A molded expanded polystyrene (EPS) cushion is a flexible, closed-cell foam that can be molded to fit any packing application and is effective at absorbing shock. However, the packaging waste of EPS cushions causes pollution to landfills and the environment. Despite being known to cause pollution, this sustainable packaging actually has the potential to reduce this environmental pollution because of its reusability. Therefore, the objective of this study is to identify the accurate design parameter that can be emphasized in producing a sustainable design of EPS cushion packaging. An experimental method of drop testing and design simulation analysis was conducted. The effectiveness of the design parameters was also verified. Based on the results, there are four main elements that necessitate careful consideration: rib positioning, EPS cushion thickness, package layout, and packing size. These parameter findings make a significant contribution to sustainable design, where these elements were integrated directly to reduce and reuse packaging material. Thus, it has been concluded that 48 percent of the development cost of the cushion was decreased, 25 percent of mold modification time was significantly saved, and 27 percent of carbon dioxide (CO₂) reduction was identified. The findings also aided in the development of productive packaging design, in which these design elements were beneficial to reduce environmental impact. These findings had a significant impact on the manufacturing industry in terms of the economics and time of the molded expanded polystyrene packaging development.

Wood–plastic composites (WPCs) offer a sustainable alternative to solid wood, yet their heterogeneous structure presents challenges in laser machining due to thermal sensitivity and inconsistent material behaviour. This study investigates the optimization of CO₂ laser-cutting parameters for WPCs, focusing on feed rate and assist-gas pressure. Using a 1500 W CO₂ laser, a full factorial experimental design was employed to cut 18 mm thick WPC panels at varying feed rates (1000–3000 mm/min) and gas pressures (1–3 bar). Statistical analyses including MANOVA and linear regression were conducted to evaluate their effects on key machining responses: cutting depth, heat-affected zone (HAZ) width, cut-edge quality, and surface finish. Results indicated that feed rate significantly influences both cutting depth and thermal damage, while gas pressure plays a major role in improving surface quality and reducing HAZ. Optimal combinations were identified for various performance goals, and validation trials at the selected parameters confirmed alignment with predicted outcomes. The optimized settings yielded high-quality cuts with reduced HAZ and enhanced surface characteristics. This study demonstrates the effectiveness of a statistical optimization approach in refining CO₂ laser-cutting conditions for WPCs, offering insights for improved process control and sustainable manufacturing applications. This study also introduces a multi-objective optimization approach that verifies the interaction effects of feed rate and assist-gas pressure, enabling precise and efficient CO₂ laser cutting of 18 mm thick WPCs.

Using cutting fluid in the machining process for Aluminum Alloy 1050 is advantageous as it helps mitigate the effects of temperature generated during cutting. It can shorten tool life and impair the quality of machine parts. Despite its benefits, cutting fluids has several disadvantages, such as high expenses, potential environmental harm, and user health risks. This research evaluates the effects of green cutting conditions, particularly nozzle types, on the metallurgical properties of the material. Their impacts on tool wear, X-Ray Diffractometer (XRD) pattern, Full Width at Half Maximum (FWHM), crystallite size, and hardness during the drilling process were investigated. The findings indicate that using chilled air with dual nozzles for cooling and lubrication is highly effective, resulting in less tool wear and a relatively purer crystalline structure of the material compared to other conditions. These results emphasize the importance of controlling cutting conditions, especially nozzle types, to produce high-quality parts with improved metallurgical properties.

Due to their low shrinkage and easy moldability, metal epoxy composites (MEC) are recognized as an alternative material that can be applied as hybrid mold inserts manufactured with rapid tooling (RT) technologies. Although many studies have been conducted on MEC or reinforced composite, research on the material properties, especially on thermal conductivity and compressive strength, that contribute to the overall mold insert performance and molded part quality are still lacking. The purpose of this research is to investigate the effect of the cooling efficiency using MEC materials. Thus, this research aims to appraise a new formulation of MEC materials as mold inserts by further improving the mold insert performance. The effects of the thermal, physical, and mechanical properties of MEC mold inserts were examined using particles of brass (EB), copper (EC), and a combination of brass + copper (EBC) in irregular shapes. These particles were weighed at percentages ranging from 10% to 60% when mixed with epoxy resin to produce specimens according to related ASTM standards. A microstructure analysis was made using a scanning electron microscope (SEM) to investigate brass and copper particle distribution. When filler composition was increased from 10% to 60%, the values of density (g/cm³), hardness (Hv), and thermal conductivity (W/mK) showed a linear upward trend, with the highest value occurring at the highest filler composition percentage. The addition of filler composition increased the compressive strength, with the highest average compressive strength value occurring between 20% and 30% filler composition. Compressive strength indicated a nonlinear uptrend and decreased with increasing composition by more than 30%. The maximum value of compressive strength for EB, EC, and EBC was within the range of 90–104 MPa, with EB having the highest value (104 MPa). The ANSYS simulation software was used to conduct a transient thermal analysis in order to evaluate the cooling performance of the mold inserts. EC outperformed the EB and EBC in terms of cooling efficiency based on the results of thermal transient analysis at high compressive strength and high thermal conductivity conditions.

The use of lightweight Aluminium Alloy 7075 (AA7075) in aerospace and automotive industries is increasing due to its exceptional properties, such as high strength, good fatigue resistance, and excellent strength-to-weight ratio. However, this alloy is difficult to machine due to high ductility and heat generation during cutting. Cutting fluids are commonly used to deal with these problems, although they raise environmental concerns. The research aims to enhance drilling efficiency for AA7075, considering environmental impacts, through a greener method, a chilled air system. Their impact on tool wear and cutting force was evaluated through spindle speed, feed rate, and nozzle types by adopting the Taguchi method. Chisel edge wear was discovered to be a major contributor to tool wear. Lower feed rate and slower spindle speed using dual nozzle yielded better tool wear and cutting force performance. These findings provide feasible recommendations for industry practitioners seeking to employ eco-friendly chilled air systems to achieve optimal drilling efficiency for this type of material.

This study investigates the effects of dry and chilled air milling on the machinability and phase transformation behaviour of martensitic and austenitic nickel-titanium (NiTi) alloys. NiTi alloys are widely used in biomedical and automotive industries for their shape memory effect and super-elasticity; however, their high ductility and temperature sensitivity pose machining challenges, leading to severe tool wear and poor surface quality. Key machinability aspects including cutting force, tool wear, burr formation, and surface roughness, were analysed alongside phase transformation characteristics using Differential Scanning Calorimetry (DSC). Results show that chilled air cutting significantly reduces cutting force for austenitic NiTi but has a limited effect on martensitic NiTi. It also lowers cutting temperatures to 40°C, enhances tool wear resistance, and minimises burr formation. Chilled air cutting also improved surface roughness by 50% and 20% for martensitic and austenitic NiTi, respectively. While neither cutting condition fully preserved NiTi transformation curves, chilled air cutting promoted the inhibition of multi-peak appearances in martensitic NiTi, potentially improving phase stability.