COVID-19 pandemic provoked a number of restrictive measures, such as the closure or severe restriction of border transit for international trading traffic, quarantines and self-isolation. This caused a series of interrelated consequences that not only prevent or slow down the spread of disease, but also impact the medical systems’ capability to treat the patients and help their recovery. In particular, steeply growing demand for medical safety goods cannot be satisfied by regular suppliers due to the shortage of raw materials originating from other countries or remotely located national sources, under conditions of quarantined manpower. The current context inevitably brings back memories (and records!) of the situation 80 years ago, when WWII necessitated major effort directed at the rapid build-up of low cost mass production to satisfy all aspects of war-time need. In the present short report we document a successful case of fast mass-production of light transparent medical safety face shields (thousands per day) realized in Skolkovo Institute of Science and Technology (Skoltech) fabrication laboratory (FabLab). The demand for safety face shields by tens of hospitals in Moscow City and Region rapidly ramped up due to the need to protect medical staff during patient collection and transportation to hospitals, and within both the infected (“red”) and uninfected (“green”) zones. Materials selection for sterilizable transparent materials was conducted based on the analysis of merit indices, namely, minimal weight at given stiffness and minimal cost at given stiffness. Due to the need for permanent wear, design was motivated by low weight and comfortable head fixation, along with high production efficiency. The selection of minimal tooling in University fabrication workshops and the use of distributed volunteer labor are discussed.

3D-printed aluminium alloy fabrications made by selective laser melting (SLM) offer a promising route for the production of small series of custom-designed heat exchangers with complex geometry and shape and miniature size. Alloy composition and printing parameters need to be optimized to mitigate fabrication defects (pores and microcracks) and enhance the part performance. The deformation response needs to be studied with adequate characterization techniques at relevant dimensional scale capturing the peculiarities of micro-mechanical behavior relevant to the particular article and specimen dimensions. Purposefully designed Al-Si-Mg 3D-printable RS-333 alloy was investigated with a number of microscopy techniques including in situ mechanical testing with a Deben Microtest 1 kN stage integrated and synchronized with Tescan Vega3 SEM to acquire high resolution image datasets for Digital Image Correlation (DIC) analysis. Dog bone specimens were 3D-printed in different orientation of gauge zone cross-section with respect to the fast laser beam scanning and growth directions. This corresponds to varying local conditions of metal solidification and cooling. Specimens show variation in mechanical properties, namely, Young’s modulus (65…78 GPa), yield stress (80–150 MPa), ultimate tensile strength (115–225 MPa) and elongation at break (0,75–1,4 %). Furthermore, the failure localization and character was altered with the change of gauge cross-section orientation. DIC analysis allowed correct strain evaluation that overcame the load frame compliance effect and helped to identify the unevenness of deformation distribution (plasticity waves) that ultimately resulted in exceptionally high strain localization near the ultimate failure crack position.

Epoxy matrix composites reinforced with high-performance fibers such as carbon, Kevlar, and glass, exhibit excellent specific stiffness and strength in many mechanical applications. However, these composites are disappointingly non-recyclable and are usually disposed of in landfill sites, with no realistic prospect for biodegradation in reasonable time. In contrast, moldable composites with carbonized elastomeric matrices developed in the last decades possess attractive mechanical properties in final net-shape products and can also be incinerated or recycled. Many carbon and inorganic fillers have recently been evaluated to adjust the properties of carbonized elastomeric composites. Renewable organic fillers such as human or animal hair offer an attractive fibrous material with substantial potential for reinforcing composites with elastomeric matrices. Samples of unidirectional fiber composites (with hair volume fraction up to 7 %) and quasi-isotropic short fiber composites (with hair volume fraction up to 20 %) of human hair-reinforced nitrile butadiene rubbers (HH-NBR) were produced in the peroxide-cured and carbonized states. The samples were characterized using SEM, Raman spectroscopy and photoacoustic microscopy. Mechanical tests were performed in tension using a miniature universal testing machine. The expected effect of fiber reinforcement on the overall mechanical performance has been demonstrated for both cured and carbonized composites. Considerable enhancement of the elastic modulus (up to 10 times), ultimate tensile strength (up to 3 times) and damage tolerance was achieved. The evidence of satisfactory interfacial bonding between hair and rubber was confirmed by SEM imaging of fracture surfaces. The suitability of photoacoustic microscopy was assessed for 3D reconstruction of the fiber sub-system spatial distribution and non-destructive testing.

Ultra high molecular weight polyethylene (UHMWPE) is a thermoplastic high-performance polymer in high demand for biomedicine, ship and machine building, anthropomorphic robots and smart prostheses. Highly oriented UHMWPE fibers possess record specific strength and may also be used for the fabrication of self-reinforced PE-PE composites (SRPEC). The temperature evolution study of the small-angle X-ray scattering (SAXS) signature of the supramolecular structure of UHMWPE can help reveal their important role in the mechanism of the shape memory effect in SRPEC. The laboratory SAXS–WAXS beamline XEUSS 3.0 was used for in situ studies of the nanostructure parameters in unidirectional SRPEC. Namely, the radius of gyration and the dimensionality factor were extracted from 2D SAXS patterns using several fitting algorithms. Significant changes of these parameters occurred in temperature ranges that correspond to the initiation of the shape memory effect and melting. The relationship between the material anisotropy and 2D SAXS patterns are discussed in the context of the supramolecular structure evolution.

The reported study was devoted to the investigation of viscoelastic behavior for solid and porous ultra-high-molecular-weight polyethylene (UHMWPE) under compression. The obtained experimental stress curves were interpreted using a two-term Prony series to represent the superposition of two coexisting activation processes corresponding to long molecular (~160 s) and short structural (~20 s) time scales, respectively, leading to good statistical correlation with the observations. In the case of porous polymer, the internal strain redistribution during relaxation was quantified using Digital Image Correlation (DIC) analysis. The strongly inhomogeneous deformation of the porous polymer was found not to affect the relaxation times. In order to generalize the results to three dimensions, X-ray tomography was used to examine the porous structure at the macro- and micro-scale levels. DIC analysis revealed positive correlation between the applied force and relative density. The apparent stiffness variation for UHMWPE foams with mixed open and closed cells was described using a newly proposed three-term expression. Furthermore, the in situ tensile loading and X-ray scattering study was applied for isotropic solid UHMWPE specimens to investigate their parameters of internal structure during orientation and stress relaxation process at another mode.

Recent years witnessed progressive broadening of the practical use of 3D-printed aluminium alloy parts, in particular for specific aerospace applications where weight saving is of great importance. Selective laser melting (SLM) is an intrinsically multi-parametric fabrication technology that offers multiple means of controlling mechanical properties (elastic moduli, yield strength, ductility) through the control over grains size, shape, and orientation. Ultimately, this approach implies that structural elements can be purposefully fabricated to reinforce specific zones and directions where higher mechanical loads are anticipated by design. Targeted control over mechanical properties is achieved through the tuning of 3D-printing parameters and may even obviate the need of heat treatment or mechanical post-processing. Systematic studies of grain structure for different printing orientation with the help of EBSD techniques in combination with mechanical testing at different dimensional levels are the necessary first steps to implement this agenda. Samples of 3D-printable Al-Mg-Si RS-333 alloy were fabricated in 3 orientations with respect to the principal build direction and the fast laser beam scanning direction. Sample structure and proper-ties were investigated using a number of techniques, including EBSD, in situ SEM tensile testing, roughness measurements and nanoindentation. The as-printed samples we found to display strong variation in Young’s modulus values from nanoindentation (from 43 to 66 GPa) and tensile tests (from 54 to 75 GPa), yield stress and ultimate tensile strength (100…195 and 130…220 MPa) in different printing orientations, and almost constant hardness of about 0.8 GPa. A further preliminary study was conducted of the effect of surface finishing on the mechanical performance. Surface polishing appears to reduce Young’s modulus and yield strength, but improves ductility, whereas the influence of sand blasting is more controversial. The experimental results are dis-cussed in connection with the grain morphology and orientation.

Porous ultra-high molecular weight polyethylene (UHMWPE) is a high performance bioinert polymer used in cranio-facial reconstructive surgery in procedures where relatively low mechanical stresses arise. As an alternative to much stiffer and costly polyether-ether-ketone (PEEK) polymer, UHMWPE finds further wide application in hierarchically structured hybrids for advanced implants mimicking cartilage, cortical and trabecular bone tissues within a single component. The mechanical behaviour of open-cell UHMWPE sponges obtained through sacrificial desalination of hot compression-moulded UHMWPE-NaCl powder mixtures shows a complex dependence on the fabrication parameters and microstructural features. In particular, similarly to other porous media it displays significant inhomogeneity of strain that readily localises within deformation bands that govern the overall response. In this article, we report advances in the development of accurate experimental techniques for operando studies of the structure-performance relationship applied to the porous UHMWPE medium with pore sizes of about 250 µm that are most well-suited for live cell proliferation and fast vascularization of implants. Samples of UHMWPE sponges were subjected to in situ compression using a micromechanical testing device within Scanning Electron Microscope (SEM) chamber, allowing the acquisition of high-resolution image sequences for Digital Image Correlation (DIC) analysis. Special masking and image processing algorithms were developed and applied to reveal the evolution of pore size and aspect ratio. Key structural evolution and deformation localisation phenomena were identified at both macro- and micro-structural levels in the elastic and plastic regimes. The motion of pore walls was quantitatively described, and the presence and influence of strain localisation zones were revealed and analysed using DIC technique.

The carbonized elastomer-based composites (CECs) possess a number of attractive features in terms of thermomechanical and electromechanical performance, durability in aggressive media and facile net-shape formability, but their relatively low ductility and strength limit their suitability for structural engineering applications. Prospective applications such as structural elements of MEMS can be envisaged, since smaller principal dimensions reduce the susceptibility of components to residual stress accumulation during carbonization, and to brittle fracture in general. We report the results of operando in-SEM study of micro-deformation and fracture behavior of CECs based on NBR elastomeric matrices filled with carbon and silicon carbide. Nanostructured carbon composite materials were manufactured via compounding of elastomeric substance with carbon and SiC fillers using mixing rolling mill, vulcanization, and low-temperature carbonization. Double Edge Notched Tensile (DENT) specimens of vulcanized and carbonized elastomeric composites were subjected to in situ tensile testing in the chamber of the scanning electron microscope (SEM) Tescan Vega 3 using Deben Microtest 1 kN Tensile Stage. The series of acquired SEM images were analyzed by means of Digital Image Correlation (DIC) using Ncorr open source software to map the spatial distribution of strain. These maps were correlated with Finite Element Modelling (FEM) simulations to refine the values of elastic moduli. Besides, the elastic moduli were derived from unloading curve nanoindentation hardness measurements carried out using NanoScan-4D tester and interpreted using the Oliver-Pharr method. Carbonization causes significant increase of elastic moduli from 0.86 ± 0.07 to 14.12 ± 1.20 GPa for the composite with graphite and carbon black fillers. Nanoindentation measurements yield somewhat lower values, namely, 0.25 ± 0.02 GPa and 9.83 ± 1.10 GPa before and after carbonization respectively. The analysis of fractography images suggests that crack initiation, growth and propagation may occur both at the notch stress concentrator and relatively far from the notch. Possible causes of such response are discussed, namely, (1) residual stresses introduced by processing; (2) shape and size of fillers; and (3) the emanation and accumulation of gases in composites during carbonization.

SLM Additive Manufacturing has demonstrated great potential for aerospace applications when structural elements of individual design and/or complex shape need to be promptly supplied. 3D-printable AlSi10Mg (RS-300) alloy is widely used for the fabrication of different structures in aerospace industry. The importance of the evaluation of residual stresses that arise as a result of complex 3D-printing process thermal history is widely discussed in literature, but systematic assessment remains lacking for their magnitude, spatial distribution, and comparative analysis of different evaluation techniques. In this study we report the results of a systematic study of residual stresses in a 3D-printed double tower shaped samples using several approaches: the contour method, blind hole drilling laser speckle interferometry, X-ray diffraction, and Xe pFIB-DIC micro-ring-core milling analysis. We show that a high level of tensile and compressive residual stresses is inherited from SLM 3D-printing and retained for longer than 6 months. The stresses vary over a significant proportion of the material yield stress. All residual stress evaluation techniques considered returned comparable values of residual stresses even regardless of dramatically different dimensional scales from millimeters for the Contour Method down, laser speckle interferometry and XRD and down to small fractions of a mm (70 μm) for Xe pFIB-DIC ring-core drilling. The use of residual stress evaluation is discussed in the context of optimizing the printing strategy to enhance the mechanical performance and long-term durability.

The structure of self-reinforced composites (SRCs) based on ultra-high molecular weight 21 polyethylene (UHMWPE) was studied by means of Wide-Angle X-Ray Scattering (WAXS), X-Ray 22 tomography, Raman spectroscopy, Scanning Electron Microscopy (SEM) and in situ tensile testing 23 in combination with advanced processing tools like Avizo, ImageJ, and Ncorr to determine the cor-24 relation between the processing conditions, on the one hand, and the molecular structure and 25 mechanical properties, on the other. SRCs were fabricated by hot compaction of UHMWPE fibers at 26 different pressure and temperature combinations without addition of polymer matrix or softener. 27 It was found by WAXS that higher compaction temperatures led to more extensive melting of 28 fibers with the corresponding reduction of the Herman’s factor reflecting the degree of molecular 29 orientation, while the increase of hot compaction pressure suppressed the melting of fibers within 30 SRCs at a given temperature. X-Ray tomography proved the absence of porosity while polarized 31 light Raman spectroscopy measurements for both longitudinal and perpendicular fiber orienta-32 tions showed qualitatively the anisotropy of SRC samples. SEM revealed that the matrix was 33 formed by interlayers of molten polymer entrapped between fibers in SRCs. Moreover, in situ 34 tensile tests demonstrated the increase of Young’s modulus and tensile strength with increasing 35 temperature.