Titanium-nickel shape memory alloy (SMA) has good biomedical application value as an implant. Alloy corrosion will promote the release of toxic nickel ions and cause allergies and poisoning of cells and tissues. With this background, surface modification of TiNi SMAs using TiC-powder-assisted micro-electrical discharge machining (EDM) was proposed. This aims to explore the effect of the electrical discharge machining (EDM) parameters and TiC powder concentration on the machining properties and surface characteristics of the TiNi SMA. It was found that the material removal rate (MRR), surface roughness, and thickness of the recast layer increased with an increase in the discharge energy. TiC powder’s addition had a positive effect on increasing the electro-discharge frequency and MRR, reducing the surface roughness, and the maximum MRR and the minimum surface roughness occurred at a mixed powder concentration of 5 g/L. Moreover, the recast layer had good adhesion and high hardness due to metallurgical bonding. XRD analysis found that the machined surface contains CuO₂, TiO₂, and TiC phases, contributing to an increase in the surface microhardness from 258.5 to 438.7 HV, which could be beneficial for wear resistance in biomedical orthodontic applications.

For obtaining 3D micro-molds with better surface quality (slight ridges) and mechanical properties, in this paper 3D micro-electrodes were fabricated and applied to micro-electrical discharge machining (micro-EDM) to process Pd₄₀Cu₃₀P₂₀Ni₁₀ metallic glass. First, 100 μm-thick Cu foil was cut to obtain multilayer 2D micro-structures and these were connected to fit 3D micro-electrodes (with feature sizes of less than 1 mm). Second, under the voltage of 80 V, pulse frequency of 0.2MHZ, pulse width of 800 ns and pulse interval of 4200 ns, the 3D micro-electrodes were applied to micro-EDM for processing Pd₄₀Cu₃₀P₂₀Ni₁₀ metallic glass. The 3D micro-molds with feature within 1 mm were obtained. Third, scanning electron microscope, energy dispersive spectroscopy and x-ray diffraction analysis were carried out on the processed results. The analysis results indicate that with an increase in the depth of micro-EDM, carbon on the processed surface gradually increased from 0.5% to 5.8%, and the processed surface contained new phases (Ni₁₂P₅ and Cu₃P).

Three-dimensional (3D) microelectrodes used for processing 3D microstructures in micro-electrical discharge machining (micro-EDM) can be readily prepared by laminated object manufacturing (LOM). However, the microelectrode surface always appears with steps due to the theoretical error of LOM, significantly reducing the surface quality of 3D microstructures machined by micro-EDM with the microelectrode. To address the problem above, this paper proposes a filling method to fabricate a composite 3D microelectrode and applies it in micro-EDM for processing 3D microstructures without steps. The effect of bonding temperature and Sn film thickness on the steps is investigated in detail. Meanwhile, the distribution of Cu and Sn elements in the matrix and the steps is analyzed by the energy dispersive X-ray spectrometer. Experimental results show that when the Sn layer thickness on the interface is 8 μm, 15 h after heat preservation under 950 °C, the composite 3D microelectrodes without the steps on the surface were successfully fabricated, while Sn and Cu elements were evenly distributed in the microelectrodes. Finally, the composite 3D microelectrodes were applied in micro-EDM. Furthermore, 3D microstructures without steps on the surface were obtained. This study verifies the feasibility of machining 3D microstructures without steps by micro-EDM with a composite 3D microelectrode fabricated via the proposed method.

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.