NiTi-Nb micro-trusses fabricated via extrusion-based 3D-printing of powders and transient-liquid-phase sintering

Additively Manufactured Zn-2Mg Alloy Porous Scaffolds with Customizable Biodegradable Performance and Enhanced Osteogenic Ability

The combination of bioactive Zn-2Mg alloy and additively manufactured porous scaffold is expected to achieve customizable biodegradable performance and enhanced bone regeneration. Herein, Zn-2Mg alloy scaffolds with different porosities, including 40% (G-40-2), 60% (G-60-2), and 80% (G-80-2), and different unit sizes, including 1.5 mm (G-60-1.5), 2 mm (G-60-2), and 2.5 mm (G-60-2.5), are manufactured by a triply periodic minimal surface design and a reliable laser powder bed fusion process. With the same unit size, compressive strength (CS) and elastic modulus (EM) of scaffolds substantially decrease with increasing porosities. With the same porosity, CS and EM just slightly decrease with increasing unit sizes. The weight loss after degradation increases with increasing porosities and decreasing unit sizes. In vivo tests indicate that Zn-2Mg alloy scaffolds exhibit satisfactory biocompatibility and osteogenic ability. The osteogenic ability of scaffolds is mainly determined by their physical and chemical characteristics. Scaffolds with lower porosities and smaller unit sizes show better osteogenesis due to their suitable pore size and larger surface area. The results indicate that the biodegradable performance of scaffolds can be accurately regulated on a large scale by structure design and the additively manufactured Zn-2Mg alloy scaffolds have improved osteogenic ability for treating bone defects.

3D Printing of Copper Using Water-Based Colloids and Reductive Sintering

Copper was manufactured by using a low-cost 3D printing device and copper oxide water-based colloids. The proposed method avoids the use of toxic volatile solvents (used in metal-based robocasting), adopting copper oxide as a precursor of copper metal due to its lower cost and higher chemical stability. The appropriate rheological properties of the colloids have been obtained through the addition of poly-ethylene oxide-co-polypropylene-co-polyethylene oxide copolymer (Pluronic P123) and poly-acrylic acid to the suspension of the oxide in water. Mixing of the components of the colloidal suspension was performed with the same syringes used for the extrusion, avoiding any material waste. The low-temperature transition of water solutions of P123 is used to facilitate the homogenization of the colloid. The copper oxide is then converted to copper metal through a reductive sintering process, performed at 1000°C for a few hours in an atmosphere of Ar-10%H2. This approach allows the obtainment of porous copper objects (up to 20%) while retaining good mechanical properties. It could be beneficial for many applications, for example current collectors in lithium batteries.

Three Dimensional Printing and Its Applications Focusing on Microneedles for Drug Delivery

Microneedles (MNs) are considered to be a novel smart injection system that causes significantly low skin invasion upon puncturing, due to the micron-sized dimensions that pierce into the skin painlessly. This allows transdermal delivery of numerous therapeutic molecules, such as insulin and vaccines. The fabrication of MNs is carried out through conventional old methods such as molding, as well as through newer and more sophisticated technologies, such as three-dimensional (3D) printing, which is considered to be a superior, more accurate, and more time- and production-efficient method than conventional methods. Three-dimensional printing is becoming an innovative method that is used in education through building intricate models, as well as being employed in the synthesis of fabrics, medical devices, medical implants, and orthoses/prostheses. Moreover, it has revolutionary applications in the pharmaceutical, cosmeceutical, and medical fields. Having the capacity to design patient-tailored devices according to their dimensions, along with specified dosage forms, has allowed 3D printing to stand out in the medical field. The different techniques of 3D printing allow for the production of many types of needles with different materials, such as hollow MNs and solid MNs. This review covers the benefits and drawbacks of 3D printing, methods used in 3D printing, types of 3D-printed MNs, characterization of 3D-printed MNs, general applications of 3D printing, and transdermal delivery using 3D-printed MNs.

Gamma Irradiation Processing on 3D PCL Devices-A Preliminary Biocompatibility Assessment

Additive manufacturing or 3D printing applying polycaprolactone (PCL)-based medical devices represents an important branch of tissue engineering, where the sterilization method is a key process for further safe application in vitro and in vivo. In this study, the authors intend to access the most suitable gamma radiation conditions to sterilize PCL-based scaffolds in a preliminary biocompatibility assessment, envisioning future studies for airway obstruction conditions. Three radiation levels were considered, 25 kGy, 35 kGy and 45 kGy, and evaluated as regards their cyto- and biocompatibility. All three groups presented biocompatible properties, indicating an adequate sterility condition. As for the cytocompatibility analysis, devices sterilized with 35 kGy and 45 kGy showed better results, with the 45 kGy showing overall improved outcomes. This study allowed the selection of the most suitable sterilization condition for PCL-based scaffolds, aiming at immediate future assays, by applying 3D-customized printing techniques to specific airway obstruction lesions of the trachea.

The role of computer aided design/computer assisted manufacturing (CAD/CAM) and 3- dimensional printing in head and neck oncologic surgery: A review and future directions

Microvascular free flap reconstruction has remained the standard of care in reconstruction of large tissue defects following ablative head and neck oncologic surgery, especially for bony structures. Computer aided design/computer assisted manufacturing (CAD/CAM) and 3-dimensionally (3D) printed models and devices offer novel solutions for reconstruction of bony defects. Conventional free hand techniques have been enhanced using 3D printed anatomic models for reference and pre-bending of titanium reconstructive plates, which has dramatically improved intraoperative and microvascular ischemia times. Improvements led to current state of the art uses which include full virtual planning (VP), 3D printed osteotomy guides, and patient specific reconstructive plates, with advanced options incorporating dental rehabilitation and titanium bone replacements into the primary surgical plan through use of these tools. Limitations such as high costs and delays in device manufacturing may be mitigated with in house software and workflows. Future innovations still in development include printing custom prosthetics, 'bioprinting' of tissue engineered scaffolds, integration of therapeutic implants, and other possibilities as this technology continues to rapidly advance. This review summarizes the literature and serves as a summary guide to the historic, current, advanced, and future possibilities of 3D printing within head and neck oncologic surgery and bony reconstruction. This review serves as a summary guide to the historic, current, advanced, and future roles of CAD/CAM and 3D printing within the field of head and neck oncologic surgery and bony reconstruction.

Grain Structure Engineering of NiTi Shape Memory Alloys by Intensive Plastic Deformation

To explore an effective route of customizing the superelasticity (SE) of NiTi shape memory alloys via modifying the grain structure, binary Ni₅₅Ti₄₅ (wt) alloys were fabricated in as-cast, hot swaged, and hot-rolled conditions, presenting contrasting grain sizes and grain boundary types. In situ synchrotron X-ray Laue microdiffraction and in situ synchrotron X-ray powder diffraction techniques were employed to unravel the underlying grain structure mechanisms that cause the diversity of SE performance among the three materials. The evolution of lattice rotation, strain field, and phase transformation has been revealed at the micro- and mesoscale, and the effect of grain structure on SE performance has been quantified. It was found that (i) the Ni₄Ti₃ and NiTi₂ precipitates are similar among the three materials in terms of morphology, size, and orientation distribution; (ii) phase transformation happens preferentially near high-angle grain boundary (HAGB) yet randomly in low-angle grain boundary (LAGB) structures; (iii) the smaller the grain size, the higher the phase transformation nucleation kinetics, and the lower the propagation kinetics; (iv) stress concentration happens near HAGBs, while no obvious stress concentration can be observed in the LAGB grain structure during loading; (v) the statistical distribution of strain in the three materials becomes asymmetric during loading; (vi) three grain lattice rotation modes are identified and termed for the first time, namely, multi-extension rotation, rigid rotation, and nondispersive rotation; and (vii) the texture evolution of B2 austenite and B19' martensite is not strongly dependent on the grain structure.

Salt Heat Treatment and Passivation to Improve the Corrosion Resistance of Nitinol (Ni-Ti)

Corrosion of nitinol (NiTi) is a major factor in the failure of implantable materials. Recently, as the importance of corrosion of metals has increased, testing according to international guidelines is essential. The purpose of this study was to evaluate the corrosion resistance of NiTi wire through heat treatment and passivation process. In this study, NiTi wire used two commercially available products and a self-manufactured stent. Experimental consideration was carried out according to ASTM standards. Heat treatment was carried out in an air or a salt furnace, and the corrosion was measured after additional process, such as passivation and scratch tests. As a result, the metal potential was rapidly decreased in the air furnace group. On the other hand, the potential of wires was dramatically increased in the salt furnace group compared to the air furnace group. The dislocation decreased below the acceptance criteria (>600 mV) within 60 s of heat treatment time in the air furnace. Moreover, the potential was dramatically improved, even after only 20 min of passivation treatment (1076 mV, 442% compared to the non-passivated group), and it continued to rise until 180 min. This phenomenon was similarly observed in the group of self-manufactured stents. The potential slightly decreased by the scratch process (93.1%) was significantly reduced by the air furnace process (315 mV, 24.4% of the nontreated group). In the passivated group of the air furnace sample with reduced potential, the potential was restored to the level before the air furnace (scratch stage) (1032 mV). In conclusion, the heat treatment is preferably carried out in a salt furnace rather than an air furnace, and the passivation process can be an advantageous tool to improve corrosion resistance by suppressing the oxidation process.

Creation of Anatomically Correct and Optimized for 3D Printing Human Bones Models

Educational institutions in several countries state that the education sector should be modernized to ensure a contemporary, individualized, and more open learning process by introducing and developing advance digital solutions and learning tools. Visualization along with 3D printing have already found their implementation in different medical fields in Pauls Stradiņš Clinical University Hospital, and Rīga Stradiņš University, where models are being used for prosthetic manufacturing, surgery planning, simulation of procedures, and student education. The study aimed to develop a detailed methodology for the creation of anatomically correct and optimized models for 3D printing from radiological data using only free and widely available software. In this study, only free and cross-platform software from widely available internet sources has been used—“Meshmixer”, “3D Slicer”, and “Meshlab”. For 3D printing, the Ultimaker 5S 3D printer along with PLA material was used. In its turn, radiological data have been obtained from the “New Mexico Decedent Image Database”. In total, 28 models have been optimized and printed. The developed methodology can be used to create new models from scratch, which can be used will find implementation in different medical and scientific fields—simulation processes, anthropology, 3D printing, bioprinting, and education.

Biomaterials by design: Harnessing data for future development

Biomaterials is an interdisciplinary field of research to achieve desired biological responses from new materials, regardless of material type. There have been many exciting innovations in this discipline, but commercialization suffers from a lengthy discovery to product pipeline, with many failures along the way. Success can be greatly accelerated by harnessing machine learning techniques to comb through large amounts of data. There are many potential benefits of moving from an unstructured empirical approach to a development strategy that is entrenched in data. Here, we discuss the recent work on the use of machine learning in the discovery and design of biomaterials, including new polymeric, metallic, ceramics, and nanomaterials, and how machine learning can interface with emerging use cases of 3D printing. We discuss the steps for closer integration of machine learning to make this exciting possibility a reality.

Establishing a point-of-care additive manufacturing workflow for clinical use

Additive manufacturing, or 3-Dimensional (3-D) Printing, is built with technology that utilizes layering techniques to build 3-D structures. Today, its use in medicine includes tissue and organ engineering, creation of prosthetics, the manufacturing of anatomical models for preoperative planning, education with high-fidelity simulations, and the production of surgical guides. Traditionally, these 3-D prints have been manufactured by commercial vendors. However, there are various limitations in the adaptability of these vendors to program-specific needs. Therefore, the implementation of a point-of-care in-house 3-D modeling and printing workflow that allows for customization of 3-D model production is desired. In this manuscript, we detail the process of additive manufacturing within the scope of medicine, focusing on the individual components to create a centralized in-house point-of-care manufacturing workflow. Finally, we highlight a myriad of clinical examples to demonstrate the impact that additive manufacturing brings to the field of medicine.

Microstructure and Mechanical Properties of NiTi-Based Eutectic Shape Memory Alloy Produced via Selective Laser Melting In-Situ Alloying by Nb

This paper presents the results of selective laser melting (SLM) process of a nitinol-based NiTiNb shape memory alloy. The eutectic alloy Ni₄₅Ti₄₅Nb₁₀ with a shape memory effect was obtained by SLM in-situ alloying using a powder mixture of NiTi and Nb powder particles. Samples with a high relative density (>99%) were obtained using optimized process parameters. Microstructure, phase composition, tensile properties, as well as martensitic phase transformations temperatures of the produced alloy were investigated in as-fabricated and heat-treated conditions. The NiTiNb alloy fabricated using the SLM in-situ alloying featured the microstructure consisting of the NiTi matrix, fine NiTi+β-Nb eutectics, as well as residual unmelted Nb particles. The mechanical tests showed that the obtained alloy has a yield strength up to 436 MPa and the tensile strength up to 706 MPa. At the same time, in-situ alloying with Nb allowed increasing the hysteresis of martensitic transformation as compared to the alloy without Nb addition from 22 to 50 °C with an increase in A_f temperature from -5 to 22 °C.

Application of Spectroscopy in Additive Manufacturing

Additive manufacturing (AM) is a rapidly expanding material production technique that brings new opportunities in various fields as it enables fast and low-cost prototyping as well as easy customisation. However, it is still hindered by raw material selection, processing defects and final product assessment/adjustment in pre-, in- and post-processing stages. Spectroscopic techniques offer suitable inspection, diagnosis and product trouble-shooting at each stage of AM processing. This review outlines the limitations in AM processes and the prospective role of spectroscopy in addressing these challenges. An overview on the principles and applications of AM techniques is presented, followed by the principles of spectroscopic techniques involved in AM and their applications in assessing additively manufactured parts.

Basic Research for Additive Manufacturing of Rubber

The dissemination and use of additive processes are growing rapidly. Nevertheless, for the material class of elastomers made of vulcanizable rubber, there is still no technical solution for producing them using 3D printing. Therefore, this paper deals with the basic investigations to develop an approach for rubber printing. For this purpose, a fused deposition modeling (FDM) 3D printer is modified with a screw extruder. Tests are carried out to identify the optimal printing parameters. Afterwards, test prints are performed for the deposition of rubber strands on top of each other and for the fabrication of simple two-dimensional geometries. The material behavior during printing, the printing quality as well as occurrences of deviations in the geometries are evaluated. The results show that the realization of 3D rubber printing is possible. However, there is still a need for research to stabilize the layers during the printing process. Additionally, further studies are necessary to determine the optimum parameters for traverse speed and material discharge, especially on contours.

Solvent-cast 3D printing of magnesium scaffolds

Biodegradable porous magnesium (Mg) scaffolds are promising for application in the regeneration of critical-sized bone defects. Although additive manufacturing (AM) carries the promise of offering unique opportunities to fabricate porous Mg scaffolds, current attempts to apply the AM approach to fabricating Mg scaffolds have encountered some crucial issues, such as those related to safety in operation and to the difficulties in composition control. In this paper, we present a room-temperature extrusion-based AM method for the fabrication of topologically ordered porous Mg scaffolds. It is composed of three steps, namely (i) preparing a Mg powder loaded ink with desired rheological properties, (ii) solvent-cast 3D printing (SC-3DP) of the ink to form scaffolds with 0 °/ 90 °/ 0 ° layers, and (iii) debinding and sintering to remove the binder in the ink and then get Mg powder particles bonded by applying a liquid-phase sintering strategy. A rheological analysis of the prepared inks with 54, 58 and 62  vol% Mg powder loading was performed to reveal their viscoelastic properties. Thermal-gravimetric analysis (TGA), Fourier transform infrared spectroscopy (FTIR), carbon/sulfur analysis and scanning electron microscopy (SEM) indicated the possibilities of debinding and sintering at one single step for fabricating pure Mg scaffolds with high fidelity and densification. The resulting scaffolds with high porosity contained hierarchical and interconnected pores. This study, for the first time, demonstrated that the SC-3DP technique presents unprecedented possibilities to fabricate Mg-based porous scaffolds that have the potential to be used as a bone-substituting material. STATEMENT OF SIGNIFICANCE: Biodegradable porous magnesium scaffolds are promising for application in the regeneration of critical-sized bone defects. Although additive manufacturing (AM) carries the promise of offering unique opportunities to fabricate porous magnesium scaffolds, current attempts to apply the AM approach to fabricating magnesium scaffolds still have some crucial limitations. This study demonstrated that the solvent-cast 3D printing technique presents unprecedented possibilities to fabricate Mg-based porous scaffolds. The judicious chosen of formulated binder system allowed for the negligible binder residue after debinding and the short-time liquid-phase sintering strategy led to a great success in sintering pure magnesium scaffolds. The resulting scaffolds with hierarchical and interconnected pores have great potential to be used as a bone-substituting material.

Progressive 3D Printing Technology and Its Application in Medical Materials

Three-dimensional (3D) printing enables patient-specific anatomical level productions with high adjustability and resolution in microstructures. With cost-effective manufacturing for high productivity, 3D printing has become a leading healthcare and pharmaceutical manufacturing technology, which is suitable for variety of applications including tissue engineering models, anatomical models, pharmacological design and validation model, medical apparatus and instruments. Today, 3D printing is offering clinical available medical products and platforms suitable for emerging research fields, including tissue and organ printing. In this review, our goal is to discuss progressive 3D printing technology and its application in medical materials. The additive overview also provides manufacturing techniques and printable materials.

Effect of Polymer Binder on the Synthesis and Properties of 3D-Printable Particle-Based Liquid Materials and Resulting Structures

Recent advances have demonstrated the ability to 3D-print, via extrusion, solvent-based liquid materials (previously named 3D-Paints) which solidify nearly instantaneously upon deposition and contain a majority by volume of solid particulate material. In prior work, the dissolved polymer binder which enables this process is a high molecular weight biocompatible elastomer, poly(lactic-co-glycolic) acid (PLGA). We demonstrate in this study an expansion of this solvent-based 3D-Paint system to two additional, less-expensive, and less-specialized polymers, polystyrene (PS) and polyethylene oxide (PEO). The polymer binder used within the 3D-Paint was shown to significantly affect the as-printed and thermal postprocessing behavior of printed structures. This development enables users to select one of several polymers to impart the most desirable properties for a given application. Additionally, 3D-Paints based on these new binders are not adversely affected by classes of particles that can chemically degrade PLGA, notably particles containing large quantities of alkali ions. This study demonstrates the ability to successfully use PS and PEO as binders in the 3D-Paint system and compares the rheological, mechanical, microstructural, and thermal properties of the modified 3D-Paints and resulting as-printed and thermally post-processed objects. These objects include, for the first time, structures resulting from 3D-Painting which mostly contain soda-lime glass and 45S5 bioactive glass.

3D ink-extrusion additive manufacturing of CoCrFeNi high-entropy alloy micro-lattices

Additive manufacturing of high-entropy alloys combines the mechanical properties of this novel family of alloys with the geometrical freedom and complexity required by modern designs. Here, a non-beam approach to additive manufacturing of high-entropy alloys is developed based on 3D extrusion of inks containing a blend of oxide nanopowders (Co₃O₄ + Cr₂O₃ + Fe₂O₃ + NiO), followed by co-reduction to metals, inter-diffusion and sintering to near-full density CoCrFeNi in H₂. A complex phase evolution path is observed by in-situ X-ray diffraction in extruded filaments when the oxide phases undergo reduction and the resulting metals inter-diffuse, ultimately forming face-centered-cubic equiatomic CoCrFeNi alloy. Linked to the phase evolution is a complex structural evolution, from loosely packed oxide particles in the green body to fully-annealed, metallic CoCrFeNi with 99.6 ± 0.1% relative density. CoCrFeNi micro-lattices are created with strut diameters as low as 100 μm and excellent mechanical properties at ambient and cryogenic temperatures.

Additive manufacturing of high entropy alloys is still an emerging field that usually relies on expensive pre-alloyed powders. Here, the authors develop a method to 3D ink-print a CoCrFeNi high entropy alloy using inexpensive blended oxide nanopowders, hydrogen reduction, and sintering.

Enhancing Mechanical Response of Monolithic Magnesium Using Nano-NiTi (Nitinol) Particles

The present study focuses on investigating the effects of Nickel-Titanium (NiTi) nanoparticles on the microstructure and properties of pure Mg. Mg composites containing varying weight percentages (0.5, 1, 1.5, 3) of NiTi nanoparticles were fabricated using Disintegrated Melt Deposition (DMD), followed by hot extrusion. The synthesized materials were characterized in order to investigate their physical, microstructural and mechanical properties. Synthesized materials were characterized for their density and porosity levels, microstructural characteristics, and mechanical response. Superior grain refinement was realized by the presence of NiTi nanoparticles in the magnesium matrix. The addition of NiTi nanoparticles resulted in strength property enhancements of pure Mg with minimal adverse effect on the ductility. Structure-property evaluations are detailed in the current study.