Rolling Bearings are crucial components for induction motors and generators in electric vehicles (EVs), as their performance considerably influences the system’s operational reliability and safety. However, the commercial greases used for bearing lubrication in EV motors pose a detrimental impact on the environment. In addition, they are ineffective in mitigating the effect of electric discharges on rolling surfaces leading to premature bearing failures. This study investigates the viability of a developed eco-friendly grease from palm olein as the base oil and glycerol monostearate as the thickener, enhanced with conductive multi-walled carbon nanotubes (MWCNTs) for EV motor bearings prone to electrical currents. Chemical–physical, tribological, and electrical tests were conducted on the developed grease samples without and with MWCNTs at 1 wt.%, 2 wt.%. and 3 wt.% concentrations and results were compared to lithium and sodium greases. Palm grease samples demonstrated a lower EDM voltage range reaching 1.0–2.2 V in case of 3 wt.% MWCNTs blends, indicating better electrical conductivity and protecting the bearing surfaces from electric-related faults. These findings were further confirmed using vibrations measurement and SEM-EDX analysis of the electrically worn bearings. Bearings lubricated with palm grease blends exhibited lower vibration levels. Palm grease with 2 wt.% MWCNTs reduced vibration amplitudes by 28.4% (vertical) and 32.3% (horizontal). Analysis of bearing damaged surfaces revealed enhanced damaged surface morphology for MWCNT-enhanced palm grease as compared to surface lubricated by commercial greases. The results of this work indicate that the proposed bio-grease is a promising candidate for future application in the field of next-generation electric mobility systems.

This paper describes an improved design of an external fixator. The new fixator comprises 13 parts which are assembled together. The proposed device materials consist of polyether ether-ketone (PEEK) and stainless steel 316L. The design was subjected to finite-element analysis, and a working model was manufactured and subjected to cyclic mechanical testing. The finite-element analysis showed that the maximum stress was 242.9 MPa and this was less than the yield strength and the fatigue endurance limits for the selected materials. Mechanical testing showed that testing reached run-out of 170,000 cycles with no cracks or damage visible in the device parts.

A failed compass hinge external fixator for fingers has been analyzed. The device consists of polymer parts manufactured from polyetherimide. Finite element analysis (FEA) was used to investigate the principal stresses in the device under different loading conditions. Scanning electron microscopy (SEM) was used to investigate the fracture surfaces. The FEA showed that the maximum principal stress was greater than the fatigue strength of polyetherimide. The SEM fractographs confirm that failure was by brittle fatigue.

Mandibular angle fractures pose a significant clinical challenge in maxillofacial surgery, and conventional fixation systems often show merely adequate biomechanical performance. This study presents a new mini-plate geometric configuration and outlines its rigorous verification and a preliminary validation procedure. The proposed ‘U’-shaped grade 4 titanium mini-plate with self-tapping screws was developed specifically for the stable fixation of mandibular angle fractures. A three-dimensional mandible model incorporating an angular fracture gap exceeding 1 mm was constructed and analyzed using SolidWorks. Finite Element Analysis (FEA) was employed as a verification tool to evaluate stress, strain, and displacement distributions in the mandibular ramus, plate, and screws under bilateral masticatory muscle loading, with material integrity assessed against yield-strength thresholds using von Mises’ stress theory. Rapid and functional prototypes were subsequently fabricated to physically validate the proposed mini-plate. The maximum stress across the entire model was 446.8 MPa, localized at the middle lower screw, while the maximum stress at the designed plate was 110 MPa, which remains well within the safe limits and is approximately 60.7% lower than the reported maximum stress values for conventional fixation systems. The new mini-plate exhibited robust biomechanical performance, offering a more favorable mechanical environment conducive to bone healing.

Additive manufacturing is a star-rising technology around the globe. It satisfies key needs in different fields of interest on a global scale. For both ongoing industrial revolutions, it is considered an enabler as well as for achieving certain Sustainable Development Goals. Regarding the manufacturing sector, the technology serves well for different delicate fields like aerospace, automotive and medicine. Polymers are amongst the wide range of materials that are utilized in additive manufacturing. They provide indispensable mechanical properties in different fields as they possess light weight with high strength and toughness. The existence of polymers in the form of waste is massive, especially after the outbreak of COVID-19. The calls for sustainable development are global. Exploitation of polymer wastes as a feedstock material for additive manufacturing can be considered an opportunity to be seized by Egyptian manufacturers. Such that producing new products, reducing wastes and costs. These piles of waste may now be viewed as wealth. Under the umbrella of the current reforms and developments taking place in the country this can be called upon to be a national project. The paper presents an overview for the opportunity of establishing such a national recycling project in Egypt that depends on 3d printing.

This paper investigates a new external fixator system for treating finger contractures. This innovative system is electric and user-friendly, providing precise readings of the angles of diseased finger joints. Accurate measurements of the angles of the diseased finger joints can assist therapists and patients during rehabilitation procedures. The fixator consists of ten parts assembled using polyether-ether-ketone (PEEK) for the plastic components and stainless steel for the metal components. The design model was engineered, drawn, and analyzed using SolidWorks Computer-Aided Design software. The verification process utilizes finite element analysis to demonstrate that the maximum stress was lower than the yield strength of the chosen materials. As a result, the new device design is robust and stable enough to withstand the anticipated loading conditions of human fingers. Subsequently, a prototype was fabricated using advanced additive manufacturing technology, specifically fused deposition modeling (FDM). The proposed fixator is simple to control, reliable, easy to use, and reproducible. It enables device users to exercise their finger joints throughout the day without requiring the assistance of specialists.