MD-Lab supported a clinical forensic engineering investigation into the mechanical failure of a proximal femoral nail assembly. The project focused on fractographic analysis of the recovered hip screw and sleeve, translating fracture-surface evidence into a clear explanation of how the implant failed.
A controlled experimental characterization project for ELVAL COLOUR S.A., focused on the damping behavior of composite aluminium plates. MD-Lab developed the mechanical test setup, manufactured a dedicated auxiliary aluminium plate and fixture system, and carried out vibration measurements according to DIN EN ISO 6721-1 and -3. Detailed numerical results and material comparisons are omitted from this public summary due to confidentiality.
The Gearless Differential project investigates a cam-track differential architecture that replaces conventional side and spider gears with identical wavy cam-track disks, guided rolling members and a geared retainer. The work formalizes the geometry required for rolling contact, verifies the kinematics through simulation, and evaluates a representative passenger-car configuration using contact stress and fatigue-life assessment.
MD-Lab research on concrete at cryogenic temperatures develops an experimental route for measuring the linear coefficient of thermal expansion of cylindrical concrete specimens down to approximately -160 °C. The work addresses the need for reliable thermal-strain data in refrigerated liquefied-gas containment structures, where concrete response is governed by coupled heat transfer, pore-water phase change and aggregate-paste mismatch.
For STASY S.A., MD-Lab developed a repeatable laboratory procedure for assessing the thermal behavior of old rail lubricating grease under controlled heating conditions. MD-Lab designed the thermal-test workflow, configured the heating and temperature-monitoring setup, recorded temperature history and timed observations, and prepared the technical documentation. Supporting chemical analysis was carried out separately by the Fuels and Lubricants Technology Laboratory of NTUA.
MD-Lab documented and interpreted the loading mechanisms of the French Wharf of Lavrion, an 1888 industrial-heritage structure built for the movement of minerals, coal and commercial goods. The project turns a corroded and partly incomplete machine system into a clear engineering narrative for restoration, public interpretation and accessible reuse.
Multi-objective optimization of gear tooth profiles to improve weight, efficiency, dynamic behavior, and wear performance, focusing on both involute macro-geometry and free-form non-involute profiles. Key results include more than 40% reduction in power losses and 35% reduction in vibration RMS for optimized involute gears. For free-form gears, reductions of up to 55% in average wear depth and 70% in maximum wear depth have been achieved.
Research on plastic gear transmissions at MD-Lab combines material-model development, finite-element and neural-network surrogate modelling, dynamic/NVH simulation, and additive manufacturing technologies. Key results include neural-network surrogates that reproduce finite-element static transmission error curves for polymer gears with 0.49% MAPE, dynamic simulations showing reduced vibration levels compared with metallic gearsets, and additive-manufacturing studies that quantify FDM and other 3D-printing accuracy limits while investigating wear resistance and wear patterns in printed gears.
MD-Lab research on coaxial magnetic gears develops fast analytical and hybrid electromagnetic models for torque prediction, topology evaluation, nonlinear dynamic response and eddy-current loss estimation. The work supports the design of contactless transmissions with reduced wear, low noise, inherent overload protection and computationally efficient early-stage optimization.
MD-Lab research on external heat engines develops design-oriented thermodynamic models for Stirling and Ericsson machines. The work focuses on transient heat transfer, real-cycle losses, valve timing and experimentally grounded performance prediction for engines that can use external heat sources such as waste heat, solar thermal energy, biomass and combustion outside the working volume.
