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 (Psf) ultrafiltration flat-sheet membranes were modified with hydroxyapatite (HA) powder during preparation using the wet-phase inversion method. HA was incorporated to enhance the protein separation capabilities. The asymmetric Psf membranes were synthesized using NMP as the solvent. Through Scanning Electron Microscopy (SEM) analysis, it was revealed that HA was distributed across the membrane. Incorporating HA led to higher flux, the improved rejection of protein, and enhanced surface hydrophilicity. The permeability flux increased with HA concentration, peaking at 0.3 wt.%, resulting in a 38% improvement to 65 LMH/bar. Whey protein separation was evaluated using the model proteins BSA and lysozyme, representing α-Lactalbumin. The results of protein rejection for the blend membranes indicated that the rejection rates for BSA and lysozyme increased to 97.2% and 73%, respectively. Both the native and blend membranes showed similar BSA rejection rates; however, the blend membranes demonstrated better performance in lysozyme separation, indicating superior selectivity compared to native membranes. The modified membranes exhibited improved hydrophilicity, with water contact angles decreasing from 66° to 53°, alongside improved antifouling properties, indicated by a lower flux decline ratio value. This simple and economical modification method enhances permeability without sacrificing separation efficiency, hence facilitating the scalability of membrane production in the whey protein separation industry.

The superiorities provided by polymeric composite membranes in comparison to the original membrane have generated increased attention, particularly in the field of protein separation applications. This work involved the fabrication of polysulfone composite membranes using variable loadings of activated carbon particle sizes, namely, 37 µm, 74 µm, 149 µm, and 297 µm. The membranes were fabricated via the phase-inversion method, employing water as the coagulant. In this study, the impact of the AC powder particle sizes on membrane morphology, water contact angle, porosity, average pore size, molecular weight cutoff, pure water flux, and protein rejection was examined. Different membrane morphologies and properties were achieved by incorporating a variety of AC particle sizes. A porous membrane with the maximum pure water flux was generated by the loading of finer AC particles. Concurrently, protein rejection is increasing as a result of the use of AC particles as an infill in the composite membrane. In comparison to all fabricated membranes, the AC filler with a particle size of 149 µm exhibited the highest rejection of the lysozyme protein, reaching up to 73.9%, with a relatively high water permeability of 33 LMH/Bar. In conclusion, this investigation provides recommendations for the selection of AC particle sizes for protein separation in conjunction with PSF ultrafiltration membranes.

The rapid proliferation of microalgae in aquatic systems poses significant environmental and public health challenges, particularly in regions lacking adequate water treatment facilities. This study reports a sustainable approach for microalgae removal through the development of low-cost membranes derived from expanded polystyrene (EPS) waste and modified with polyethylene glycol (PEG) as a pore-forming agent. Membranes were fabricated via non-solvent-induced phase separation with PEG loadings of 0–20 wt.% and characterized in terms of morphology, porosity, wettability, and hydraulic performance. Filtration efficiency was evaluated using Spirulina platensis as a model microalga. Incorporation of PEG (up to 15 wt.%) enhanced membrane porosity (77–84%), improved hydrophilicity (water contact angle reduced from 68° to 48°), and increased water flux (10.98–39.2 L·m⁻²·h⁻¹), while maintaining complete microalgal rejection (100%). Optimized membranes exhibited asymmetric finger-like structures, contributing to improved permeability.