High-performance medical-grade resin radically reinforced with cellulose nanofibers for 3D printing

Custom nasal obturator for velopharyngeal dysfunction: Digitizing the fabrication process

Nasal obturation using a removable medical device is a suitable treatment option for patients with velopharyngeal dysfunction. In the United Kingdom in recent years, the use of nasal obturation has increased because of the successful collaborations among the Speech and Language Therapy, Restorative Dentistry, and Maxillofacial departments. However, fabrication of the devices requires specialist skill and considerable time. A digital process which facilitates the rapid, cost effective production of a light, comfortable, unobtrusive nasal obturator is described.

Manufacturing Process, Tensile-Compressive, and Impact Properties of Tungsten (W)-Particle-Reinforced SLA Methacrylate

The interest in research and development for additive manufacturing (AM) processes has grown significantly over the last years and attracts both industry and academia alike. Among the available AM technologies, stereolithography (SLA) is one of the most discussed, researched, and employed. On the other hand, being based on thermoset resins, all the limitations of this typology of materials still apply, limiting the range of applications of this highly versatile process. To overcome these limitations, especially brittleness, this research analyzes the effects of Tungsten (W) micro-size (average size 1 μm) particles reinforcement on a methacrylate base material. First, the manufacturing process for creating the W-reinforced methacrylate material is presented and investigated to define the effect of pre- and post-processing operations on the quality of the pre-cured solution considering 4% and 10% wt. W particles concentrations. Afterward, tensile, compressive, and impact specimens were manufactured with both concentrations and compared with the experimental results from clear (unfilled) resin-based specimens used as the benchmark. The addition of tungsten particles showed a strong improvement in the impact strength of the methacrylate base material, quantified in 28% for the 4% and 55% for the 10% wt., respectively, although at the expense of a slight reduction in elastic and yield properties on average -12%. Furthermore, using Scanning Electron Microscope (SEM) analyses, the particle-matrix interaction was investigated, showing the interaction between the polymer matrix and the reinforcement and the mechanism by which the impact resistance is enhanced.

Mechanical strength predictability of full factorial, Taguchi, and Box Behnken designs: Optimization of thermal settings and Cellulose Nanofibers content in PA12 for MEX AM

Optimization of reinforced nanocomposites for MEX 3D-printing remain strong industrial claims. Herein, the efficacy of three modeling methods, i.e., full factorial (FFD), Taguchi (TD), and Box-Behnken (BBD), on the performance of MEX 3D printed nanocomposites was investigated, aiming to reduce the experimental effort. Filaments of medical-grade Polyamide 12 (PA12) reinforced with Cellulose NanoFibers (CNF) were evolved. Besides the CNF loading, 3D printing settings such as Nozzle (NT) and Bed (BΤ) Temperatures were optimization goals aiming to maximize the mechanical response. Three parameters and three levels of FFD were compliant with the ASTM-D638 standard (27 runs, five repetitions). An L9 orthogonal TD and a 15 runs BBD were compiled. In FFD, wt.3%CNF, 270 °C NT, and 80 °C BΤ led to 24% higher tensile strength compared to pure PA12. TGA, RAMAN, and SEM analyses interpreted the reinforcement mechanisms. TD and BBD exhibited fair approximations, requiring 7.4% and 11.8% of the FFD experimental effort.

A miniaturized genotoxicity evaluation system for fast biomaterial-related risk assessment

Implants and prostheses are widely used to either repair damaged tissues or treat different diseases. Before an implant reaches the market, multiple preclinical and clinical tests must be performed. Along with cytotoxicity or hemocompatibility preclinical tests, genotoxicity is an essential feature to investigate. Indeed, the materials used for implantation should be non-genotoxic, i.e. they should not promote mutations that can potentially lead to tumour formation. However, given the complexity level of genotoxicity tests, such tests are not readily available to biomaterials researchers, which is the reason why this aspect is severely underreported in the literature. To solve this problem, we developed a simplified genotoxicity test that can be further adapted by standard biomaterials laboratories. We started by simplifying the classic Ames test in Petri dishes, after which we developed a miniaturized test in a microfluidic chip, which takes only 24 hours, requiring significantly less material and space. An automatization option with a customized testing chamber architecture and microfluidics-based control system has been designed as well. This optimized microfluidic chip system can significantly improve the availability of genotoxicity tests for biomaterials developers, with the additional benefit of more in-depth observation and quantitative comparison due to the availability of processable image components.

Synthesis and Physicochemical Properties of Acrylate Anion Based Ionic Liquids

Two polymerizable ionic liquids (or monomeric ionic liquids, mILs) namely 1-butyl-3-methylimidazolium and choline acrylates ([C4mim]A and ChA, respectively) were synthesized using the modified Fukumoto method from corresponding chlorides. The chemical structure of the prepared mILs was confirmed with FTIR and NMR study. Investigation of the thermal properties with DSC demonstrates that both mILs have a Tg temperature of about 180 K and a melting point around 310 K. It was shown that the temperature dependence of FTIR confirm the Tg to be below 200. Both mILs exhibited non-Newtonian shear thinning rheological behavior at shear rates >4 s−1. It was shown that [C4mim]A is able to dissolve bacterial cellulose (BC) leading to a decrease in its degree of polymerization and recrystallisation upon regeneration with water; although in the ChA, the crystalline structure and nanofibrous morphology of BC was preserved. It was demonstrated that the thixotropic and rheological properties of cellulose dispersion in ChA at room temperature makes this system a prospective ink for 3D printing with subsequent UV-curing. The 3D printed filaments based on ChA, containing 2 wt% of BC, and 1% of N,N′-methylenebisacrylamide after radical polymerization induced with 1% 2-hydroxy-2-methylpropiophenone, demonstrated Young’s modulus 7.1 ± 1.0 MPa with 1.2 ± 0.1 MPa and 40 ± 5% of strength and ultimate elongation, respectively.

Multifunctional Medical Grade Resin with Enhanced Mechanical and Antibacterial Properties: The Effect of Copper Nano-Inclusions in Vat Polymerization (VPP) Additive Manufacturing

Vat photopolymerization (VPP) is an additive manufacturing process commonly used in medical applications. This work aims, for the first time in the literature, to extend and enhance the performance of a commercial medical-grade resin for the VPP process, with the development of nanocomposites, using Copper (Cu) nanoparticles as the additive at two different concentrations. The addition of the Cu nanoparticles was expected to enhance the mechanical properties of the resin and to enable biocidal properties on the nanocomposites since Cu is known for its antibacterial performance. The effect of the Cu concentration was investigated. The nanocomposites were prepared with high-shear stirring. Specimens were 3D printed following international standards for mechanical testing. Their thermal and spectroscopic response was also investigated. The morphological characteristics were examined. The antibacterial performance was evaluated with an agar well diffusion screening process. The experimental results were analyzed with statistical modeling tools with two control parameters (three levels each) and eleven response parameters. Cu enhanced the mechanical properties in all cases studied. 0.5 wt.% Cu nanocomposite showed the highest improvement (approximately 11% in tensile and 10% in flexural strength). The antibacterial performance was sufficient against S. aureus and marginal against E. coli.