International Journal of Manufacturing Research (12 papers in press)

Regular Issues

• Open Access

  Study of the crosslinking of phenol-formaldehyde resins using diffuse reflectance infrared Fourier transform spectroscopy ( Free Full-text Access )

  by Bart?omiej Milewski, Piotr Jele?, Robert Antosz, Jadwiga Laska 
  Abstract: Comprehensive understanding of curing of phenolic resins in a complex system of abrasive materials is essential for improving quality and repeatability of high performance abrasive tools. In order to study crosslinking of phenol-formaldehyde resins, diffuse reflectance infrared Fourier transform spectroscopy (DRIFT) was used. Measurements were conducted in a heated chamber in the temperature range of 20-300Comprehensive understanding of curing of phenolic resins in a complex system of abrasive materials is essential for improving quality and repeatability of high performance abrasive tools. In order to study crosslinking of phenol-formaldehyde resins, diffuse reflectance infrared Fourier transform spectroscopy (DRIFT) was used. Measurements were conducted in a heated chamber in the temperature range of 20300C. The spectra made it possible to observe chemical changes occurring in the resin during the curing process. A detailed analysis of changes in the intensity of the bands related to the presence of the curing agent, active groups of resole resin and appearance of methylene bridges enabled the development of a method for monitoring the cross-linking process. Study showed that simultaneous crosslinking of resole and novolac occurs at significantly lower temperature, when compared to separate processes.
  Keywords: drifts; resin; phenolic; resole; novolac; ftir; spectroscopy; abrasive; manufacturing; curing; crosslinking.
  DOI: 10.1504/IJMR.2026.10079647
   
  

• Open Access

  Operational efficiency of industrial hydraulic drive systems ( Free Full-text Access )

  by Oleh Levchenko, Olexsander Gubarev, Kostjantyn Belikov, Yurii Tsybrii 
  Abstract: This article focuses on the hydraulic drive systems optimisation in terms of both energy efficiency and operational performance. The inconsistencies between schematics and system actions in an operating cycle as the main cause of energy losses was identified. To evaluate the overall efficiency, an integral efficiency coefficient was introduced, which is calculated over a complete cycle, considering the circuit configuration, the operating cycle, and the actuators characteristics. Since this coefficient alone does not take into account equipment cost and lifetime, the article proposes the operating efficiency coefficient, which integrates the energy equivalent equipment cost, lifetime, cycle parameters, and energy consumption. The comparison of the operating efficiency coefficient between different design options enables a quick selection of the optimal hydraulic schematic without detailed pre-calculations. This solution accelerates decision-making, helps engineers identify efficient configurations early, rationalizes hydraulic system design to balance energy efficiency, cost, and lifetime for high-performance, cost-effective hydraulic drives.
  Keywords: hydraulic drive system; operating efficiency coefficient; energy consumption; actuator; simplified simulation.
  DOI: 10.1504/IJMR.2026.10079648
   
  

• Open Access

  Development of Adjustable Conical Air Bearings for Non-Contact Direct Machine Drives ( Free Full-text Access )

  by Oleksii Breshev, Oleksandr Bashta, Pavlo Nosko, Alla Bashta, Karolina Chodnicka-Wszelak, Felix Unger, Eckart Uhlmann 
  Abstract: This paper presents improvements in non-contact direct machine drives through the development of adjustable conical air bearings that provide variable stiffness and load capacity over a wide range of rotational speeds and loads An analytical model of bearing systems based on parametric conversion of conical bearings into equivalent radial and thrust bearings is proposed Analytical relationships between the geometrical, structural and gas-dynamic parameters of the bearings are established The mathematical model is developed to investigate the system behaviour under resonant vibrations and an analytical criterion for the dynamic stability of the rotor is determined Pneumatic spindle was designed based on adjustable conical air bearings with different geometries An experimental test rig was developed and methodology for full-scale spindle testing was established Experimental verification of the modified design resulted in weight reduction by 11%, reduction in overall dimensions by 17 3%, reduction in air consumption by 25% and improved operating characteristics.
  Keywords: conical air bearings; manufacturing research; noncontact machine drives; gas-dynamic parameters; dynamic stability criterion; pneumatic spindle; bearing geometry.
  DOI: 10.1504/IJMR.2026.10079893
   
  

• Open Access

  Development of a model and strength assessment of an innovative multifunctional freight wagon ( Free Full-text Access )

  by Oleksiy Fomin, Pavlo Prokopenko, Oleksiy Melnyk, Tetiana Sotnikova, Vitaliy Lisnychiy, Ievgen Medvediev 
  Abstract: The current state of railway transport is characterized by continuously increasing requirements for the efficiency, safety, and versatility of rolling stock. The existing fleet of freight wagons often does not meet these demands, as most of them are highly specialized. This leads to inefficient use of the wagon fleet, empty runs, and increased operating costs. This paper presents the results of research on the development of a new model of an innovative multifunctional freight wagon and an assessment of its strength. Within the framework of the study, an analysis of the current state and development trends of multifunctional freight wagon designs was carried out. A conceptual model of an innovative multifunctional freight wagon has been developed, taking into account the requirements for versatility and the transportation of various types of cargo (bulk, packaged, and long-length). Strength calculations of the proposed design have been performed.
  Keywords: Innovations in manufacturing; railway transport; wagons; strength; reliability; load-bearing systems; computer modeling; simulations; multifunctionality; calculations.
  DOI: 10.1504/IJMR.2026.10080332
   
  

• Open Access

  FEM modelling of the influence of anti-vibration coatings on a gondola car ( Free Full-text Access )

  by Oleksiy Fomin, Oleksandr Kozynka, Tetiana Yarkho, Oleksiy Melnyk, Oleksandr Cherkashin, Ievgen Medvediev 
  Abstract: This study presents an analysis of the dynamic behavior of a freight gondola car using the finite element method (FEM), with a focus on the impact of anti-vibration coatings. A 3D model of the structure was developed in SolidWorks, taking into account the physical and mechanical properties of the materials. Modal and harmonic analyses were carried out to assess the influence of damping materials on vibration reduction and stress concentration mitigation. The results demonstrated the effectiveness of localized application of coatings in areas with high dynamic activity. Practical recommendations are provided regarding the selection of materials and integration methods into the structure to increase the service life of the gondola car and improve its vibroacoustic performance. The study also highlights the role of manufacturing innovations in enhancing structural reliability and operational efficiency in the railway sector.
  Keywords: manufacturing innovation; railway transport; railcars; operation; vibrations; strength; reliability; load-bearing structures; FEM modeling; protective coatings; automation; computer modeling; testing.
  DOI: 10.1504/IJMR.2026.10080333
   
  

• Open Access

  The application of mSLA printed micro-abrasive tools in precision machining of 41Cr4 alloy steel ( Free Full-text Access )

  by Dawid Zieliński, Mariusz Deja, Weronika Lubecka, Angelos P. Markopoulos 
  Abstract: The authors proposed a novel tool design with strictly defined external geometry that includes open gaps that serve as reservoirs for retaining the abrasive paste. It was possible to conduct precision-free abrasive machining with a dominant 3-body abrasive mechanism. The tools were reinforced with diamond abrasive grains just after printing and employed for precision surface machining of 41Cr4 alloy steel. The preliminary results demonstrated notable modifications in the surface topography of 41Cr4 samples as a function of cutting depth. As a result of the machining process, a significant improvement in surface quality was observed, as evidenced by a reduction in the values of the surface roughness parameters Sa and Sq. However, a basic evaluation of the surface of the tool after finishing the machining tests indicated relatively low wear. The free spaces designed into the working surface to act as reservoirs for collecting the abrasive paste had not been blurred.
  Keywords: precision machining; mSLA method; liquid resins; Rapid Tooling; surface topography.
  
  

• Open Access

  Development of an extrusion-based 3D-printing head with multiple nozzles supporting multiple layer heights ( Free Full-text Access )

  by George Tzanakis, George-Christopher Vosniakos 
  Abstract: One of the biggest drawbacks of 3D printing is low material deposition rate. The variable layer height technique can rectify this deficiency respecting at the same time dimensional accuracy and surface quality. In this work, a print head that automatically swaps printing nozzles of different diameter is proposed as a feasible way to printing artefacts by combining layers of different height. A systematic workflow from user requirements through to design, prototyping and testing is presented. The device that was developed exploits a rotary system around an inclined axis with respect to the vertical that allows the nozzles to be swapped, thus removing the inactive ones from the printing plane. The device was designed to be easily mechanically integrated in commercially available 3D printers and easily connected to its central control system with some adjustments. Tests were carried out confirming functionality of the device. The printing time is substantially reduced depending on the parts complexity, without compromising the curved geometry that requires a low layer height.
  Keywords: 3D printing; layer height; filament extrusion; nozzle; printing head; printing time; printing quality; multiple nozzles.
  DOI: 10.1504/IJMR.2026.10081711
   
  

• Open Access

  Digital transformation of manufacturing companies: mapping cross-domain interactions - case studies ( Free Full-text Access )

  by Damian Ciachorowski, Anna Maria Lis, Marek Chodnicki, Xi Wang 
  Abstract: The rapid development of technologies such as artificial intelligence has increased the pressure on manufacturing companies to deliver not only economic results but also to generate broader organisational and societal value. This article fills the gap by focusing on the interactions occurring during the digital transformation process at various levels of manufacturing enterprises. An analysis of cross-domain interactions showed that although the main sources of transformation are technological and managerial areas, its effects are most evident in the social and organisational dimensions. The article makes a theoretical contribution by reinforcing the discussion on the paradigm shift from Industry 4.0 to Industry 5.0. Furthermore, it argues for a stronger integration of sustainability-related dimensions in digital transformation, while pointing to the limitations of traditional frameworks such as the Triple Bottom Line or ESG, which, although useful, prove too simplistic to capture the complexity and dynamics of the interactive processes accompanying digital transformation.
  Keywords: Industry 4.0; Industry 5.0; cross-domain interactions; case study; sustainable digital transformation; dynamic capabilities; data management; socio-technical systems; organisational procedures; change management.
  
  

• Open Access

  Human-Robot Collaboration in Virtual Reality: Evaluating the Effects of Vibrotactile Feedback and Safety Information on Efficiency ( Free Full-text Access )

  by My Legendi, Anna Syberfeldt, Goran Grahn, Maurice Lamb 
  Abstract: A key challenge is ensuring safe human-robot collaboration, which relies on operators knowledge of the robots safety capabilities. We propose that virtual reality (VR) combined with vibrotactile feedback synchronised with the robots speed can act as a signifier of a collaborative robots motion affordance. In a pilot study, we examine whether this vibrotactile feedback is sufficient to improve task efficiency and whether prior information about the safety function, the vibrotactile representations, and procedural guidance influences it. The safety function limits the maximum allowed speed and can reduce task efficiency if repeatedly activated. Thirty participants were divided into two groups: one received minimal information, and the other received additional information and procedural guidance. Both groups completed the same task under three conditions: no vibrotactile feedback, constant, and varied, which represented the robots speed. The repeated-measures MANOVA indicated an overall group difference, but the follow-up ANOVAs did not support this effect.
  Keywords: Industry 5.0; Collaborative Robots; Human-Robot Collaboration; safety function; vibrotactile feedback; Virtual Reality; Affordance; Signifier; Trust in Robotics.
  DOI: 10.1504/IJMR.2026.10081841
   
  
• Dynamic response mechanism of SLM molding process parameters for high Solid Ratio AlSi10Mg alloys  
  by Dianwen Zhao, Jun Zhang, Fangyu Liu, Xingyan Li, Jianxin Xu 
  Abstract: Numerical simulations were conducted using Ansys Additive to investigate the variations in single-track melt pool dimensions and solid ratio of AlSi10Mg during SLM by controlling laser scanning speed. Results demonstrate that as the scanning speed decreases from 1,300 mm/s to 600 mm/s, the increased linear energy density induces significant melt pool expansion driven by heat accumulation effects predominantly under conduction-dominated mode. When the ratio of melt pool depth to powder layer thickness reaches 1.9, the solid ratio approaches unity. This condition ensures complete penetration through the current powder layer for high densification while eliminating underlying defects through remelting of the previous layer. By optimising the overlap ratio to 47.38%, appropriate inter-track bonding was achieved with reduced thermal stress and enhanced density. The study reveals that controlled energy input through velocity adjustment enables effective regulation of melt pool characteristics and defect mitigation in SLM-processed aluminium alloys.
  Keywords: SLM; Melt pool size; AlSi10Mg; Solid ratio; Powder thickness; Scanning speed; Melt pool depth; Melt pool width; Overlap length; Overlap ratio.
  DOI: 10.1504/IJMR.2026.10079424
   
  
• Bionic Structural Materials for Engineering and Biomedical Use: A Systematic Review of Fabrication and Functional Properties  
  by Mahesh Bhong, G. Murali, N. Bharathiraja, Sugumaran S, Vakiti Sreelatha Reddy, Ganesh Kondhalkar, Anant Kurhade 
  Abstract: Bionic structural materials are a new breed of bioinspired materials that have light-weightiness, mechanical strength, multifunctionality and modularity for engineering and biomedical applications. This systematic review utilises the PRISMA methodology to analyse 111 peer-reviewed studies and focuses on advances in their design, fabrication, performance, and applications from 20102025. The most prevalent fabrication strategies are additive manufacturing, freeze casting, layer-by-layer assembly, self-assembly, biomineralization, solgel processing and bio-manufacturing. Compared with traditional materials, these materials have excellent mechanical strength, fracture toughness, thermal insulation and acoustic damping properties, as well as good biocompatibility and self-healing ability. Their uses range from aerospace to biomedical implants, through civil infrastructure, robotics and protective systems. Therefore, future research should focus on AI-assisted design, sustainable bio-manufacturing and microorganism-assisted processing and advanced additive manufacturing, which would drive this biopolymer towards large scale industrial application.
  Keywords: Bionic materials; biomimicry; additive manufacturing; self-healing composites; biocompatibility; structural applications; sustainable materials.
  DOI: 10.1504/IJMR.2026.10080624
   
  
• Study on Axial Force and Delamination Defects in CFRP Low-Frequency Vibration Drilling Based on Orthogonal Experiments  
  by Zhenchao Yang, Shuhao Zhang, Yanfei Zhang, Meiling Guo, Feilong Liu, Quandai Wang 
  Abstract: To investigate the effects of low-frequency vibration drilling parameters on CFRP materials, orthogonal experiments varying drilling speed, feed rate, and amplitude were conducted. Range analysis examined average axial force and torque, while multiple linear regression established predictive models. An image processing method calculated delamination defect areas at hole entrances, determining delamination factors through predictive modeling. Results showed feed rate significantly influenced average axial force, torque, and delamination factor. Within the tested amplitude range, both axial force and delamination factor decreased with increasing amplitude, demonstrating that low-frequency vibration drilling effectively reduces delamination defects in CFRP hole processing.
  Keywords: CFRP; Low-frequency Vibration Drilling; Orthogonal Experiments; Axial Force; Delamination Factor.
  DOI: 10.1504/IJMR.2026.10080725