3D printing with polymers: Challenges among expanding options and opportunities

Novel implant for peri-prosthetic proximal tibia fractures

BACKGROUND

Repair of peri-prosthetic proximal tibia fractures is very challenging in patients with a total knee replacement or arthroplasty. The tibial component of the knee implant severely restricts the fixation points of the tibial implant to repair peri-prosthetic fractures. A novel implant has been designed with an extended flange over the anterior of tibial condyle to provide additional points of fixation, overcoming limitations of existing generic locking plates used for proximal tibia fractures. Furthermore, the screws fixed through the extended flange provide additional support to prevent the problem of subsidence of tibial component of knee implant.

METHODS

The design methodology involved extraction of bone data from CT scans into a flexible CAD format, implant design and structural evaluation and optimisation using FEM as well as prototype development and manufacture by selective laser melting 3D printing technology with Ti6Al4 V powder.

RESULTS

A prototype tibia implant was developed based on a patient-specific bone structure, which was regenerated from the CT images of patient's tibia. The design is described in detail and being applied to fit up to 80% of patients, for both left and right sides based on the average dimensions and shape of the bone structure from a wide range of CT images.

CONCLUSION

A novel tibial implant has been developed to repair peri-prosthetic proximal tibia fractures which overcomes significant constraints from the tibial component of existing knee implant.

3D-Printing of Functional Biomedical Microdevices via Light- and Extrusion-Based Approaches

3D-printing is a powerful additive manufacturing tool, one that enables fabrication of biomedical devices and systems that would otherwise be challenging to create with more traditional methods such as machining or molding. Many different classes of 3D-printing technologies exist, most notably extrusion-based and light-based 3D-printers, which are popular in consumer markets, with advantages and limitations for each modality. The focus here is primarily on showcasing the ability of these 3D-printing platforms to create different types of functional biomedical microdevices-their advantages and limitations are covered with respect to other classes of 3D-printing, as well as the past, recent, and future efforts to advance the functional microdevice domain. In particular, the fabrication of micromachines/robotics, drug-delivery devices, biosensors, and microfluidics is addressed. The current challenges associated with 3D-printing of functional microdevices are also addressed, as well as future directions to improve both the printing techniques and the performance of the printed products.

Fabrication of fillable microparticles and other complex 3D microstructures

Three-dimensional (3D) microstructures created by microfabrication and additive manufacturing have demonstrated value across a number of fields, ranging from biomedicine to microelectronics. However, the techniques used to create these devices each have their own characteristic set of advantages and limitations with regards to resolution, material compatibility, and geometrical constraints that determine the types ofmicrostructures that can be formed.We describe a microfabrication method, termed StampEd Assembly of polymer Layers (SEAL), and create injectable pulsatile drug-delivery microparticles, pH sensors, and 3D microfluidic devices that we could not produce using traditional 3D printing. SEAL allows us to generate microstructures with complex geometry at high resolution, produce fully enclosed internal cavities containing a solid or liquid, and use potentially any thermoplastic material without processing additives.

Polymeric 3D Printed Structures for Soft-Tissue Engineering

3D printing, or rapid prototyping, is a fabrication technique that is used for various engineering applications with advantages such as mass production and fine tuning of spatial-dimensional properties. Recently, this fabrication method has been adopted for tissue engineering applications due to its ability to finely tune porosity and create precise, uniform, and repeatable structures. This review aims to introduce 3D printing applications in soft tissue engineering and regenerative medicine including state-of-the-art scaffolds and key future challenges. Furthermore, 3D printing of individual cells, an evolution of traditional 3D printing technology which represents a cutting-edge technique for the creation of cell seeded scaffolds in vitro, is discussed. Key advances demonstrate the advantages of 3D printing, while also highlighting potential shortcomings to improve upon. It is clear that as 3D printing technology continues to develop, it will serve as a truly revolutionary means for fabrication of structures and materials for regenerative applications.

Long-term antibacterial performances of biodegradable polylactic acid materials with direct absorption of antibiotic agents

In this study, polylactic acid (PLA) disks with antibacterial performances were prepared using 3D printing technology combined with direct adsorption of the antibiotic agents in solution baths. The effects of the layer thicknesses for the building of the 3D printing PLA disks and the amounts of antibiotic agents absorbed onto the sample surfaces on their antibacterial activities were investigated. The antibiotic agent release profiles from the samples surface into the buffer solution show that the antibacterial performances of these samples can reach up to 28 days. With a decrease in the concentration of antibiotic agent in the solution bath, the amount of antibiotic agent adsorbed on the sample surfaces also decreases, but their antibacterial performances can still maintain at least 7 days. In the bioactivity tests of the various organisms, the release amount of antibiotic agent from the sample can inhibit E. coli and S. aureus for over 80% up to 28 days. In the antibacterial activity tests, a PLA disk with suitable antibiotic agents covering its surface has a good inhibitory effect on the growth ability of S. aureus of less than 50% in six hours.

In this study, we developed a surface modification of 3D printing PLA disks. The relative optical density of the S. aureus in the solution can reduce to 40% using the PLA disk directly absorbed with suitable antibiotic agents.

3D printing of photopolymers

Recent progress in the photoinitiators and monomers/oligomers of photopolymers for 3D printing is presented in the review.

N-[2-(Dimethylamino)ethyl]-1,8-naphthalimide derivatives as photoinitiators under LEDs

Four N-[2-(dimethylamino)ethyl]-1,8-naphthalimide derivatives (ANNs) with different substituents in the naphthalimide skeleton have been synthesized and can be used as versatile photoinitiators under various LEDs.

A thermoreversible, photocrosslinkable collagen bio-ink for free-form fabrication of scaffolds for regenerative medicine

As a biomaterial, collagen has been used throughout tissue engineering and regenerative medicine. Collagen is native to the body, is highly biocompatible, and naturally promotes cell adhesion and regeneration. However, collagen fibers and the inherent weak mechanical properties of collagen hydrogels interfere with further development of collagen as a bio-ink. Herein, we demonstrate the use of a modified type-I collagen, collagen methacrylamide (CMA), as a fibril-forming bio-ink for free-form fabrication of scaffolds. Like collagen, CMA can self-assemble into a fibrillar hydrogel at physiological conditions. In contrast, CMA is photocrosslinkable and thermoreversible, and photocrosslinking eliminates thermoreversibility. Free-form fabrication of CMA was performed through self-assembly of the CMA hydrogel, photocrosslinking the structure of interest using a photomask, and cooling the entire hydrogel, which results in cold-melting of unphotocrosslinked regions. Printed hydrogels had a resolution on the order of ~350 μm, and can be fabricated with or without cells and maintain viability or be further processed into freeze-dried sponges, all while retaining pattern fidelity. A subcutaneous implant study confirmed the biocompatibility of CMA in comparison to collagen. Free-form fabrication of CMA allows for printing of macroscale, customized scaffolds with good pattern fidelity and can be implemented with relative ease for continued research and development of collagen-based scaffolds in tissue engineering.

A novel fabrication method of carbon electrodes using 3D printing and chemical modification process

Three-dimensional (3D) printing is an emerging technique in the field of biomedical engineering and electronics. This paper presents a novel biofabrication method of implantable carbon electrodes with several advantages including fast prototyping, patient-specific and miniaturization without expensive cleanroom. The method combines stereolithography in additive manufacturing and chemical modification processes to fabricate electrically conductive carbon electrodes. The stereolithography allows the structures to be 3D printed with very fine resolution and desired shapes. The resin is then chemically modified to carbon using pyrolysis to enhance electrochemical performance. The electrochemical characteristics of 3D printing carbon electrodes are assessed by cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS). The specific capacitance of 3D printing carbon electrodes is much higher than the same sized platinum (Pt) electrode. In-vivo electromyography (EMG) recording, 3D printing carbon electrodes exhibit much higher signal-to-noise ratio (40.63 ± 7.73) than Pt electrodes (14.26 ± 6.83). The proposed biofabrication method is envisioned to enable 3D printing in many emerging applications in biomedical engineering and electronics.

Position Accuracy of Implant Analogs on 3D Printed Polymer versus Conventional Dental Stone Casts Measured Using a Coordinate Measuring Machine

PURPOSE

To compare the accuracy of implant analog positions on complete edentulous maxillary casts made of either dental stone or additive manufactured polymers using a coordinate measuring machine (CMM).

MATERIAL AND METHODS

A completely edentulous maxillary model of a patient with 7 implant analogs was obtained. From this model, two types of casts were duplicated, namely conventional dental stone (CDS) using a custom tray impression technique after splinting (N = 5) and polymer cast using additive manufacturing based on the STL file generated. Polymer casts (N = 20; n = 5 per group) were fabricated using 4 different additive manufacturing technologies (multijet printing-MJP1, direct light processing-DLP, stereolithography-SLA, multijet printing-MJP2). CMM was used to measure the correct position of each implant, and distortion was calculated for each system at x-, y-, and z-axes. Measurements were repeated 3 times per specimen in each axis yielding a total of 546 measurements. Data were analyzed using ANOVA, Sheffé tests, and Bonferroni correction (α = 0.05).

RESULTS

Compared to CMM, the mean distortion (μm) ranged from 22.7 to 74.9, 23.4 to 49.1, and 11.0 to 85.8 in the x-, y-, and z-axes, respectively. CDS method (x-axis: 37.1; z-axis: 27.62) showed a significant difference compared to DLP on the x-axis (22.7) (p = 0.037) and to MJP1 on the z-axis (11.0) (p = 0.003). Regardless of the cast system, x-axes showed more distortion (42.6) compared to y- (34.6) and z-axes (35.97). Among additive manufacturing technologies, MJP2 presented the highest (64.3 ± 83.6), and MJP1 (21.57 ± 16.3) and DLP (27.07 ± 20.23) the lowest distortion, which was not significantly different from CDS (32.3 ± 22.73) (p > 0.05).

CONCLUSION

For the fabrication of the definitive casts for implant prostheses, one of the multijet printing systems and direct light processing additive manufacturing technologies showed similar results to conventional dental stone.

CLINICAL SIGNIFICANCE

Conventional dental stone casts could be accurately duplicated using some of the additive manufacturing technologies tested.

Modular Elastomer Photoresins for Digital Light Processing Additive Manufacturing

A series of photoresins suitable for the production of elastomeric objects via digital light processing additive manufacturing are reported. Notably, the printing procedure is readily accessible using only entry-level equipment under ambient conditions using visible light projection. The photoresin formulations were found to be modular in nature, and straightforward adjustments to the resin components enabled access to a range of compositions and mechanical properties. Collectively, the series includes silicones, hydrogels, and hybrids thereof. Printed test specimens displayed maximum elongations of up to 472% under tensile load, a tunable swelling behavior in water, and Shore A hardness values from 13.7 to 33.3. A combination of the resins was used to print a functional multimaterial three-armed pneumatic gripper. These photoresins could be transformative to advanced prototyping applications such as simulated human tissues, stimuli-responsive materials, wearable devices, and soft robotics.

Advances in the generation of bioengineered bile ducts

The generation of bioengineered biliary tissue could contribute to the management of some of the most impactful cholangiopathies associated with liver transplantation, such as biliary atresia or ischemic cholangiopathy. Recent advances in tissue engineering and in vitro cholangiocyte culture have made the achievement of this goal possible. Here we provide an overview of these developments and review the progress towards the generation and transplantation of bioengineered bile ducts. This article is part of a Special Issue entitled: Cholangiocytes in Health and Diseaseedited by Jesus Banales, Marco Marzioni and Peter Jansen.

3D printed versus conventionally cured provisional crown and bridge dental materials

OBJECTIVES

To optimize the 3D printing of a dental material for provisional crown and bridge restorations using a low-cost stereolithography 3D printer; and compare its mechanical properties against conventionally cured provisional dental materials.

METHODS

Samples were 3D printed (25×2×2mm) using a commercial printable resin (NextDent C&B Vertex Dental) in a FormLabs1+ stereolithography 3D printer. The printing accuracy of printed bars was determined by comparing the width, length and thickness of samples for different printer settings (printing orientation and resin color) versus the set dimensions of CAD designs. The degree of conversion of the resin was measured with FTIR, and both the elastic modulus and peak stress of 3D printed bars was determined using a 3-point being test for different printing layer thicknesses. The results were compared to those for two conventionally cured provisional materials (Integrity^®, Dentsply; and Jet^®, Lang Dental Inc.).

RESULTS

Samples printed at 90° orientation and in a white resin color setting was chosen as the most optimal combination of printing parameters, due to the comparatively higher printing accuracy (up to 22% error), reproducibility and material usage. There was no direct correlation between printing layer thickness and elastic modulus or peak stress. 3D printed samples had comparable modulus to Jet^®, but significantly lower than Integrity^®. Peak stress for 3D printed samples was comparable to Integrity^®, and significantly higher than Jet^®. The degree of conversion of 3D printed samples also appeared higher than that of Integrity^® or Jet^®.

SIGNIFICANCE

Our results suggest that a 3D printable provisional restorative material allows for sufficient mechanical properties for intraoral use, despite the limited 3D printing accuracy of the printing system of choice.

Dental ceramics: a review of new materials and processing methods

The evolution of computerized systems for the production of dental restorations associated to the development of novel microstructures for ceramic materials has caused an important change in the clinical workflow for dentists and technicians, as well as in the treatment options offered to patients. New microstructures have also been developed by the industry in order to offer ceramic and composite materials with optimized properties, i.e., good mechanical properties, appropriate wear behavior and acceptable aesthetic characteristics. The objective of this literature review is to discuss the main advantages and disadvantages of the new ceramic systems and processing methods. The manuscript is divided in five parts: I) monolithic zirconia restorations; II) multilayered dental prostheses; III) new glass-ceramics; IV) polymer infiltrated ceramics; and V) novel processing technologies. Dental ceramics and processing technologies have evolved significantly in the past ten years, with most of the evolution being related to new microstructures and CAD-CAM methods. In addition, a trend towards the use of monolithic restorations has changed the way clinicians produce all-ceramic dental prostheses, since the more aesthetic multilayered restorations unfortunately are more prone to chipping or delamination. Composite materials processed via CAD-CAM have become an interesting option, as they have intermediate properties between ceramics and polymers and are more easily milled and polished.

Fabrication, characterization, and application of polyester/wood flour composites

The mechanical properties, thermal properties, antibacterial activity, and fabrication of three-dimensional (3D) printing strips of composite materials containing polyhydroxyalkanoate (PHA) and wood flour (WF) were evaluated. Maleic anhydride (MA)-grafted PHA (PHA-g-MA) and WF were used to enhance the desired characteristics of these composites. The PHA-g-MA/WF composites had better mechanical properties than the PHA/WF composites did. This effect was attributed to a greater compatibility between the grafted polyester and WF. Additionally, the PHA-g-MA/WF composites provided higher quality 3D printing strips and were more easily processed because of ester formation. The water resistance of the PHA-g-MA/WF composite was greater than that of PHA/WF. Moreover, WF enhanced the antibacterial activity of the composites. Composites of PHA-g-MA or PHA containing WF had better antibacterial activity.

3D Printing Polymers with Supramolecular Functionality for Biological Applications

Supramolecular chemistry continues to experience widespread growth, as fine-tuned chemical structures lead to well-defined bulk materials. Previous literature described the roles of hydrogen bonding, ionic aggregation, guest/host interactions, and π-π stacking to tune mechanical, viscoelastic, and processing performance. The versatility of reversible interactions enables the more facile manufacturing of molded parts with tailored hierarchical structures such as tissue engineered scaffolds for biological applications. Recently, supramolecular polymers and additive manufacturing processes merged to provide parts with control of the molecular, macromolecular, and feature length scales. Additive manufacturing, or 3D printing, generates customizable constructs desirable for many applications, and the introduction of supramolecular interactions will potentially increase production speed, offer a tunable surface structure for controlling cell/scaffold interactions, and impart desired mechanical properties through reinforcing interlayer adhesion and introducing gradients or self-assembled structures. This review details the synthesis and characterization of supramolecular polymers suitable for additive manufacture and biomedical applications as well as the use of supramolecular polymers in additive manufacturing for drug delivery and complex tissue scaffold formation. The effect of supramolecular assembly and its dynamic behavior offers potential for controlling the anisotropy of the printed objects with exquisite geometrical control. The potential for supramolecular polymers to generate well-defined parts, hierarchical structures, and scaffolds with gradient properties/tuned surfaces provides an avenue for developing next-generation biomedical devices and tissue scaffolds.

Application of an Addition-Fragmentation-Chain Transfer Monomer in Di(meth)acrylate Network Formation to Reduce Polymerization Shrinkage Stress

A new addition-fragmentation chain transfer (AFT) capable moiety was incorporated into a dimethacrylate monomer that participated readily in network formation by copolymerizing with multifunctional methacrylates or acrylates. The process of AFT occurred simultaneously with photopolymerization of the AFT monomer (AFM) and other (meth)acrylate monomers leading to polymer stress relaxation via network reconfiguration. At low loading levels of the AFM, a significant reduction in shrinkage stress, especially for acrylate monomers, was observed with nominal effects on conversion. At higher loading levels of the AFM, the photopolymerization reaction kinetics and final double bond conversion were significantly lowered along with a delay in the gel-point conversion. Electron paramagnetic resonance studies during polymerization revealed the presence of a distinct radical species that was present in proportional quantities to the AFM content in the system. The lifetime and the character of the persistent radicals were altered due to the presence of the distinctive radical, in turn affecting the polymerization kinetics. With polymerization conducted at higher irradiance, the differential conversion between the control resin and samples with moderate AFM content was minimal, especially for the methacrylate-based formulations.

Polymers for 3D Printing and Customized Additive Manufacturing

Additive manufacturing (AM) alias 3D printing translates computer-aided design (CAD) virtual 3D models into physical objects. By digital slicing of CAD, 3D scan, or tomography data, AM builds objects layer by layer without the need for molds or machining. AM enables decentralized fabrication of customized objects on demand by exploiting digital information storage and retrieval via the Internet. The ongoing transition from rapid prototyping to rapid manufacturing prompts new challenges for mechanical engineers and materials scientists alike. Because polymers are by far the most utilized class of materials for AM, this Review focuses on polymer processing and the development of polymers and advanced polymer systems specifically for AM. AM techniques covered include vat photopolymerization (stereolithography), powder bed fusion (SLS), material and binder jetting (inkjet and aerosol 3D printing), sheet lamination (LOM), extrusion (FDM, 3D dispensing, 3D fiber deposition, and 3D plotting), and 3D bioprinting. The range of polymers used in AM encompasses thermoplastics, thermosets, elastomers, hydrogels, functional polymers, polymer blends, composites, and biological systems. Aspects of polymer design, additives, and processing parameters as they relate to enhancing build speed and improving accuracy, functionality, surface finish, stability, mechanical properties, and porosity are addressed. Selected applications demonstrate how polymer-based AM is being exploited in lightweight engineering, architecture, food processing, optics, energy technology, dentistry, drug delivery, and personalized medicine. Unparalleled by metals and ceramics, polymer-based AM plays a key role in the emerging AM of advanced multifunctional and multimaterial systems including living biological systems as well as life-like synthetic systems.

Current and emerging applications of 3D printing in medicine

Three-dimensional (3D) printing enables the production of anatomically matched and patient-specific devices and constructs with high tunability and complexity. It also allows on-demand fabrication with high productivity in a cost-effective manner. As a result, 3D printing has become a leading manufacturing technique in healthcare and medicine for a wide range of applications including dentistry, tissue engineering and regenerative medicine, engineered tissue models, medical devices, anatomical models and drug formulation. Today, 3D printing is widely adopted by the healthcare industry and academia. It provides commercially available medical products and a platform for emerging research areas including tissue and organ printing. In this review, our goal is to discuss the current and emerging applications of 3D printing in medicine. A brief summary on additive manufacturing technologies and available printable materials is also given. The technological and regulatory barriers that are slowing down the full implementation of 3D printing in the medical field are also discussed.

Colloidal assembly and 3D shaping by dielectrophoretic confinement

For decades, scientists and engineers have strived to design means of assembling colloids into ordered structures. By now, the literature is quite peppered with reports of colloidal assemblies. However, the available methods can assemble only a narrow range of structures or are applicable to specific types of colloids. There are still only few generic methods that would lead to arbitrary colloidal arrays or would shape colloidal assemblies into predesigned structures. Here, we first discuss in detail how to spatially control the assembly and crystallization of colloids through the balance of dielectrophoretic and dipolar forces. Furthermore, we demonstrate how to flexibly program and shape arrays of 3D microstructures that can be permanently affixed by in situ UV polymerization and calcination by using two facing similar or distinct micro-fabricated electrodes.

In-office fabrication of dental implant surgical guides using desktop stereolithographic printing and implant treatment planning software: A clinical report

Guided surgery is accepted as the most accurate way to place an implant and predictably relate the implant to its definitive prosthesis, although few clinicians use it. However, recent developments in high-quality desktop 3-dimensional stereolithographic printers have led to the in-office fabrication of stereolithographic surgical guides at reduced cost. This clinical report demonstrates a protocol for using a cost-effective, in-office rapid prototyping technique to fabricate a surgical guide for dental implant placement.

Digital light procession three-dimensional printing acrylate/collagen composite airway stent for tracheomalacia

Recently, more and more researchers have focused on airway stent applied in tracheomalacia. The airway stents for clinical application were usually manufactured in accordance with a fixed pattern, which were difficult to perfect match with children, especially infants. Digital light procession of light curing acrylate resin implantation showed higher accuracy and printing speed over traditional three-dimensional printing techniques. In this article, a novel personalized airway stent was developed by digital light procession three-dimensional printing and was modified by collagen I extracted from the fish scales. The morphology of the collagen-modified airway stent was examined by scanning electron microscopy, and the chemical structures were examined by attenuated total internal reflectance Fourier transform infrared spectroscopy. The biocompatibility of this synthetic acrylate/collagen composite airway stent was characterized by water contact angle test and cell culture. The results confirmed that the composite airway stent was hydrophilic and non-cytotoxic toward a cultured human bronchial epithelial cell line with good cell viability and show excellent physicochemical and biological properties. In conclusion, this study presented the three-dimensional printing composite acrylate and collagen airway stent may have potential in customized treatment for tracheomalacia.

Fit of interim crowns fabricated using photopolymer-jetting 3D printing

STATEMENT OF PROBLEM

The fit of interim crowns fabricated using 3-dimensional (3D) printing is unknown.

PURPOSE

The purpose of this in vitro study was to evaluate the fit of interim crowns fabricated using photopolymer-jetting 3D printing and to compare it with that of milling and compression molding methods.

MATERIAL AND METHODS

Twelve study models were fabricated by making an impression of a metal master model of the mandibular first molar. On each study model, interim crowns (N=36) were fabricated using compression molding (molding group, n=12), milling (milling group, n=12), and 3D polymer-jetting methods. The crowns were prepared as follows: molding group, overimpression technique; milling group, a 5-axis dental milling machine; and polymer-jetting group using a 3D printer. The fit of interim crowns was evaluated in the proximal, marginal, internal axial, and internal occlusal regions by using the image-superimposition and silicone-replica techniques. The Mann-Whitney U test and Kruskal-Wallis tests were used to compare the results among groups (α=.05).

RESULTS

Compared with the molding group, the milling and polymer-jetting groups showed more accurate results in the proximal and marginal regions (P<.001). In the axial regions, even though the mean discrepancy was smallest in the molding group, the data showed large deviations. In the occlusal region, the polymer-jetting group was the most accurate, and compared with the other groups, the milling group showed larger internal discrepancies (P<.001).

CONCLUSIONS

Polymer-jet 3D printing significantly enhanced the fit of interim crowns, particularly in the occlusal region.

Direct-Write Fabrication of 4D Active Shape-Changing Structures Based on a Shape Memory Polymer and Its Nanocomposite

Four-dimensional (4D) active shape-changing structures based on shape memory polymers (SMPs) and shape memory nanocomposites (SMNCs) are able to be controlled in both space and time and have attracted increasing attention worldwide. However, conventional processing approaches have restricted the design space of such smart structures. Herein, 4D active shape-changing architectures in custom-defined geometries exhibiting thermally and remotely actuated behaviors are achieved by direct-write printing of ultraviolet (UV) cross-linking poly(lactic acid)-based inks. The results reveal that, by the introduction of a UV cross-linking agent, the printed objects present excellent shape memory behavior, which enables three-dimensional (3D)-one-dimensional (1D)-3D, 3D-two-dimensional (2D)-3D, and 3D-3D-3D configuration transformations. More importantly, the addition of iron oxide successfully integrates 4D shape-changing objects with fast remotely actuated and magnetically guidable properties. This research realizes the printing of both SMPs and SMNCs, which present an effective strategy to design 4D active shape-changing architectures with multifunctional properties. This paves the way for the further development of 4D printing, soft robotics, flexible electronics, minimally invasive medicine, etc.

Strength and Performance Enhancement of Bonded Joints by Spatial Tailoring of Adhesive Compliance via 3D Printing

Adhesive bonding continues to emerge as a preferred route for joining materials with broad applications including advanced structures, microelectronics, biomedical systems, and consumer goods. Here, we study the mechanics of deformation and failure of tensile-loaded single-lap joints with a compliance-tailored adhesive. Tailoring of the adhesive compliance redistributes stresses and strains to reduce both shear and peel concentrations at the ends of the adhesive that determine failure of the joint. Utilizing 3D printing, the modulus of the adhesive is spatially varied along the bondlength. Experimental strength testing, including optical strain mapping, reveals that the strain redistribution results in a greater than 100% increase in strength and toughness concomitant with a 50% increase in strain-to-break while maintaining joint stiffness. The tailoring demonstrated here is immediately realizable in a broad array of 3D printing applications, and the level of performance enhancement suggests that compliance tailoring of the adhesive is a generalizable route for achieving superior performance of joints in other applications, such as advanced structural composites.

Advances in polymeric materials for dental applications

This review focuses on the relationship between the structures and properties of various polymers for different applications in dentistry.

3D Bioprinting for Organ Regeneration

Regenerative medicine holds the promise of engineering functional tissues or organs to heal or replace abnormal and necrotic tissues/organs, offering hope for filling the gap between organ shortage and transplantation needs. Three-dimensional (3D) bioprinting is evolving into an unparalleled biomanufacturing technology due to its high-integration potential for patient-specific designs, precise and rapid manufacturing capabilities with high resolution, and unprecedented versatility. It enables precise control over multiple compositions, spatial distributions, and architectural accuracy/complexity, therefore achieving effective recapitulation of microstructure, architecture, mechanical properties, and biological functions of target tissues and organs. Here we provide an overview of recent advances in 3D bioprinting technology, as well as design concepts of bioinks suitable for the bioprinting process. We focus on the applications of this technology for engineering living organs, focusing more specifically on vasculature, neural networks, the heart and liver. We conclude with current challenges and the technical perspective for further development of 3D organ bioprinting.

Fit of pressed crowns fabricated from two CAD-CAM wax pattern process plans: A comparative in vitro study

STATEMENT OF PROBLEM

Subtractive and additive computer-aided design and computer-aided manufacturing (CAD-CAM) wax pattern processing are 2 methods of fabricating a pressed ceramic crown. Whether a subtractive milled wax pattern or a pattern from the micro-stereolithography additive process produces lithium disilicate crowns with better marginal and internal fit is unclear.

MATERIALS AND METHODS

Ten silicone impressions were made for a prepared canine tooth. Each die received 2 lithium disilicate (IPS e.max) copings, 1 from milled wax blocks and 1 from additive wax. The replica technique was used to measure the fit by scanning electron microscopy at ×80 magnification. Collected data were analyzed using the paired Student t test for the marginal and internal fit. For the occlusal fit, the difference in scores did not follow a normal distribution, and the Wilcoxon signed rank test was used (α=.05).

RESULTS

The mean marginal, axial, and occlusal fit showed no significant differences when the 2 CAD-CAM manufacturing processes were compared (P>.05). For the marginal fit, the mean (±SD) values were 105.1 μm ±39.6 with the milled process and 126.2 μm ±25.2 for the additive process. The mean values were 98.1 μm ±26.1 for the axial fit in the milled process and 106.8 μm ±21.2 in the additive process. For the occlusal fit, median values (interquartile interval) were 199.0 μm (141.5 to 269.9) for subtractive manufacturing and 257.2 μm (171.6 to 266.0) for micro-SLA manufacturing.

CONCLUSIONS

No significant difference was found between the fit of the 2 techniques. The mean values of axial and occlusal median values were 10 and 5 to 6 times greater than machine's nominal values.

Testing a Novel 3D Printed Radiographic Imaging Device for Use in Forensic Odontology

There are specific challenges related to forensic dental radiology and difficulties in aligning X-ray equipment to teeth of interest. Researchers used 3D printing to create a new device, the combined holding and aiming device (CHAD), to address the positioning limitations of current dental X-ray devices. Participants (N = 24) used the CHAD, soft dental wax, and a modified external aiming device (MEAD) to determine device preference, radiographer's efficiency, and technique errors. Each participant exposed six X-rays per device for a total of 432 X-rays scored. A significant difference was found at the 0.05 level between the three devices (p = 0.0015), with the MEAD having the least amount of total errors and soft dental wax taking the least amount of time. Total errors were highest when participants used soft dental wax-both the MEAD and the CHAD performed best overall. Further research in forensic dental radiology and use of holding devices is needed.

Frontal Conversion and Uniformity in 3D Printing by Photopolymerisation

We investigate the impact of the non-uniform spatio-temporal conversion, intrinsic to photopolymerisation, in the context of light-driven 3D printing of polymers. The polymerisation kinetics of a series of model acrylate and thiol-ene systems, both neat and doped with a light-absorbing dye, is investigated experimentally and analysed according to a descriptive coarse-grained model for photopolymerisation. In particular, we focus on the relative kinetics of polymerisation with those of 3D printing, by comparing the evolution of the position of the conversion profile (z_f) to the sequential displacement of the object stage (∆z). After quantifying the characteristic sigmoidal monomer-to-polymer conversion of the various systems, with a combination of patterning experiments, FT-IR mapping, and modelling, we compute representative regimes for which z_f is smaller, commensurate with, or larger than ∆z. While non-monotonic conversion can be detrimental to 3D printing, for instance in causing differential shrinkage of inhomogeneity in material properties, we identify opportunities for facile fabrication of modulated materials in the z-direction (i.e., along the illuminated axis). Our simple framework and model, based on directly measured parameters, can thus be employed in photopolymerisation-based 3D printing, both in process optimisation and in the precise design of complex, internally stratified materials by coupling the z-stage displacement and frontal polymerisation kinetics.