rapid prototyping process. A number of studies have also shown the possibility of FFF being used for the fabrication of functional products, such as biomedical implants and automotive components. However, the poor mechanical properties possessed by FFF-processed products are considered one of the major shortcomings of this technique. Over the last decade, many researchers have attempted to improve the mechanical properties of FFF-processed products using several strategies—for instance, by applying the short fiber reinforcement (SFR), continuous fiber reinforcement (CFR), powder addition reinforcement (PAR), vibration-assisted FFF (VA-FFF) methods, as well as annealing. In this paper, the details of all these reinforcement techniques are reviewed. The abilities of each method in improving tensile, flexural, and compressive strength are discussed.

Micromachining in the micro-electric discharge machining (μ-EDM) process requires high material-removal rate with good surface quality. Power-mixed μ-EDM, a modified machining process by introducing specific powder into the dielectric fluid, is among the key inventions to achieving these requirements. This article presents a review of the implementation of powder-mixed micro-EDM processes for microfabrication. Special attention was given to the influence of the powder characteristics, such as the concentration, electrical conductivity, shape and size of the powder. Subsequently, when describing the use of powder for obtaining a high material-removal rate and surface quality, other major applications in μ-EDM for surface modification and geometrical accuracy were also discussed. Finally, some of the varied methods that are used in powder-mixed μ-EDM and industrialization challenges are extensively elaborated.

Polysulfone ultrafiltration membranes were fabricated using various sizes (20, 40, and 90–210 nm) of silver nanoparticles (nAg) blended in a dope solution. To characterize the performance and properties of the prepared membranes, scanning electron microscopy (SEM), water contact angle, protein separation, water flux, and antibacterial tests were conducted. The characterization results revealed that when nAg particles (20 nm) were blended into the base polymer PSF, the PSF/nAg blended membrane had the lowest contact angle (58.5°) and surface energy (110.7 mN/m). When experimenting with ultrafiltration using protein solutions, bare PSF and PSF/nAg-20 blended membranes gave similar values of protein rejection: 93% of bovine serum albumin (BSA) and 70% of lysozyme rejection. Furthermore, SEM studies showed that the surface pore size was reduced by adding 20 nm nAg particles in the casting solution. Most importantly, the introduction of 40 nm nAg particles reduced the growth of bacterial colonies on the membrane surface by up to 72%. These findings revealed that nAg particles are expected to be a potential modifier for the fabrication of an ultrafiltration membrane.

Ultrafiltration membrane technology holds promise for wastewater treatment, but its widespread application is hindered by fouling and flux reduction issues. One effective strategy for enhancing ultrafiltration membranes involves incorporating activated carbon powder. In this study, composite polyethersulfone (PES) ultrafiltration membranes were fabricated to include activated carbon powder concentrations between 0 and 1.5 wt.%, with carbon size fixed at 200 mesh. The ultrafiltration membranes were evaluated in terms of membrane morphology, hydrophilicity, pure water flux, equilibrium water content, porosity, average pore size, protein separation, and E-coli bacteria removal. It was found that the addition of activated carbon to PES membranes resulted in improvements in some key properties. By incorporating activated carbon powder, the hydrophilicity of PES membranes was enhanced, lowering the contact angle from 60° to 47.3° for composite membranes (1.0 wt.% of activated carbon) compared to the pristine PES membrane. Water flux tests showed that the 1.0 wt.% composite membrane yielded the highest flux, with an improvement of nearly double the initial value at 2 bar, without compromising bovine serum albumin rejection or bacterial removal capabilities. This study also found that the inclusion of activated carbon had a minor impact on the membrane’s porosity and equilibrium water content. Overall, these insights will be beneficial in determining the optimal concentration of activated carbon powder for PES ultrafiltration membranes.

Titanium is widely used in biomedical components. As a promising advanced manufacturing process, electropolishing (EP) has advantages in polishing the machined surfaces of material that is hard and difficult to cut. This paper presents the fabrication of a titanium microchannel using the EP process. The Taguchi method was adopted to determine the optimal process parameters by which to obtain high surface quality using an L₉ orthogonal array. The Pareto analysis of variance was utilized to analyze the three machining process parameters: applied voltage, concentration of ethanol in an electrolyte solution, and machining gap. In vitro experiments were conducted to investigate the fouling effect of blood on the microchannel. The result shows that an applied voltage of 20 V, an ethanol concentration of 20 vol.%, and a machining gap of 10 mm are the optimum machining parameters by which to enhance the surface quality of a titanium microchannel. Under the optimized machining parameters, the surface quality improved from 1.46 to 0.22 μm. Moreover, the adhesion of blood on the surface during the fouling experiment was significantly decreased, thus confirming the effectiveness of the proposed method.

Material removal rate in electropolishing is often overlooked because this process generally addressed for surface finish; however, it is paramount on metallic sheet machining possessed with intricate geometry. Electropolishing removes metallic material from the surface of a workpiece based on anodic dissolution process. The material removal rate depends on the current density, electrolyte, the strength of the magnetic field, polishing time and temperature. In this study, three factors of applied voltage, electrolyte composition and magnetic field were evaluated using Taguchi approach to improve the material removal rate in the electropolishing of a pure titanium (99.5%) workpiece. The experiments were undertaken as per Taguchi L₉ (3³) orthogonal array, and further analyzed using Pareto ANOVA to determine the most significant parameter. It was found that the optimum parametric combination to maximize the material removal rate were, applied voltage of 15 V, ethanol concentration of 20 vol.% and magnetic field of 0.51 T. The experimental results show that the responses in electropolishing process can be improved through this approach.