Mechanical properties of tissue-mimicking composites formed by material jetting additive manufacturing

Digital Multiphase Composites via Additive Manufacturing

Mechanical properties of traditional engineering materials are typically coupled to each other, presenting a challenge to practitioners with multi-dimensional material property requirements. In this work, continuous, independent control over multiple mechanical properties is demonstrated in composite materials realized using additive manufacturing. For the first time, composites additively manufactured from rigid plastic, soft elastomer, and liquid constituents are experimentally characterized, demonstrating materials which span four orders of magnitude in modulus and two orders of magnitude in toughness. By forming analytical mappings between relative concentrations of constituents at the microscale and resulting macroscale material properties, inverse material design is enabled; the method is showcased by printing artifacts with prescribed toughness and elasticity distributions. The properties of these composites are placed in the context of biological tissues, showing they have promise as mechanically plausible tissue mimics.

Measured and simulated mechanical properties of additively manufactured matrix-inclusion multimaterials fabricated by material jetting

Modern additive manufacturing enables the simultaneous processing of different materials during the printing process. While multimaterial 3D printing allows greater freedom in part design, the prediction of the mix-material properties becomes challenging. One type of multimaterials are matrix-inclusion composites, where one material contains inclusions of another material. Aim of this study was to develop a method to predict the uniaxial Young's modulus and Poisson's ratio of material jetted matrix-inclusion composites by a combination of simulations and experimental data.Fifty samples from commercially available materials in their pure and matrix-inclusion mixed forms, with cubic inclusions, have been fabricated using material jetting and mechanically characterized by uniaxial tensile tests. Multiple simulation approaches have been assessed and compared to the measurement results in order to find and validate a method to predict the multimaterials' properties. Optical coherence tomography and microscopy was used to characterize the size and structure of the multimaterials, compared to the design.The materials exhibited Young's moduli in the range of 1.4 GPa to 2.5 GPa. The multimaterial mixtures were never as stiff as the weighted volume average of the primary materials (up to [Formula: see text] softer for 45% RGD8530-DM inclusions in VeroClear matrix). Experimental data could be predicted by finite element simulations by considering a non-ideal contact stiffness between matrix and inclusion ([Formula: see text] for RGD8530-DM, [Formula: see text] for RGD8430-DM), and geometries of the printed inclusions that deviated from the design (rounded edge radii of [Formula: see text]m). Not considering this would lead to a difference of the estimation result of up to [Formula: see text]MPa (44%), simulating an inclusion volume fraction of 45% RGD8530-DM.Prediction of matrix-inclusion composites fabricated by multimaterial jetting printing, is possible, however, requires a priori knowledge or additional measurements to characterize non-ideal contact stiffness between the components and effective printed geometries, precluding therefore a simple multimaterial modelling.

Puncturing of soft tissues: experimental and fracture mechanics-based study

The integrity of soft materials against puncturing is of great relevance for their performance because of the high sensitivity to local rupture caused by rigid sharp objects. In this work, the mechanics of puncturing is studied with respect to a sharp-tipped rigid needle with a circular cross section, penetrating a soft target solid. The failure mode associated with puncturing is identified as a mode-I crack propagation, which is analytically described by a two-dimensional model of the target solid, taking place in a plane normal to the penetration axis. It is shown that the force required for the onset of needle penetration is dependent on two energy contributions, that are, the strain energy stored in the target solid and the energy consumed in crack propagation. More specifically, the force is found to be dependent on the fracture toughness of the material, its stiffness and the sharpness of the penetrating tool. The reference case within the framework of small strain elasticity is first investigated, leading to closed-form toughness parameters related to classical linear elastic fracture mechanics. Then, nonlinear finite element analyses for an Ogden hyperelastic material are presented. Supporting the proposed theoretical framework, a series of puncturing experiments on two commercial silicones is presented. The combined experimental-theoretical findings suggest a simple, yet reliable tool to easily handle and assess safety against puncturing of soft materials.

Influence of Post-Processing on the Properties of Multi-Material Parts Obtained by Material Projection AM

The great geometric complexity that additive manufacturing allows in parts, together with the possibility of combining several materials in the same part, establishes a new design and manufacturing paradigm. Despite the interest of many leading sectors, the lack of standardization still makes it necessary to carry out characterization work to enjoy these advantages in functional parts. In many of these techniques, the process does not end with the end of the machine cycle, but different post-processing must be carried out to consider the part finished. It has been found that the type of post process applied can have a similar effect on part quality as other further studied process parameters. In this work, the material projection technique was used to manufacture multi-material parts combining resins with different mechanical properties. The influence of different post-processing on the tensile behavior of these parts was analyzed. The results show the detrimental effect of ultrasonic treatment with isopropyl alcohol in the case of the more flexible resin mixtures, being advisable to use ultrasonic with mineral oil or furnace treatment. For more rigid mixtures, the furnace is the best option, although the other post-processing techniques do not significantly deteriorate their performance.