Finite-element analysis of different fixation types after Enneking II + III pelvic tumor resection.

The current primary treatment approach for malignant pelvic tumors involves hemipelvic prosthesis reconstruction following tumor resection. In cases of Enneking type II + III pelvic tumors, the prosthesis necessitates fixation to the remaining iliac bone. Prevailing methods for prosthesis fixation include the saddle prosthesis, ice cream prosthesis, modular hemipelvic prosthesis, and personalized prosthetics using three-dimensional printing. To prevent failure of hemipelvic arthroplasty protheses, a novel fixation method was designed and finite element analysis was conducted. In clinical cases, the third and fourth sacral screws broke, a phenomenon also observed in the results of finite element analysis. Based on the original surgical model, designs were created for auxiliary dorsal iliac, auxiliary iliac bottom, auxiliary sacral screw, and auxiliary pubic ramus fixation. A nonlinear quasi-static finite element analysis was then performed under the maximum load of the gait cycle, and the results indicated that assisted sacral dorsal fixation significantly reduces stress on the sacral screws and relative micromotion exceeding 28 µm. The fixation of the pubic ramus further increased the initial stability of the prosthesis and its interface osseointegration ability. Therefore, for hemipelvic prostheses, incorporating pubic ramus support and iliac back fixation is advisable, as it provides new options for the application of hemipelvic tumor prostheses.

Crack-Deflecting Lattice Metamaterials Inspired by Precipitation Hardening.

Lattice structures, comprising nodes and struts arranged in an array, are renowned for their lightweight and unique mechanical deformation characteristics. Previous studies on lattice structures have revealed that failure often originates from stress concentration points and spreads throughout the material. This results in collapse failure, similar to the accumulation of damage at defects in metallic crystals. Here the precipitation hardening mechanism found in crystalline materials is employed to deflect the initial failure path, through the strategic placement of strengthening units at stress concentration points using the finite element method. Both the mesostructure, inspired by the arrangement of crystals, and the inherent microstructure of the base materials have played crucial roles in shaping the mechanical properties of the macro-lattices. As a result, a groundbreaking multiscale hierarchical design methodology, offering a spectrum of design concepts for engineering materials with desired properties is introduced.

In vitro evaluation of the biocompatibility and bioactivity of a SLM-fabricated NiTi alloy with superior tensile property.

Because nickel-titanium (NiTi) alloys have unique functions, such as superelasticity, shape memory, and hysteresis similar to bone in the loading-unloading cycles of their recoverable deformations. They likely offer good bone integration, a low loosening rate, individual customization, and ease of insertion. Due to the poor processability of NITI, traditional methods cannot manufacture NiTi products with complex shapes. Orthopedic NiTi implants need to show an adequate fracture elongation of at least 8%. Additive manufacturing can be used to prepare NiTi implants with complex structures and tunable porosity. However, as previously reported, additively manufactured NiTi alloys could only exhibit a maximum tensile fracture strain of 7%. In new reports, a selective laser melting (SLM)-NiTi alloy has shown greater tensile strain (15.6%). Nevertheless, due to the unique microstructure of additive manufacturing NiTi that differs from traditional NITI, the biocompatibility of SLM-NITI manufactured by this new process requires further evaluation In this study, the effects of the improved NiTi alloy on bone marrow mesenchymal stem cell (BMSC) proliferation, adhesion, and cell viability were investigated via in vitro studies. A commercial Ti-6Al-4V alloy was studied side-by-side for comparison. Like the Ti-6Al-4V alloy, the SLM-NiTi alloy exhibited low cytotoxicity toward BMSCs and similar effect on cell adhesion or cell viability. This study demonstrates that the new SLM-NiTi alloy, which has exhibited improved mechanical properties, also displays excellent biocompatibility. Therefore, this alloy may be a superior implant material in biomedical implantation.

Study of the influence of macro-structure and micro-structure on the mechanical properties of stag beetle upper jaw.

Macrostructural control of stress distribution and microstructural influence on crack propagation is one of the strategies for obtaining high mechanical properties in stag beetle upper jaws. The maximum bending fracture force of the stag beetle upper jaw is approximately 154, 000 times the weight of the upper jaw. Here, we explore the macro and micro-structural characteristics of two stag beetle upper jaws and reveal the resulting differences in mechanical properties and enhancement mechanisms. At the macroscopic level, the elliptic and triangular cross-sections of the upper jaw of the two species of stag beetles have significant effects on the formation of cracks. The crack generated by the upper jaws with a triangular section grows slowly and deflects easily. At the microscopic level, the upper jaw of the two species is a chitin cross-layered structure, but the difference between the two adjacent fiber layers at 45° and 50° leads to different deflection paths of the cracks on the exoskeleton. The mechanical properties of the upper jaw of the two species of stag beetle were significantly different due to the interaction of macro-structure and micro-structure. In addition, a series of bionic samples with different cross-section geometries and different fiber cross angles were designed, and mechanical tests were carried out according to the macro-structure and micro-structure characteristics of the stag beetle upper jaw. The effects of cross-section geometry and fiber cross angle on the mechanical properties of bionic samples are compared and analyzed. This study provides new ideas for designing and optimizing highly loaded components in engineering. STATEMENT OF SIGNIFICANCE: The upper jaw of the stag beetle is composed of a complex arrangement of chitin and protein fibers, providing both rigidity and flexibility. This structure is designed to withstand various mechanical stresses, including impacts and bending forces, encountered during its burrowing activities and interactions with its environment. The study of the upper jaw of the stag beetle can provide an efficient structural design for engineering components that are subjected to high loads. Understanding the relationship between structure and mechanical properties in the stag beetle upper jaw holds significant implications for biomimetic design and engineering.

Research on Friction Performance of Friction Stir Welding Tools Based on Non-Smooth Structure.

In this study, based on the principles of bionics, we fabricated a bionic non-smooth concave pit structure on the shoulders of friction stir welding tools and detected the thermal cycling curve, downforce, and torque of the tool in the welding process. We tested the wear loss weight and analyzed the surface morphology of the shoulder surfaces after welding for 200 m. This study found that as the distance between the concave pits decreased and the number of concave pits increased, the maximum downforce, torque, and temperature in the welding process showed a decreasing trend. As the speed increased, no matter how the tool structure changed, the downforce and torque decreased, while the peak thermal cycle temperature increased. The experimental welding results show that the wear loss weight of the non-smooth structure tool significantly reduced. The lowest wear loss weight of the tool with a concave pit interval of 1.125 mm was only 0.1529 g, which is 27% lower than that of the conventional tool. Our observations of the surface morphology of the tool shoulder after welding showed that the amount of aluminum swarf on the tool shoulder of the welding tool gradually declined with the increasing density of the uneven pits. The lowest number of aluminum chips adhered to a welding tool with a pit distance of 1.125 mm. Therefore, friction stir welding tools with biomimetic structures have better wear resistance and adhesion resistance.

Highly Robust and Self-Adhesive Soft Strain Gauge via Interface Design Engineering.

Highly robust soft strain gauges are rapidly emerging as a promising candidate in the fields of vital signs and machine conditions monitoring. However, it is still a key challenge to achieve high-performance strain sensing in these sensors with mechanical/electrical robustness for long-term usage. The multilayer structural design of sensors enhances sensing performance while the interfacial connection of heterogeneous materials between different layers is weak. Herein, inspired by the efficient perception mechanism of scorpion slit sensilla with tough interface interconnections, the synergy of ultra-high electrical performance and mechanical robustness is successfully achieved via interface design engineering. The developed multilayer soft strain gauge (MSSG) exhibits a strain sensitivity beyond 105, a lower detection limit of 8.3 µm, a frequency resolution within 0.1 Hz, and cyclic stability over 63 000 strain cycles. Also, the tough interface improves the level of heterogeneous integration in the MSSG which allows to endure different stresses. Furthermore, an MSSG-based wireless strain monitoring system is developed that enables applications on different complex dynamic surfaces, including accurate identification of human throat activity and monitoring of rolling bearing conditions.

Strengthening and Toughening of ZG25SiMn2CrB Steel without Tempering Brittleness via Electropulsing Treatment.

High-strength low-alloy steels are widely used, but their traditional heat-treatment process is complex, energy-intensive, and makes it difficult to fully exploit the material's potential. In this paper, the electropulsing processing technology was applied to the quenching and tempering process of ZG25SiMn2CrB steel. Through microstructural characterization and mechanical property testing, the influence of electropulsing on the solid-state phase transition process of annealing steel was systematically studied. The heating process of the specimen with the annealing state (initial state) is the diffusion-type transition. As the discharge time increased, the microstructure gradually transformed from ferrite/pearlitic to slate martensite. Optimal mechanical properties and fine microstructure were achieved after quenching at 500 ms. The steel subjected to rapid tempering with 160 ms electropulsing exhibited good, comprehensive mechanical properties (tensile strength 1609 MPa, yield strength 1401.27 MPa, elongation 11.63%, and hardness 48.68 HRC). These favorable mechanical properties are attributed to the coupled impact of thermal and non-thermal effects induced by high-density pulse current. Specifically, the thermal effect provides the thermodynamic conditions for phase transformation, while the non-thermal effect reduces the nucleation barrier of austenite, which increases the nucleation rate during instantaneous heating, and the following rapid cooling suppresses the growth of austenite grains. Additionally, the fine microstructure prevents the occurrence of temper brittleness.

Surface Finish Analysis of Gradient Voltage Electrochemical Polishing of 316L Stainless Steel Parts Forming by Laser Powder Bed Fusion.

Laser powder bed fusion (LPBF) of complex-structure 316L stainless steel (316L ss) parts has a wide application prospects in aerospace, biomedical, and defense industry fields. However, the surface roughness (Ra) of the LPBF sample is unsatisfactory due to the process characteristics of layer-by-layer selective melting and cumulative forming, which limits its applications in the engineering field. Herein, a gradient voltage electrochemical polishing strategy is proposed based on the characteristics of electrochemical polishing technology, which can polish complex structures. The mechanisms of polishing process parameters and polishing strategy on the surface finish of LPBF parts are investigated. The gradient voltage polishing strategy is extended to complex structures, and the Ra of the inner surfaces of square and round tubes are successfully reduced to about 1 µm. The gradient electrochemical polishing process for surface finish post-treatment of LPBF parts can broaden the engineering applications of complex-structure metal parts.

Non-invasive in vivo study of morphology and mechanical properties of the median nerve.

The current literature studied the median nerve (MN) at specific locations during joint motions. As only a few particular parts of the nerve are depicted, the relevant information available is limited. This experiment investigated the morphological and biomechanical properties of the MN. The effects of the shoulder and wrist motions on MN were explored as well. Eight young healthy female individuals were tested with two-dimensional ultrasound and shear wave elastography (SWE). The morphological and biomechanical properties were examined in limb position 1, with the wrist at the neutral position, the elbow extended at 180°, and the shoulder abducted at 60°. In addition, the experiment assessed the differences among the wrist, forearm, elbow, and upper arm with Friedman's test and Bonferroni post hoc analysis. Two groups of limb positions were designed to explore the effects of shoulder movements (shoulder abducted at 90° and 120°) and wrist movements (wrist extended at 45° and flexed at 45°) on the thickness and Young's modulus. Differences among the distributions of five limb positions were tested as well. The ICC3, 1 values for thickness and Young's modulus were 0.976 and 0.996, respectively. There were differences among the MN thicknesses of four arm locations in limb position 1, while Young's modulus was higher at the elbow and wrist than at the forearm and upper arm. Compared to limb position 1, only limb position 4 had an effect on MN thickness at the wrist. Both shoulder and wrist motions affected MN Young's modulus, and the stiffness variations at typical locations all showed a downward trend proximally in all. The distributions of MN thickness and Young's modulus showed fold line patterns but differed at the wrist and the pronator teres. The MN in the wrist is more susceptible to limb positions, and Young's modulus is sensitive to nerve changes and is more promising for the early diagnosis of neuropathy.

An Improved Extreme Learning Machine (ELM) Algorithm for Intent Recognition of Transfemoral Amputees With Powered Knee Prosthesis.

To overcome the challenges posed by the complex structure and large parameter requirements of existing classification models, the authors propose an improved extreme learning machine (ELM) classifier for human locomotion intent recognition in this study, resulting in enhanced classification accuracy. The structure of the ELM algorithm is enhanced using the logistic regression (LR) algorithm, significantly reducing the number of hidden layer nodes. Hence, this algorithm can be adopted for real-time human locomotion intent recognition on portable devices with only 234 parameters to store. Additionally, a hybrid grey wolf optimization and slime mould algorithm (GWO-SMA) is proposed to optimize the hidden layer bias of the improved ELM classifier. Numerical results demonstrate that the proposed model successfully recognizes nine daily motion modes including low-, mid-, and fast-speed level ground walking, ramp ascent/descent, sit/stand, and stair ascent/descent. Specifically, it achieves 96.75% accuracy with 5-fold cross-validation while maintaining a real-time prediction time of only 2 ms. These promising findings highlight the potential of onboard real-time recognition of continuous locomotion modes based on our model for the high-level control of powered knee prostheses.

Soft Actuator with Biomass Porous Electrode: A Strategy for Lowering Voltage and Enhancing Durability.

Electroactive artificial muscles with deformability have attracted widespread interest in the field of soft robotics. However, the design of artificial muscles with low-driven voltage and operational durability remains challenging. Herein, novel biomass porous carbon (BPC) electrodes are proposed. The nanoporous BPC enables the electrode to provide exposed active surfaces for charge transfer and unimpeded channels for ion migration, thus decreasing the driving voltage, enhancing time durability, and maintaining the actuation performances simultaneously. The proposed actuator exhibits a high displacement of 13.6 mm (bending strain of 0.54%) under 0.5 V and long-term durability of 99.3% retention after 550,000 cycles (∼13 days) without breaks. Further, the actuators are integrated to perform soft touch on a smartphone and demonstrated as bioinspired robots, including a bionic butterfly and a crawling robot (moving speed = 0.08 BL s-1). This strategy provides new insight into the design and fabrication of high-performance electroactive soft actuators with great application potential.

Multi-Level Structural Enhancement Mechanism of the Excellent Mechanical Properties of Dung Beetle Leg Joint.

The multi-level structure is a strategy to enhance the mechanical properties of dung beetle leg joints. Under external loads, the microstructure facilitates energy dissipation and prevents crack extension. The macrostructure aids in transferring the load to more reliable parts. The connection established by the two hemispheres is present in the dung beetle leg joint. The micron-layered and nanoscale crystal structures further constitute the leg joint with excellent mechanical properties. The maximum compression fracture force is ≈101000 times the weight of the leg. Here, the structural design within the dung beetle leg joints and reveal the resulting mechanical response and enhancement mechanisms is determined. A series of beetle leg joints where the macrostructure and microstructure of the dung beetle leg provide mechanical strength at critical strains while avoiding catastrophic failure by transferring the load from the joint to the exoskeleton of the femur is highlighted. Nanocrystalline structures and fiber layers contribute to crack propagation of the exoskeleton. Based on this, the bionic joint with multi-level structures using resin and conducted a series of tests to verify their effectiveness is prepared. This study provides a new idea for designing and optimizing high-load joints in engineering.

Bio-Inspired Interlocking Structures for Enhancing Flexible Coatings Adhesion.

The flexible protective coatings and substrates frequently exhibit unstable bonding in industrial applications. For strong interfacial adhesion of heterogeneous materials and long-lasting adhesion of flexible protective coatings even in harsh corrosive environments. Inspired by the interdigitated structures in Phloeodes diabolicus elytra, a straightforward magnetic molding technique is employed to create an interlocking microarray for reinforced heterogeneous assembly. Benefiting from this bio-inspired microarrays, the interlocking polydimethylsiloxane (PDMS) coating recorded a 270% improvement in tensile adhesion and a 520% increase in shear resistance, approaching the tensile limitation of PDMS. The elastic polyurethane-polyamide (PUPI) coating equipped with interlocking structures demonstrated a robust adhesion strength exceeding 10.8 MPa and is nearly unaffected by the corrosion immersion. In sharp contrast, its unmodified counterpart exhibited low initial adhesion and maintain ≈20% of its adhesion strength after 30 d of immersion. PUPI coating integrated with microarrays exhibits superior resistance to corrosion (30 d, |Z|0.01HZ ≈1010 Ω cm2, Rct≈108 Ω cm2), cavitation and long-term adhesion retention. These interlocking designs can also be adapted to curved surfaces by 3D printing and enhances heterogeneous assembly of non-bonded materials like polyvinylidene fluoride (PTFE) and PDMS. This bio-inspired interlocking structures offers a solution for durably bonding incompatible interfaces across varied engineering applications.

Flexible Multimodal Sensing System Based on a Vertical Stacking Strategy for Efficiently Decoupling Multiple Signals.

Multisensory integration enables the simultaneous perception of multiple environmental stimuli while minimizing size and energy consumption. However, conventional multifunctional integration in flexible electronics typically requires large-scale horizontal sensing arrays (such as flexible printed circuit boards), posing decoupling complexities, tensile strain limitation, and spatial constraints. Herein, a fully flexible multimodal sensing system (FMSS) is developed by coupling biomimetic stretchable conductive films (BSCFs) and strain-insensitive communication interfaces using a vertical stacking integration strategy. The FMSS achieves vertical integration without additional adhesives, and it can incorporate individual sensing layers and stretchable interconnects without any essential constraint on their deformations. Accordingly, the temperature and pressure are precisely decoupled simultaneously, and tensile stress can be accurately discerned in different directions. This vertical stacking integration strategy is expected to offer a new approach to significantly streamline the design and fabrication of multimodal sensing systems and enhance their decoupling capabilities.

Underwater Bionic Self-Healing Superhydrophobic Coating with the Synergetic Effect Of Hydrogen Bonds and Self-Formed Bubbles.

The self-healing ability of superhydrophobic surfaces in air has attracted tremendous additions in recent years. Once the superhydrophobic surface is damaged underwater, water seeps into gaps among micro/nano structures. The air film diffuses into water and eventually disappears during immersion without actively replenishing the gas, which results in the impossible of self-healing. Here, an underwater self-healing superhydrophobic coating with the synergetic effect of hydrogen bonds and self-formed bubbles via the spraying method is fabricated. The movement of hydrogen bonds of the prepared polyurethane enables microstructures to reconstruct at room temperature and self-formed bubbles of effervescent materials underwater actively replenish gas before microstructures completely self-healing, achieving the self-healing property of the superhydrophobic coating. Moreover, the hydrophilic effervescent material is sprayed along with unmodified micron-scaled particles because modified nano-scale particles are key factors for the realization of superhydrophobic coating. An underwater stable superhydrophobic surface with pressure resistance (4.9 kPa) is demonstrated. This superhydrophobic coating also shows excellent drag reduction, anti-icing, and anti-corrosion properties. This facile and scalable method offers a new route that an underwater self-healing superhydrophobic coating executes the gas film recovery.

Novel-Ink-Based Direct Ink Writing of Ti6Al4V Scaffolds with Sub-300 µm Structural Pores for Superior Cell Proliferation and Differentiation.

Ti6Al4V scaffolds with pore sizes between 300 and 600 µm are deemed suitable for bone tissue engineering. However, a significant proportion of human bone pores are smaller than 300 µm, playing a crucial role in cell proliferation, differentiation, and bone regeneration. Ti6Al4V scaffolds with these small-sized pores are not successfully fabricated, and their cytocompatibility remains unknown. The study presents a novel ink formula specifically tailored for fabricating Ti6Al4V scaffolds featuring precise and unobstructed sub-300 µm structural pores, achieved by investigating the rheological properties and printability of five inks containing 60-77.5 vol% Ti6Al4V powders and bisolvent binders. Ti6Al4V scaffolds with 50-600 µm pores are fabricated via direct ink writing and subjected to in vitro assays with MC3T3-E1 and bone marrow mesenchymal stem cells. The 100 µm pore-sized scaffolds exhibit the highest cell adhesion and proliferation capacity based on live/dead assay, FITC-phalloidin/4',6-diamidino-2-phenylindole staining, and cell count kit 8 assay. The alizarin red staining, real-time quantitative PCR assay, and immunocytochemical staining demonstrate the superior osteogenic differentiation potential of 100 and 200 µm pore-sized scaffolds. The importance of sub-300 µm structrual pores is highlighted, redefining the optimal pore size for Ti6Al4V scaffolds and advancing bone tissue engineering and clinical medicine development.

Study on Osseointegration Capability of ß-Type Ti-Nb-Zr-Ta-Si Alloy for Orthopedic Implants.

Osseointegration is the basic condition for orthopedic implants to maintain long-term stability. In order to achieve osseointegration, a low elastic modulus is the most important performance indicator. It is difficult for traditional titanium alloys to meet this requirement. A novel ß-titanium alloy (Ti-35Nb-7Zr-5Ta)98Si2 was designed, which had excellent strength (a yield strength of 1296 MPa and a breaking strength 3263 MPa), an extremely low elastic modulus (37 GPa), and did not contain toxic elements. In previous in vitro studies, we confirmed the good biocompatibility of this alloy and similar bioactivity to Ti-6Al-4V, but no in vivo study was performed. In this study, Ti-6Al-4V and (Ti-35Nb-7Zr-5Ta)98Si2 were implanted into rabbit femurs. Imaging evaluation and histological morphology were performed, and the bonding strength and bone contact ratio of the two alloys were measured and compared. The results showed that both alloys remained in their original positions 3 months after implantation, and neither imaging nor histological observations found inflammatory reactions in the surrounding bone. The bone-implant contact ratio and bonding strength of (Ti-35Nb-7Zr-5Ta)98Si2 were significantly higher than those of Ti-6Al-4V. The results confirmed that (Ti-35Nb-7Zr-5Ta)98Si2 has a better osseointegration ability than Ti-6Al-4V and is a promising material for orthopedic implants.

High-Fidelity, Low-Hysteresis Bionic Flexible Strain Sensors for Soft Machines.

Stretchable flexible strain sensors based on conductive elastomers are rapidly emerging as a highly promising candidate for popular wearable flexible electronic and soft-mechanical sensing devices. However, due to the intrinsic limitations of low fidelity and high hysteresis, existing flexible strain sensors are unable to exploit their full application potential. Herein, a design strategy for a successive three-dimensional crack conductive network is proposed to cope with the uncoordinated variation of the output resistance signal arising from the conductive elastomer. The electrical characteristics of the sensor are dominated by the successive crack conductive network through a greater resistance variation and a concise sensing mechanism. As a result, the developed elastomer bionic strain sensors exhibit excellent sensing performance in terms of a smaller overshoot response, a lower hysteresis (∼2.9%), and an ultralow detection limit (0.00179%). What's more, the proposed strategy is universal and applicable to many conductive elastomers with different conductive fillers (including 0-D, 1-D, and 2-D conductive fillers). This approach improves the sensing signal accuracy and reliability of conductive elastomer strain sensors and holds promising potential for various applications in the fields of e-skin and soft robotic systems.

Bioinspired Structural Composite Flexible Material with High Cushion Performance.

Impacts occur everywhere, and they pose a serious threat to human health and production safety. Flexible materials with efficient cushioning and energy absorption are ideal candidates to provide protection from impacts. Despite the high demand, the cushioning capacity of protective materials is still limited. In this study, an integrated bionic strategy is proposed, and a bioinspired structural composite material with highly cushioning performance is developed on the basis of this strategy. The results demonstrated that the integrated bionic material, an S-spider web-foam, has excellent energy storage and dissipation as well as cushioning performance. Under impact loading, S-spider web-foam can reduce peak impact forces by a factor of 3.5 times better than silicone foam, achieving unprecedented cushioning performance. The results of this study deepen the understanding of flexible cushioning materials and may provide new strategies and inspiration for the preparation of high-performance flexible cushioning materials.