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

Nanomaterial Patterning in 3D Printing

The synergistic integration of nanomaterials with 3D printing technologies can enable the creation of architecture and devices with an unprecedented level of functional integration. In particular, a multiscale 3D printing approach can seamlessly interweave nanomaterials with diverse classes of materials to impart, program, or modulate a wide range of functional properties in an otherwise passive 3D printed object. However, achieving such multiscale integration is challenging as it requires the ability to pattern, organize, or assemble nanomaterials in a 3D printing process. This review highlights the latest advances in the integration of nanomaterials with 3D printing, achieved by leveraging mechanical, electrical, magnetic, optical, or thermal phenomena. Ultimately, it is envisioned that such approaches can enable the creation of multifunctional constructs and devices that cannot be fabricated with conventional manufacturing approaches.

Two-Step 3 D-Printing Approach toward Sustainable, Repairable, Fluorescent Shape-Memory Thermosets Derived from Cellulose and Rosin

Efficiently converting biomass into multifunctional polymerized materials is a challenge to effect high-valued utilization of biomass resources. A two-step 3 D-printing approach has been developed to fabricate a class of robust, fluorescent shape-memory thermosets from cellulose and rosin-based photosensitive 3 D-printing resin solution. The stereolithography 3 D printing was first performed to form the first crosslinked network by UV-induced chain-growth polymerization, which fixed the shape of thermoset. Subsequently, isocyanate was applied to react with hydroxy in the monomer to form the second crosslinked network by thermally induced step-growth polymerization. The formation of a dual-cure network, leading to phase separation and increased crosslinking density, could greatly improve the mechanical and thermal properties of 3 D-printed thermosets and endow them with thermally triggered shape-memory properties and excellent repairability. The 3 D-printed thermosets are found to have strong luminescence resulting from aggregation-induced emission originating from rosin. In addition, these 3 D-printed thermosets could degrade in the presence of NaOH aqueous solution and in situ achieved a range of flexible conductive hydrogels that have important potential application in the flexible electronic materials and smart photoelectric materials.

Three-dimensional printing technology as a promising tool in bioavailability enhancement of poorly water-soluble molecules: A review

Poor aqueous solubility of active pharmaceutical ingredients (API) is nowadays a major issue in the pharmaceutical field. The combinatorial chemistry provides more and more API with a great therapeutic potential, but with a low aqueous solubility. Among the strategies to overcome this drawback, the use of amorphous solid dispersions (ASD), as well as the increase of surface area, is widely used. The three dimensional (3D) printing technologies appear to be innovative tools allowing the construction of any unconventional forms with different composition, structure or infill; especially by using ASD materials. This review aims to deliver notions about the different 3D printing techniques found in the literature to improve aqueous solubility of several API, namely nozzle-based method, inkjet methods and laser- based methods, as well as guide formulator in terms of formulation parameters that have to be optimized to allow the most suitable impression of innovative medicines.

3D Printing for the Clinic: Examining Contemporary Polymeric Biomaterials and Their Clinical Utility

The advent of additive manufacturing offered the potential to revolutionize clinical medicine, particularly with patient-specific implants across a range of tissue types. However, to date, there are very few examples of polymers being used for additive processes in clinical settings. The state of the art with regards to 3D printable polymeric materials being exploited to produce novel clinically relevant implants is discussed here. We focus on the recent advances in the development of implantable, polymeric medical devices and tissue scaffolds without diverging extensively into bioprinting. By introducing the major 3D printing techniques along with current advancements in biomaterials, we hope to provide insight into how these fields may continue to advance while simultaneously reviewing the ongoing work in the field.

Layer-by-Layer Printing of Photopolymers in 3D: How Weak is the Interface?

Additive manufacturing or, as also called, three-dimensional (3D) printing is considered as a game-changer in replacing traditional processing methods in numerous applications; yet, it has one intrinsic potential weakness related to bonding of layers formed during the printing process. Prior to finding solutions for improvement, a thorough quantitative understanding of the mechanical properties of the interface is needed. Here, a quantitative analysis of the nanomechanical properties in 3D printed photopolymers formed by digital light processing (DLP) stereolithography (SLA) is shown. Mapping of the contact Young's modulus across the layered structure is performed by atomic force microscopy (AFM) with a submicrometer resolution. The peakforce quantitative nanomechanical mapping (PF-QNM) mode was employed in the AFM experiments. The layered specimens were obtained from an acrylate-based resin (PR48, Autodesk), containing also a light-absorbing dye. We observed local depressions with values up to 30% of the maximum stiffness at the interface between the consecutively deposited layers, indicating local depletion of molecular cross-link density. The thickness values of the interfacial layers were approximately 11 μm, which corresponds to ∼22% of the total layer thickness (50 μm). We attribute this to heterogeneities of the photopolymerization reaction, related to (1) atmospheric oxygen inhibition and (2) molecular diffusion across the interface. Additionally, a pronounced stiffness decay was observed across each individual layer with a skewed profile. This behavior was rationalized by a spatial variation of the polymer cross-link density related to the variations of light absorption within the layers. This is caused by the presence of light absorbers in the printed material, resulting in a spatial decay of light intensity during photopolymerization.

Carbon Dots as a Promising Green Photocatalyst for Free Radical and ATRP-Based Radical Photopolymerization with Blue LEDs

Carbon dots (CDs) have been used for the first time as a sensitizer to initiate and activate free radical and controlled radical polymerization, respectively, based on an ATRP protocol with blue LEDs. Consideration of diverse heteroatom-doped CDs indicated that N-doped CDs could serve as an effective photocatalyst and photosensitizer in combination with LEDs emitting either at 405 nm or 470 nm. Free radical polymerization was initiated by combining the CDs with an iodonium or sulfonium salt in tri(propylene glycol) diacrylate. Polymerization of methyl methacrylate (MMA) by photo-induced ATRP was achieved with CDs and ethyl α-bromophenylacetate using CuII as catalyst in the ppm range. The polymers obtained showed temporal control, narrower dispersity ≲1.5, and chain-end fidelity. The first-order kinetics and ON/OFF experiments additionally gave evidence of the constant concentration of polymer radicals. No remarkable cytotoxic activity was observed for the CDs, underlining their biocompatibility.

Chairside fabrication of provisional crowns on FDM 3D-printed PVA model

PURPOSE

The purpose of this study was to evaluate the dimensional accuracy of crowns fabricated using a polyvinyl alcohol (PVA) dental model.

METHODS

An intraoral scanner (LAVA TDS) was used to scan a prepared molar abutment as a master model. The STL file obtained from the scanning process was transferred into the FDM 3D printer (Value 3D Magix MF-1000) and then models were fabricated with PVA filament. In order to compare with the conventional method, an impression of the master model was taken using silicone impression material to fabricate the conventional stone cast model (Conv). An indirect resin composite (Gradia) and self-cured acrylic resin (Curergrace) were used to fabricate crowns (n = 20) according to the manufacturer's instructions. Surface accuracy of the Conv and PVA models and internal accuracy of the crowns set on the models were measured using two methods; 3D digital analysis and silicon-fitting evaluation. Statistical analysis of the results was done using t-test and Willcoxon signed rank test with Bonferroni correction at 5% significance.

RESULTS

Digital analysis showed the Root Mean Square (RMS) value of PVA model surface was higher than that of Conv, while there was no significant difference between the two crown materials. However, the silicon-fitting analysis showed marginal discrepancy of crowns fabricated on PVA model were within 100 µm.

CONCLUSION

3D printed PVA model can be used for chairside crown fabrication with an acceptable accuracy.

Additive manufacturing of dental polymers: An overview on processes, materials and applications

Additive manufacturing (AM) processes are increasingly used in dentistry. The underlying process is the joining of material layer by layer based on 3D data models. Four additive processes (laser stereolithography, polymer jetting, digital light processing, fused deposition modeling) are mainly used for processing dental polymers. The number of polymer materials that can be used for AM in dentistry is small compared to other areas. Applications in dentistry using AM are limited (e.g. study models, maxillo-facial prostheses, orthodontic appliances etc.). New and further developments of materials are currently taking place due to the increasing demand for safer and other applications. Biocompatibility and the possibility of using materials not only as temporarily but as definitive reconstructions under oral conditions, mechanically more stable materials where less or no post-processing is needed are current targets in AM technologies. Printing parameters are also open for further development where optical aspects are also important.

Kale M, Divakaran N, Senthil T, P. S, Wu L, Wang J. A Novel Approach to Enhance Mechanical and Thermal Properties of SLA 3D Printed Structure by Incorporation of Metal-Metal Oxide Nanoparticles

Silver (Ag) ornamented TiO₂ semiconducting nanoparticles were synthesized through the sol-gel process to be utilized as nanofillers with photo resin to enhance the mechanical and thermal properties of stereolithography 3D printed objects. The as-prepared Ag-TiO₂ nanoparticles (Ag-TNP) were typified and qualified by XRD, XPS, Raman, and FESEM; TEM analysis dissected the morphologies. The enhancement in the tensile and flexural strengths of SLR/Ag-TNP nanocomposites was noted as 60.8% and 71.8%, respectively, at the loading content of 1.0% w/w Ag-TNP within the SLR (stereolithography resin) matrix. Similarly, the thermal conductivity and thermal stability were observed as higher for SLR/Ag-TNP nanocomposites, equated to neat SLR. The nanoindentation investigation shows an excerpt hike in reduced modulus and hardness by the inclusion of Ag-TNP. The resulted thermal analysis discloses that the introduction of Ag-TNP can appreciably augment the glass transition temperature (T_g), and residual char yield of SLR nanocomposites remarkably. Hence, the significant incorporation of as-prepared Ag-TNP can act as effective nanofillers to enhance the thermal and mechanical properties of photo resin.

Chemical and Physical Characterization of 3D Printer Aerosol Emissions with and without a Filter Attachment

Fused filament fabrication three-dimensional (3D) printers have been shown to emit ultrafine particles (UFPs) and volatile organic compounds (VOCs). Previous studies have quantified bulk 3D printer particle and VOC emission rates, as well as described particle chemical composition via ex situ analysis. Here, we present size-resolved aerosol composition measurements from in situ aerosol mass spectrometry and ex situ transmission electron microscopy (TEM). Particles were sampled for in situ analysis during acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) 3D printing activities and ex situ analysis during ABS printing. We examined the effect of a high-efficiency particulate air filter attachment on ABS emissions and particle chemical composition and demonstrate that filtration was effective in preventing UFP emissions and that particles sampled during filtered prints did not have a high contribution (∼4% vs ∼10%) from aromatic ions in the mass spectrum. Ex situ analysis of particles collected during ABS printing was performed via TEM and electron energy loss spectroscopy, which indicated a high level of sp² bonding type consistent with polymeric styrene. One 3D print with PLA resulted in an aerosol mass size distribution with a peak at ∼300 nm. Unfiltered ABS prints resulted in particle mass size distributions with peak diameters of ∼100 nm.

Intaglio Surface Dimension and Guide Tube Deviations of Implant Surgical Guides Influenced by Printing Layer Thickness and Angulation Setting

PURPOSE

To measure overall intaglio dimensional and tube deviations of implant guides printed at 50 and 100 µm layer thickness at 0°, 45°, and 90° angulation using a stereolithographic (SLA) printer.

MATERIALS AND METHODS

A surgical implant guide design from a subject missing a maxillary right central incisor, used as the original standard tessellation language (STL) were stereolithographically fabricated at each thickness and angulation, 50 and 100 µm layer thickness at 0°, 45°, and 90° angulation (n = 10 each group). The guide was then scanned using cone beam computed tomography. The digital imaging and communications in medicine (DICOM) scanned files were then converted to an STL format. The overall dimensional deviations of the intaglio surface and the positioning of the implant guide tube were then superimposed onto the original designed STL file using best-fitting alignment. A t-test and an F-test as well as ANOVA followed by a post hoc t-test were used to determine statistical significant differences (α = 0.05) for the intaglio surface and guide tube deviation, respectively.

RESULTS

The overall intaglio surface discrepancies (µm) printed at 0°, 45°, and 90° were 55.07 ± 1.36, 52.39 ± 2.09, and 61.02 ± 15.96 for 50 µm layer; and 98.38 ± 10.55, 84.47 ± 10.61, and 90.26 ± 5 for 100 µm layer with statistically significant differences for both t-test and F-test, p < 0.001. The maximal guide tube linear deviations (µm) printed at 0°, 45°, and 90° were 10.78 ± 3.84, 8.16 ± 3.68, and 12.57 ± 5.39 for 50 µm layer (ANOVA, p = 0.096); and 10.95 ± 5.23, 16.79 ± 4.97, and 22.63 ± 2.81 for 100 µm layer (ANOVA, p < 0.001). The maximal guide tube angular deviations (°) printed at 0°, 45°, and 90° were 1.29 ± 0.30, 0.64 ± 0.13, and 0.56 ± 0.21 for 50 µm layer (ANOVA, p < 0.001); and 1.57 ± 0.29, 0.86 ± 0.14, and 1.02 ± 0.31 for 100 µm layer (ANOVA, p = 0.034). There was a statistical difference in the deviations between 50 and 100 µm layer printing in all printed angulations except at 0° (t-test, p = 0.05, p = 0.03, and p = 0.001 for 0°, 45°, and 90°) and linear deviations (t-test, p < 0.001, p = 0.009, and p = 0.001 for 0°, 45°, and 90°).

CONCLUSION

Printing at 50 µm layer reduces dimensional intaglio deviations in general and reduces tube angular deviations with different angulations of printing. However, the deviations were only ∼60 to 100 µm for the intaglio dimension deviations; and ∼0.04 to 0.26 mm and ∼0.25° to ∼2° for tube deviations.

Tissue surface adaptation of CAD-CAM maxillary and mandibular complete denture bases manufactured by digital light processing: A clinical study

STATEMENT OF PROBLEM

Clinical studies evaluating the tissue surface adaptation of complete denture bases fabricated by digital light processing (DLP) are lacking.

PURPOSE

The purpose of this clinical study was to assess the tissue surface adaptation of complete denture bases generated by the DLP technique and to compare the adaptation with that of denture bases manufactured by 5-axis milling (MIL) and pack-and-press (PAP) method.

MATERIAL AND METHODS

A total of 9 participants with 12 edentulous arches (7 maxillary and 5 mandibular) were included in this study. For each edentulous arch, the complete denture bases with occlusion rims were prepared by 3 different techniques (PAP, MIL, and DLP). A virtual denture base with occlusion rim was designed by means of a digital subtraction tool and served to fabricate the DLP and MIL denture bases. The complete denture bases were placed intraorally with an indicator applied to the intaglio surfaces. The thickness of the indicator was measured within the denture-bearing areas and anatomic landmarks of the edentulous arch to obtain the absolute tissue surface adaptation (ATA) value. The relative tissue surface adaptation (RTA) value was calculated from the differences between the ATA values of DLP or MIL techniques and those of the PAP technique. The Kruskal-Wallis test and the McNemar test were used for statistical analysis (α=.05).

RESULTS

No statistically significant differences were found among the 3 denture base fabrication techniques with respect to the ATA values of either arch (P>.05). In terms of the RTA values for the maxillary arch, the DLP base was significantly different from the MIL base in the RC and P areas (both P<.05). The DLP base exhibited a higher frequency of negative RTA values than the MIL base. Regarding the RTA values for the mandibular arch, no significant differences were detected between the DLP and MIL denture bases (P>.05).

CONCLUSIONS

The DLP and MIL denture bases demonstrated clinically acceptable tissue surface adaptation to both edentulous the maxilla and mandible. The DLP denture base was likely to exhibit intimate tissue adaptation in the stress-bearing areas of maxillary arches compared with the PAP denture base. The maxillary MIL denture base was likely to exhibit small gaps between the supporting tissue and denture base. Both DLP and MIL mandibular denture bases were likely to show intimate adaptation on the lingual slope compared with the PAP base.

Additive manufacture of lightly crosslinked semicrystalline thiol-enes for enhanced mechanical performance

Photopolymerizable semicrystalline thermoplastics resulting from thiol-ene polymerizations were formed via fast polymerizations and achieved excellent mechanical properties. These materials have been shown to produce materials desirable for additive manufacturing (3D printing), especially for recyclable printing and investment casting. However, while well-resolved prints were previously achieved with the thiol-ene thermoplastics, the remarkable elongation at break (ϵmax) and toughness (T) attained in bulk were not realized for 3D printed components (ϵmax,bulk ~ 790%, Tbulk ~ 102 MJ m-3 vs. ϵmax,print < 5%, Tprint < 0.5 MJ m-3). In this work, small concentrations (5-10 mol%) of a crosslinker were added to the original thiol-ene resin composition without sacrificing crystallization potential to achieve semicrystalline, covalently crosslinked networks with enhanced mechanical properties. Improvements in ductility and overall toughness were observed for printed crosslinked structures, and substantial mechanical augmentation was further demonstrated with post-manufacture thermal conditioning of printed materials above the melting temperature (Tm). In some instances, this thermal conditioning to reset the crystalline component of the crosslinked prints yielded mechanical properties that were comparable or superior to its bulk counterpart (ϵmax ~ 790%, T ~ 95 MJ m-3). These unique photopolymerizations and their corresponding monomer compositions exhibited concurrent polymerization and crystallization along with mechanical properties that were tunable by changes to the monomer composition, photopolymerization conditions, and post-polymerization conditioning. This is the first example of a 3D printed semicrystalline, crosslinked material with thermally tunable mechanical properties that are superior to many commercially-available resins.

Fused Deposition Modeling of Poly (lactic acid)/Macadamia Composites-Thermal, Mechanical Properties and Scaffolds

In this work Macadamia nutshell (MS) was used as filler in fused deposition modeling (FDM) of Poly (lactic acid) (PLA) composites filaments. Composites containing MS both treated and untreated with alkali and silane were investigated by means of Fourier transform infrared spectroscopy (FTIR), X-Ray diffraction (XRD), Thermogravimetry (TG), scanning electron microscopy (SEM). The results showed that the treated MS composites had better thermal stability. Furthermore, compression tests were carried out. The PLA with 10 wt% treated MS composite was found possessing the best mechanical properties which was almost equivalent to that of the pure PLA. Finally, porous scaffolds of PLA/10 wt% treated MS were fabricated. The scaffolds exhibited various porosities in range of 30–65%, interconnected holes in size of 0.3–0.5 mm, micro pores with dimension of 0.1–1 μm and 37.92–244.46 MPa of elastic modulus. Those values indicated that the FDM of PLA/MS composites have the potential to be used as weight lighter and structural parts.

Comparative Studies on Polyurethane Composites Filled with Polyaniline and Graphene for DLP-Type 3D Printing

Digital light processing (DLP)-type 3D printing ensures several advantages, such as an easy solution process, a short printing time, high-quality printing, and selective light curing. Furthermore, polyurethane (PU) is among the promising candidates for 3D printing because of its wide range of applications. This work reports comparative studies on the fabrication and optimization of PU composites using a polyaniline (PANI) nanomaterial and a graphene sheet (GS) for DLP-type 3D printing. The morphologies and dispersion of the printed PU composites were studied by field emission scanning electron microscope (FE-SEM) images. Bonding structures in the PU composites were investigated by Fourier-transform infrared (FT-IR) spectroscopy. As-prepared PU/PANI and PU/GS composites with different filler contents were successfully printed into sculptures with different sizes and shapes. The PU/PANI and PU/GS composites exhibit the improved sheet resistance, which is up to 8.57 × 10⁴ times (1.19 × 10⁶ ohm/sq) lower and 1.27 × 10⁵ times (8.05 × 10⁵ ohm/sq) lower, respectively, than the pristine PU (1.02 × 10¹¹ ohm/sq). Moreover, the PU/PANI and PU/GS composites demonstrate 1.41 times (44.5 MPa) higher and 2.19 times (69.3 MPa) higher tensile strengths compared with the pristine PU (31.6 MPa). This work suggests the potential uses of highly conductive PU composites for DLP-type 3D printing.

Hierarchical ordering in light-triggered additive manufacturing

Herein, recent developments in the 3D printing of materials with structural hierarchy and their future prospects are reviewed. It is shown that increasing the extent of ordering, is essential to access novel properties and functionalities.

In silico rational design by molecular modeling of new ketones as photoinitiators in three-component photoinitiating systems: application in 3D printing

New photoinitiators for 3D printing were in silico developed by molecular modeling.

Enhanced Mechanical and Thermal Properties of Stereolithography 3D Printed Structures by the Effects of Incorporated Controllably Annealed Anatase TiO2 Nanoparticles

Fabrication of low-cost, durable and efficient metal oxide nanocomposites were successfully synthesized and reinforced with photo-resin via 3-dimensional printing. Here, we put forward a novel approach to enhance the mechanical and thermal behaviors of stereolithography (SLA) 3D printed architecture by adding TiO₂ nanoparticles (TNPs) in different crystalline phases (anatase and rutile), which were obtained at different annealing temperatures from 400 °C to 1000°C. The heat-treated anatase TNPs were scrutinized by X-ray diffraction(XRD), X-ray photoelectron spectroscopy (XPS), Raman spectroscopy, diffusive reflectance spectroscopy (DRS), and transmission electron microscopy (TEM) analysis. Among all the samples, at 800 °C, annealed anatase TNPs exposed a highly crystalline anatase phase, having a low energy bandgap and a comparably high tensile strength (47.43 MPa) and high elastic modulus (2.261 GPa) for the 3D printed samples, showing improvement by 103% and 32%, respectively, compared with the printed pristine stereolithography resin (SLR) sample. Moreover, enhanced storage modulus and tan δ values were achieved via the better interfacial interactions between the incorporated nanofillers and the SLR matrix. In addition to this, enhanced thermal conductivity and thermal stability of the SLR matrix were also noted. The low energy bandgap and nanoscale size of the fillers helped to achieve good dispersion and allowed the UV light to penetrate at a maximum depth through the photo resin.

3D Printing of Textiles: Potential Roadmap to Printing with Fibers

3D printing (3DP) has transformed engineering, manufacturing, and the use of advanced materials due to its ability to produce objects from a variety of materials, ranging from soft polymers to rigid ceramics. 3DP offers the advantage of being able to print at a variety of lengths scales; from a few micrometers to many meters. 3DP has the unique ability to produce customized small lots, efficiently. Yet, one crucial industry that has not been able to adequately explore its potential is textile manufacturing. The research in 3DP of textiles has lagged behind other areas primarily due to the difficulty in obtaining some of the unique characteristics of strength, flexibility, etc., of textiles, utilizing a fundamentally different manufacturing technology. Textiles are their own class of materials due to the specific structural developments that occur during the various stages of textile manufacturing: from fiber extrusion to assembly of the fibers to fabrics. Here, the current 3DP technologies are reviewed with emphasis on soft and anisotropic structures, as well as the efforts toward 3DP of textiles. Finally, a potential pathway to 3DP of textiles, dubbed as printing with fibers to create textile structures is proposed for further exploration.

Alternating ring-opening copolymerization of epoxides with saturated and unsaturated cyclic anhydrides: reduced viscosity poly(propylene fumarate) oligomers for use in cDLP 3D printing

A ring-opening copolymerization of propylene oxide with saturated and unsaturated anhydrides using Mg(BHT)₂(THF)₂ catalyst followed by an isomerization yields poly(propylene fumarate) (PPF) oligomers with improved properties for 3D printing.

Three-Dimensional Printing of a LiFePO4/Graphite Battery Cell via Fused Deposition Modeling

Among the 3D-printing technologies, fused deposition modeling (FDM) represents a promising route to enable direct incorporation of the battery within the final 3D object. Here, the preparation and characterization of lithium iron phosphate/polylactic acid (LFP/PLA) and SiO2/PLA 3D-printable filaments, specifically conceived respectively as positive electrode and separator in a lithium-ion battery is reported. By means of plasticizer addition, the active material loading within the positive electrode is raised as high as possible (up to 52 wt.%) while still providing enough flexibility to the filament to be printed. A thorough analysis is performed to determine the thermal, electrical and electrochemical effect of carbon black as conductive additive in the positive electrode and the electrolyte uptake impact of ceramic additives in the separator. Considering both optimized filaments composition and using our previously reported graphite/PLA filament for the negative electrode, assembled and "printed in one-shot" complete LFP/Graphite battery cells are 3D-printed and characterized. Taking advantage of the new design capabilities conferred by 3D-printing, separator patterns and infill density are discussed with a view to enhance the liquid electrolyte impregnation and avoid short-circuits.

Filament Extrusion and Its 3D Printing of Poly(Lactic Acid)/Poly(Styrene-co-Methyl Methacrylate) Blends

Herein, we report the melt blending of amorphous poly(lactide acid) (PLA) with poly(styrene-co-methyl methacrylate) (poly(S-co-MMA)). The PLAx/poly(S-co-MMA)y blends were made using amorphous PLA compositions from 50, 75, and 90wt.%, namely PLA50/poly(S-co-MMA)50, PLA75/poly(S-co-MMA)25, and PLA90/poly(S-co-MMA)10, respectively. The PLAx/poly(S-co-MMA)y blend pellets were extruded into filaments through a prototype extruder at 195 °C. The 3D printing was done via fused deposition modeling (FDM) at the same temperature and a 40 mm/s feed rate. Furthermore, thermogravimetric curves of the PLAx/poly(S-co-MMA)y blends showed slight thermal decomposition with less than 0.2% mass loss during filament extrusion and 3D printing. However, the thermal decomposition of the blends is lower when compared to amorphous PLA and poly(S-co-MMA). On the contrary, the PLAx/poly(S-co-MMA)y blend has a higher Young’s modulus (E) than amorphous PLA, and is closer to poly(S-co-MMA), in particular, PLA90/poly(S-co-MMA)10. The PLAx/poly(S-co-MMA)y blends proved improved properties concerning amorphous PLA through mechanical and rheological characterization.

Assessment of the Adaptation of Interim Crowns using Different Measurement Techniques

PURPOSE

To compare the internal fit and marginal discrepancy of acrylic resin interim crowns fabricated by different manufacturing methods, and to test the consistency of measuring marginal discrepancy and internal fit between different measuring techniques.

MATERIALS AND METHODS

A dentoform mandibular left first molar was prepared for an all-ceramic crown. Thirty-six interim crowns were fabricated and divided into three groups (n = 12): group BAC (Bis-acrylic composite, fabricated manually), group CAM (CAD/CAM polymethylmethacrylate resin, milled), and group 3DP (3D printed methacrylic oligomers, printed). The internal fit of the interim crowns was evaluated by the silicone replica technique and by X-ray microcomputed tomography (µCT) technique. The marginal discrepancy of the interim crowns was evaluated by the vinyl polysiloxane (VPS) (Aquasil Ultra XLV) impression technique and by optical coherence tomography (OCT) technique. Data were statistically analyzed using ANOVA and Turkey tests at α = 0.05. Pearson correlation test was used to evaluate the correlation between the different measurement techniques and marginal discrepancy/internal fit.

RESULTS

The manually fabricated interim crowns (group BAC) had significantly greater discrepancy of internal fit than did the digitally fabricated crowns (group CAM and group 3DP) measured by both silicone replica technique and µCT 2-dimensional (2D) image measurement. There were no statistically significant differences in the cement space volume values obtained by the µCT image technique between group BAC and group 3DP (p = 0.285). The coefficient of determination between the two volumetric measurement techniques was low (R² = 0.30). For marginal discrepancy, the manually fabricated interim crowns had a wider absolute marginal discrepancy than both digitally fabricated groups (p < 0.05). In both the VPS impression and OCT assessment, there was no statistically significant difference between group CAM and group 3DP (p = 0.798 and 0.994, respectively). The coefficient of determination between the VPS impression and OCT techniques for marginal discrepancy measurement was low (R² = 0.23).

CONCLUSIONS

Digitally fabricated interim crowns (group CAM and group 3DP) had better internal fit and smaller marginal discrepancy than manually fabricated interim crowns (group BAC). For comparison of the different evaluation techniques, the silicone replica technique and µCT measurements had low correlation for internal fit assessment, as did the PVS impression and OCT techniques for marginal discrepancy test.

The status and challenges of replicating the mechanical properties of connective tissues using additive manufacturing

The ability to fabricate complex structures via precise and heterogeneous deposition of biomaterials makes additive manufacturing (AM) a leading technology in the creation of implants and tissue engineered scaffolds. Connective tissues (CTs) remain attractive targets for manufacturing due to their "simple" tissue compositions that, in theory, are replicable through choice of biomaterial(s) and implant microarchitecture. Nevertheless, characterisation of the mechanical and biological functions of 3D printed constructs with respect to their host tissues is often limited and remains a restriction towards their translation into clinical practice. This review aims to provide an update on the current status of AM to mimic the mechanical properties of CTs, with focus on arterial tissue, articular cartilage and bone, from the perspective of printing platforms, biomaterial properties, and topological design. Furthermore, the grand challenges associated with the AM of CT replacements and their subsequent regulatory requirements are discussed to aid further development of reliable and effective implants.

A Versatile 3D and 4D Printing System through Photocontrolled RAFT Polymerization

Reversible addition-fragmentation chain-transfer (RAFT) polymerization is a valuable tool for synthesizing macromolecules with controlled topologies and diverse chemical functionalities. However, the application of RAFT polymerization to additive-manufacturing processes has been prevented due to the slow polymerization rates of typical systems. In this work, we developed and optimized a rapid visible (green) light mediated RAFT polymerization process and applied it to an open-air 3D printing system. The reaction components are non-toxic, metal free and environmentally friendly, which tailors these systems toward biomaterial fabrication. The inclusion of RAFT agent in the photosensitive resin provided control over the mechanical properties of 3D printed materials and allowed these materials to be post-functionalized after 3D printing. Additionally, photoinduced spatiotemporal control of the network structure provided a one-pass approach to 4D printed materials. This RAFT-mediated 3D and 4D printing process should provide access to a range of new functional and stimuli-responsive materials.

Effects of Ultrasonic Impact Treatment on the Stress-Controlled Fatigue Performance of Additively Manufactured DMLS Ti-6Al-4V Alloy

Additive manufacturing (AM) offers many advantages for the mechanical design of metal components. However, the benefits of AM are offset to a certain extent by the poor surface finish and high residual stresses resulting from the printing process, which consequently compromise the mechanical properties of the parts, particularly their fatigue performance. Ultrasonic impact treatment (UIT) is a surface modification process which is often used to increase the fatigue life of welds in ship hulls and steel bridges. This paper studies the effect of UIT on the fatigue life of Ti-6Al-4V manufactured by Direct Metal Laser Sintering (DMLS). The surface properties before and after the UIT are characterized by surface porosity, roughness, hardness and residual stresses. Results show that UIT enhances the fatigue life of DMLS Ti-6Al-4V parts by suppressing the surface defects originating from the DMLS process and inducing compressive residual stresses at the surface. At the adopted UIT application parameters, the treatment improved the fatigue performance by 200%, significantly decreased surface porosity, reduced the surface roughness by 69%, and imposed a compressive hydrostatic stress of 1644 MPa at the surface.

Hydrophilic excipients in digital light processing (DLP) printing of sustained release tablets: Impact on internal structure and drug dissolution rate

Three-dimensional (3D) printing enables the production of different objects adjusted for the specific application, which has particular importance of providing personalized therapy, whereby the challenge is to apply pharmaceutical materials into 3D printing technology. In this study, effect of poly(ethylene glycol) 400 (PEG 400), sodium chloride (NaCl), and mannitol, as hydrophilic excipients, was investigated in order to overcome very slow and incomplete drug release from tablets (printlets) fabricated by photopolymerization using digital light processing (DLP) technology. Paracetamol (acetaminophen) was used as a model drug, while polyethylene glycol diacrylate (PEGDA) was used as a photopolymer and diphenyl (2,4,6-trimethylbenzoyl) phosphine oxide as a photoinitiator in photoreactive mixtures. Most of printlet formulations exhibit sustained release over 8 h, wherein drug release kinetics is the best described with Korsmeyer-Peppas kinetics. Variation in the content of photopolymer and excipients had an influence on the dissolution rate, mechanical characteristics, and internal structure of the investigated samples. The addition of hydrophilic polymers increased drug release rate, while PEGDA had the greatest influence on the tensile strength of printlets. The results indicate the possibility of implementation of traditional excipients into different formulations for photopolymerization based 3D printing for the production of small batches of tablets with tailored drug release.

Minimal invasive microscopic tooth preparation in esthetic restoration: a specialist consensus

By removing a part of the structure, the tooth preparation provides restorative space, bonding surface, and finish line for various restorations on abutment. Preparation technique plays critical role in achieving the optimal result of tooth preparation. With successful application of microscope in endodontics for >30 years, there is a full expectation of microscopic dentistry. However, as relatively little progress has been made in the application of microscopic dentistry in prosthodontics, the following assumptions have been proposed: Is it suitable to choose the tooth preparation technique under the naked eye in the microscopic vision? Is there a more accurate preparation technology intended for the microscope? To obtain long-term stable therapeutic effects, is it much easier to achieve maximum tooth preservation and retinal protection and maintain periodontal tissue and oral function health under microscopic vision? Whether the microscopic prosthodontics is a gimmick or a breakthrough in obtaining an ideal tooth preparation should be resolved in microscopic tooth preparation. This article attempts to illustrate the concept, core elements, and indications of microscopic minimally invasive tooth preparation, physiological basis of dental pulp, periodontium and functions involved in tool preparation, position ergonomics and visual basis for dentists, comparison of tooth preparation by naked eyes and a microscope, and comparison of different designs of microscopic minimally invasive tooth preparation techniques. Furthermore, a clinical protocol for microscopic minimally invasive tooth preparation based on target restorative space guide plate has been put forward and new insights on the quantity and shape of microscopic minimally invasive tooth preparation has been provided.

3D printing using powder melt extrusion

Additive manufacturing promises to revolutionize manufacturing industries. However, 3D printing of novel build materials is currently limited by constraints inherent to printer designs. In this work, a bench-top powder melt extrusion (PME) 3D printer head was designed and fabricated to print parts directly from powder-based materials rather than filament. The final design of the PME printer head evolved from the Rich Rap Universal Pellet Extruder (RRUPE) design and was realized through an iterative approach. The PME printer was made possible by modifications to the funnel shape, pressure applied to the extrudate by the auger, and hot end structure. Through comparison of parts printed with the PME printer with those from a commercially available fused filament fabrication (FFF) 3D printer using common thermoplastics poly(lactide) (PLA), high impact poly (styrene) (HIPS), and acrylonitrile butadiene styrene (ABS) powders (< 1 mm in diameter), evaluation of the printer performance was performed. For each build material, the PME printed objects show comparable viscoelastic properties by dynamic mechanical analysis (DMA) to those of the FFF objects. However, due to a significant difference in printer resolution between PME (X-Y resolution of 0.8 mm and a Z-layer height calibrated to 0.1 mm) and FFF (X-Y resolution of 0.4 mm and a Z-layer height of 0.18 mm), as well as, an inherently more inconsistent feed of build material for PME than FFF, the resulting print quality, determined by a dimensional analysis and surface roughness comparisons, of the PME printed objects was lower than that of the FFF printed parts based on the print layer uniformity and structure. Further, due to the poorer print resolution and inherent inconsistent build material feed of the PME, the bulk tensile strength and Young's moduli of the objects printed by PME were lower and more inconsistent (49.2 ± 10.7 MPa and 1620 ± 375 MPa, respectively) than those of FFF printed objects (57.7 ± 2.31 MPa and 2160 ± 179 MPa, respectively). Nevertheless, PME print methods promise an opportunity to provide a platform on which it is possible to rapidly prototype a myriad of thermoplastic materials for 3D printing.

Development of 18 Quality Control Gates for Additive Manufacturing of Error Free Patient-Specific Implants

Unlike subtractive manufacturing technologies, additive manufacturing (AM) can fabricate complex shapes from the macro to the micro scale, thereby allowing the design of patient-specific implants following a biomimetic approach for the reconstruction of complex bone configurations. Nevertheless, factors such as high design variability and changeable customer needs are re-shaping current medical standards and quality control strategies in this sector. Such factors necessitate the urgent formulation of comprehensive AM quality control procedures. To address this need, this study explored and reported on a variety of aspects related to the production and the quality control of additively manufactured patient-specific implants in three different AM companies. The research goal was to develop an integrated quality control procedure based on the synthesis and the adaptation of the best quality control practices with the three examined companies and/or reported in literature. The study resulted in the development of an integrated quality control procedure consisting of 18 distinct gates based on the best identified industry practices and reported literature such as the Food and Drug Administration (FDA) guideline for AM medical devices and American Society for Testing and Materials (ASTM) standards, to name a few. This integrated quality control procedure for patient-specific implants seeks to prepare the AM industry for the inevitable future tightening in related medical regulations. Moreover, this study revealed some critical success factors for companies developing additively manufactured patient-specific implants, including ongoing research and development (R&D) investment, investment in advanced technologies for controlling quality, and fostering a quality improvement organizational culture.

Biomimetic Polymer-Based Engineered Scaffolds for Improved Stem Cell Function

Scaffolds are considered promising materials for tissue engineering applications due to their unique physiochemical properties. The high porosity and adequate mechanical properties of the scaffolds facilitate greater cell adhesion, proliferation, and differentiation. Stem cells are frequently applied in tissue engineering applications due to their excellent potential. It has been noted that cell functions are profoundly affected by the nature of the extracellular matrix (ECM). Naturally derived ECM contains the bioactive motif that also influences the immune response of the organism. The properties of polymer scaffolds mean they can resemble the native ECM and can regulate cellular responses. Various techniques such as electrospinning and 3D printing, among others, are frequently used to fabricate polymer scaffolds, and their cellular responses are different with each technique. Furthermore, enhanced cell viability, as well as the differentiation ability of stem cells on the surface of scaffolds, opens a fascinating approach to the formation of ECM-like environments for tissue engineering applications.

Review of alginate-based hydrogel bioprinting for application in tissue engineering

The dawn of 3D printing in medicine has given the field the hope of vitality in many patients fighting a multitude of diseases. Also entitled bioprinting, this appertains to its sequential printing of precursor ink, embodying cells and polymer/composite in a predetermined trajectory. The precursor ink, in addition to cells, is predominantly constituted of hydrogels due to its biodegradability and ability to mimic the body's anatomy and mechanical features, e.g. bones, etc. This review paper is devoted to explicating the bioprinting (3D/4D) of alginate hydrogels, which are extracts from brown algae, through extrusion additive manufacturing. Alginates are salt derivatives of alginic acid and constitute long chains of polysaccharides, which provides pliability and gelling adeptness to their structure. Alginate hydrogel (employed for extrusion) can be pristine or composite relying on the requisite properties (target application controlled or in vivo environment), e.g. alginate-natural (gelatin/agarose/collagen/hyaluronic acid/etc) and alginate-synthetic (polyethylene glycol (PEG)/pluronic F-127/etc). Extrusion additive manufacturing of alginate is preponderate among others with its uncomplicated processing, material efficiency (cut down on wastage), and outspread adaptability for viscosities (0.03-6 * 10⁴ Pa.s), but the procedure is limited by resolution (200 μm) in addition to accuracy. However, 3D-fabricated biostructures display rigidness (unvarying with conditions) i.e. lacks a smart response, which is reassured by accounting time feature as a noteworthy accessory to printing, interpreted as 4D bioprinting. This review propounds the specific processing itinerary for alginate (meanwhile traversing across its composites/blends with natural and synthetic consideration) in extrusion along with its pre-/during/post-processing parameters intrinsic to the process. Furthermore, propensity is also presented in its (alginate extrusion processing) application for tissue engineering, i.e. bones, cartilage (joints), brain (neural), ear, heart (cardiac), eyes (corneal), etc, due to a worldwide quandary over accessibility to natural organs for diverse types of diseases. Additionally, the review contemplates recently invented advance printing, i.e. 4D printing for biotic species, with its challenges and future opportunities.

A Collaborative and Ubiquitous System for Fabricating Dental Parts Using 3D Printing Technologies

Three-dimensional (3D) printing has great potential for establishing a ubiquitous service in the medical industry. However, the planning, optimization, and control of a ubiquitous 3D printing network have not been sufficiently discussed. Therefore, this study established a collaborative and ubiquitous system for making dental parts using 3D printing. The collaborative and ubiquitous system split an order for the 3D printing facilities to fulfill the order collaboratively and forms a delivery plan to pick up the 3D objects. To optimize the performance of the two tasks, a mixed-integer linear programming (MILP) model and a mixed-integer quadratic programming (MIQP) model are proposed, respectively. In addition, slack information is derived and provided to each 3D printing facility so that it can determine the feasibility of resuming the same 3D printing process locally from the beginning without violating the optimality of the original printing and delivery plan. Further, more slack is gained by considering the chain effect between two successive 3D printing facilities. The effectiveness of the collaborative and ubiquitous system was validated using a regional experiment in Taichung City, Taiwan. Compared with two existing methods, the collaborative and ubiquitous 3D printing network reduced the manufacturing lead time by 45% on average. Furthermore, with the slack information, a 3D printing facility could make an independent decision about the feasibility of resuming the same 3D printing process locally from the beginning.

Ultrastable, Deformable, and Stretchable Luminescent Organic-Inorganic Perovskite Nanocrystal-Polymer Composites for 3D Printing and White Light-Emitting Diodes

Organic-inorganic perovskite nanocrystals with excellent optoelectronic properties have been utilized in various applications, despite their stability issues. The perovskite materials are sensitive to environments such as polar solvents, moisture, and heat. Thus, they are not used for extrusion three-dimensional (3D) printing, as it is usually conducted in the ambient environment and requires heating to liquefy the printed materials. In this work, 11 thermoplastic polymers conventionally used for extrusion 3D printing were investigated to test their capability as protective encapsulation materials for perovskite nanocrystals. Three of them exhibited good protective properties, and one (polycaprolactone, PCL) of these three could be blended with perovskite nanocrystals to form perovskite nanocrystal-PCL composites, which were deformable and stretchable once heated. Because of the low melting point of PCL, the perovskite nanocrystals maintained their optical properties after 3D printing, and the printed objects were still having fluorescent behavior. Moreover, fluorescent micrometer-sized fibers based on the perovskite nanocrystal-PCL composites could also be simply prepared using cotton candy makers. Perovskite nanocrystal-PCL composite films with different emission wavelengths were incorporated with blue light-emitting diodes (LEDs) to realize white LEDs with Commission Internationale de l'Éclairage chromaticity coordinates of (0.33, 0.33).

Mechanics of shape distortion of DLP 3D printed structures during UV post-curing

Digital light processing (DLP) three-dimensional (3D) printing technology has advantages of fast printing speed and high printing precision. It can print objects with small and complex geometrical features and has been widely used in jewelry manufacturing and dentistry. In DLP printing, it is common to use post-treatment with UV light irradiation to improve the final mechanical properties. However, it was found that the UV post-curing process can lead to shape distortion and thus reduction of dimension accuracy. In this paper, we combined photopolymerization reaction kinetics and Euler-Bernoulli beam theory to study UV post-curing induced shape distortion of thin structures prepared by DLP 3D printing. Experiments were conducted to characterize the evolution of mechanical behavior of printed samples during the post-printing process, which was correlated to printing parameters (printing time of single-layer, height of single-layer and printing UV intensity), post-curing UV light intensity and the thickness of the strip. Moreover, post-curing induced distortion was used for the fabrication of 3D structures.

Effects of Printing Parameters on the Fit of Implant-Supported 3D Printing Resin Prosthetics

The purpose of the study was to investigate the influence of 3D printing parameters on fit and internal gap of 3D printed resin dental prosthesis. The dental model was simulated and fabricated for three-unit prostheses with two implants. One hundred prostheses were 3D printed with two-layer thicknesses for five build orientations using a resin (NextDent C&B; 3D systems, Soesterberg, The Netherlands) and ten prostheses were manufactured with a milling resin as control. The prostheses were seated and scanned with micro-CT (computerized tomography). Internal gap volume (IGV) was calculated from 3D reconstructed micro-CT data. IGV, marginal fit, and lengths of internal gaps were measured, and the values were analyzed statistically. For the 3D printed prostheses, IGV was smaller at 45°, 60°, and 90° compared to other build orientations. The marginal fit evaluated by absolute marginal discrepancy was smaller than other build orientations at 45° and 60°. IGV was smaller at 50 µm layer thickness than at 100 µm layer thickness, but the marginal fit was smaller at 100 µm layer thickness than at 50 µm layer thickness. The 3D printed prosthesis had smaller internal gap than the milled prosthesis. The marginal fit of the 3D printed resin prosthesis was clinically acceptable, and build orientation of 45° and 60° would be recommended when considering fit and internal gap.

3D printing with peptide-polymer conjugates for single-step fabrication of spatially functionalized scaffolds

Biodegradable polymer-based scaffolds are widely used to provide support during early stages of regeneration and can be functionalized with various chemical groups or bioactive cues to promote desired cellular behavior. However, these scaffolds are often modified post-fabrication, which can lead to undesired changes and homogeneously distributed chemistries that fail to mimic the spatial biochemical organization found in native tissues. To address these challenges, surface functionalization can be achieved by 3D printing with pre-functionalized biodegradable polymers, such as peptide-modified polymer conjugates, to control the deposition of preferred chemistries. Peptide-PCL conjugates were synthesized with the canonical cell adhesion peptide motif RGDS or its negative control RGES and 3D printed into scaffolds displaying one or both peptides. The peptides were also modified with bioorthogonal groups, biotin and azide, to visualize peptide concentration and location by labeling with complementary fluorophores. Peptide concentration on the scaffold surface increased with increasing peptide-PCL conjugate concentration added to the ink prior to 3D printing, and scaffolds printed with the highest RGDS(biotin)-PCL concentrations showed a significant increase in NIH3T3 fibroblast adhesion. To demonstrate spatial control of peptide functionalization, multiple printer heads were used to print both peptide-PCL conjugates into the same construct in alternating patterns. Cells preferentially attached and spread on RGDS(biotin)-PCL fibers compared to RGES(azide)-PCL fibers, illustrating how spatial functionalization can be used to influence local cell behavior within a single biomaterial. This presents a versatile platform to generate multifunctional biomaterials that can mimic the biochemical organization found in native tissues to support functional regeneration.

3D-printed pediatric temporal bone models for surgical training: a patient-specific and low-cost alternative

Aim: To determine the usefulness of low-cost 3D-printed pediatric temporal bone models and to define if they could be used as a tool for large-scale surgical training based on their affordability. Materials & methods: Prototypes of a pediatric temporal bone were printed using fused deposition modeling 3D printing technique. The prototypes were drilled. The surgical simulation experience was registered by means of a Likert scale questionnaire. Results: The prototypes adequately simulated a cadaveric temporal bone. The costs associated with production were low compared with other commercial models making it a cost-effective alternative for a temporal bone laboratory. Conclusion: Printed temporal bones created by means of fused deposition modeling are useful for surgical simulation and training in otolaryngology, and it is possible to achieve detailed low-cost models.