Functionally Graded Scaffolds with Programmable Pore Size Distribution Based on Triply Periodic Minimal Surface Fabricated by Selective Laser Melting

Optimization of functionally graded solid-network TPMS meta-biomaterials

The current study enhances the performance of solid-network triply periodic minimal surface (TPMS) cellular materials through using cell size grading along with the Taguchi method. Cell size grading is a novel technique used to control the size of pores and the surface area without changing the relative density. In this context, experimental compression testing was conducted on six distinct geometries of cell size graded TPMS structures (Diamond, Fischer-Koch S, Gyroid, IWP, Primitive, and Schoen-F-RD) manufactured with dental resin using a masked stereolithography (MSLA) printer. The findings indicated that mean total energy absorption was greater for smaller initial cell sizes (4 and 6 mm) compared to larger sizes (12 mm). Consistent patterns were also observed with respect to final cell sizes. Upon examination of the stress-strain relationships between D and I-WP, it is evident that D exhibits a higher initial peak stress point. However, subsequent to a significant decline, it exhibits a tremendous degree of volatility before recovering. Conversely, I-WP demonstrated greater stability throughout the experiments, with a notably greater maximum stress effect. A significant influence was observed from the initial cell size on stress, with larger sizes leading to a reduction in absorbed energy. The acquired results serve as an essential basis for the identification of optimized designs that may be implemented to enhance the structures' durability.

Design of 3D printing osteotomy block for foot based on triply periodic minimal surface

The ankle joint, which connects the lower limbs and the sole of the foot, is prone to sprain during walking and sports, which leads to ankle arthritis. Supratroleolar osteotomy is an ankle preserving operation for the treatment of ankle arthritis, in which the osteotomy is an important fixing and supporting part. In order to avoid stress shielding effect as much as possible, the osteotomy block is designed as a porous structure. In this study, the osteotomy block was designed based on three-period minimal surface, and the designed structure was manufactured by 3D printing. The mechanical properties of different structures were studied by mechanical test and finite element simulation. In mechanical tests, the Gyroid structure showed a progressive failure mechanism from bottom to bottom, while the Diamond structure showed a shear failure zone at 45° Angle, which was not conducive to energy absorption and was more prone to brittle fracture than the Gyroid structure. Therefore, the Gyroid structure is valuable for further research in the development of porous osteotomy.

Experimental and Numerical Investigation of Polymer-Based 3D-Printed Lattice Structures with Largely Tunable Mechanical Properties Based on Triply Periodic Minimal Surface

Triply periodic minimal surfaces (TPMSs) have demonstrated significant potential in lattice structure design and have been successfully applied across multiple industrial fields. In this work, a novel lattice structure with tunable anisotropic properties is proposed based on two typical TPMS types, and their mechanical performances are studied both experimentally and numerically after being fabricated using a polymer 3D printing process. Initially, adjustments are made to the original TPMS lattice structures to obtain honeycomb lattice structures, which are found to possess significant anisotropy, by utilizing numerical homogenization methods. Based on this, a continuous self-twisting deformation is proposed to change the topology of the honeycomb lattice structures to largely tune the mechanical properties. Quasi-static compression experiments are conducted with different twisting angles, and the results indicate that self-twisting can affect the mechanical properties in specific directions of the structure, and also enhance the energy absorption capacity. Additionally, it mitigates the risk of structural collapse and failure during compression while diminishing structural anisotropy. The proposed self-twisting strategy, based on honeycomb lattice structures, has been proven valuable in advancing the investigation of lattice structures with largely tunable mechanical properties.

The Potential of 3D Printing in Thermal Insulating Composite Materials-Experimental Determination of the Impact of the Geometry on Thermal Resistance

This paper focuses on the analysis of the thermal properties of prototype insulation structures produced using SLS and SLA additive technologies. There is a noticeable lack of analysis in the scientific literature regarding the geometry of 3D-printed structures in terms of their thermal properties. The aim of this paper was to analyze printed samples of prototype thermal insulation composite structures and their potential for use in building applications. The research material consisted of closed and open cell foams of varying structural complexity. Increasing the complexity of the composite core structure resulted in a statistically significant decrease in the value of the thermal conductivity coefficient λ and the heat transfer coefficient U, and an increase in the thermal resistance Rc. The experimental results showed that the geometric structure of the air voids in the material is a key factor in regulating heat transfer. The control of porosity in materials produced by additive technology can be an effective tool for designing structures with high insulation efficiency. The best performance of the prototype materials produced by the SLS method was a three-layer cellular composite with a gyroid core structure. It was also shown that the four-layer gyroid structure panels with an outer layer of metallized polyethylene film produced using 3D SLA printing had the best thermal insulation. As a result, the analysis confirmed the possibility of producing energy-efficient insulation materials using 3D printing. These materials can be used successfully in construction and other industries. Further research will significantly improve the quality, accuracy, and speed of printing insulation materials, reduce the negative impact on the natural environment, and develop intelligent adaptive solutions.

Design, Stereolithographic 3D Printing, and Characterization of TPMS Scaffolds

Anatomical and functional tissue loss is one of the most debilitating problems and involves a great cost to the international health-care sector. In the field of bone tissue, the use of scaffolds to promote tissue regeneration is a topic of great interest. In this study, a combination of additive manufacturing and computational methods led to creating porous scaffolds with complex microstructure and mechanical behavior comparable to those of cancellous bone. Specifically, some representative models of triply periodic minimal surfaces (TPMSs) were 3D-printed through a stereolithographic technique using a dental resin. Schwarz primitive and gyroid surfaces were created computationally: they are characterized by a complex geometry and a high pore interconnectivity, which play a key role in the mechanism of cell proliferation. Several design parameters can be varied in these structures that can affect the performance of the scaffold: for example, the larger the wall thickness, the lower the elastic modulus and compressive strength. Morphological and mechanical analyses were performed to experimentally assess the properties of the scaffolds. The relationship between relative density and elastic modulus has been analyzed by applying different models, and a power-law equation was found suitable to describe the trend in both structures.

Novel 3D printed TPMS scaffolds: microstructure, characteristics and applications in bone regeneration

Bone defect disease seriously endangers human health and affects beauty and function. In the past five years, the three dimension (3D) printed radially graded triply periodic minimal surface (TPMS) porous scaffold has become a new solution for repairing bone defects. This review discusses 3D printing technologies and applications for TPMS scaffolds. To this end, the microstructural effects of 3D printed TPMS scaffolds on bone regeneration were reviewed and the structural characteristics of TPMS, which can promote bone regeneration, were introduced. Finally, the challenges and prospects of using TPMS scaffolds to treat bone defects were presented. This review is expected to stimulate the interest of bone tissue engineers in radially graded TPMS scaffolds and provide a reliable solution for the clinical treatment of personalised bone defects.

Functionally graded stem optimizes the fixed and sliding surface coupling mechanism

Whether the optimization of fixed surface and sliding surface coupling mechanism is related to the hierarchical level of functionally graded porous stem is unknown. The functionally graded porous finite element stem models were constructed using tetrahedral microstructure with the porosities of 47-95%. The stress distribution for femoral bone gradually strengthened, the stress shielding was decreased along the increase of hierarchical levels of the stem after implantation. The coupling mechanism of fixed and sliding surfaces can be optimized by the functional gradient porous stem, the performance advantages become more prominent with the increase of hierarchical levels of the structure.

A flexible design framework to design graded porous bone scaffolds with adjustable anisotropic properties

Since the success of bone regenerative medicine depends on scaffold morphological and mechanical properties, numerous scaffolds designs have been proposed in the last decade, including graded structures that are suited to enhance tissue ingrowth. Most of these structures are based either on foams with a random pore definition, or on the periodic repetition of a unit cell (UC). These approaches are limited by the range of target porosities and obtained effective mechanical properties, and do not permit to easily generate a pore size gradient from the core to the periphery of the scaffold. In opposition, the objective of the present contribution is to propose a flexible design framework to generate various three-dimensional (3D) scaffolds structures including cylindrical graded scaffolds from the definition of a UC by making use of a non-periodic mapping. Conformal mappings are firstly used to generate graded circular cross-sections, while 3D structures are then obtained by stacking the cross-sections with or without a twist between different scaffold layers. The effective mechanical properties of different scaffold configurations are presented and compared using an energy-based efficient numerical method, pointing out the versatility of the design procedure to separately govern longitudinal and transverse anisotropic scaffold properties. Among these configurations, a helical structure exhibiting couplings between transverse and longitudinal properties is proposed and permits to extend the adaptability of the proposed framework. In order to investigate the capacity of common additive manufacturing techniques to fabricate the proposed structures, a subset of these configurations is elaborated using a standard SLA setup, and subjected to experimental mechanical testing. Despite observed geometric differences between the initial design and the actual obtained structures, the effective properties are satisfyingly predicted by the proposed computational method. Promising perspectives are offered concerning the design of self-fitting scaffolds with on-demand properties depending on the clinical application.

Mathematical surface function-based design and 3D printing of airway stents

BACKGROUND

Three-dimensional (3D) printing is a method applied to build a 3D object of any shape from a digital model, and it provides crucial advantages especially for transferring patient-specific designs to clinical settings. The main purpose of this study is to introduce the newly designed complex airway stent models that are created through mathematical functions and manufactured with 3D printing for implementation in real life.

METHODS

A mathematical modeling software (MathMod) was used to design five different airway stents. The highly porous structures with designated scales were fabricated by utilizing a stereolithography-based 3D printing technology. The fine details in the microstructure of 3D printed parts were observed by a scanning electron microscope (SEM). The mechanical properties of airway stents with various designs and porosity were compared by compression test.

RESULTS

The outputs of the mathematical modeling software were successfully converted into 3D printable files and airway stents with a porosity of more than 85% were 3D printed. SEM images revealed the layered topography of high-resolution 3D printed parts. Compression tests have shown that the mathematical function-based design offers the opportunity to adjust the mechanical strength of airway stents without changing the material or manufacturing method.

CONCLUSIONS

A novel approach, which includes mathematical function-based design and 3D printing technology, is proposed in this study for the fabrication of airway stents as a promising tool for future treatments of central airway pathologies.

The Thermal Properties of a Prototype Insulation with a Gyroid Structure—Optimization of the Structure of a Cellular Composite Made Using SLS Printing Technology

This paper focuses on the search for novel insulating structures, and the generation of them by means of a state-of-the-art manufacturing method—3D printing. Bionic structures, which are successfully used in many branches of technology, were chosen as the source of inspiration for the research. The paper presents a design of spatial structures with a gyroid infill (e.g., TPMS), the shape of which reflects the bionic structure of the inside of a bone. For SLS printed single- and multi-layered structures, the design value of the thermal conductivity coefficient was determined through measurements and calculations. A statistical analysis was carried out to determine the effect of the direction of heat flow, as well as the internal structure and layering of the prototype materials, on the values of the thermal conductivity coefficient and the thermal resistance coefficient. On the basis of the multicriteria analysis, the composite’s optimal composition according to the adopted optimization criteria was determined. The lowest possible thermal conductivity of the insulation was equal to 0.033 W/(m × K). The highest possible thermal resistance was equal to 0.606 m2K/W. Thermal insulation made of the prototype insulating partitions with a gyroidal structure is characterized by good insulating parameters.

Recent Advances in the Development of Highly Conductive Structured Supports for the Intensification of Non-adiabatic Gas-Solid Catalytic Processes: The Methane Steam Reforming Case Study

Structured catalysts are strong candidates for the intensification of non-adiabatic gas-solid catalytic processes thanks to their superior heat and mass transfer properties combined with low pressure drops. In the past two decades, different types of substrates have been proposed, including honeycomb monoliths, open-cell foams and, more recently, periodic open cellular structures produced by additive manufacturing methods. Among others, thermally conductive metallic cellular substrates have been extensively tested in heat-transfer limited exo- or endo-thermic processes in tubular reactors, demonstrating significant potential for process intensification. The catalytic activation of these geometries is critical: on one hand, these structures can be washcoated with a thin layer of catalytic active phase, but the resulting catalyst inventory is limited. More recently, an alternative approach has been proposed, which relies on packing the cavities of the metallic matrix with catalyst pellets. In this paper, an up-to-date overview of the aforementioned topics will be provided. After a brief introduction concerning the concept of structured catalysts based on highly conductive supports, specific attention will be devoted to the most recent advances in their manufacturing and in their catalytic activation. Finally, the application to the methane steam reforming process will be presented as a relevant case study of process intensification. The results from a comparison of three different reactor layouts (i.e. conventional packed bed, washcoated copper foams and packed copper foams) will highlight the benefits for the overall reformer performance resulting from the adoption of highly conductive structured internals.

An advanced method to design graded cylindrical scaffolds with versatile effective cross-sectional mechanical properties

The selection of the most-suited bone scaffold for a given clinical application is challenging, and has motivated numerous studies. They are mostly based on the characterization of cellular structures, generated from the three-dimensional repetition of a unit cell. However, the interest of circular graded bone scaffolds has been emphasized since they facilitate nutrient transport from the periphery to the core of the scaffold. In the present contribution, we present an advanced and versatile method to design graded circular porous 2D structures based on the conformal mapping of unit cells. We propose a method to generate 3D porous scaffolds by a multilayer repetition of the circular cross-section, resulting in tunable anisotropy depending on the clinical application. We then analyze the link between the porosities of the obtained structures and their effective elastic mechanical cross-sectional properties, making use of a novel and computationally efficient method allowing exhaustive parametric studies. The comparison of various conformal transformations and unit cell designs emphasizes the extent of mechanical properties and porosities that may be reached for a given constitutive material, including non-standard mechanical properties that open large perspectives towards the development of self-fitting scaffolds.

Regenerative Medicine Technologies to Treat Dental, Oral, and Craniofacial Defects

Additive manufacturing (AM) is the automated production of three-dimensional (3D) structures through successive layer-by-layer deposition of materials directed by computer-aided-design (CAD) software. While current clinical procedures that aim to reconstruct hard and soft tissue defects resulting from periodontal disease, congenital or acquired pathology, and maxillofacial trauma often utilize mass-produced biomaterials created for a variety of surgical indications, AM represents a paradigm shift in manufacturing at the individual patient level. Computer-aided systems employ algorithms to design customized, image-based scaffolds with high external shape complexity and spatial patterning of internal architecture guided by topology optimization. 3D bioprinting and surface modification techniques further enhance scaffold functionalization and osteogenic potential through the incorporation of viable cells, bioactive molecules, biomimetic materials and vectors for transgene expression within the layered architecture. These computational design features enable fabrication of tissue engineering constructs with highly tailored mechanical, structural, and biochemical properties for bone. This review examines key properties of scaffold design, bioresorbable bone scaffolds produced by AM processes, and clinical applications of these regenerative technologies. AM is transforming the field of personalized dental medicine and has great potential to improve regenerative outcomes in patient care.