Multi-Material 3D and 4D Printing: A Survey

Evaluating the Piezoelectric Energy Harvesting Potential of 3D-Printed Graphene Prepared Using Direct Ink Writing and Fused Deposition Modelling

This research aims to use energy harvested from conductive materials to power microelectronic components. The proposed method involves using vibration-based energy harvesting to increase the natural vibration frequency, reduce the need for battery replacement, and minimise chemical waste. Piezoelectric transduction, known for its high-power density and ease of application, has garnered significant attention. Additionally, graphene, a non-piezoelectric material, exhibits good piezoelectric properties. The research explores a novel method of printing graphene material using 3D printing, specifically Direct Ink Writing (DIW) and fused deposition modelling (FDM). Both simulation and experimental techniques were used to analyse energy harvesting. The experimental technique involved using the cantilever beam-based vibration energy harvesting method. The results showed that the DIW-derived 3D-printed prototype achieved a peak power output of 12.2 µW, surpassing the 6.4 µW output of the FDM-derived 3D-printed prototype. Furthermore, the simulation using COMSOL Multiphysics yielded a harvested output of 0.69 µV.

Nozzle Innovations That Improve Capacity and Capabilities of Multimaterial Additive Manufacturing

Multimaterial additive manufacturing incorporates multiple species within a single 3D-printed object to enhance its material properties and functionality. This technology could play a key role in distributed manufacturing. However, conventional layer-by-layer construction methods must operate at low volumetric throughputs to maintain fine feature resolution. One approach to overcome this challenge and increase production capacity is to structure multimaterial components in the printhead prior to deposition. Here we survey four classes of multimaterial nozzle innovations, nozzle arrays, coextruders, static mixers, and advective assemblers, designed for this purpose. Additionally, each design offers unique capabilities that provide benefits associated with accessible architectures, interfacial adhesion, material properties, and even living-cell viability. Accessing these benefits requires trade-offs, which may be mitigated with future investigation. Leveraging decades of research and development of multiphase extrusion equipment can help us engineer the next generation of 3D-printing nozzles and expand the capabilities and practical reach of multimaterial additive manufacturing.

Bioprinted research models of urological malignancy

Urological malignancy (UM) is among the leading threats to health care worldwide. Recent years have seen much investment in fundamental UM research, including mechanistic investigation, early diagnosis, immunotherapy, and nanomedicine. However, the results are not fully satisfactory. Bioprinted research models (BRMs) with programmed spatial structures and functions can serve as powerful research tools and are likely to disrupt traditional UM research paradigms. Herein, a comprehensive review of BRMs of UM is presented. It begins with a brief introduction and comparison of existing UM research models, emphasizing the advantages of BRMs, such as modeling real tissues and organs. Six kinds of mainstream bioprinting techniques used to fabricate such BRMs are summarized with examples. Thereafter, research advances in the applications of UM BRMs, such as culturing tumor spheroids and organoids, modeling cancer metastasis, mimicking the tumor microenvironment, constructing organ chips for drug screening, and isolating circulating tumor cells, are comprehensively discussed. At the end of this review, current challenges and future development directions of BRMs and UM are highlighted from the perspective of interdisciplinary science.

Recent Advances in 4D Printing of Advanced Materials and Structures for Functional Applications

4D printing has attracted tremendous worldwide attention during the past decade. This technology enables the shape, property, or functionality of printed structures to change with time in response to diverse external stimuli, making the original static structures alive. The revolutionary 4D-printing technology offers remarkable benefits in controlling geometric and functional reconfiguration, thereby showcasing immense potential across diverse fields, including biomedical engineering, electronics, robotics, and photonics. Here, a comprehensive review of the latest achievements in 4D printing using various types of materials and different additive manufacturing techniques is presented. The state-of-the-art strategies implemented in harnessing various 4D-printed structures are highlighted, which involve materials design, stimuli, functionalities, and applications. The machine learning approach explored for 4D printing is also discussed. Finally, the perspectives on the current challenges and future trends toward further development in 4D printing are summarized.

Recent Advances in 3D Printing of Smart Scaffolds for Bone Tissue Engineering and Regeneration

The repair and functional reconstruction of bone defects resulting from severe trauma, surgical resection, degenerative disease, and congenital malformation pose significant clinical challenges. Bone tissue engineering (BTE) holds immense potential in treating these severe bone defects, without incurring prevalent complications associated with conventional autologous or allogeneic bone grafts. 3D printing technology enables control over architectural structures at multiple length scales and has been extensively employed to process biomimetic scaffolds for BTE. In contrast to inert and functional bone grafts, next-generation smart scaffolds possess a remarkable ability to mimic the dynamic nature of native extracellular matrix (ECM), thereby facilitating bone repair and regeneration. Additionally, they can generate tailored and controllable therapeutic effects, such as antibacterial or antitumor properties, in response to exogenous and/or endogenous stimuli. This review provides a comprehensive assessment of the progress of 3D-printed smart scaffolds for BTE applications. It begins with an introduction to bone physiology, followed by an overview of 3D printing technologies utilized for smart scaffolds. Notable advances in various stimuli-responsive strategies, therapeutic efficacy, and applications of 3D-printed smart scaffolds are discussed. Finally, the review highlights the existing challenges in the development and clinical implementation of smart scaffolds, as well as emerging technologies in this field.

Multimaterial 3D and 4D Bioprinting of Heterogenous Constructs for Tissue Engineering

Additive manufacturing (AM), which is based on the principle of layer-by-layer shaping and stacking of discrete materials, has shown significant benefits in the fabrication of complicated implants for tissue engineering (TE). However, many native tissues exhibit anisotropic heterogenous constructs with diverse components and functions. Consequently, the replication of complicated biomimetic constructs using conventional AM processes based on a single material is challenging. Multimaterial 3D and 4D bioprinting (with time as the fourth dimension) has emerged as a promising solution for constructing multifunctional implants with heterogenous constructs that can mimic the host microenvironment better than single-material alternatives. Notably, 4D-printed multimaterial implants with biomimetic heterogenous architectures can provide a time-dependent programmable dynamic microenvironment that can promote cell activity and tissue regeneration in response to external stimuli. This paper first presents the typical design strategies of biomimetic heterogenous constructs in TE applications. Subsequently, the latest processes in the multimaterial 3D and 4D bioprinting of heterogenous tissue constructs are discussed, along with their advantages and challenges. In particular, the potential of multimaterial 4D bioprinting of smart multifunctional tissue constructs is highlighted. Furthermore, this review provides insights into how multimaterial 3D and 4D bioprinting can facilitate the realization of next-generation TE applications.

Toward Multiscale, Multimaterial 3D Printing

Biological materials and organisms possess the fundamental ability to self-organize, through which different components are assembled from the molecular level up to hierarchical structures with superior mechanical properties and multifunctionalities. These complex composites inspire material scientists to design new engineered materials by integrating multiple ingredients and structures over a wide range. Additive manufacturing, also known as 3D printing, has advantages with respect to fabricating multiscale and multi-material structures. The need for multifunctional materials is driving 3D printing techniques toward arbitrary 3D architectures with the next level of complexity. In this paper, the aim is to highlight key features of those 3D printing techniques that can produce either multiscale or multimaterial structures, including innovations in printing methods, materials processing approaches, and hardware improvements. Several issues and challenges related to current methods are discussed. Ultimately, the authors also provide their perspective on how to realize the combination of multiscale and multimaterial capabilities in 3D printing processes and future directions based on emerging research.

Recent advances in implantable sensors and electronics using printable materials for advanced healthcare

This review article focuses on the recent printing technological progress in healthcare, underscoring the significant potential of implantable devices across diverse applications. Printing technologies have widespread use in developing health monitoring devices, diagnostic systems, and surgical devices. Recent years have witnessed remarkable progress in fabricating low-profile implantable devices, driven by advancements in printing technologies and nanomaterials. The importance of implantable biosensors and bioelectronics is highlighted, specifically exploring printing tools using bio-printable inks for practical applications, including a detailed examination of fabrication processes and essential parameters. This review also justifies the need for mechanical and electrical compatibility between bioelectronics and biological tissues. In addition to technological aspects, this article delves into the importance of appropriate packaging methods to enhance implantable devices' performance, compatibility, and longevity, which are made possible by integrating cutting-edge printing technology. Collectively, we aim to shed light on the holistic landscape of implantable biosensors and bioelectronics, showcasing their evolving role in advancing healthcare through innovative printing technologies.

Additively Manufactured Flexible Liquid Metal-Coated Self-Powered Magnetoelectric Sensors with High Design Freedom

Although additive manufacturing enables controllable structural design and customized performance for magnetoelectric sensors, their design and fabrication still require careful matching of the size and modulus between the magnetic and conductive components. Achieving magnetoelectric integration remains challenging, and the rigid coils limit the flexibility of the sensors. To overcome these obstacles, this study proposes a composite process combining selective laser sintering (SLS) and 3D transfer printing for fabricating flexible liquid metal-coated magnetoelectric sensors. The liquid metal forms a conformal conductive network on the SLS-printed magnetic lattice structure. Deformation of the structure alters the magnetic flux passing through it, thereby generating voltage. A reverse model segmentation and summation method is established to calculate the theoretical magnetic flux. The impact of the volume fraction, unit size, and height of the sensors on the voltage is studied, and optimization of these factors yields a maximum voltage of 45.6 µV. The sensor has excellent sensing performance with a sensitivity of 10.9 kPa-1 and a minimum detection pressure of 0.1 kPa. The voltage can be generated through various external forces. This work presents a significant advancement in fabricating liquid metal-based magnetoelectric sensors by improving their structural flexibility, magnetoelectric integration, and design freedom.

Material Compatibility in 4D Printing: Identifying the Optimal Combination for Programmable Multi-Material Structures

This study identifies the optimal combination of active and passive thermoplastic materials for producing multi-material programmable 3D structures. These structures can undergo shape changes with varying radii of curvature over time when exposed to hot water. The research focuses on examining the thermal, thermomechanical, and mechanical properties of active (PLA) and passive (PRO-PLA, ABS, and TPU) materials. It also includes the experimental determination of the radius of curvature of the programmed 3D structures. The pairing of active PLA with passive PRO-PLA was found to be the most effective for creating complex programmable 3D structures capable of two-sided transformation. This efficacy is attributed to the adequate apparent shear strength, significant differences in thermomechanical shrinkage between the two materials, identical printing parameters for both materials, and the lowest bending storage modulus of PRO-PLA among the passive materials within the activation temperature range. Multi-material 3D printing has also proven to be a suitable method for producing programmable 3D structures for practical applications such as phone stands, phone cases, door hangers, etc. It facilitates the programming of the active material and ensures the dimensional stability of the passive components of programmable 3D structures during thermal activation.

Hybrid Zwitterionic Hydrogels with Encoded Differential Swelling and Programmed Deformation for Small-Scale Robotics

Stimuli-responsive shape-morphing hydrogels with self-healing and tunable physiochemical properties are excellent candidates for functional building blocks of untethered small-scale soft robots. With mechanical properties similar to soft organs and tissues, such robots enable minimally invasive medical procedures, such as cargo/cell transportation. In this work, responsive hydrogels based on zwitterionic/acrylate chemistry with self-healing and stimuli-responsiveness are synthesized. Such hydrogels are then judiciously cut and pasted to form hybrid constructs with predetermined swelling and elastic anisotropy. This method is used to program hydrogel constructs with predetermined 2D-to-3D deformation upon exposure to different environmental ionic strengths. Untethered soft robotic functionalities are demonstrated, such as actuation, magnetic locomotion, and targeted transport of soft and light cargo in flooded media. The proposed hydrogel expands the repertoire of functional materials for fabricating small-scale soft robots.

A novel semi-flexible coaxial nozzle based on fluid dynamics effects and its self-centering performance study

Coaxial nozzles are widely used to produce fibers with core-shell structures. However, conventional coaxial nozzles cannot adjust the coaxiality of the inner and outer needles in real-time during the fiber production process, resulting in uneven fiber wall thickness and poor quality. Therefore, we proposed an innovative semi-flexible coaxial nozzle with a dynamic self-centering function. This new design addresses the challenge of ensuring the coaxiality of the inner and outer needles of the coaxial nozzle. First, based on the principles of fluid dynamics and fluid-structure interaction, a self-centering model for a coaxial nozzle is established. Second, the influence of external fluid velocity and inner needle elastic modulus on the centering time and coaxiality error is analyzed by finite element simulation. Finally, the self-centering performance of the coaxial nozzle is verified by observing the coaxial extrusion process online and measuring the wall thickness of the formed hollow fiber. The results showed that the coaxiality error increased with the increase of Young's modulus E and decreased with the increase of flow velocity. The centering time required for the inner needle to achieve force balance decreases with the increase of Young's modulus ( E ) and fluid velocity ( v f ). The nozzle exhibits significant self-centering performance, dynamically reducing the initial coaxiality error from 380 to 60 μm within 26 s. Additionally, it can mitigate the coaxiality error caused by manufacturing and assembly precision, effectively controlling them within 8 μm. Our research provides valuable references and solutions for addressing issues such as uneven fiber wall thickness caused by coaxiality errors.

Design-encoded dual shape-morphing and shape-memory in 4D printed polymer parts toward cellularized vascular grafts

Current additive manufacturing technologies wherein as-printed simple two-dimensional (2D) structures morph into complex tissue mimetic three-dimensional (3D) shapes are limited to multi-material hydrogel systems, which necessitates multiple fabrication steps and specific materials. This work utilizes a single shape memory thermoplastic polymer (SMP), PLMC (polylactide-co-trimethylene carbonate), to achieve programmable shape deformation through anisotropic design and infill angles encoded during 3D printing. The shape changes were first computationally predicted through finite element analysis (FEA) simulations and then experimentally validated through quantitative correlation. Rectangular 2D sheets could self-roll into complete hollow tubes of specific diameters (ranging from ≈6 mm to ≈10 mm) and lengths (as long as 40 mm), as quantitatively predicted from FEA simulations within one minute at relatively lower temperatures (≈80 °C). Furthermore, shape memory properties were demonstrated post-shape change to exhibit dual shape morphing at temperatures close to physiological levels. The tubes (retained as the permanent shape) were deformed into flat sheets (temporary shape), seeded with endothelial cells (at T < Tg), and thereafter triggered at ≈37 °C back into tubes (permanent shape), utilizing the shape memory properties to yield bioresorbable tubes with cellularized lumens for potential use as vascular grafts with improved long-term patency. Additionally, out-of-plane bending and twisting deformation were demonstrated in complex structures by careful control of infill angles that can unprecedently expand the scope of cellularized biomimetic 3D shapes. This work demonstrates the potential of the combination of shape morphing and SMP behaviors at physiological temperatures to yield next-generation smart implants with precise control over dimensions for tissue repair and regeneration.

Multi-color dual wavelength vat photopolymerization 3D printing via spatially controlled acidity

Dual wavelength vat photopolymerization (DW-VP) has emerged as a powerful approach to create multimaterial objects. However, only a limited range of properties have been showcased. In this work, we report the 3D printing (3DP) of multi-color objects from a single resin vat using DW-VP. This was accomplished by concurrently curing resin with visible light and modulating local resin color with 365-nm ultraviolet (UV) light. The key advance was to use a photoacid generator (PAG) in combination with pH responsive dyes in the 3DP resins. The specific color is dictated by the extent of reaction, or local acidity in our case, and controlled by the light dosage and pattern of UV light applied. Multi-color object formation was implemented in two-step processes involving first 3DP to set the object structure, followed by UV exposure, as well as single processes that leveraged DW-VP to create a broad range of vibrant colors and patterns.

3D printing of heart valves

3D printing technologies have the potential to revolutionize the manufacture of heart valves through the ability to create bespoke, complex constructs. In light of recent technological advances, we review the progress made towards 3D printing of heart valves, focusing on studies that have utilised these technologies beyond manufacturing patient-specific moulds. We first overview the key requirements of a heart valve to assess functionality. We then present the 3D printing technologies used to engineer heart valves. By referencing International Organisation for Standardisation (ISO) Standard 5840 (Cardiovascular implants - Cardiac valve prostheses), we provide insight into the achieved functionality of these valves. Overall, 3D printing promises to have a significant positive impact on the creation of artificial heart valves and potentially unlock full complex functionality.

A review of the recent achievements and future trends on 3D printed microfluidic devices for bioanalytical applications

3D printing has revolutionized the manufacturing process of microanalytical devices by enabling the automated production of customized objects. This technology promises to become a fundamental tool, accelerating investigations in critical areas of health, food, and environmental sciences. This microfabrication technology can be easily disseminated among users to produce further and provide analytical data to an interconnected network towards the Internet of Things, as 3D printers enable automated, reproducible, low-cost, and easy fabrication of microanalytical devices in a single step. New functional materials are being investigated for one-step fabrication of highly complex 3D printed parts using photocurable resins. However, they are not yet widely used to fabricate microfluidic devices. This is likely the critical step towards easy and automated fabrication of sophisticated, complex, and functional 3D-printed microchips. Accordingly, this review covers recent advances in the development of 3D-printed microfluidic devices for point-of-care (POC) or bioanalytical applications such as nucleic acid amplification assays, immunoassays, cell and biomarker analysis and organs-on-a-chip. Finally, we discuss the future implications of this technology and highlight the challenges in researching and developing appropriate materials and manufacturing techniques to enable the production of 3D-printed microfluidic analytical devices in a single step.

The status and challenging perspectives of 3D-printed micro-batteries

In the era of the Internet of Things and wearable electronics, 3D-printed micro-batteries with miniaturization, aesthetic diversity and high aspect ratio, have emerged as a recent innovation that solves the problems of limited design diversity, poor flexibility and low mass loading of materials associated with traditional power sources restricted by the slurry-casting method. Thus, a comprehensive understanding of the rational design of 3D-printed materials, inks, methods, configurations and systems is critical to optimize the electrochemical performance of customizable 3D-printed micro-batteries. In this review, we offer a key overview and systematic discussion on 3D-printed micro-batteries, emphasizing the close relationship between printable materials and printing technology, as well as the reasonable design of inks. Initially, we compare the distinct characteristics of various printing technologies, and subsequently emphatically expound the printable components of micro-batteries and general approaches to prepare printable inks. After that, we focus on the outstanding role played by 3D printing design in the device architecture, battery configuration, performance improvement, and system integration. Finally, the future challenges and perspectives concerning high-performance 3D-printed micro-batteries are adequately highlighted and discussed. This comprehensive discussion aims at providing a blueprint for the design and construction of next-generation 3D-printed micro-batteries.

4D Printed Protein-AuNR Nanocomposites with Photothermal Shape Recovery

4D printing is the 3D printing of objects that change chemically or physically in response to an external stimulus over time. Photothermally responsive shape memory materials are attractive for their ability to undergo remote activation. While photothermal methods using gold nanorods (AuNRs) have been used for shape recovery, 3D patterning of these materials into objects with complex geometries using degradable materials has not been addressed. Here, we report on the fabrication of 3D printed shape memory bioplastics with photo-activated shape recovery. Protein-based nanocomposites based on bovine serum albumin (BSA), poly (ethylene glycol) diacrylate and gold nanorods were developed for vat photopolymerization. These 3D printed bioplastics were mechanically deformed under high loads, and the proteins served as mechanoactive elements that unfolded in an energy-dissipating mechanism that prevented fracture of the thermoset. The bioplastic object maintained its metastable shape-programmed state under ambient conditions. Subsequently, up to 99% shape recovery was achieved within 1 min of irradiation with near-infrared light. Mechanical characterization and small angle X-ray scattering (SAXS) analysis suggest that the proteins mechanically unfold during the shape programming step and may refold during shape recovery. These composites are promising materials for the fabrication of biodegradable shape-morphing devices for robotics and medicine.

Fabrication of translucent graded dental crown using zirconia-yttrium multi-slurry tape casting 3D printer

This paper aims to fabricate functionally graded dental crown using a multi-slurry tape casting additive manufacturing technology. The different luminescence of the dental crown was obtained with different composition of zirconia and yttria. Zirconia with tunable mechanical properties and translucency are obtained by adding 3, 3.5, 4, 4.5, and 5 mol% of yttrium oxide to zirconia powder. After obtaining the printable slurry with maximum solid loading, the green bodies are prepared using the in-house built high-speed multi-ceramic tape casting technology. They are later sintered with two-stage sintering method. After the successful fabrication, the mechanical properties and translucency of the specimens were evaluated with Vickers hardness, three-point bending and translucency parameter tests. Finally, an FGM tooth crown with five photocurable slurries is proposed to demonstrate the translucent gradient effect of sintered part. The solid loading of 80% zirconia and 20% resin delivered samples without any surface cracks. The shrinkage ratio analysis showed that the sintered sample dimension was reduced by 20%, 20%, and 23% along X, Y, and Z directions. The samples fabricated with 3% yttrium oxide to zirconia delivered excellent hardness (1687 HV) and flexural strength (650.6 MPa). However, the relative luminescence increased with increasing the yttrium oxide for 3-5 mol%. With the optimized process parameters, the proposed dental crown is fabricated and analyzed for their shrinkage ratio, mechanical, and translucency properties. The study proposes the potential of fabricating customized dental crown with gradient translucent appearance.

Energy Absorption of 3D Printed ABS and TPU Multimaterial Honeycomb Structures

Advances in multimaterial 3D printing are enabling the construction of advantageous engineering structures that benefit from material synergies. Cellular structures, such as honeycombs, provide high-energy absorption to weight ratios that could benefit from multimaterial strategies to improve the safety and performance of engineered systems. In this study, we investigate the energy absorption for honeycombs with square and hexagonal unit cells constructed from acrylonitrile butadiene styrene (ABS) and thermoplastic polyurethane (TPU). Honeycombs were fabricated and tested for out-of-plane and in-plane compression using ABS, TPU, and a combination of ABS with a central TPU band of tunable height. Out-of-plane energy absorption for square honeycombs increased from 2.2 kN·mm for TPU samples to 11.5 kN·mm for ABS samples and energy absorption of hexagonal honeycombs increased from 2.9 to 15.1 kN·mm as proportions of TPU/ABS were altered. In-plane loading demonstrated a sequential collapse of unit cell rows in square honeycombs with energy absorption of 0.1 to 2.6 kN·mm and a gradual failure of hexagonal honeycombs with energy absorption of 0.6 to 2.0 kN·mm. These results demonstrate how multimaterial combinations affect honeycomb compressive response by highlighting their benefits for controlled energy absorption and deformation for tunable performance in diverse engineering applications.

Programmable and Modularized Gas Sensor Integrated by 3D Printing

The rapid advancement of intelligent manufacturing technology has enabled electronic equipment to achieve synergistic design and programmable optimization through computer-aided engineering. Three-dimensional (3D) printing, with the unique characteristics of near-net-shape forming and mold-free fabrication, serves as an effective medium for the materialization of digital designs into usable devices. This methodology is particularly applicable to gas sensors, where performance can be collaboratively optimized by the tailored design of each internal module including composition, microstructure, and architecture. Meanwhile, diverse 3D printing technologies can realize modularized fabrication according to the application requirements. The integration of artificial intelligence software systems further facilitates the output of precise and dependable signals. Simultaneously, the self-learning capabilities of the system also promote programmable optimization for the hardware, fostering continuous improvement of gas sensors for dynamic environments. This review investigates the latest studies on 3D-printed gas sensor devices and relevant components, elucidating the technical features and advantages of different 3D printing processes. A general testing framework for the performance evaluation of customized gas sensors is proposed. Additionally, it highlights the superiority and challenges of programmable and modularized gas sensors, providing a comprehensive reference for material adjustments, structure design, and process modifications for advanced gas sensor devices.

3D Printing of Self-Healing Materials

This review article presents a comprehensive overview of the latest advances in the field of 3D printable structures with self-healing properties. Three-dimensional printing (3DP) is a versatile technology that enables the rapid manufacturing of complex geometric structures with precision and functionality not previously attainable. However, the application of 3DP technology is still limited by the availability of materials with customizable properties specifically designed for additive manufacturing. The addition of self-healing properties within 3D printed objects is of high interest as it can improve the performance and lifespan of structural components, and even enable the mimicking of living tissues for biomedical applications, such as organs printing. The review will discuss and analyze the most relevant results reported in recent years in the development of self-healing polymeric materials that can be processed via 3D printing. After introducing the chemical and physical self-healing mechanism that can be exploited, the literature review here reported will focus in particular on printability and repairing performances. At last, actual perspective and possible development field will be critically discussed.

A Comprehensive Overview of Additive Manufacturing Processes Through a Time-Based Classification Model

The ongoing crisis caused by the COVID-19 pandemic produced major reshuffles on the world map, bringing imbalance, uncertainty, and accumulated stress. Due to supply chain disruptions, the need for innovation has emerged both as a priority and a necessity and three-dimensional printing (3DP) proved to be a primary, smart, effective, and innovative additive manufacturing (AM) method. AM refers to the direct fabrication of complex geometries, using a computer-aided design (CAD) model or a three-dimensional scanner output. This article presents a literature review of AM technologies, chronologically sorted, and proposes a multilevel classification model. The suggested research approach appears a triangular methodology that encompasses the current ISO/ASTM 52900:2021 report. The first objective of this article is to form two double-level classification models of AM processes, depending on the technology and material factors. The second objective is to clarify in which of the proposed categories each AM process is included; and the third one is to investigate if the proposed taxonomy is related to the time spot, in which AM processes were invented. The contribution of this article lies in determining the factors that are crucial for the growth of AM ecosystem. The novelty of the proposed classification lies in the definition of an optimal option for each industrial application based on the different AM processes, the variety of materials, and the evolution of technology over the years. In this way, investing in AM is more systematic and less risky.

Additive manufacturing of NiTi shape memory alloy and its industrial applications

NiTi shape memory alloys are the prime choice for many engineering and biomedical applications due to their unique response to environmental/external stimuli. The capability of laser powder bed fusion (LPBF) to additively manufacture high-quality density NiTi alloy with intricate geomaterial configuration, good surface quality, and chemical homogeneity makes the LPBF process the preferred choice among other additive manufacturing (AM) methods for manufacturing the NiTi alloy. The AM process parameters have a decisive effect on the functional and mechanical properties of NiTi alloy. There is a need to understand the resultant effect of the interrelationship between the process parameters on the final NiTi additive manufactured structures. The inherent high rate of melting and cooling of the LPBF process resulting in high internal stress could cause adverse effects such as cracks and Ni-loss which are detrimental to the phase transformation temperature of the NiTi alloy. Despite the current challenges, the literature reveals that LPBF NiTi components demonstrated functional and mechanical properties according to the ASTM standard and have been used widely for biomedical applications due to its stress-strain hysteresis, which is similar to bone tissues. The alloy is also used extensively for high-value engineering applications such as the automotive and aerospace industries due to its actuation properties.

Fabrication and Performance of Continuous 316 Stainless Steel Fibre-Reinforced 3D-Printed PLA Composites

This study investigates the feasibility of 3D printing continuous stainless steel fibre-reinforced polymer composites. The printing study was carried out using 316L stainless steel fibre (SSF) bundles with an approximate diameter of 0.15 mm. This bundle was composed of 90 fibres with a 14 μm diameter. This fibre bundle was first coated with polylactic acid (PLA) in order to produce a polymer-coated continuous stainless steel filament, with diameters tailored in the range from 0.5 to 0.9 mm. These filaments were then used to print composite parts using the material extrusion (MEX) technique. The SSF's volume fraction (Vf) was controlled in the printed composite structures in the range from 4 to 30 Vf%. This was facilitated by incorporating a novel polymer pressure vent into the printer nozzle, which allowed the removal of excess polymer. This thus enabled the control of the metal fibre content within the printed composites as the print layer height was varied in the range from 0.22 to 0.48 mm. It was demonstrated that a lower layer height yielded a more homogeneous distribution of steel fibres within the PLA polymer matrix. The PLA-SSF composites were assessed to evaluate their mechanical performance, volume fraction, morphology and porosity. Composite porosities in the range of 2-21% were obtained. Mechanical testing demonstrated that the stainless steel composites exhibited a twofold increase in interlaminar shear strength (ILSS) and a fourfold increase in its tensile strength compared with the PLA-only polymer prints. When comparing the 4 and 30 Vf% composites, the latter exhibited a significant increase in both the tensile strength and modulus. The ILSS values obtained for the steel composites were up to 28.5 MPa, which is significantly higher than the approximately 13.8 MPa reported for glass fibre-reinforced PLA composites.

Smart alginate inks for tissue engineering applications

Amazing achievements have been made in the field of tissue engineering during the past decades. However, we have not yet seen fully functional human heart, liver, brain, or kidney tissue emerge from the clinics. The promise of tissue engineering is thus still not fully unleashed. This is mainly related to the challenges associated with producing tissue constructs with similar complexity as native tissue. Bioprinting is an innovative technology that has been used to obliterate these obstacles. Nevertheless, natural organs are highly dynamic and can change shape over time; this is part of their functional repertoire inside the body. 3D-bioprinted tissue constructs should likewise adapt to their surrounding environment and not remain static. For this reason, the new trend in the field is 4D bioprinting - a new method that delivers printed constructs that can evolve their shape and function over time. A key lack of methodology for printing approaches is the scalability, easy-to-print, and intelligent inks. Alginate plays a vital role in driving innovative progress in 3D and 4D bioprinting due to its exceptional properties, scalability, and versatility. Alginate's ability to support 3D and 4D printing methods positions it as a key material for fueling advancements in bioprinting across various applications, from tissue engineering to regenerative medicine and beyond. Here, we review the current progress in designing scalable alginate (Alg) bioinks for 3D and 4D bioprinting in a "dry"/air state. Our focus is primarily on tissue engineering, however, these next-generation materials could be used in the emerging fields of soft robotics, bioelectronics, and cyborganics.

Shape Memory Polymer Composites: 4D Printing, Smart Structures, and Applications

Shape memory polymers (SMPs) and their composites (SMPCs) are smart materials that can be stably deformed and then return to their original shape under external stimulation, thus having a memory of their shape. Three-dimensional (3D) printing is an advanced technology for fabricating products using a digital software tool. Four-dimensional (4D) printing is a new generation of additive manufacturing technology that combines shape memory materials and 3D printing technology. Currently, 4D-printed SMPs and SMPCs are gaining considerable research attention and are finding use in various fields, including biomedical science. This review introduces SMPs, SMPCs, and 4D printing technologies, highlighting several special 4D-printed structures. It summarizes the recent research progress of 4D-printed SMPs and SMPCs in various fields, with particular emphasis on biomedical applications. Additionally, it presents an overview of the challenges and development prospects of 4D-printed SMPs and SMPCs and provides a preliminary discussion and useful reference for the research and application of 4D-printed SMPs and SMPCs.

3D/4D printing of cellulose nanocrystals-based biomaterials: Additives for sustainable applications

Cellulose nanocrystals (CNCs) have gained significant attraction from both industrial and academic sectors, thanks to their biodegradability, non-toxicity, and renewability with remarkable mechanical characteristics. Desirable mechanical characteristics of CNCs include high stiffness, high strength, excellent flexibility, and large surface-to-volume ratio. Additionally, the mechanical properties of CNCs can be tailored through chemical modifications for high-end applications including tissue engineering, actuating, and biomedical. Modern manufacturing methods including 3D/4D printing are highly advantageous for developing sophisticated and intricate geometries. This review highlights the major developments of additive manufactured CNCs, which promote sustainable solutions across a wide range of applications. Additionally, this contribution also presents current challenges and future research directions of CNC-based composites developed through 3D/4D printing techniques for myriad engineering sectors including tissue engineering, wound healing, wearable electronics, robotics, and anti-counterfeiting applications. Overall, this review will greatly help research scientists from chemistry, materials, biomedicine, and other disciplines to comprehend the underlying principles, mechanical properties, and applications of additively manufactured CNC-based structures.

Personalized 3D-Printed Scaffolds with Multiple Bioactivities for Bioroot Regeneration

Recent advances in 3D printing offer a prospective avenue for producing transplantable human tissues with complex geometries; however, the appropriate 3D-printed scaffolds possessing the biological compatibility for tooth regeneration remain unidentified. This study proposes a personalized scaffold of multiple bioactivities, including induction of stem cell proliferation and differentiation, biomimetic mineralization, and angiogenesis. A brand-new bioink system comprising a biocompatible and biodegradable polymer is developed and reinforced with extracellular matrix generated from dentin tissue (treated dentin matrix, TDM). Adding TDM optimizes physical properties including microstructure, hydrophilicity, and mechanical strength of the scaffolds. Proteomics analysis reveals that the released proteins of the 3D-printed TDM scaffolds relate to multiple biological processes and interact closely with each other. Additionally, 3D-printed TDM scaffolds establish a favorable microenvironment for cell attachment, proliferation, and differentiation in vitro. The 3D-printed TDM scaffolds are proangiogenic and facilitate whole-thickness vascularization of the graft in a subcutaneous model. Notably, the personalized TDM scaffold combined with dental follicle cells mimics the anatomy and physiology of the native tooth root three months after in situ transplantation in beagles. The remarkable in vitro and in vivo outcomes suggest that the 3D-printed TDM scaffolds have multiple bioactivities and immense clinical potential for tooth-loss therapy.

Intelligent Vascularized 3D/4D/5D/6D-Printed Tissue Scaffolds

Blood vessels are essential for nutrient and oxygen delivery and waste removal. Scaffold-repairing materials with functional vascular networks are widely used in bone tissue engineering. Additive manufacturing is a manufacturing technology that creates three-dimensional solids by stacking substances layer by layer, mainly including but not limited to 3D printing, but also 4D printing, 5D printing and 6D printing. It can be effectively combined with vascularization to meet the needs of vascularized tissue scaffolds by precisely tuning the mechanical structure and biological properties of smart vascular scaffolds. Herein, the development of neovascularization to vascularization to bone tissue engineering is systematically discussed in terms of the importance of vascularization to the tissue. Additionally, the research progress and future prospects of vascularized 3D printed scaffold materials are highlighted and presented in four categories: functional vascularized 3D printed scaffolds, cell-based vascularized 3D printed scaffolds, vascularized 3D printed scaffolds loaded with specific carriers and bionic vascularized 3D printed scaffolds. Finally, a brief review of vascularized additive manufacturing-tissue scaffolds in related tissues such as the vascular tissue engineering, cardiovascular system, skeletal muscle, soft tissue and a discussion of the challenges and development efforts leading to significant advances in intelligent vascularized tissue regeneration is presented.

4D-Printed Hydrogel Actuators through Diffusion-Path Architecture Design

Recently, smart hydrogels have garnered considerable attention as biomedical devices, and several approaches have been introduced for their fabrication, including the incorporation of stimulus-responsive additives, utilization of molecular imprinting techniques, and application of multilayered hydrogels. However, the nonuniform properties resulting from these approaches limit the practical applications of hydrogels by causing inconsistent performance and behavior. In this study, we propose a novel approach to manipulating the swelling kinetics of hydrogels by engineering their diffusion-path architecture. By simply adjusting the diffusion path length within the hydrogel, we achieved a significant change in swelling kinetics. This approach enables precise control over the diffusion and transport processes within the hydrogel, resulting in enhanced swelling kinetics when reducing the diffusion path length. Furthermore, by strategically designing the diffusion-path architecture of a 3D-printed hydrogel specimen, we can fabricate smart hydrogel actuators that exhibit reversible shape transformations during swelling and deswelling through a nonequilibrium differential swelling. The proposed approach eliminates the need to modify the spatial properties of hydrogel structures such as cross-linking density, polymer, or additive compositions, thereby achieving uniform properties throughout the hydrogel and creating new possibilities for the development of advanced 4D-printed biomedical devices.

Additive Manufacturing for Bioinspired Structures: Experimental Study to Improve the Multimaterial Adhesion Between Soft and Stiff Materials

The fabrication of bioinspired structures has recently gained an increasing popularity: mimicking the way in which nature develops structures is a vital prerequisite in soft robotics to achieve multiple benefits. Stiff structures connected by soft joints (recalling, for instance, human bones connected by cartilage) are highly appealing: several prototypes have been manufactured and tested, demonstrating their full potential. In the present research, the material extrusion (MEX) additive manufacturing technology has been used to manufacture stiff-soft bioinspired structures activated by shape memory alloy (SMA) actuators. First, three commercially available stiff composite plastic materials were investigated and linked to different 3D printing infills. Surprisingly, we found that the "gyroid" infill was correlated to the mechanical properties, demonstrating that it produces better results in terms of Young's modulus and ultimate tensile strength (UTS) than the widely studied "lines" infill. The primary focus of the research is an experimental study aimed at improving the adhesion at the interface between stiff and soft materials using an inexpensive method (i.e., MEX). Three different variables that have significant effects on the interface bonding were studied: (1) the interface geometry between stiff and soft parts, (2) the mesh overlapping process parameter, and (3) the annealing post-treatment. By optimizing the three variables, a Young's modulus of 48.8 MPa and a UTS of 3.8 MPa were achieved, when nylon+glass fiber (a stiff material) and thermoplastic polyurethane (a soft material) were 3D printed together. In particular, the 3.8 MPa UTS is 48% higher than the highest adhesion between the soft and stiff material (thermoplastic polyurethane [TPU] and acrylonitrile butadiene styrene) reported in literature. Finally, taking advantage of the improved stiff-soft adhesion, a bioinspired robotic finger has been fabricated and tested using an SMA actuator, showing an enormous potential for the proposed additive manufacturing approach in realizing bioinspired systems.

3D Printed Customizable Microsampling Devices for Neuroscience Applications

Multifunctional devices that incorporate chemical or physical measurements combined with ways to manipulate brain tissue via drug delivery, electrical stimulation, or light for optogenetics are desired by neuroscientists. The next generation in vivo brain devices will likely utilize the extensive flexibility and rapid processing of 3D printing. This Perspective demonstrates how close we are to this reality for advanced neuroscience measurements. 3D printing provides the opportunity to improve microsampling-based devices in ways that have not been previously available. Not only can 3D printing be used for actual device creation, but it can also allow printing of peripheral objects necessary to assemble functional devices. The most probable 3D printing set up for microsampling devices with appropriate nm to μm feature size will likely require 2-photon polymerization-based printers. This Perspective describes the advantages and challenges for 3D printing of microsampling devices as an initial step to meet the next generation device needs of neuroscientists.

Tunable resins with PDMS-like elastic modulus for stereolithographic 3D-printing of multimaterial microfluidic actuators

Stereolithographic 3D-printing (SLA) permits facile fabrication of high-precision microfluidic and lab-on-a-chip devices. SLA photopolymers often yield parts with low mechanical compliancy in sharp contrast to elastomers such as poly(dimethyl siloxane) (PDMS). On the other hand, SLA-printable elastomers with soft mechanical properties do not fulfill the distinct requirements for a highly manufacturable resin in microfluidics (e.g., high-resolution printability, transparency, low-viscosity). These limitations restrict our ability to print microfluidic actuators containing dynamic, movable elements. Here we introduce low-viscous photopolymers based on a tunable blend of the monomers poly(ethylene glycol) diacrylate (PEGDA, Mw ∼ 258) and the monoacrylate poly(ethylene glycol methyl ether) methacrylate (PEGMEMA, Mw ∼ 300). In these blends, which we term PEGDA-co-PEGMEMA, tuning the PEGMEMA content from 0% to 40% (v/v) alters the elastic modulus of the printed plastics by ∼400-fold, reaching that of PDMS. Through the addition of PEGMEMA, moreover, PEGDA-co-PEGMEMA retains desirable properties of highly manufacturable PEGDA such as low viscosity, solvent compatibility, cytocompatibility and low drug absorptivity. With PEGDA-co-PEGMEMA, we SLA-printed drastically enhanced fluidic actuators including microvalves, micropumps, and microregulators with a hybrid structure containing a flexible PEGDA-co-PEGMEMA membrane within a rigid PEGDA housing. These components were built using a custom "Print-Pause-Print" protocol, referred to as "3P-printing", that allows for fabricating high-resolution multimaterial parts with a desktop SLA printer without the need for post-assembly. SLA-printing of multimaterial microfluidic actuators addresses the unmet need of high-performance on-chip controls in 3D-printed microfluidic and lab-on-a-chip devices.

3D Filaments Based on Polyhydroxy Butyrate-Micronized Bacterial Cellulose for Tissue Engineering Applications

In this work, scaffolds based on poly(hydroxybutyrate) (PHB) and micronized bacterial cellulose (BC) were produced through 3D printing. Filaments for the printing were obtained by varying the percentage of micronized BC (0.25, 0.50, 1.00, and 2.00%) inserted in relation to the PHB matrix. Despite the varying concentrations of BC, the biocomposite filaments predominantly contained PHB functional groups, as Fourier transform infrared spectroscopy (FTIR) demonstrated. Thermogravimetric analyses (i.e., TG and DTG) of the filaments showed that the peak temperature (Tpeak) of PHB degradation decreased as the concentration of BC increased, with the lowest being 248 °C, referring to the biocomposite filament PHB/2.0% BC, which has the highest concentration of BC. Although there was a variation in the thermal behavior of the filaments, it was not significant enough to make printing impossible, considering that the PHB melting temperature was 170 °C. Biological assays indicated the non-cytotoxicity of scaffolds and the provision of cell anchorage sites. The results obtained in this research open up new paths for the application of this innovation in tissue engineering.

Going below and beyond the surface: Microneedle structure, materials, drugs, fabrication, and applications for wound healing and tissue regeneration

Microneedle, as a novel drug delivery system, has attracted widespread attention due to its non-invasiveness, painless and simple administration, controllable drug delivery, and diverse cargo loading capacity. Although microneedles are initially designed to penetrate stratum corneum of skin for transdermal drug delivery, they, recently, have been used to promote wound healing and regeneration of diverse tissues and organs and the results are promising. Despite there are reviews about microneedles, few of them focus on wound healing and tissue regeneration. Here, we review the recent advances of microneedles in this field. We first give an overview of microneedle system in terms of its potential cargos (e.g., small molecules, macromolecules, nucleic acids, nanoparticles, extracellular vesicle, cells), structural designs (e.g., multidrug structures, adhesive structures), material selection, and drug release mechanisms. Then we briefly summarize different microneedle fabrication methods, including their advantages and limitations. We finally summarize the recent progress of microneedle-assisted wound healing and tissue regeneration (e.g., skin, cardiac, bone, tendon, ocular, vascular, oral, hair, spinal cord, and uterine tissues). We expect that our article would serve as a guideline for readers to design their microneedle systems according to different applications, including material selection, drug selection, and structure design, for achieving better healing and regeneration efficacy.

Fault Detection in 3D Printing: A Study on Sensor Positioning and Vibrational Patterns

This work examines the use of accelerometers to identify vibrational patterns that can effectively predict the state of a 3D printer, which could be useful for predictive maintenance. Prototypes using both a simple rectangular shape and a more complex Octopus shape were fabricated and evaluated. Fast Fourier Transform, Spectrogram, and machine learning models, such as Principal Component Analysis and Support Vector Machine, were employed for data analysis. The results indicate that vibrational signals can be used to predict the state of a 3D printer. However, the position of the accelerometers is crucial for vibration-based fault detection. Specifically, the sensor closest to the nozzle could predict the state of the 3D printer faster at a 71% greater sensitivity compared to sensors mounted on the frame and print bed. Therefore, the model presented in this study is appropriate for vibrational fault detection in 3D printers.

Interface Healing Between Adjacent Tracks in Fused Filament Fabrication Using In-Process Laser Heating

Fused filament fabrication is one of the most desired thermal plastic additive manufacturing processes because of its ability to fabricate complex objects with high accessibility. However, due to the extrusion track-based direct write process mechanism, parts built using this method exhibit anisotropic mechanical properties. In this work, an in-process laser heating method is introduced to heal interface adhesion between adjacent deposited tracks by increasing the interface temperature to promote polymer reptation and enhance bonding strength of the interface of adjacent tracks. With the use of laser heating induced interface healing, the measured flexural strength between adjacent tracks in the same layer increased and exceeded that of the control sample tested along the track direction. The effect of laser on interface healing was also verified by investigating the load-displacement curve and morphology analysis of the fractured surface.

Additive manufacturing of multi-material parts - Design guidelines for manufacturing of 316L/CuCrZr in laser powder bed fusion

Additive manufacturing (AM) can be used to produce multi-material parts in which the material can be varied voxel-wise in all three spatial directions. This means that the paradigm of the homogeneous material can be abandoned and local effects such as heat conduction or damping can be selectively adjusted in the part. Recently, continuous development of machine technology has allowed the production of multi-metal materials in laser powder bed fusion (PBF-LB/MM). Compared to other additive manufacturing processes for multi-material production, this allows greater design freedom and detail accuracy to be realized. However, due to the novel character of multi-material manufacturing in PBF-LB, the process knowledge for successful and reproducible fabrication is currently lacking. This paper focuses on establishing design guidelines for manufacturing the material pairing of stainless steel 316L (1.4404) and copper alloy CuCrZr (CW106C). The article is accompanied by the development of a specific process chain. As a result of this work, design guidelines for multi-material parts are available for the first time, in regard to arrangement, size, overhangs, economy, powder quality and laser scanning.

A Review on Multiplicity in Multi-Material Additive Manufacturing: Process, Capability, Scale, and Structure

Additive manufacturing (AM) has experienced exponential growth over the past two decades and now stands on the cusp of a transformative paradigm shift into the realm of multi-functional component manufacturing, known as multi-material AM (MMAM). While progress in MMAM has been more gradual compared to single-material AM, significant strides have been made in exploring the scientific and technological possibilities of this emerging field. Researchers have conducted feasibility studies and investigated various processes for multi-material deposition, encompassing polymeric, metallic, and bio-materials. To facilitate further advancements, this review paper addresses the pressing need for a consolidated document on MMAM that can serve as a comprehensive guide to the state of the art. Previous reviews have tended to focus on specific processes or materials, overlooking the overall picture of MMAM. Thus, this pioneering review endeavors to synthesize the collective knowledge and provide a holistic understanding of the multiplicity of materials and multiscale processes employed in MMAM. The review commences with an analysis of the implications of multiplicity, delving into its advantages, applications, challenges, and issues. Subsequently, it offers a detailed examination of MMAM with respect to processes, materials, capabilities, scales, and structural aspects. Seven standard AM processes and hybrid AM processes are thoroughly scrutinized in the context of their adaptation for MMAM, accompanied by specific examples, merits, and demerits. The scope of the review encompasses material combinations in polymers, composites, metals-ceramics, metal alloys, and biomaterials. Furthermore, it explores MMAM's capabilities in fabricating bi-metallic structures and functionally/compositionally graded materials, providing insights into various scale and structural aspects. The review culminates by outlining future research directions in MMAM and offering an overall outlook on the vast potential of multiplicity in this field. By presenting a comprehensive and integrated perspective, this paper aims to catalyze further breakthroughs in MMAM, thus propelling the next generation of multi-functional component manufacturing to new heights by capitalizing on the unprecedented possibilities of MMAM.

Recent Progress and Trends in the Development of Electrospun and 3D Printed Polymeric-Based Materials to Overcome Antimicrobial Resistance (AMR)

Antimicrobial resistance (AMR) developed by microorganisms is considered one of the most critical public health issues worldwide. This problem is affecting the lives of millions of people and needs to be addressed promptly. Mainly, antibiotics are the substances that contribute to AMR in various strains of bacteria and other microorganisms, leading to infectious diseases that cannot be effectively treated. To avoid the use of antibiotics and similar drugs, several approaches have gained attention in the fields of materials science and engineering as well as pharmaceutics over the past five years. Our focus lies on the design and manufacture of polymeric-based materials capable of incorporating antimicrobial agents excluding the aforementioned substances. In this sense, two of the emerging techniques for materials fabrication, namely, electrospinning and 3D printing, have gained significant attraction. In this article, we provide a summary of the most important findings that contribute to the development of antimicrobial systems using these technologies to incorporate various types of nanomaterials, organic molecules, or natural compounds with the required property. Furthermore, we discuss and consider the challenges that lie ahead in this research field for the coming years.

Digital Light Processing 3D Printing of Soft Semicrystalline Acrylates with Localized Shape Memory and Stiffness Control

Multimaterial three-dimensional (3D) printing of objects with spatially tunable thermomechanical properties and shape-memory behavior provides an attractive approach toward programmable "smart" plastics with applications in soft robotics and electronics. To date, digital light processing 3D printing has emerged as one of the fastest manufacturing methods that maintains high precision and resolution. Despite the common utility of semicrystalline polymers in stimuli-responsive materials, few reports exist whereby such polymers have been produced via digital light processing (DLP) 3D printing. Herein, two commodity long-alkyl chain acrylates (C₁₈, stearyl and C₁₂, lauryl) and mixtures therefrom are systematically examined as neat resin components for DLP 3D printing of semicrystalline polymer networks. Tailoring the stearyl/lauryl acrylate ratio results in a wide breadth of thermomechanical properties, including tensile stiffness spanning three orders of magnitude and temperatures from below room temperature (2 °C) to above body temperature (50 °C). This breadth is attributed primarily to changes in the degree of crystallinity. Favorably, the relationship between resin composition and the degree of crystallinity is quadratic, making the thermomechanical properties reproducible and easily programmable. Furthermore, the shape-memory behavior of 3D-printed objects upon thermal cycling is characterized, showing good fatigue resistance and work output. Finally, multimaterial 3D-printed structures with vertical gradation in composition are demonstrated where concomitant localization of thermomechanical properties enables multistage shape-memory and strain-selective behavior. The present platform represents a promising route toward customizable actuators for biomedical applications.

Material Extrusion of Multi-Polymer Structures Utilizing Design and Shrinkage Behaviors: A Design of Experiment Study

Material extrusion (ME) is an additive manufacturing technique capable of producing functional parts, and its use in multi-material fabrication requires further exploration and expansion. The effectiveness of material bonding is one of the main challenges in multi-material fabrication using ME due to its processing capabilities. Various procedures for improving the adherence of multi-material ME parts have been explored, such as the use of adhesives or the post-processing of parts. In this study, different processing conditions and designs were investigated with the aim of optimizing polylactic acid (PLA) and acrylonitrile-butadiene-styrene (ABS) composite parts without the need for pre- or post-processing procedures. The PLA-ABS composite parts were characterized based on their mechanical properties (bonding modulus, compression modulus, and strength), surface roughness (Ra, Rku, Rsk, and Rz), and normalized shrinkage. All process parameters were statistically significant except for the layer composition parameter in terms of Rsk. The results show that it is possible to create a composite structure with good mechanical properties and acceptable surface roughness values without the need for costly post-processing procedures. Furthermore, the normalized shrinkage and the bonding modulus were correlated, indicating the ability to utilize shrinkage in 3D printing to improve material bonding.

Digital light processing 3D printing of dynamic magneto-responsive thiol-acrylate composites

Additive manufacturing is one of the most promising processing techniques for fabricating customized 3D objects. For the 3D printing of functional and stimuli-triggered devices, interest is steadily growing in processing materials with magnetic properties. Synthesis routes for magneto-responsive soft materials typically involve the dispersion of (nano)particles into a non-magnetic polymer matrix. Above their glass transition temperature, the shape of such composites can be conveniently adjusted by applying an external magnetic field. With their rapid response time, facile controllability, and reversible actuation, magnetically responsive soft materials can be used in the biomedical field (e.g. drug delivery, minimally invasive surgery), soft robotics or in electronic applications. Herein, we combine the magnetic response with thermo-activated healability by introducing magnetic Fe₃O₄ nanoparticles into a dynamic photopolymer network, which undergoes thermo-activated bond exchange reactions. The resin is based on a radically curable thiol-acrylate system, whose composition is optimized towards processability via digital light processing 3D printing. A mono-functional methacrylate phosphate is applied as a stabilizer to increase the resins' shelf life by preventing thiol-Michael reactions. Once photocured, the organic phosphate further acts as a transesterification catalyst and activates bond exchange reactions at elevated temperature, which render the magneto-active composites mendable and malleable. The healing performance is demonstrated by recovering magnetic and mechanical properties after the thermally triggered mending of 3D-printed structures. We further demonstrate the magnetically driven movement of 3D-printed samples, which gives rise to the potential use of these materials in healable soft devices activated by external magnetic fields.

Multi-Stimuli Dually-Responsive Intelligent Woven Structures with Local Programmability for Biomimetic Applications

This work focuses on multi-stimuli-responsive materials with distinctive abilities, that is, color-changing and shape-memory. Using metallic composite yarns and polymeric/thermochromic microcapsule composite fibers, processed via a melt-spinning technique, an electrothermally multi-responsive fabric is woven. The resulting smart-fabric transfers from a predefined structure to an original shape while changing color upon heating or applying an electric field, making it appealing for advanced applications. The shape-memory and color-changing features of the fabric can be controlled by rationally controlling the micro-scale design of the individual fibers in the structure. Thus, the fibers' microstructural features are optimized to achieve excellent color-changing behavior along with shape fixity and recovery ratios of 99.95% and 79.2%, respectively. More importantly, the fabric's dual-response by electric field can be achieved by a low voltage of 5 V, which is smaller than the previously reported values. Above and beyond, the fabric is able to be meticulously activated by selectively applying a controlled voltage to any part of the fabric. The precise local responsiveness can be bestowed upon the fabric by readily controlling its macro-scale design. A biomimetic dragonfly with the shape-memory and color-changing dual-response ability is successfully fabricated, broadening the design and fabrication horizon of groundbreaking smart materials with multiple functions.

Additive manufacturing of sustainable biomaterials for biomedical applications

Biopolymers are promising environmentally benign materials applicable in multifarious applications. They are especially favorable in implantable biomedical devices thanks to their excellent unique properties, including bioactivity, renewability, bioresorbability, biocompatibility, biodegradability and hydrophilicity. Additive manufacturing (AM) is a flexible and intricate manufacturing technology, which is widely used to fabricate biopolymer-based customized products and structures for advanced healthcare systems. Three-dimensional (3D) printing of these sustainable materials is applied in functional clinical settings including wound dressing, drug delivery systems, medical implants and tissue engineering. The present review highlights recent advancements in different types of biopolymers, such as proteins and polysaccharides, which are employed to develop different biomedical products by using extrusion, vat polymerization, laser and inkjet 3D printing techniques in addition to normal bioprinting and four-dimensional (4D) bioprinting techniques. This review also incorporates the influence of nanoparticles on the biological and mechanical performances of 3D-printed tissue scaffolds. This work also addresses current challenges as well as future developments of environmentally friendly polymeric materials manufactured through the AM techniques. Ideally, there is a need for more focused research on the adequate blending of these biodegradable biopolymers for achieving useful results in targeted biomedical areas. We envision that biopolymer-based 3D-printed composites have the potential to revolutionize the biomedical sector in the near future.

A Review of the Extruder System Design for Large-Scale Extrusion-Based 3D Concrete Printing

Extrusion-based 3D concrete printing (E3DCP) has been appreciated by academia and industry as the most plausible candidate for prospective concrete constructions. Considerable research efforts are dedicated to the material design to improve the extrudability of fresh concrete. However, at the time of writing this paper, there is still a lack of a review paper that highlights the significance of the mechanical design of the E3DCP system. This paper provides a comprehensive review of the mechanical design of the E3DCP extruder system in terms of the extruder system, positioning system and advanced fittings, and their effects on the extrudability are also discussed by relating to the extrusion driving forces and extrusion resistive forces which may include chamber wall shear force, shaping force, nozzle wall shear force, dead zone shear force and layer pressing force. Moreover, a classification framework of the E3DCP system as an extension of the DFC classification framework was proposed. The authors reckoned that such a classification framework could assist a more systematic E3DCP system design.

Heterogeneous Multi-Material Flexible Piezoresistive Sensor with High Sensitivity and Wide Measurement Range

Flexible piezoresistive sensors (FPSs) have the advantages of compact structure, convenient signal acquisition and fast dynamic response; they are widely used in motion detection, wearable electronic devices and electronic skins. FPSs accomplish the measurement of stresses through piezoresistive material (PM). However, FPSs based on a single PM cannot achieve high sensitivity and wide measurement range simultaneously. To solve this problem, a heterogeneous multi-material flexible piezoresistive sensor (HMFPS) with high sensitivity and a wide measurement range is proposed. The HMFPS consists of a graphene foam (GF), a PDMS layer and an interdigital electrode. Among them, the GF serves as a sensing layer, providing high sensitivity, and the PDMS serves as a supporting layer, providing a large measurement range. The influence and principle of the heterogeneous multi-material (HM) on the piezoresistivity were investigated by comparing the three HMFPS with different sizes. The HM proved to be an effective way to produce flexible sensors with high sensitivity and a wide measurement range. The HMFPS-10 has a sensitivity of 0.695 kPa^-1, a measurement range of 0-14,122 kPa, fast response/recovery (83 ms and 166 ms) and excellent stability (2000 cycles). In addition, the potential application of the HMFPS-10 in human motion monitoring was demonstrated.

Camera-based radiotherapy dosimetry using dual-material 3D printed scintillator arrays

PURPOSE AND OBJECTIVE

To describe a methodology for the dual-material fused deposition modeling (FDM) 3D printing of plastic scintillator arrays, to characterize their light output under irradiation using an sCMOS camera, and to establish a methodology for the dosimetric calibration of planar array geometries.

MATERIALS AND METHODS

We have published an investigation into the fabrication and characterization of single element FDM printed scintillators intending to produce customizable dosimeters for radiation therapy applications. ¹ This work builds on previous investigations by extending the concept to the production of a high-resolution (scintillating element size 3 × 3 × 3 mm³ ) planar scintillator array. The array was fabricated using a BCN3D Epsilon W27 3D printer and composed of polylactic acid (PLA) filament and BCF-10 plastic scintillator. The array's response was initially characterized using a 20 × 20 cm² 6 MV photon field with a source-to-surface (SSD) distance of 100 cm and the beam incident on the top of the array. The light signals emitted under irradiation were imaged using 200 ms exposures from a sCMOS camera positioned at the foot of the treatment couch (210 cm from the array). The collected images were then processed using a purpose-built software to correct known optical artefacts and determine the light output for each scintillating element. The light output was then corrected for element sensitivity and calibrated to dose using Monte Carlo simulations of the array and irradiation geometry based on the array's digital 3D print model. To assess the accuracy of the array calibration both a 3D beam and a clinical VMAT plan were delivered. Dose measurements using the calibrated array were then compared to EBT3 GAFChromic film and OSLD measurements, as well as Monte Carlo simulations and TPS calculations.

RESULTS

Our results establish the feasibility of dual-material 3D printing for the fabrication of custom plastic scintillator arrays. Assessment of the 3D printed scintillators response across each row of the array demonstrated a nonuniform response with an average percentage deviation from the mean of 2.1% ± 2.8%. This remains consistent with our previous work on individual 3D printed scintillators which showed an average difference of 2.3% and a maximum of 4.0% between identically printed scintillators.¹ Array dose measurements performed following calibration indicate difficulty in differentiating the scintillator response from ambient background light contamination at low doses (<20-25 cGy) and dose rates (≤100 MU/min). However, when analysis was restricted to exclude dose values less than 10% of the Monte Carlo simulated max dose the average absolute percentage dose difference between Monte Carlo simulation and array measurement was 5.3% ± 4.8% for the fixed beam delivery and 5.4% ± 5.2% for the VMAT delivery CONCLUSION: In this study, we developed and characterized a 3D printed array of plastic scintillators and demonstrated a methodology for the dosimetric calibration of a simple array geometry.

Complex Living Materials Made by Light-Based Printing of Genetically Programmed Bacteria

Living materials with embedded microorganisms can genetically encode attractive sensing, self-repairing, and responsive functionalities for applications in medicine, robotics, and infrastructure. While the synthetic toolbox for genetically engineering bacteria continues to expand, technologies to shape bacteria-laden living materials into complex 3D geometries are still rather limited. Here, it is shown that bacteria-laden hydrogels can be shaped into living materials with unusual architectures and functionalities using readily available light-based printing techniques. Bioluminescent and melanin-producing bacteria are used to create complex materials with autonomous chemical-sensing capabilities by harnessing the metabolic activity of wild-type and engineered microorganisms. The shaping freedom offered by printing technologies and the rich biochemical diversity available in bacteria provides ample design space for the creation and exploration of complex living materials with programmable functionalities for a broad range of applications.