Effect of Autoclave Pressure and Temperature on Consolidation of Layers and Mechanical Properties of Additively Manufactured (FDM) Products with PLA

Effect of Sterilization on the Dimensional and Mechanical Behavior of Polylactic Acid Pieces Produced by Fused Deposition Modeling

To successfully implement additive manufacturing (AM) techniques for custom medical device (MD) production with low-cost resources, it is imperative to understand the effect of common and affordable sterilization processes, such as formaldehyde or steam sterilization, on pieces manufactured by AM. In this way, the performance of low-risk MDs, such as biomodels and surgical guides, could be assessed for complying with safety, precision, and MD delivery requirements. In this context, the aim of the present work was to evaluate the effect of formaldehyde and steam sterilization on the dimensional and mechanical stability of standard polylactic acid (PLA) test pieces produced by fused deposition modeling (FDM). To achieve this, PLA samples were sterilized according to the sterilization protocol of a public hospital in the city of Bucaramanga, Colombia. Significant changes regarding mechanical and dimensional properties were found as a function of manufacturing parameters. This research attempts to contribute to the development of affordable approaches for the fabrication of functional and customized medical devices through AM technologies, an issue of particular interest for low- and middle-income countries.

Additive Manufacturing: An Opportunity for the Fabrication of Near-Net-Shape NiTi Implants

Nickel–titanium (NiTi) is a shape-memory alloy, a type of material whose name is derived from its ability to recover its original shape upon heating to a certain temperature. NiTi falls under the umbrella of metallic materials, offering high superelasticity, acceptable corrosion resistance, a relatively low elastic modulus, and desirable biocompatibility. There are several challenges regarding the processing and machinability of NiTi, originating from its high ductility and reactivity. Additive manufacturing (AM), commonly known as 3D printing, is a promising candidate for solving problems in the fabrication of near-net-shape NiTi biomaterials with controlled porosity. Powder-bed fusion and directed energy deposition are AM approaches employed to produce synthetic NiTi implants. A short summary of the principles and the pros and cons of these approaches is provided. The influence of the operating parameters, which can change the microstructural features, including the porosity content and orientation of the crystals, on the mechanical properties is addressed. Surface-modification techniques are recommended for suppressing the Ni ion leaching from the surface of AM-fabricated NiTi, which is a technical challenge faced by the long-term in vivo application of NiTi.

Manufacturing of Biocomposites for Domestic Applications Using Bio-Based Filler Materials

Filler materials are considered added value (volume) to composite materials. The addition of filler materials leads to altering the material characteristics. Nowadays, there has been a notable increase in bio-based materials in polymers and polymer composites. In this regard, agricultural wastes (low-cost renewable substrates) are used as filler content to prepare bioplastic composites, as they are available plenty in quantity and economical in price. Bioplastics composite samples are compounded by adding different amounts of eggshell powder and walnut shell powder in weight proportion to the plasticized PLA. The plasticization is realized with 5 wt.% of Epoxidized Soybean Oil. The prepared bioplastic granules are further processed by injection molding to dog bone-shaped samples subjected to different mechanical, thermal, and optical microscopy tests. Mechanical tests such as Tensile, Charpy Impact, and Flexural tests yielded decreased properties compared to virgin PLA. However, the properties of plasticized PLA–ES composite showed better results than plasticized PLA–WS composite.

3D Printing under High Ambient Pressures and Improvement of Mechanical Properties of Printed Parts

Contrary to other polymer processing methods, additive manufacturing processes do not require any pressure during the consolidation of layers. This study investigates the effect of high ambient pressure on the consolidation of layers during the FDM process and their analysis of mechanical properties. An experimental setup was arranged, consisting of a 3D printer integrated into a customized Autoclave, to achieve high strength properties for 3D printed parts as like injection-molded specimens. The autoclave can maintain 135 bar of pressure and a maximum temperature of 185 °C. 3D printing with PLA was carried out at 0 bar, 5 bar, and 10 bar. Tensile, flexural, and Charpy tests were conducted on printed specimens, and the effect of pressure and temperature on 3D-printed samples were analyzed. It could be shown that autoclave preheating before printing and autoclave pressure during printing improves the consolidation of layers immensely. The pressure inside the autoclave provokes a more intimate contact between the layer surfaces and results in higher mechanical properties such as yield strength, Young’s modulus, and impact strength. The properties could be raised 100%.