Open Access
Novel sensorized additive manufacturing-based enlighted tooling concepts for aeronautical parts
(Springer Nature, 2024-07-31) Uralde Jiménez, Virginia; Veiga Suárez, Fernando; Suárez, Alfredo; López, Alberto; Goenaga, Igor; Ballesteros Egüés, Tomás; Ingeniería; Ingeniaritza; Institute of Smart Cities - ISC
This paper presents lightweight tooling concepts based on additive manufacturing, with the aim of developing advanced tooling systems as well as installing sensors for real-time monitoring and control during the anchoring and manufacturing of aeronautical parts. Leveraging additive manufacturing techniques in the production of tooling yields benefits in manufacturing flexibility and material usage. These concepts transform traditional tooling systems into active, intelligent tools, improving the manufacturing process and part quality. Integrated sensors measure variables such as displacement, humidity and temperature allowing data analysis and correlation with process quality variables such as accuracy errors, tolerances achieved and surface finish. In addition to sensor integration, additive manufacturing by directed energy arc and wire deposition (DED-arc) has been selected for part manufacturing. The research includes the mechanical characterisation of the material and the microstructure of the material once manufactured by DED-arc. Design for additive manufacturing" principles guide the design process to effectively exploit the capabilities of DED-arc. These turrets, equipped with sensors, allow real-time monitoring and control of turret deformation during clamping and manufacturing of aeronautical parts. As a first step, deformation monitoring is carried out within the defined tolerance of ± 0.15, which allows a control point to be established in the turret. Future analysis of the sensor data will allow correlations with process quality variables to be established. Remarkably, the optimised version of the turret after applying DED technology weighed only 2.2 kg, significantly lighter than the original 6 kg version. Additive manufacturing and the use of lightweight structures for fixture fabrication, followed by the addition of sensors, provide valuable information and control, improving process efficiency and part quality. This research contributes to the development of intelligent and efficient tool systems for aeronautical applications.
Embargo
Rol enfermero en la rehabilitación de pacientes con ictus
(2025) Ballesteros Egüés, Tomás; Insausti Serrano, Ana María; Facultad de Ciencias de la Salud; Osasun Zientzien Fakultatea
Introducción. Las enfermedades cerebrovasculares, segunda causa de muerte en España en 2022 y principal causa de discapacidad en adultos, demandan enfoques innovadores en rehabilitación. El rol del trabajo de enfermería es un pilar imprescindible en la coordinación de los distintos profesionales que participan en dicha rehabilitación. En este TFG, se muestra el trabajo integrador de enfermería en un proyecto de investigación de la UPNA que evalúa la terapia subacuática como alternativa para pacientes con secuelas de ictus Objetivo. Integración del rol enfermero como coordinador de un proyecto de investigación multidisciplinar que compara los efectos de la terapia subacuática frente a terapias convencionales de rehabilitación en el paciente con ictus. Metodología. Se realizó una revisión bibliográfica sistemática en Medline, Web of Science, Scopus y PEDro, seleccionando 21 artículos (2016-2025) según criterios como estudios clínicos con pacientes post-ictus. Resultados: La terapia acuática mejoró significativamente la marcha, el equilibrio, la fuerza muscular y la calidad de vida en el 60% de los casos, superando a las terapias tradicionales, y resaltó la importancia de cuidados de enfermería como la monitorización de riesgos y la educación del paciente durante el tratamiento. Conclusiones: La terapia acuática es una alternativa prometedora para la rehabilitación post-ictus, requiriendo formación especializada en enfermería para su implementación segura. Se está realizando un proyecto de investigación, enlazado con este TFG, donde Enfermería además asume un rol de coordinación.
Open Access
Development of an inexpensive rollover energy dissipation device to improve safety provided by ROPS
(Elsevier, 2019-02-21) Latorre Biel, Juan Ignacio; Ballesteros Egüés, Tomás; Arana Navarro, Ignacio; Alfaro López, José Ramón; Ingeniería; Ingeniaritza; Institute of Smart Cities - ISC
Open Access
Advancements and methodologies in directed energy deposition (DED-Arc) manufacturing: design strategies, material hybridization, process optimization and artificial intelligence
(IntechOpen, 2024-09-27) Uralde Jiménez, Virginia; Suárez, Alfredo; Veiga Suárez, Fernando; Villanueva Roldán, Pedro; Ballesteros Egüés, Tomás; Ingeniería; Ingeniaritza; Institute of Smart Cities - ISC
This chapter explores the latest advancements and methodologies in directed energy deposition (DED-arc) manufacturing. The introduction sets the stage for understanding the significance of these developments in the context of modern manufacturing needs. The discussion includes design strategies for DED-arc, emphasizing topological optimization, functional design, and generative design, alongside the application of artificial intelligence (AI) in enhancing design processes. Innovative approaches to material hybridization are detailed, focusing on both multilayer and in situ techniques for combining different materials to optimize component performance. The paper also covers slicing and pathing, examining slicing strategies, the use of lattice structures, and the implementation of 2D and 3D patterns to improve manufacturing efficiency and product quality. The conclusion summarizes key findings, discusses their implications for the additive manufacturing industry, and suggests potential future research directions in DED-arc technology, highlighting the emerging trends and innovations that are shaping the field.
Open Access
Wall fabrication by direct energy deposition (DED) combining mild steel (ER70) and stainless steel (SS 316L): microstructure and mechanical properties
(MDPI, 2022) Uralde Jiménez, Virginia; Suárez, Alfredo; Aldalur, Eider; Veiga Suárez, Fernando; Ballesteros Egüés, Tomás; Ingeniería; Ingeniaritza
Direct energy deposition is gaining much visibility in research as one of the most adaptable additive manufacturing technologies for industry due to its ease of application and high deposition rates. The possibility of combining these materials to obtain parts with variable mechanical properties is an important task to be studied. The combination of two types of steel, mild steel ER70-6 and stainless steel SS 316L, for the fabrication of a wall by direct energy deposition was studied for this paper. The separate fabrication of these two materials was studied for the microstructurally flawless fabrication of bimetallic walls. As a result of the application of superimposed and overlapped strategies, two walls were fabricated and the microstructure, mechanical properties and hardness of the resulting walls are analyzed. The walls obtained with both strategies present dissimilar regions; the hardness where the most present material is ER70-6 is around 380 HV, and for SS 316L, it is around 180 HV. The average values of ultimate tensile strength (UTS) are 869 and 628 MPa, yield strength (YS) are 584 and 389 MPa and elongation at break are 20% and 36%, respectively, in the cases where we have more ER70-6 in the sample than SS 316L. This indicates an important relationship between the distribution of the materials and their mechanical behavior.
Open Access
Development and tests of a neonatal portable foldable emergency incubator
(World Scientific, 2018-08-03) Ballesteros Egüés, Tomás; Arana Navarro, Ignacio; Pérez Ezcurdia, Amaya; Alfaro López, José Ramón; Ingeniería; Ingeniaritza; Institute of Smart Cities - ISC
Open Access
Analysis of the machining process of short carbon fiber-reinforced polyamide additive manufactured parts
(Elsevier, 2024) Suárez, Alfredo; Veiga Suárez, Fernando; Penalva Oscoz, Mariluz; Ramiro, Pedro; Ballesteros Egüés, Tomás; Ingeniería; Ingeniaritza
In recent years, additive manufacturing technologies have revolutionized the production of parts, particularly in the aeronautical sector. This new manufacturing paradigm has created significant challenges and opportunities for researchers in materials and manufacturing processes. One important aspect is the development of optimal strategies for finishing-oriented machining of parts produced through additive manufacturing. This article focuses on the analysis of reinforced polyamide materials and the integration of large-scale additive manufacturing using Big Area Additive Manufacturing (BAAM) technology, along with robotic systems for subtractive machining. The aim is to explore the potential of integrating additive and subtractive processes to produce high-quality, large-scale components. The study examines the production and subsequent machining of reinforced polyamide parts using BAAM technology, showcasing the advantages and promising results observed. By combining additive manufacturing with subtractive machining, this research contributes to the ongoing advancements in the field of manufacturing, particularly in relation to reinforced polyamide materials. The findings presented in this article shed light on the potential of integrating additive and subtractive processes in the manufacturing industry, paving the way for more efficient and high-quality production methods.
Open Access
Application-oriented data analytics in large-scale metal sheet bending
(MDPI, 2023) Penalva Oscoz, Mariluz; Martín, Ander; Martínez, Víctor; Veiga Suárez, Fernando; Gil del Val, Alain; Ballesteros Egüés, Tomás; Favieres Ruiz, Cristina; Ingeniería; Ingeniaritza
The sheet-metal-forming process is crucial in manufacturing various products, including pipes, cans, and containers. Despite its significance, controlling this complex process is challenging and may lead to defects and inefficiencies. This study introduces a novel approach to monitor the sheet-metal-forming process, specifically focusing on the rolling of cans in the oil-and-gas sector. The methodology employed in this work involves the application of temporal-signal-processing and artificial-intelligence (AI) techniques for monitoring and optimizing the manufacturing process. Temporal-signal-processing techniques, such as Markov transition fields (MTFs), are utilized to transform time series data into images, enabling the identification of patterns and anomalies. synamic time warping (DTW) aligns time series data, accommodating variations in speed or timing across different rolling processes. K-medoids clustering identifies representative points, characterizing distinct phases of the rolling process. The results not only demonstrate the effectiveness of this framework in monitoring the rolling process but also lay the foundation for the practical application of these methodologies. This allows operators to work with a simpler characterization source, facilitating a more straightforward interpretation of the manufacturing process.
Open Access
Augmented reality for intramuscular injection training: a cluster randomized controlled trial
(Elsevier, 2025-07-01) Soto Ruiz, María Nelia; Escalada Hernández, Paula; Bujanda Sainz de Murieta, Arantxa; Ballesteros Egüés, Tomás; Larráyoz Jiménez, Ana; San Martín Rodríguez, Leticia; Ciencias de la Salud; Osasun Zientziak; Institute of Smart Cities - ISC
Background: The acquisition of clinical skills, such as intramuscular injection, is crucial in nursing education, traditionally taught through theory and practice. Recent studies suggest that augmented reality (AR) enhances students' learning. Aim: To evaluate the effect of an augmented reality application (ARSim2care) for training intramuscular injections technique among undergraduate nursing students. Methods: A cluster randomized controlled trial was conducted. A total of 72 nursing students participated in the study (32 in the intervention group and 40 in the control group). Sociodemographic variables and dependent variables such as knowledge, skills, satisfaction and self-confidence with learning were measured. Results: The groups showed statistically significant differences in age. Knowledge acquisition in the intervention group was 0.56 points higher, this difference was statistically significant. No significant differences were found in technical skills, satisfaction and self-confidence although both groups showed positive results. Conclusions: The ARSim2care application enhanced nursing students' theoretical knowledge of intramuscular injections, although no significant improvements in technical skills were observed. Augmented reality shows potential as an educational tool; however, further research is required to evaluate its long-term effectiveness.
Open Access
AI-driven predictive modeling of homogeneous bead geometry for WAAM processes
(Springer, 2025-07-15) Fernández Zabalza, Aitor; Rodríguez Díaz, Álvaro; Veiga Suárez, Fernando; Suárez, Alfredo; Uralde Jiménez, Virginia; Ballesteros Egüés, Tomás; Alfaro López, José Ramón; Ingeniería; Ingeniaritza; Universidad Pública de Navarra / Nafarroako Unibertsitate Publikoa
With the increasing number of applications employing additive manufacturing solutions, these deposition processes must become more autonomous, which can be helped by the application of machine learning monitoring. This study presents a fully online, low-cost framework for real-time quality control in Invar wire-arc additive manufacturing (WAAM). Synchronized current and voltage signals are transformed into spatial heatmaps and temporal Markov transition images, which are processed by an optimized ResNet-18 to classify the quality of each layer on-the-fly. Validation using cross-validation on an internal Invar dataset yields an accuracy of up to 94% under clean conditions, with inference times below 20 ms per layer, enabling deployment during natural cooling between layers. These results demonstrate the feasibility of non-intrusive signal-based anomaly detection, enabling rapid identification of weld spalls and useful for scalable and automated WAAM monitoring in industrial environments.