Overview of current additive manufacturing technologies and selected applications

Surface characteristics, cytotoxicity, and microbial adhesion of 3D-printed hybrid resin-ceramic materials for definitive restoration

OBJECTIVE

This study investigated the surface properties, cytotoxicity, and microbial adhesion of 3D-printed specimens made from hybrid resin-ceramic materials intended for use in definitive crowns.

METHODS

Disc-shaped specimens were 3D-printed using six different hybrid resin-ceramic materials recommended for definitive restorations: Crowntec (CT), VarseoSmile Crown Plus (VS), Tera Harz TC-80DP Graphy (TH), C&B Permanent ODS (CB), Formlabs Permanent Crown (FP), and HeyGears (HG). Surface topography, surface roughness, and water contact angle values were measured for each material (n = 6). Cytotoxicity was assessed using direct contact and extract tests on human gingival fibroblasts (n = 4). Additionally, the adhesion of mixed oral bacteria to the surfaces of the specimens was evaluated by counting colony-forming units (CFUs) after a 2-hour incubation period (n = 6).

RESULTS

The TH group exhibited significantly lower surface roughness (Ra: 0.28 ± 0.13 μm) compared to the other materials (CT: 1.87 ± 0.34 μm; VS: 1.13 ± 0.09 μm; CB: 2.91 ± 0.27 μm; FP: 2.50 ± 0.08 μm; HG: 1.50 ± 0.55 μm). The VS group had the highest water contact angle (129.5 ± 1.1°), indicating greater hydrophobicity, in contrast to the other groups (CT: 72.6 ± 2.1°; TH: 75.0 ± 0.3°; CB: 69.1 ± 0.2°; FP: 93.0 ± 1.6°; HG: 77.7 ± 0.3°). Cytotoxicity testing showed no harmful effects, as relative cell viability exceeded 70 %, and lactate dehydrogenase (LDH) release remained below 30 % for all materials. The TH specimens also demonstrated the lowest bacterial adhesion.

CONCLUSIONS

The surface characteristics of the tested resin-ceramic materials varied significantly, with TH showing the smoothest surface and the least bacterial adhesion. All materials were found to be non-toxic. Therefore, TH material has the potential to provide definitive restorations with less microbial adhesion.

CLINICAL SIGNIFICANCE

The type of resin-ceramic material significantly affects the surface properties of 3D-printed specimens. These findings are crucial for selecting the appropriate resin-ceramic material for definitive restorations.

Influence of print orientation on the accuracy (trueness and precision) of diagnostic casts manufactured with a daylight polymer printer

STATEMENT OF PROBLEM

Print orientation may affect the manufacturing accuracy of vat-polymerized diagnostic casts. However, its influence should be analyzed based on the manufacturing trinomial (technology, printer, and material) and printing protocol used to manufacture the casts.

PURPOSE

The purpose of this in vitro study was to measure the influence of different print orientations on the manufacturing accuracy of vat-polymerized polymer diagnostic casts.

MATERIAL AND METHODS

A standard tessellation language (STL) reference file containing a maxillary virtual cast was used to manufacture all specimens using a vat-polymerization daylight polymer printer (Photon mono SE. LCD 2K) and a model resin (Phrozen Aqua Gray 4K). All specimens were manufactured using the same printing parameters, except for print orientation. Five groups were created depending on the print orientation: 0, 22.5, 45, 67.5, and 90 degrees (n=10). Each specimen was digitized using a desktop scanner. The discrepancy between the reference file and each of the digitized printed casts was measured using the Euclidean measurements and root mean square (RMS) error (Geomagic Wrap v.2017). Independent (unpaired) sample t tests and multiple pairwise comparisons using the Bonferroni test were used to analyze the trueness of the Euclidean distances and RMS data. Precision was assessed using the Levene test (α=.05).

RESULTS

In terms of Euclidean measurements, significant differences in trueness and precision values were found among the groups tested (P<.001). The 22.5- and 45-degree groups resulted in the best trueness values, and the 67.5-degree group had the lowest trueness value. The 0- and 90-degree groups led to the best precision values, while the 22.5-, 45-, and 67.5-degree groups showed the lowest precision values. Analyzing the RMS error calculations, significant differences in trueness and precision values were found among the groups tested (P<.001). The 22.5-degree group had the best trueness value, and the 90-degree group resulted in the lowest trueness value among the groups. The 67.5-degree group led to the best precision value, and the 90-degree group to the lowest precision value among the groups.

CONCLUSIONS

Print orientation influenced the accuracy of diagnostic casts fabricated by using the selected printer and material. However, all specimens had clinically acceptable manufacturing accuracy ranging between 92 μm and 131 μm.

Adjustment of Mechanical Properties of 3D Printed Continuous Carbon Fiber-Reinforced Thermoset Composites by Print Parameter Adjustments

Reinforcing thermoset polymers with continuous carbon fiber (CF) tow has emerged as a promising avenue to overcome the thermal and mechanical performance limitations of 3D printed polymeric structures for load-bearing applications. Unlike traditional methods, manufacturing continuous fiber-reinforced composites by 3D printing has the unique capability of locally varying the mechanical properties of the composites. In this study, continuous CF thermoset composite specimens were printed with varying line spacing, resin flow rate, and nozzle sizes. The resin flow rates for different line spacings and nozzle sizes were optimized by topographic analysis. Printed composite mechanical properties were evaluated, and their trends were correlated with the trend of print parameter changes. Results showed that tensile strength and modulus could be altered and improved by ~50% by adjusting the printing process parameters. Higher composite strength and modulus were obtained by shortening the line spacing and nozzle diameter.

Materials for 3D printing in healthcare sector: A review

Additive Manufacturing (AM) encompasses various techniques creating intricate components from digital models. The aim of incorporating 3D printing (3DP) in the healthcare sector is to transform patient care by providing personalized solutions, improving medical procedures, fostering research and development, and ultimately optimizing the efficiency and effectiveness of healthcare delivery. This review delves into the historical beginnings of AM's 9 integration into medical contexts exploring various categories of AM methodologies and their roles within the medical sector. This survey also dives into the issue of material requirements and challenges specific to AM's medical applications. Emphasis is placed on how AM processes directly enhance human well-being. The primary focus of this paper is to highlight the evolution and incentives for cross-disciplinary AM applications, particularly in the realm of healthcare by considering their principle, materials and applications. It is designed for a diverse audience, including manufacturing professionals and researchers, seeking insights into this transformative technology's medical dimensions.

Reinforcement of 3D-printed resins for denture base by adding aramid fibers: Effect on mechanical, surface, and optical properties

PURPOSE

The present study evaluated the mechanical, surface, and optical properties of 3D-printed resins for removable prostheses reinforced by the addition of aramid fibers.

MATERIALS AND METHODS

According to ISO 20795-1:2013 standards, specimens were printed using a digital light processing 3D printer and divided into two groups (n = 06/group): 3D-printed resin for denture base as the control group, and a group with the same 3D-printed resin in addition of 5% aramid fibers as the experimental group. Red aramid fibers were chosen for aesthetic characterization. The specimens were evaluated for their mechanical properties, such as elastic modulus (GPa), flexural strength (MPa), and superficial properties by their surface microhardness (KHN), surface roughness (μm), and surface free energy (mJ/m2). Optical properties were evaluated by the color difference (∆E00) between groups. The statistical test chosen after the exploratory analysis of the data was One-way ANOVA followed by Tukey's HSD (α = 0.05).

RESULTS

The results showed statistical differences in elastic modulus (p < 0.0001), flexural strength (p < 0.0001), surface free energy polar variable (p = 0.0322), total surface free energy (p = 0.0344), with higher values for the experimental. Surface hardness and surface roughness showed no statistical difference (p ≥ 0.05). The color difference (∆E00) obtained through the CIEDE2000 calculus was below the perceptibility threshold (≤1.1).

CONCLUSION

Adding aramid fibers to 3D-printed resin for denture bases resulted in better mechanical properties, without major alterations in surface properties. In addition, it is an easy-to-apply choice for mechanical reinforcement and aesthetic characterization, with the expression of small blood vessels in the 3D-printed resin for removable denture bases.

3D-printed temporal bone models for training: Does material transparency matter?

PURPOSE

To investigate the impact of 3D-printed temporal bone models with two different material transparencies on trainees' mastoidectomy performance.

METHODS

Eleven ORL residents performed two anatomical mastoidectomies with posterior tympanotomy on two 3D-printed models with different transparency and VR simulation training. Participants where divided into two groups based on their experience. Within each group participants were randomized to start with the model printed in a completely opaque material or in a material featuring some degree of transparency. After drilling on 3D-printed models, the participants performed two similar mastoidectomies on human cadavers: one on the left side of one cadaver and one on the right side of another cadaver. After drilling 3D-printed models and cadavers, the final-product performances were evaluated by two experienced raters using the 26-item modified Welling Scale. Participants also evaluated the models using a questionnaire.

RESULTS

Overall, the participants performed 25 % better on the 3D-printed models featuring transparency compared to the opaque models (18.6 points vs 14.9 points, mean difference = 3.7, 95 % CI 2.0-5.3, P < 0.001)). This difference in performance was independent of which material the participants had drilled first. In addition, the residents also subjectively rated the transparent model to be closer to cadaver dissection. The experienced group starting with the 3D-printed models scored 21.5 points (95 % CI 20.0-23.1), while the group starting with VR simulation training score 18.4 points (95 % CI 16.6-20.3).

CONCLUSION

We propose that material used for 3D-printing temporal bone models should feature some degree of transparency, like natural bone, for trainees to learn and exploit key visual cues during drilling.

Impact of Printing Orientation on the Accuracy of Additively Fabricated Denture Base Materials: A Systematic Review

Printing orientation is one of the printing parameters that affect the properties of three-dimensional (3D)-printed resins. Different printing orientations and directions have been suggested; however, no clear and specific orientations are recommended in the literature in terms of the printing orientation effect on the accuracy and fit of 3D-printed removable dental prostheses. This review aimed to evaluate the effect of printing orientation on the fit and accuracy of 3D-printed removable dental prostheses. The PubMed, Scopus, and Web of Science databases were searched for published articles that investigated the effect of printing orientations on the accuracy and fit of the 3D-printed denture base. Full-length English published articles were searched between January 2010 and December 2023, which examined topics related to printing orientations, building angles, 3D printing, printing technology, accuracy, dimensional changes, internal fit, marginal integrity, marginal discrepancies, trueness, precision, and adaptation. Of the ten included studies, one investigated maxillary and mandibular denture bases, seven assessed maxillary denture bases, and two evaluated mandibular bases. Different printing orientations, ranging from 0° to 315°, were explored, with a higher prevalence of 0°, 45°, and 90°. The included studies utilized stereolithography and digital light processing printing technologies. High accuracy was observed at 45°, followed by 90. Additional struts and bars on the cameo surface increased the accuracy of the 3D-printed denture base. These results shows that printing orientation has a significant effect on the accuracy of 3D-printed resin, with 45° exhibiting the highest accuracy. In addition to the support structure, the density and position can impact the accuracy.

Self-assembled monolayers of reduced graphene oxide for robust 3D-printed supercapacitors

Herein, additive manufacturing, which is extremely promising in different sectors, has been adopted in the electrical energy storage field to fabricate efficient materials for supercapacitor applications. In particular, Al2O3-, steel-, and Cu-based microparticles have been used for the realization of 3D self-assembling materials covered with reduced graphene oxide to be processed through additive manufacturing. Functionalization of the particles with amino groups and a subsequent "self-assembly" step with graphene oxide, which was contextually partially reduced to rGO, was carried out. To further improve the electrical conductivity and AM processability, the composites were coated with a polyaniline-dodecylbenzene sulfonic acid complex and further blended with PLA. Afterward, they were extruded in the form of filaments, printed through the fused deposition modeling technique, and assembled into symmetrical solid-state devices. Electrochemical tests showed a maximum mass capacitance of 163 F/g, a maximum energy density of 15 Wh/Kg at 10 A/g, as well as good durability (85% capacitance retention within 5000 cycles) proving the effectiveness of the preparation and the efficiency of the as-manufactured composites.

Two-piece magnet-retained shell manufactured by using milled and vat-polymerized methods for direct interim restorations

The shell technique has been described for fabricating direct interim restorations by using conventional and computer-aided design and computer-aided manufacturing (CAD-CAM) methods. However, the positioning of the shell over the tooth preparations can be challenging. In the present manuscript, the clinical and laboratory steps for manufacturing a 2-piece magnet-retained shell for direct interim restoration fabrication are described. The 2-piece shell was produced by combining milling and additive manufacturing procedures. The described technique aims to simplify the correct positioning of the shell and facilitate direct interim restoration fabrication.

Evaluation of fit and accuracy of single crowns fabricated from self-glazed zirconia compared with milled zirconia

STATEMENT OF PROBLEM

Self-glazed zirconia is a novel dental material fabricated with a combination of subtractive and additive manufacturing techniques. However, how the marginal and internal fit of these restorations compare with conventionally fabricated zirconia is unclear.

PURPOSE

The purpose of this in vitro study was to evaluate the marginal and internal fit and internal accuracy of single crowns made from self-glazed zirconia compared with those made from milled zirconia.

MATERIAL AND METHODS

A metal die was scanned, and a crown was designed using a computer-aided-design program. The computer-aided-manufacturing milling method (conventional technique) was used to produce 10 zirconia crowns, and additive manufacturing was used to produce 10 self-glazed zirconia crowns. Internal and marginal fit measurements were made by using the silicone replica method; marginal fit was also measured by using the direct-view technique. An independent t test was performed to compare both types of crowns and test the null hypothesis (α=.05).

RESULTS

For the occlusal, internal, and total mean distances, significant differences were found between self-glazed and milled zirconia crowns (P<.001). With the direct-view technique, a significant difference (P=.004) between the 2 techniques was found in the marginal area. The accuracy for the axial and occlusal areas combined for self-glazed and milled zirconia was 27 μm and 49 μm, respectively.

CONCLUSIONS

Both techniques produced crowns with clinically acceptable marginal and internal fit. The self-glazed zirconia crowns had higher accuracy of internal fit than milled zirconia crowns.

Enabling the design of surgical instruments for under-resourced patients through metal additive manufacturing: ulnar shortening osteotomy as an example

BACKGROUND

Ulnar shortening osteotomy (USO) has demonstrated good outcomes for patients with ulnar impaction syndrome. To minimize complications such as non-union, precise osteotomy and firm fixation are warranted. Despite various ulnar shortening systems have been developed, current technology does not meet all needs. A considerable portion of patients could not afford those designated USO systems. To tackle this challenge, our team reported successful results in standardized free-hand predrilled USO technique. However, it is still technical demanding and requires sufficient experience and confidence to excel. Therefore, our team designed an ulnar shortening system based on our free-hand technique principle, using metal additive manufacturing technology. The goal of this study is to describe the development process and report the performance of the system.

METHODS

Utilizing metal additive manufacturing technology, our team developed an ulnar shortening system that requires minimal exposure, facilitates precise cutting, and allows for the easy placement of a 3.5 mm dynamic compression plate, available to patients at zero out-of-pocket cost. For performance testing, two surgeons with different levels of experience in ulnar shortening procedures were included: one fellow-trained hand and wrist surgeon and one senior resident. They performed ulnar shortening osteotomy (USO) using both the free-hand technique and the USO system-assisted technique on ulna sawbones, repeating each method three times. The recorded parameters included time-to-complete-osteotomy, total procedure time, chip diameter, shortening length, maximum residual gap, and deviation angle.

RESULTS

For the hand and wrist fellow, with the USO system, the time-to-complete osteotomy was significantly reduced. (468.7 ± 63.6 to 260.0 ± 5 s, p < 0.05). Despite the preop goal was shortening 3 mm, the average shortening length was significantly larger in the free-hand group (5 ± 0.1; 3.2 ± 0.2 mm, p < 0.05). Both maximum residual gap and deviation angle reported no statistical difference between the two techniques for the hand surgeon. As for the senior resident, the maximum residual gap was significantly reduced, using the USO system (2.9 ± 0.8; 0.4 ± 0.4 mm, p = 0.02). Between two surgeons, significant larger maximum residual gap and deviation angle were noted on the senior resident doctor, in the free-hand technique group, but not in the USO system group.

CONCLUSION

The developed USO system may serve as a valuable tool, aiding in reliable and precise cutting as well as fixation for patients undergoing ulnar shortening osteotomy with a 3.5 mm dynamic compression plate, even for less experienced surgeons. The entire process, from concept generation and sketching to creating the CAD file and final production, serves as a translatable reference for other surgical scenarios.

Influence of postprocessing rinsing solutions and duration on flexural strength of aged and nonaged additively manufactured interim dental material

STATEMENT OF PROBLEM

Additive manufacturing procedures for fabricating interim restorations include rinsing postprocessing procedures. However, the impact of different rinsing solutions and times on flexural strength is unknown.

PURPOSE

The purpose of this in vitro study was to assess the influence of the rinsing solutions and duration, as well as accelerated aging (thermocycling) procedures, on the flexural strength and Weibull characteristics of an additively manufactured interim dental material.

MATERIAL AND METHODS

A bar design (25×2×2 mm) file was used to fabricate all the specimens with 3D printing and an interim material (Nextdent C&B MFH). Five groups were created based on the rinsing solution used during the postprocessing procedures: 91% isopropyl alcohol (IPA) (control or IPA-91), 99% IPA (IPA-99 group), bio-ethyl alcohol 100% (BE group), tripropylene glycol monomethyl ether (TPM) 100% (TPM group), and water miscible formula (Resinaway) (RA group). Each group was divided into 4 subgroups depending on the total rinsing time: 5, 6, 7, and 8 minutes (5, 6, 7, and 8 subgroups). Additionally, each subgroup was distributed between nonaged and aged thermocycling procedures (n=10). Flexural strength measurements were made by using a universal testing machine. Two-parameter Weibull distribution values, including the Weibull modulus, scale (m), and shape (0), were calculated. Three-way ANOVA and pairwise multiple comparison Tukey tests were used to analyze the data (α=.05).

RESULTS

Three-way ANOVA showed that the rinsing solution (P<.001), rinsing time (P=.004), and thermocycling procedures (P<.001) were significant predictors of the flexural strength values obtained. The IPA-91 and IPA-99 groups obtained the highest flexural strength, while the RA, TPM, and BE groups obtained the lowest flexural strength. The 7- and 8-minute subgroups obtained the highest flexural strength, while the 5-minute subgroup obtained the lowest flexural strength. The nonaged specimens obtained significantly higher mean flexural strength values than the aged specimens.

CONCLUSIONS

The vat-polymerized additively manufactured interim dental material tested with differing rinsing solutions and times demonstrated significant differences in the flexural strength values measured. Accelerated artificial aging procedures significantly decreased the flexural strength of the vat-polymerized interim dental material tested.

Wear at the implant-framework interface between titanium implant platform and the additively manufactured titanium and cobalt-chromium frameworks

PURPOSE

To measure the wear at the implant interface between the Grade 4 titanium (Ti) of the implant and frameworks fabricated using two additively manufactured alloys (Ti alloy and cobalt-chromium [Co-Cr]) pre- and post-artificial aging.

MATERIAL AND METHODS

Three-unit frameworks supported by two implants were additively manufactured (Atlantis; Dentsply Sirona) using Ti and Co-Cr dental alloys. Two implants (OsseoSpeed EV, Astra Tech; Dentsply Sirona) were torqued on each non-engaging framework. The assembled implant-frameworks were secured into polyurethane foam blocks. Groups were created based on the material and surface assessed: framework (Ti-framework and Co-Cr-framework groups) and implant (Ti-implant group). Two subgroups were created depending on the location: premolar (PM) and molar (M). Computed tomography images were obtained pre- (as manufactured) and post-simulated mastication procedures. The pre- and post-simulated mastication files of each specimen were aligned using the best-fit algorithm using a metrology program. Wear was measured by calculating the volumetric discrepancies at the implant interface on 64 measurement points per area analyzed. Three-way ANOVA and Tukey tests were used to analyze the data (α = 0.05).

RESULTS

The mean volumetric discrepancy values ranged from 0.8 to 3.1 µm among all the subgroups tested. The group (framework vs. implant) (p < 0.001) and tooth location (p < 0.001) were significant factors of the mean volumetric discrepancy values obtained. The framework group presented with significantly lower volumetric discrepancy mean values (1 µm) compared with the implant group (3 µm), whereas the premolar area obtained significantly lower mean volumetric discrepancy values (1.9 µm) compared with the molar location (2.3 µm).

CONCLUSIONS

Volumetric discrepancies were found at the implant-framework interface tested between the pre- and post-artificial aging measurements ranging from 1 to 3 µm after 1,200,000 cyclic loading that simulated approximately 12 months of function.

3D printing metal implants in orthopedic surgery: Methods, applications and future prospects

Background

Currently, metal implants are widely used in orthopedic surgeries, including fracture fixation, spinal fusion, joint replacement, and bone tumor defect repair. However, conventional implants are difficult to be customized according to the recipient's skeletal anatomy and defect characteristics, leading to difficulties in meeting the individual needs of patients. Additive manufacturing (AM) or three-dimensional (3D) printing technology, an advanced digital fabrication technique capable of producing components with complex and precise structures, offers opportunities for personalization.

Methods

We systematically reviewed the literature on 3D printing orthopedic metal implants over the past 10 years. Relevant animal, cellular, and clinical studies were searched in PubMed and Web of Science. In this paper, we introduce the 3D printing method and the characteristics of biometals and summarize the properties of 3D printing metal implants and their clinical applications in orthopedic surgery. On this basis, we discuss potential possibilities for further generalization and improvement.

Results

3D printing technology has facilitated the use of metal implants in different orthopedic procedures. By combining medical images from techniques such as CT and MRI, 3D printing technology allows the precise fabrication of complex metal implants based on the anatomy of the injured tissue. Such patient-specific implants not only reduce excessive mechanical strength and eliminate stress-shielding effects, but also improve biocompatibility and functionality, increase cell and nutrient permeability, and promote angiogenesis and bone growth. In addition, 3D printing technology has the advantages of low cost, fast manufacturing cycles, and high reproducibility, which can shorten patients' surgery and hospitalization time. Many clinical trials have been conducted using customized implants. However, the use of modeling software, the operation of printing equipment, the high demand for metal implant materials, and the lack of guidance from relevant laws and regulations have limited its further application.

Conclusions

There are advantages of 3D printing metal implants in orthopedic applications such as personalization, promotion of osseointegration, short production cycle, and high material utilization. With the continuous learning of modeling software by surgeons, the improvement of 3D printing technology, the development of metal materials that better meet clinical needs, and the improvement of laws and regulations, 3D printing metal implants can be applied to more orthopedic surgeries.

The translational potential of this paper

Precision, intelligence, and personalization are the future direction of orthopedics. It is reasonable to believe that 3D printing technology will be more deeply integrated with artificial intelligence, 4D printing, and big data to play a greater role in orthopedic metal implants and eventually become an important part of the digital economy. We aim to summarize the latest developments in 3D printing metal implants for engineers and surgeons to design implants that more closely mimic the morphology and function of native bone.

Finite Element Analysis and Computational Fluid Dynamics Verification of Molten Pool Characteristics During Selective Laser Melting of Ti-6Al-4V Plates

The finite element (FE) method is used to characterize the thermal gradient, solidification rate, and molten pool sizes of Ti-6Al-4V plates in the process of selective laser melting (SLM). The results are verified by using the computational fluid dynamics (CFD) simulation. The proposed FE model contains a series of toolpath information that is directly converted from a G-code file, including hatch spacing, laser power, layer thickness, dwell time, and scanning speed generated by using Slic3r software from a CAD file. A proposed multi-layer, multi-track FE model is used to investigate the influence of the laser power, scanning speed, and scanning path on the microstructure in the Ti-6Al-4V plate built via SLM. The processing window is also determined based on the proposed FE model. The FE results indicate that, with a decrease in the laser power and an increase in the scanning speed, the morphology of the crystal grains, showing fully columnar crystals, gradually deviates from the fully equiaxed region. The formed grains are dependent on the laser power, scanning speed, and deposition position, but they are not sensitive to the scanning path, and with the deposition from the bottom layer to the top layer, the size of the formed grains is gradually increasing, which shows a good agreement with the experimental results.

Experimental, Theoretical and Numerical Studies on Thermal Properties of Lightweight 3D Printed Graphene-Based Discs with Designed Ad Hoc Air Cavities

The current state of the art on material science emphasizes recent research efforts aimed at designing novel materials characterized by low-density and advanced properties. The present article reports the experimental, theoretical and simulation results on the thermal behavior of 3D printed discs. Filaments of pure poly (lactic acid) PLA and filled with 6 wt% of graphene nanoplatelets (GNPs) are used as feedstocks. Experiments indicate that the introduction of graphene enhances the thermal properties of the resulting materials since the conductivity passes from the value of 0.167 [W/mK] for unfilled PLA to 0.335 [W/mK] for reinforced PLA, which corresponds to a significantly improvement of 101%. Exploiting the potential of 3D printing, different air cavities have been intentionally designed to develop new lightweight and more cost-effective materials without compromising their thermal performances. Furthermore, some cavities are equal in volume but different in the geometry; it is necessary to investigate how this last characteristic and its possible orientations affect the overall thermal behavior compared to that of an air-free specimen. The influence of air volume is also investigated. Experimental results are supported by theoretical analysis and simulation studies based on the finite element method. The results aim to be a valuable reference resource in the field of design and optimization of lightweight advanced materials.

Accuracy of five different 3D printing workflows for dental models comparing industrial and dental desktop printers

OBJECTIVES

The aim of this study was to evaluate the accuracy, in terms of trueness and precision, of printed models using five different industrial and dental desktop 3D printers.

MATERIALS AND METHODS

Full-arch digital models with scanbodies of 15 patients were printed with five different 3D printers. The industrial printers were 3D system Project MJP2500 (3DS) and Objet30 OrthoDesk (Obj). The dental desktop printers were NextDent 5100 (ND), Formlabs Form 2 (FL) and Rapidshape D30 (RS). A total of 225 printed models were analysed. The printed models were digitized and compared with the reference cast model using the Control X software (Geomagic). The descriptive statistics and one-way ANOVA with the post hoc Tukey test were performed (α = 0.05).

RESULTS

The one-way ANOVA for the trueness and precision of the printed model presented the best results for the 3DS, followed by ND, Obj, FL and RS (P < 0.01). In the scanbody zone, the best results were for the 3DS group, followed by Obj, ND, FL and RS (P < 0.01). Comparing the technologies, the Multijet technology used in industrial printers presented better results than the DLP and SLA technologies used in dental desktop printers (P > 0.01).

CONCLUSIONS

There were statistically significant differences in terms of the accuracy of the printed models, with better results for the industrial than the dental desktop 3D printers.

CLINICAL RELEVANCE

The industrial 3D printers used in dental laboratories presented better accuracy than the in-office dental desktop 3D printers, and this should be considered when the best accuracy is needed to perform final prosthetic restorations.

Predicting Failure of Additively Manufactured Specimens with Holes

Experimental and computational studies were conducted to predict failure loads of specimens containing different-sized holes made using the additive manufacturing (AM) technique. Two different types of test specimens were prepared. Flat specimens, manufactured from polylactic acid (PLA), were subjected to uniaxial loading. Tubular specimens, made of polycarbonate (PC), were subjected to combined loading that was applied using uniaxial testing equipment. Test specimens were uniquely designed and printed to apply the combined bending and torsional loads to tubular specimens. A newly developed failure theory was applied to predict the loads that would result in the fracture of these test specimens. This theory is composed of two conditions related to stress and the stress gradient to be simultaneously satisfied to predict failure. The failure loads predicted using the new failure criteria were compared closely with the experimental data for all test specimens. In addition, a semi-empirical equation was developed to predict the critical failure surface energy for different printing angles. The critical failure surface energy is a material property and is used for the stress gradient condition. Using the semi-empirically determined values for the failure criterion provided close agreement with experimental results.

A Mechanical Performance Study of Dual Cured Thermoset Resin Systems 3D-Printed with Continuous Carbon Fiber Reinforcement

Additive manufacturing (AM) is one of the fastest-growing manufacturing technologies in modern times. One of the major challenges in the application of 3D-printed polymeric objects is expanding the applications to structural components, as they are often limited by their mechanical and thermal properties. To enhance the mechanical properties of 3D-printed thermoset polymer objects, reinforcing the polymer with continuous carbon fiber (CF) tow is an expanding direction of research and development. A 3D printer was constructed capable of printing with a continuous CF-reinforced dual curable thermoset resin system. Mechanical performance of the 3D-printed composites varied with the utilization of different resin chemistries. Three different commercially available violet light curable resins were mixed with a thermal initiator to improve curing by overcoming the shadowing effect of violet light by the CF. The resulting specimens’ compositions were analyzed, and then the specimens were mechanically characterized for comparison in tensile and flexural performance. The 3D-printed composites’ compositions were correlated to the printing parameters and resin characteristics. Slight enhancements in tensile and flexural properties from some commercially available resins over others appeared to be the result of better wet-out and adhesion.

Three-Dimensional Printing of Cylindrical Nozzle Elements of Bernoulli Gripping Devices for Industrial Robots

The application of additive technologies, namely, fused deposition modeling, is a new reality for prototyping gripping devices of industrial robots. However, during 3D printing of holes and nozzle elements, difficulties arise with reducing their diameter. Therefore, this article conducts a comprehensive study of the Bernoulli gripping device prototype with a cylindrical nozzle, manufactured by fused deposition modeling 3D printing. The three main reasons for reducing the diameter of the gripper nozzle after printing were due to the poor-quality model, excessive extrusion of plastic in the middle of the arc printing path, and linear shrinkage of printing material after cooling. The proposed methodology consisted of determining the three coefficients that allowed the determination of the diameter of the designed nozzle. The use of air pressure distributions on the surface of the manipulation object, and lifting forces of gripping devices with different 3D printing layer heights were found. It was experimentally determined that as the height of the printing layer increased, the lifting force decreased. This was due to the formation of swirls due to the increased roughness of the grip surface. It was proven that as the height between the manipulation object and the grip increased, the effect of surface roughness on the lifting force decreased, resulting in an increase in the lifting force. Determination of the rational operating parameters of gripping devices manufactured by 3D printing from the point of view of maximum lifting force, were determined.

Advanced Formulations Based on Poly(ionic liquid) Materials for Additive Manufacturing

Innovation in materials specially formulated for additive manufacturing is of great interest and can generate new opportunities for designing cost-effective smart materials for next-generation devices and engineering applications. Nevertheless, advanced molecular and nanostructured systems are frequently not possible to integrate into 3D printable materials, thus limiting their technological transferability. In some cases, this challenge can be overcome using polymeric macromolecules of ionic nature, such as polymeric ionic liquids (PILs). Due to their tuneability, wide variety in molecular composition, and macromolecular architecture, they show a remarkable ability to stabilize molecular and nanostructured materials. The technology resulting from 3D-printable PIL-based formulations represents an untapped array of potential applications, including optoelectronic, antimicrobial, catalysis, photoactive, conductive, and redox applications.

Surface roughness and marginal adaptation of stereolithography versus digital light processing three-dimensional printed resins: An in-vitro study

Aim

The aim of this study was to assess surface roughness and marginal adaptation of Stereolithographic versus Digital Light Processed three-dimensional (3D) printed provisional resins.

Materials and Methods

A 3-unit fixed partial denture (FPD) preparation was done on ideal model irrespective to 44-46. The Model was scanned and a 3-unit FPD was designed using 3-shape software. The STL file was transferred to two different 3D printers - Sprintray digital light processing (DLP) and Formlabs stereolithography (SLA). Eight samples were printed per group (total of 16 samples) using C and B temporary tooth-colored resin and cured according to the manufacturer's instructions. Marginal adaptation was checked for six surfaces per tooth for all the samples using a stereomicroscope. Surface roughness was also calculated for four samples from each group before and after polishing (pumice slurry + rouge and cotton buff) using a contact profilometer.

Results

The mean maximum marginal gap overall, was seen for the DLP group on the mesiobuccal surface of the first premolar, i.e., 178.8 ± 8.35 μm, while the minimal marginal gap was seen for the SLA group on the mesiolingual surface of first molar - 32.5 ± 7.07 μm. Furthermore, all the DLP samples showed a statistically significant higher mean marginal gap as compared to SLA samples (P < 0.005). All the samples showed surface roughness within the acceptable range. There was a statistically significant difference noted in Rz (roughness depth) before and after polishing (P < 0.05).

Conclusion

3D printed temporary resin FPD via SLA showed a much better marginal adaptation (49.6 μm mean marginal gap for 46 and 106.8 μm for 44) as compared to those printed via DLP (101.8 μm mean marginal gap for 46 and 157.5 μm for 44). All the samples showed an acceptable surface roughness.

Clinical Relevance

3D printed temporaries have shown good marginal fit and adaptation and are a viable choice in patients where temporaries has to be given for long term before a final prosthesis can be fabricated (especially for full mouth rehabilitations).

Influence of the layer thickness on the flexural strength of aged and non-aged additively manufactured interim dental material

PURPOSE

To measure the flexural strength and Weibull characteristics of aged and non-aged printed interim dental material fabricated with different layer thickness.

MATERIAL AND METHODS

Bars (25×2×2 mm) were additively fabricated by using a polymer printer (Asiga Max) and an interim resin (Nexdent C&B MFH). Specimens were fabricated with the same printing parameters and postprocessing procedures, but with 7 different layer thickness: 50 (control or 50-G group), 10 (10-G group), 25 (25-G group), 75 (75-G group), 100 (100-G group), 125 (125-G group), and 150 μm (150-G group). Two subgroups were created: non-aged and aged subgroups (n = 10). A universal testing machine was selected to measure flexural strength. Two-parameter Weibull distribution values were computed. Two-way ANOVA and Tukey tests were elected to examine the data (α = .05).

RESULTS

Artificial aging methods (P<.001) were a significant predictor of the flexural strength computed. Aged specimens acquired less flexural strength than non-aged specimens. The Weibull distribution obtained the highest shape for non-aged 50-G and 75-G group specimens compared with those of other non-aged groups, while the Weibull distribution showed the highest shape for aged 125-G specimens.

CONCLUSIONS

The flexural strength of the additively fabricated interim material examined was not influenced by the layer thickness at which the specimens were fabricated; however, artificial aging techniques reduced its flexural strength. Aged specimens presented lower Weibull distribution values compared with non-aged specimens, except for the 125-G specimens. This article is protected by copyright. All rights reserved.

Osseointegration of two types of titanium cylinders with geometric or trabecular microarchitecture: A nanotomographic and histomorphometric study

Porous biomaterials promote osseointegration. We have prepared porous titanium cylinders by additive manufacturing from titanium beads. Two types of morphology were tested: cylinders with geometric pores or mimicking trabecular microarchitecture. Cylinders were decontaminated and cleaned by HF/HNO₃ to remove unmelted balls. Surgical implantation in ewes was performed under general anesthesia and the animals were housed for 90 and 270days. The femoral condyles were collected and analyzed by nanoCT, embedded in pMMA and analyzed by histomorphometry. No significant difference was found in terms of bone volume or bone/titanium interface between the two types of cylinders. There was no evolution over time except for the mineralization rates which decreased, reflecting the effect of the aging of the animals. The influence of the pores (geometrical or "natural") did not influence osseointegration. HF/HNO₃ etching treatments are effective on the outermost surfaces but do not seem to reach the central cavities of the samples. Finally, osseointegration seems to occur only in the few millimeters around the periphery of the implants and does not extend in the center. This is explained by the absence of stress transmission within the very rigid metal cylinders, preventing bone modeling and remodeling.

Exploration of the Effects of Metallic Powder Handling and Storage Conditions on Flowability and Moisture Content for Additive Manufacturing Applications

Metal powder-based additive manufacturing (AM) relies on consistently successful processing of feedstock powder, necessitating through-process predictability in powder properties and behavior. However, routine powder handling and storage may degrade powder performance by influencing flowability and moisture content through exposure to ambient conditions. Therefore, this study aimed to evaluate the effects of repeated environmental exposure on the flowability and moisture content of Al 5056 and Ta powders for AM applications. Using Carney Funnel flow tests, thermogravimetric analysis, and particle size/shape analysis, powder characterization helped elucidate powder property and behavioral changes with exposure. Results indicated inconsistent flowability and moisture content changes for both material types when exposure conditions were altered. Correlational statistics highlighted the most influential particle characteristics on powder behavior after exposure; particle morphology was most impactful for the semi-spherical Al 5056, whereas moisture content and particle size were most significant for the angular Ta. While exposure to laboratory conditions minimally changed powder performance in this study, caution is advised when handling and storing powders in more “extreme” environments. Powder users are urged to implement quality controls alongside powder characterization to pinpoint how specific powders should be treated, handled, and stored in a given environment for successful processing in AM.

Additive manufacturing of titanium-based alloys- A review of methods, properties, challenges, and prospects

The development of materials for biomedical, aerospace, and automobile industries has been a significant area of research in recent years. Various metallic materials, including steels, cast iron, nickel-based alloys, and other metals with exceptional mechanical properties, have been reportedly utilized for fabrication in these industries. However, titanium and its alloys have proven to be outstanding due to their enhanced properties. The β-titanium alloys with reduced modulus compared with the human bone have found more usage in the biomedical industry. In contrast, the α and α+β titanium alloys are more utilized to fabricate parts in the automobile and aerospace industries due to their relatively lightweight. Amongst the numerous additive manufacturing (AM) techniques, selective laser and electron beam melting techniques are frequently used for the fabrication of metallic components due to the full densification and high dimensional accuracy they offer. This paper reviews and discusses the different types of AM techniques, attention is also drawn to the properties and challenges associated with additively manufactured titanium -based alloys. The outcome from this study shows that 3D printed titanium and titanium-alloys exhibit huge prospects for various applications in the medical and aerospace industries. Also, laser-assisted 3D technologies were found to be the most effective AM method for achieving enhanced or near-full densification.

Digital technologies, healthcare and Covid-19: insights from developing and emerging nations

COVID-19 pandemic created a global health crisis affecting every nation. The essential smart medical devices/accessories, quarantine facilities, surveillance systems, and related digital technologies are in huge demand. Healthcare, manufacturing industries, and educational institutions need technologies that allow working from a safe location. Digital technologies and Industry 4.0 tools have the potential to fulfil these customized requirements during and post COVID-19 crisis. The purpose of this research is to provide understanding to healthcare professionals, government policymakers, researchers, industry professionals, academics, and students/learners of the paradigm of different Digital technologies, Industry 4.0 tools, and their applications during the COVID-19 pandemic. Digital technologies, Industry 4.0 tools and their current and potential applications have been reviewed. The use of different Digital technologies and Industry 4.0 tools is identified. Digital technologies and Industry 4.0 tools (3D Printing, Artificial Intelligence, Cloud Computing, Autonomous Robot, Biosensor, Telemedicine service, Internet of Things (IoT), Virtual reality, and holography) offer opportunities for effective delivery of healthcare service(s), online education, and Work from Home (WFH) environment. The article emphasises the usefulness, most recent development, and implementation of Digital technologies, Industry 4.0 techniques, and tools in fighting the COVID-19 pandemic worldwide.

Understanding the Role of Surface Modification of Randomized Trabecular Titanium Structures in Bone Tissue Regeneration: An Experimental Study

Background and Objectives: Three-dimensional (3D) metallic trabecular structures made by additive manufacturing (AM) technologies promote new bone formation and osteointegration. Surface modifications by chemical treatments can improve the osteoconductive properties of metallic structures. An in vivo study in sheep was conducted to assess the bone response to randomized trabecular titanium structures that underwent a surface modification by chemical treatment compared to the bone response to the untreated specimens. Material and Methods: Sixteen specimens with a randomized trabecular titanium structure were implanted in the spongious bone of the distal femur and proximal tibia and the cortical bone of the tibial diaphysis of two sheep. Of them, eight implants had undergone a chemical treatment (treated) and were compared to eight implants with the same structure but native surfaces (native). The sheep were sacrificed at 6 weeks. Surface features of the lattice structures (native and treated) were analyzed using a 3D non-contact profilometer. Compression tests of 18 lattice cubes were performed to investigate the mechanical properties of the two structures. Excellent biocompatibility for the trabecular structures was demonstrated in vitro using a cell mouse fibroblast culture. Histomorphometric analysis was performed to evaluate bone implant contact and bone ingrowth. Results: A compression test of lattice cubic specimens revealed a comparable maximum compressive strength value between the two tested groups (5099 N for native surfaces; 5558 N for treated surfaces; p > 0.05). Compared to native surfaces, a homogenous formation of micropores was observed on the surface of most trabeculae that increased the surface roughness of the treated specimens (4.3 versus 3.2 µm). The cellular viability of cells seeded on three-dimensional structure surfaces increased over time compared to that on plastic surfaces. The histomorphometric data revealed a similar behavior and response in spongious and cortical bone formation. The percentage of the implant surface in direct contact with the regenerated bone matrix (BIC) was not significantly different between the two groups either in the spongious bone (BIC: 27% for treated specimens versus 30% for native samples) or in the cortical bone (BIC: 75% for treated specimens versus 77% for native samples). Conclusions: The results of this study reveal rapid osseointegration and excellent biocompatibility for the trabecular structure regardless of surface treatment using AM technologies. The application of implant surfaces can be optimized to achieve a strong press-fit and stability, overcoming the demand for additional chemical surface treatments.

Chondrosarcoma of the proximal radius treated by wide resection and reconstructed by 3D printed implant: A case report and description of surgical technique

Introduction

Chondrosarcoma is the second most common primary malignancy of bone that can occur in multiple locations in the skeleton. It has been rarely reported in the proximal radius. While surgical resection is the primary treatment modality for individuals with localized disease, reconstruction can be challenging in the elbow joint due to its complex anatomy. 3D printing technology can be used in such complex cases to restore the normal anatomy after resection.

Case presentation

We present a case of mesenchymal chondrosarcoma in a 33-year-old male occurring in the proximal radius, restricting his elbow motion. That was resected and reconstructed using 3D modeling. Restoring a functional range of motion without instability.

Discussion

Many surgical options for chondrosarcoma presented over the years including en bloc resection, resection with or without reconstruction, or amputation. Usage of 3D modeling in the orthopedic surgery field is relatively new and it can be used in pre-operative planning and shortens surgical time. 3D printing in our case helped in obtaining a full range of motion (flexion, extension, pronation, and supination) for the patient.

Conclusion

It's important to reconstruct elbow joint support structure and function after resection of such a large malignant tumor in young patients. We used 3D printed implant to maintain a functional limb and it was an excellent alternative treatment.

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Chondrosarcoma occurring in the proximal radius is very rare. Up to our knowledge, this is the second case report.

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We report a case of proximal radius chondrosarcoma managed by reconstruction with Three-Dimension printed implant.

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3D printing in the field of orthopedic surgery is relatively new and has upscaled medical management.

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A description of a surgical technique to reconstruct proximal radius and maintaining full range of motion of the elbow.

Innovative Design Methodology for Patient-Specific Short Femoral Stems

The biomechanical performance of hip prostheses is often suboptimal, which leads to problems such as strain shielding, bone resorption and implant loosening, affecting the long-term viability of these implants for articular repair. Different studies have highlighted the interest of short stems for preserving bone stock and minimizing shielding, hence providing an alternative to conventional hip prostheses with long stems. Such short stems are especially valuable for younger patients, as they may require additional surgical interventions and replacements in the future, for which the preservation of bone stock is fundamental. Arguably, enhanced results may be achieved by combining the benefits of short stems with the possibilities of personalization, which are now empowered by a wise combination of medical images, computer-aided design and engineering resources and automated manufacturing tools. In this study, an innovative design methodology for custom-made short femoral stems is presented. The design process is enhanced through a novel app employing elliptical adjustment for the quasi-automated CAD modeling of personalized short femoral stems. The proposed methodology is validated by completely developing two personalized short femoral stems, which are evaluated by combining in silico studies (finite element method (FEM) simulations), for quantifying their biomechanical performance, and rapid prototyping, for evaluating implantability.

Carbon fibre-graphene composite polylactic acid (PLA) material for COVID shield frame

Challenges in the development of carbon fibre and graphene reinforced composite polylactic acid material is reserved in this research. A screw extrusion process is used to blend the carbon fibre particle (1 wt.%) and graphene (1 wt.%) with poly lactic acid pellets (98 wt.%) to extrude and draw a continuous composite poly lactic acid wire. The size of the wire drawn is 1.75 mm and it is found uniform in shape. Through electron microscope, the dispersion of carbon fibre and graphene in the polylactic acid material is confirmed with good bonding. Subsequently, the presence of carbon fibre and graphene reinforcement in polylactic acid material is confirmed through the x-ray diffraction peaks. The composite polylactic acid material developed through screw extrusion is to build a mechanical test sample. The strength of composite polylactic acid material is 31 MPa and 3D printed composite polylactic acid material is 63 MPa. The density of the composite material is found increased in 3D printed material than the raw polylactic acid material. With valid mechanical and thermal properties of composite polylactic acid material, a commercial product is developed. An autoclavable COVID -19 face shield is designed and developed through Fused filament fabrication 3D printer and the same was implemented.

Bending properties of additively manufactured commercially pure titanium (CPTi) limited contact dynamic compression plate (LC-DCP) constructs: Effect of surface treatment

Additive manufacturing of metallic materials, a layer-wise manufacturing method, is currently gaining attention in the biomedical industry because of its capability to fabricate complex geometries including customized parts fitting to patient requirements. However, one of the major challenges hindering the full implementation of additively manufactured parts in safety-critical applications is their poor mechanical performance under cyclic loading. This study investigated both quasi-static bending properties (bending stiffness, bending structural stiffness, and bending strength) and bending fatigue properties of additively manufactured (AM) commercially pure titanium (CPTi) limited contact dynamic compression plate (LC-DCP) constructs based on ASTM International standard for metallic bone plates (ASTM F382). In addition, the effect of post surface treatment methods including single shot-peened (SP), dual shot-peened (DP), and chemically assisted surface enhancement (CASE) on bending fatigue performance was also evaluated. Results indicated that bending stiffness and bending structural stiffness of AM CPTi LC-DCPs are comparable to conventionally manufactured (CM) counterparts; however, the bending strength of AM CPTi LC-DCPs is lower than CM counterparts. While the fatigue strength of as-built AM CPTi LC-DCPs is lower compared to the CM counterparts, AM CPTi LC-DCPs after post surface treatments (SP, DP, and CASE) exhibit statistically comparable fatigue strength to the CM CPTi LC-DCPs.

Localized Corrosion Resistance on Additively Manufactured Ti Alloys by Means of Electrochemical Critical Localized Corrosion Potential in Biomedical Solution Environments

This study proposes a new method, electrochemical critical localized corrosion potential (E-CLCP), in order to evaluate localized corrosion resistance of biomedical additive manufacturing (AM) titanium (Ti) alloys. The procedures for determining E-CLCP are completely different from that of the electrochemical critically localized corrosion temperature (E-CLCT) method (ISO 22910:2020). However, its application should be limited to pH and temperature of the human body because of the temperature scan. E-CLCP displays the localized corrosion resistance of AM Ti alloys based on the human body's repassivation kinetics, whereas E-CLCT displays the localized corrosion resistance of the alloys based on passive film breakdown in much harsher corrosive environments.

3D Printing Polymeric Materials for Robots with Embedded Systems

The fabrication of robots and their embedded systems is challenging due to the complexity of the interacting components. The integration of additive manufacturing (AM) to robotics has made advancements in robotics manufacturing through sophisticated and state-of-the-art AM technologies and materials. With the emergence of 3D printing, 3D printing materials are also being considered and engineered for specific applications. This study reviews different 3D printing materials for 3D printing embedded robotics. Materials such as polyethylene glycol diacrylate (PEGDA), acrylonitrile butadiene styrene (ABS), flexible photopolymers, silicone, and elastomer-based materials were found to be the most used 3D printing materials due to their suitability for robotic applications. This review paper revealed that the key areas requiring more research are material formulations for improved mechanical properties, cost, and the inclusion of materials for specific applications. Future perspectives are also provided.

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.

3D Printing of Fiber-Reinforced Plastic Composites Using Fused Deposition Modeling: A Status Review

Composite materials are a combination of two or more types of materials used to enhance the mechanical and structural properties of engineering products. When fibers are mixed in the polymeric matrix, the composite material is known as fiber-reinforced polymer (FRP). FRP materials are widely used in structural applications related to defense, automotive, aerospace, and sports-based industries. These materials are used in producing lightweight components with high tensile strength and rigidity. The fiber component in fiber-reinforced polymers provides the desired strength-to-weight ratio; however, the polymer portion costs less, and the process of making the matrix is quite straightforward. There is a high demand in industrial sectors, such as defense and military, aerospace, automotive, biomedical and sports, to manufacture these fiber-reinforced polymers using 3D printing and additive manufacturing technologies. FRP composites are used in diversified applications such as military vehicles, shelters, war fighting safety equipment, fighter aircrafts, naval ships, and submarine structures. Techniques to fabricate composite materials, degrade the weight-to-strength ratio and the tensile strength of the components, and they can play a critical role towards the service life of the components. Fused deposition modeling (FDM) is a technique for 3D printing that allows layered fabrication of parts using thermoplastic composites. Complex shape and geometry with enhanced mechanical properties can be obtained using this technique. This paper highlights the limitations in the development of FRPs and challenges associated with their mechanical properties. The future prospects of carbon fiber (CF) and polymeric matrixes are also mentioned in this study. The study also highlights different areas requiring further investigation in FDM-assisted 3D printing. The available literature on FRP composites is focused only on describing the properties of the product and the potential applications for it. It has been observed that scientific knowledge has gaps when it comes to predicting the performance of FRP composite parts fabricated under 3D printing (FDM) techniques. The mechanical properties of 3D-printed FRPs were studied so that a correlation between the 3D printing method could be established. This review paper will be helpful for researchers, scientists, manufacturers, etc., working in the area of FDM-assisted 3D printing of FRPs.

Laser-based bioprinting for multilayer cell patterning in tissue engineering and cancer research

3D printing, or additive manufacturing, is a process for patterning functional materials based on the digital 3D model. A bioink that contains cells, growth factors, and biomaterials are utilized for assisting cells to develop into tissues and organs. As a promising technique in regenerative medicine, many kinds of bioprinting platforms have been utilized, including extrusion-based bioprinting, inkjet bioprinting, and laser-based bioprinting. Laser-based bioprinting, a kind of bioprinting technology using the laser as the energy source, has advantages over other methods. Compared with inkjet bioprinting and extrusion-based bioprinting, laser-based bioprinting is nozzle-free, which makes it a valid tool that can adapt to the viscosity of the bioink; the cell viability is also improved because of elimination of nozzle, which could cause cell damage when the bioinks flow through a nozzle. Accurate tuning of the laser source and bioink may provide a higher resolution for reconstruction of tissue that may be transplanted used as an in vitro disease model. Here, we introduce the mechanism of this technology and the essential factors in the process of laser-based bioprinting. Then, the most potential applications are listed, including tissue engineering and cancer models. Finally, we present the challenges and opportunities faced by laser-based bioprinting.

The Effects on Thermal Efficiency of Yttria-Stabilized Zirconia and Lanthanum Zirconate-Based Thermal Barrier Coatings on Aluminum Heating Block for 3D Printer

Fused filament fabrication is an important additive manufacturing method, for which 3D printers are the most commonly used printing tools. In this method, there are many factors that affect the printing quality, chief among which is temperature. The fusion temperature of the material is created by an aluminum heating block in the extruder. Stability and a constant temperature for the aluminum heating block are inevitable requirements for print quality. This study aims to use the thermal barrier coating method to increase the thermal efficiency and stability of the aluminum heating block by reducing heat loss. Furthermore, it aims to perform steady-state thermal analysis using finite element analysis software. The analyses are carried out in stagnant air environment and at the printing temperature of acrylonitrile butadiene styrene material. In order to examine the effects of different coating materials, blocks coated with two different coating materials, as well as uncoated blocks, were used in the analyses. The coating made with yttria-stabilized zirconia and pyrochlore-type lanthanum zirconate materials, together with the NiCRAl bond layer, prevent temperature fluctuation by preventing heat loss. The effects of the coating method on average heat flux density, temperature distribution of blocks, and temperature distribution of the filament tube hole were investigated. Additionally, changes in flow velocity were determined by examining the effects of the thermal barrier coating method on temperature distribution. The average heat flux density in the coated blocks decreased by 10.258%. Throughout the investigation, the temperature distributions in the coated blocks became homogeneous. It was also observed that both coating materials produce the same effect. This article performs a steady-state thermal analysis of a conventional model and thermal-barrier-coated models to increase print quality by reducing heat loss from the aluminum heating block.

A Review on Additive Manufacturing of Pure Copper

With the development of the aerospace and automotive industries, high heat exchange efficiency is a challenge facing the development of various industries. Pure copper has excellent mechanical and physical properties, especially high thermal conductivity and electrical conductivity. These excellent properties make pure copper the material of choice for the manufacture of heat exchangers and other electrical components. However, the traditional processing method is difficult to achieve the production of pure copper complex parts, so the production of pure copper parts through additive manufacturing has become a problem that must be overcome in industrial development. In this article, we not only reviewed the current status of research on the structural design and preparation of complex pure copper parts by researchers using selective laser melting (SLM), selective electron beam melting (SEBM) and binder jetting (BJ) in recent years, but also reviewed the forming, physical properties and mechanical aspects of pure copper parts prepared by different additive manufacturing methods. Finally, the development trend of additive manufacturing of pure copper parts is also prospected.

A New Approach to Optimize the Relative Clearance for Cylindrical Joints Manufactured by FDM 3D Printing Using a Hybrid Genetic Algorithm Artificial Neural Network and Rational Function

Nowadays, FDM technology permits obtaining functional prototypes or even end parts. The process parameters, such as layer thickness, building orientation, fill density, type of support, etc., have great influence on the quality, functionality and behavior of the obtained parts during their lifetime. In this paper, we present a study concerning the possibilities of obtaining certain values for clearance in revolute joints of non-assembly mechanisms manufactured by FDM 3D Printing. To ensure the functioning of the assembly, one must know the relationship between the imposed and measured clearances by taking into account the significant input data. One way is to use the automat learning method with an artificial neuronal network (ANN). The data necessary for the training, testing, and validation of ANN were experimentally obtained, using a complete L 27 Taguchi experimental plan. A total of 27 samples were printed with different values of the following parameters: the infill density, the imposed clearance between the shaft and the hole, and the layer thickness. ANN architecture corresponds to the Hecht–Kolmogorov theorem. Genetic algorithms (GA) were used for the optimization of the output. The Neural Network Toolbox from MATLAB was used for training the network and a hybrid tool genetic algorithm artificial neural network (GA-ANN) was used to minimize the value of the absolute relative clearance (arc). The minimum value of the absolute relative clearance established by GA-ANN was 0.0385788. This value was validated experimentally, with a relative difference of 4%. We also introduced a rational function to approximate the correlation between the input and output parameters. This function fulfills some frontier conditions resulted from practice. In addition, the function may be used to establish the designed clearance in order to obtain an imposed one.

3D Printing in Digital Prosthetic Dentistry: An Overview of Recent Developments in Additive Manufacturing

Popular media now often present 3D printing as a widely employed technology for the production of dental prostheses. This article aims to show, based on factual information, to what extent 3D printing can be used in dental laboratories and dental practices at present. It attempts to present a rational evaluation of todays´ applications of 3D printing technology in the context of dental restorations. In addition, the article discusses future perspectives and examines the ongoing viability of traditional dental laboratory services and manufacturing processes. It also shows which expertise is needed for the digital additive manufacturing of dental restorations.

Novel Shape-Stabilized Phase Change Material with Cascade Character: Synthesis, Performance and Shaping Evaluation

Thermal Energy Storage (TES) materials, such as Phase Change Materials (PCMs) are proven to enhance the energy efficiency in many fields, such as automotive and building sectors, which correspond to the most energy intensive ones. Shape-stabilized PCM and cascade PCM are procedures to overcome the most important barriers when PCMs are applied since PCMs need to be encapsulated for their technical use: the leakage of the liquid phase, corrosion, low heat transfer and narrow temperature of application. In the present study, a novel shape stabilized PCM with cascade performance (cascade shape stabilized phase change material, CSS-PCM) is synthesized via dissolution, which allows up to 60 wt.% of a paraffin-PCM in the final composition. The novel CSS-PCM is based on a biopolymer, the polycaprolactone (PCL), a low melting temperature polyester as polymeric matrix and RT27 and Micronal DS 5040 acting as PCM. To evaluate the performance of the new TES materials developed, several techniques have been used: Differential Scanning Calorimetry (DSC), and Fourier-Transformed Infrared (FT-IR) spectroscopy were used to evaluate the thermophysical properties and the chemical properties of the different formulations. The CSS-PCM show an increment of storage capacity by increasing the PCM content, and the thermal reliability was also tested: some of the CSS-PCM formulations were stable for up to 500 thermal cycles. Finally, as a potential application of the new polymeric-based PCM 3D, a printing attempt was performed in order to analyze the viability of the formulations to be used as 3D printing material as a first proof of concept.

3D porous Ti6Al4V-beta-tricalcium phosphate scaffolds directly fabricated by additive manufacturing

3D Ti6Al4V-beta-tricalcium phosphate (TCP) hybrid scaffolds with interconnected porous network and controllable porosity and pore size were successfully produced by three-dimensional fiber deposition (3DF). The macrostructure of scaffolds was determined by the 3D design, whereas the micro- and submicron structure were derived from the Ti6Al4V powder sintering and the crystalline TCP powder, respectively. Ti6Al4V-TCP slurry was developed for 3DF by optimizing the TCP powder size, Ti6Al4V-to-TCP powder ratio and Ti6Al4V-TCP powder content. Moreover, the air pressure and fiber deposition rate were optimized. A maximum achievable ceramic content in the Ti6Al4V-TCP slurry that enables 3DF manufacturing was 10 wt%. The chemical analysis showed that limited contamination occurred during sintering. The compressive strength and Young's modulus of the scaffolds exhibited values between those of cancellous and cortical bone. The 3D Ti6Al4V-TCP scaffolds with 10 wt% TCP allowed deposition of a calcium phosphate layer on the surface in a simulated body fluid. Cumulative release of calcium and phosphate ions from the scaffolds was observed in a simulated physiological solution, in contrast to a cell culture medium. A pilot in vivo study, in which the scaffolds were implanted intramuscularly in dogs showed ectopic bone formation in the Ti6Al4V-TCP scaffolds with 10 wt% TCP, showing their osteoinductive potential. The porous 3D Ti6Al4V-TCP scaffolds developed here combine the mechanical properties of the metal with the bioactivity of the ceramic and are therefore likely to yield more effective strategies to control the implant-bone interface and thereby improve long-term clinical results in orthopaedics and craniomaxillofacial surgery. STATEMENT OF SIGNIFICANCE: In this work, 3D porous hybrid scaffolds made of a titanium alloy and a beta-tricalcium phosphate ceramic (Ti6Al4V-TCP) were developed using the direct additive manufacturing technique 3D fiber deposition. Upon optimization of the powders and slurry, scaffolds with up to 10 wt.% TCP with good mechanical properties and controllable porous structure at different length scales were successfully manufactured. A preliminary in vivo study in an intramuscular model demonstrated that the addition of TCP to the metal alloy improved its bioactivity. The combination of the two materials and the use of a direct additive manufacturing technique resulted in scaffolds that may lead to more effective strategies to control the implant-bone interface and thereby improve long-term clinical results in orthopaedics and craniomaxillofacial surgery.