PurposeThe purpose of this paper is to present a hybrid manufacturing system that integrates stereolithography (SL) and direct print (DP) technologies to fabricate three‐dimensional (3D) structures with embedded electronic circuits. A detailed process was developed that enables fabrication of monolithic 3D packages with electronics without removal from the hybrid SL/DP machine during the process. Successful devices are demonstrated consisting of simple 555 timer circuits designed and fabricated in 2D (single layer of routing) and 3D (multiple layers of routing and component placement).Design/methodology/approachA hybrid SL/DP system was designed and developed using a 3D Systems SL 250/50 machine and an nScrypt micro‐dispensing pump integrated within the SL machine through orthogonally‐aligned linear translation stages. A corresponding manufacturing process was also developed using this system to fabricate 2D and 3D monolithic structures with embedded electronic circuits. The process involved part design, process planning, integrated manufacturing (including multiple starts and stops of both SL and DP and multiple intermediate processes), and post‐processing. SL provided substrate/mechanical structure manufacturing while interconnections were achieved using DP of conductive inks. Simple functional demonstrations involving 2D and 3D circuit designs were accomplished.FindingsThe 3D micro‐dispensing DP system provided control over conductive trace deposition and combined with the manufacturing flexibility of the SL machine enabled the fabrication of monolithic 3D electronic structures. To fabricate a 3D electronic device within the hybrid SL/DP machine, a process was developed that required multiple starts and stops of the SL process, removal of uncured resin from the SL substrate, insertion of active and passive electronic components, and DP and laser curing of the conductive traces. Using this process, the hybrid SL/DP technology was capable of successfully fabricating, without removal from the machine during fabrication, functional 2D and 3D 555 timer circuits packaged within SL substrates.Research limitations/implicationsResults indicated that fabrication of 3D embedded electronic systems is possible using the hybrid SL/DP machine. A complete manufacturing process was developed to fabricate complex, monolithic 3D structures with electronics in a single set‐up, advancing the capabilities of additive manufacturing (AM) technologies. Although the process does not require removal of the structure from the machine during fabrication, many of the current sub‐processes are manual. As a result, further research and development on automation and optimization of many of the sub‐processes are required to enhance the overall manufacturing process.Practical implicationsA new methodology is presented for manufacturing non‐traditional electronic systems in arbitrary form, while achieving miniaturization and enabling rugged structure. Advanced applications are demonstrated using a semi‐automated approach to SL/DP integration. Op...

The term Industry 4.0, coined to be the fourth industrial revolution, refers to a higher level of automation for operational productivity and efficiency by connecting virtual and physical worlds in an industry. With Industry 4.0 being unable to address and meet increased drive of personalization, the term Industry 5.0 was coined for addressing personalized manufacturing and empowering humans in manufacturing processes. The onset of the term Industry 5.0 is observed to have various views of how it is defined and what constitutes the reconciliation between humans and machines. This serves as the motivation of this paper in identifying and analyzing the various themes and research trends of what Industry 5.0 is using text mining tools and techniques. Toward this, the abstracts of 196 published papers based on the keyword “Industry 5.0” search in IEEE, science direct and MDPI data bases were extracted. Data cleaning and preprocessing were performed for further analysis to apply text mining techniques of key terms extraction and frequency analysis. Further topic mining i.e., unsupervised machine learning method was used for exploring the data. It is observed that the terms artificial intelligence (AI), big data, supply chain, digital transformation, machine learning, internet of things (IoT), are among the most often used and among several enablers that have been identified by researchers to drive Industry 5.0. Five major themes of Industry 5.0 addressing, supply chain evaluation and optimization, enterprise innovation and digitization, smart and sustainable manufacturing, transformation driven by IoT, AI, and Big Data, and Human-machine connectivity were classified among the published literature, highlighting the research themes that can be further explored. It is observed that the theme of Industry 5.0 as a gateway towards human machine connectivity and co-existence is gaining more interest among the research community in the recent years.

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