Process Phenomena and Material Properties in Selective Laser Sintering of Polymers: A Review

Unravelling the role of microneedles in drug delivery: Principle, perspectives, and practices

In recent year, the research of transdermal drug delivery systems has got substantial attention towards the development of microneedles (MNs). This shift has occurred due to multifaceted advantages of MNs as they can be utilized to deliver the drug deeper to the skin with minimal invasion, offer successful delivery of drugs and biomolecules that are susceptible to degradation in gastrointestinal tract (GIT), act as biosensors, and help in monitoring the level of biomarkers in the body. These can be fabricated into different types based on their applications as well as material for fabrication. Some of their types include solid MNs, hollow MNs, coated MNs, hydrogel forming MNs, and dissolving MNs. These MNs deliver the therapeutics via microchannels deeper into the skin. The coated and hollow MNs have been found successful. However, they suffer from poor drug loading and blocking of pores. In contrast, dissolving MNs offer high drug loading. These MNs have also been utilized to deliver vaccines and biologicals. They have also been used in cosmetics. The current review covers the different types of MNs, materials used in their fabrication, properties of MNs, and various case studies related to their role in delivering therapeutics, monitoring level of biomarkers/hormones in body such as insulin. Various patents and clinical trials related to MNs are also covered. Covered are the major bottlenecks associated with their clinical translation and potential future perspectives.

3D printing technology and its revolutionary role in stent implementation in cardiovascular disease

Cardiovascular disease (CVD), exemplified by coronary artery disease (CAD), is a global health concern, escalating in prevalence and burden. The etiology of CAD is intricate, involving different risk factors. CVD remains a significant cause of mortality, driving the need for innovative interventions like percutaneous coronary intervention and vascular stents. These stents aim to minimize restenosis, thrombosis, and neointimal hyperplasia while providing mechanical support. Notably, the challenges of achieving ideal stent characteristics persist. An emerging avenue to address this involves enhancing the mechanical performance of polymeric bioresorbable stents using additive manufacturing techniques And Three-dimensional (3D) printing, encompassing various manufacturing technologies, has transcended its initial concept to become a tangible reality in the medical field. The technology's evolution presents a significant opportunity for pharmaceutical and medical industries, enabling the creation of targeted drugs and swift production of medical implants. It revolutionizes medical procedures, transforming the strategies of doctors and surgeons. Patient-specific 3D-printed anatomical models are now pivotal in precision medicine and personalized treatment approaches. Despite its ongoing development, additive manufacturing in healthcare is already integrated into various medical applications, offering substantial benefits to a sector under pressure for performance and cost reduction. In this review primarily emphasizes stent technology, different types of stents, highlighting its application with some potential complications. Here we also address their benefits, potential issues, effectiveness, indications, and contraindications. In future it can potentially reduce complications and help in improving patients' outcomes. 3DP technology offers the promise to customize solutions for complex CVD conditions and help or fostering a new era of precision medicine in cardiology.

3D Printing of Polysaccharide-Based Hydrogel Scaffolds for Tissue Engineering Applications: A Review

In tissue engineering, 3D printing represents a versatile technology employing inks to construct three-dimensional living structures, mimicking natural biological systems. This technology efficiently translates digital blueprints into highly reproducible 3D objects. Recent advances have expanded 3D printing applications, allowing for the fabrication of diverse anatomical components, including engineered functional tissues and organs. The development of printable inks, which incorporate macromolecules, enzymes, cells, and growth factors, is advancing with the aim of restoring damaged tissues and organs. Polysaccharides, recognized for their intrinsic resemblance to components of the extracellular matrix have garnered significant attention in the field of tissue engineering. This review explores diverse 3D printing techniques, outlining distinctive features that should characterize scaffolds used as ideal matrices in tissue engineering. A detailed investigation into the properties and roles of polysaccharides in tissue engineering is highlighted. The review also culminates in a profound exploration of 3D polysaccharide-based hydrogel applications, focusing on recent breakthroughs in regenerating different tissues such as skin, bone, cartilage, heart, nerve, vasculature, and skeletal muscle. It further addresses challenges and prospective directions in 3D printing hydrogels based on polysaccharides, paving the way for innovative research to fabricate functional tissues, enhancing patient care, and improving quality of life.

Optimization of Mechanical Properties and Evaluation of Fatigue Behavior of Selective Laser Sintered Polyamide-12 Components

In this paper, a comprehensive study of the mechanical properties of selective laser sintered polyamide components is presented, for various different process parameters as well as environmental testing conditions. For the optimization of the static and dynamic mechanical load behavior, different process parameters, e.g., laser power, scan speed, and build temperature, were varied, defining an optimal parameter combination. First, the influence of the different process parameters was tested, leading to a constant energy density for different combinations. Due to similarities in mechanical load behavior, the energy density was identified as a decisive factor, mostly independent of the input parameters. Thus, secondly, the energy density was varied by the different parameters, exhibiting large differences for all levels of fatigue behavior. An optimal parameter combination of 18 W for the laser power and a scan speed of 2666 mm/s was determined, as a higher energy density led to the best results in static and dynamic testing. According to this, the variation in build temperature was investigated, leading to improvements in tensile strength and fatigue strength at higher build temperatures. Furthermore, different ambient temperatures during testing were evaluated, as the temperature-dependent behavior of polymers is of high importance for industrial applications. An increased ambient temperature as well as active cooling during testing was examined, having a significant impact on the high cycle fatigue regime and on the endurance limit.

3D printed osteochondral scaffolds: design strategies, present applications and future perspectives

Articular osteochondral (OC) defects are a global clinical problem characterized by loss of full-thickness articular cartilage with underlying calcified cartilage through to the subchondral bone. While current surgical treatments can relieve pain, none of them can completely repair all components of the OC unit and restore its original function. With the rapid development of three-dimensional (3D) printing technology, admirable progress has been made in bone and cartilage reconstruction, providing new strategies for restoring joint function. 3D printing has the advantages of fast speed, high precision, and personalized customization to meet the requirements of irregular geometry, differentiated composition, and multi-layered boundary layer structures of joint OC scaffolds. This review captures the original published researches on the application of 3D printing technology to the repair of entire OC units and provides a comprehensive summary of the recent advances in 3D printed OC scaffolds. We first introduce the gradient structure and biological properties of articular OC tissue. The considerations for the development of 3D printed OC scaffolds are emphatically summarized, including material types, fabrication techniques, structural design and seed cells. Especially from the perspective of material composition and structural design, the classification, characteristics and latest research progress of discrete gradient scaffolds (biphasic, triphasic and multiphasic scaffolds) and continuous gradient scaffolds (gradient material and/or structure, and gradient interface) are summarized. Finally, we also describe the important progress and application prospect of 3D printing technology in OC interface regeneration. 3D printing technology for OC reconstruction should simulate the gradient structure of subchondral bone and cartilage. Therefore, we must not only strengthen the basic research on OC structure, but also continue to explore the role of 3D printing technology in OC tissue engineering. This will enable better structural and functional bionics of OC scaffolds, ultimately improving the repair of OC defects.

Shape Memory Polymer Composites: 4D Printing, Smart Structures, and Applications

Shape memory polymers (SMPs) and their composites (SMPCs) are smart materials that can be stably deformed and then return to their original shape under external stimulation, thus having a memory of their shape. Three-dimensional (3D) printing is an advanced technology for fabricating products using a digital software tool. Four-dimensional (4D) printing is a new generation of additive manufacturing technology that combines shape memory materials and 3D printing technology. Currently, 4D-printed SMPs and SMPCs are gaining considerable research attention and are finding use in various fields, including biomedical science. This review introduces SMPs, SMPCs, and 4D printing technologies, highlighting several special 4D-printed structures. It summarizes the recent research progress of 4D-printed SMPs and SMPCs in various fields, with particular emphasis on biomedical applications. Additionally, it presents an overview of the challenges and development prospects of 4D-printed SMPs and SMPCs and provides a preliminary discussion and useful reference for the research and application of 4D-printed SMPs and SMPCs.

Mechanical and Surface Characteristics of Selective Laser Melting-Manufactured Dental Prostheses in Different Processing Stages

Due to the expansion of the use of powder bed fusion metal additive technologies in the medical field, especially for the realization of dental prostheses, in this paper, the authors propose a comparative experimental study of the mechanical characteristics and the state of their microscale surfaces. The comparison was made from material considerations starting from two dental alloys commonly used to realize dental prostheses: Ni-Cr and Co-Cr, but also technologies for obtaining selective laser melting (SLM) and conventional casting. In addition, to compare the performances with the classical casting technology, for the dental prostheses obtained through SLM, the post-processing stage in which they are in a preliminary finishing and polished state was considered. Therefore, for the determination of important mechanical characteristics and the comparative study of dental prostheses, the indentation test was used, after which the hardness, penetration depths (maximum, permanent, and contact depth), contact stiffness, and contact surface were established, and for the determination of the microtopography of the surfaces, atomic force microscopy (AFM) was used, obtaining the local areal roughness parameters at the miniaturized scale-surface average roughness, root-mean-square roughness (RMS), and peak-to-peak values. Following the research carried out, several interesting conclusions were drawn, and the superiority of the SLM technology over the classic casting method for the production of dental prostheses in terms of some mechanical properties was highlighted. At the same time, the degree of finishing of dental prostheses made by SLM has a significant impact on the mechanical characteristics and especially the local roughness parameters on a miniaturized scale, and if we consider the same degree of finishing, no major differences are observed in the roughness parameters of the surfaces of the prostheses produced by different technologies.

Recycled PLA for 3D Printing: A Comparison of Recycled PLA Filaments from Waste of Different Origins after Repeated Cycles of Extrusion

The objective of this work is to evaluate the reprocessing of PLA 3D printing waste from different origins, into filaments and films, and without the addition of any additive. Two types of waste were considered: a blend of different printing wastes (masks, visors, other components) of personal protective equipment coming from an association of Spanish coronamakers, and PLA waste from a single known commercial source. Both types of materials were subjected to repeated extrusion cycles and processed into films by compression molding. Samples were characterized after each cycle and their mechanical and viscosity properties evaluated. Diffusion-ordered NMR spectroscopy (DOSY) experiments were also carried out to estimate molecular weights. The results show a better performance for the PLA waste from the known origin, capable of withstanding up to three re-extrusion cycles per two for the waste blending, without significant degradation. Additionally, a model to address collection and mechanical recycling cycles under two different scenarios (full traceability and not full traceability) was proposed.

3D and 4D printing hydroxyapatite-based scaffolds for bone tissue engineering and regeneration

The osseous tissue can be classified as a nanocomposite that encompasses a complex interweaving of organic and inorganic matrices. This intricate amalgamation consists of a collagen component and a mineral phase that are intricately arranged to form elaborate and perforated configurations. Hydroxyapatite, whether synthesized artificially or obtained from natural sources, has garnered considerable attention as a composite material in the field of bone tissue engineering due to its striking resemblance to bone in terms of structure and characteristics. Hydroxyapatite (HA) constitutes the predominant ceramic biomaterial for biomedical applications due to its ability to replicate the mineral composition of vertebrate bone. Nonetheless, it is noteworthy that the present biomimetic substance exhibits unfavorable mechanical characteristics, characterized by insufficient tensile and compressive strength, thus rendering it unsuitable for effective employment in the field of bone tissue engineering. Due to its beneficial attributes, hydroxyapatite (HA) is frequently employed in conjunction with various polymers and crosslinkers as composites to enhance mechanical properties and overall efficacy of implantable biomaterials engineered. The restoration of skeletal defects through the use of customized replacements is an effective way to replace damaged or lost bone structures. This method not only restores the bones' original functions but also reinstates their initial aesthetic appearance. The utilization of hydroxyapatite-polymer composites within 3D-printed grafts necessitates meticulous optimization of both mechanical and biological properties, in order to ensure their suitability for employment in medical devices. The utilization of 3D-printing technology represents an innovative approach in the manufacturing of HA-based scaffolds, which offers advantageous prospects for personalized bone regeneration. The expeditious prototyping method, with emphasis on the application of 3D printing, presents a viable approach in the development of bespoke prosthetic implants, grounded on healthcare data sets. 4D printing approach is an evolved form of 3D printing that utilizes programmable materials capable of altering the intended shape of printed structures, contingent upon single or dual stimulating factors. These factors include aspects such as pH level, temperature, humidity, crosslinking degree, and leaching factors.

Surface Roughness and Grain Size Variation When 3D Printing Polyamide 11 Parts Using Selective Laser Sintering

Selective laser sintering (SLS) is a well-established technology that is used for additive manufacturing. Significant efforts have been made to improve SLS by optimizing the powder deposition, laser beam parameters, and temperature settings. The purpose is to ensure homogeneous sintering and prevent geometric and appearance inaccuracies in the manufactured objects. We evaluated the differences in the surface roughness and grain size of curved objects manufactured by using upcoming SLS technology that features two CO laser sources. Our analysis was carried out on polyamide 11 (PA11), which is a sustainable biobased polymer that has been gaining popularity due to its high-performance properties: its low melting point, high viscosity, and excellent mechanical properties. By using a Taguchi experimental design and analysis of variance (ANOVA), we examined the influence on the surface roughness and grain size of the build setup, the presence of thin walls, and the position of the sample on the powder bed. We found significant differences in some surface roughness and grain size measurements when these parameters were changed.

Study of Biomass Composite Workpiece Support Structure Based on Selective Laser Sintering Technology

When using selective laser sintering to print parts with thin-walled structures, the thermal action of the laser can cause thermal stresses that lead to plastic deformation, resulting in large warpage and dimensional deviations. To address this issue, this study proposes a bottom support method for selective laser sintering. The impact of lattice-type, concentric-type, and cross-type support structures with varying filling densities and thicknesses on the suppression of warpage and dimensional errors was investigated. The optimal process parameters for each support structure were then determined through optimization. The findings of this study demonstrated a reduction in Z-axis dimensional errors of the workpiece following the addition of supports. The reduction amounted to 33.809%, 86.160%, and 66.214%, respectively, compared to the original workpiece. Moreover, the corresponding warpage was reduced by 35.673%, 46.189%, and 46.059% for each respective case, showcasing an improvement in the printing precision. Therefore, the bottom support effectively reduces dimensional and shape errors in thin-walled parts printed by selective laser sintering. Specifically, the results obtained indicated that the concentric type of support is more effective in reducing dimensional errors and enhancing the shape accuracy of the printed workpiece. Conversely, the cross type of support demonstrated superior capabilities in minimizing the consumption of printing materials while still delivering satisfactory results. Thus, this study holds promise for contributing to the advancement of thin-walled part quality using selective laser sintering technology. This research can contribute to achieving greater accuracy in the fabrication of parts through 3D printing.

Biomass 3D Printing: Principles, Materials, Post-Processing and Applications

Under the background of green and low-carbon era, efficiently utilization of renewable biomass materials is one of the important choices to promote ecologically sustainable development. Accordingly, 3D printing is an advanced manufacturing technology with low energy consumption, high efficiency, and easy customization. Biomass 3D printing technology has attracted more and more attentions recently in materials area. This paper mainly reviewed six common 3D printing technologies for biomass additive manufacturing, including Fused Filament Fabrication (FFF), Direct Ink Writing (DIW), Stereo Lithography Appearance (SLA), Selective Laser Sintering (SLS), Laminated Object Manufacturing (LOM) and Liquid Deposition Molding (LDM). A systematic summary and detailed discussion were conducted on the printing principles, common materials, technical progress, post-processing and related applications of typical biomass 3D printing technologies. Expanding the availability of biomass resources, enriching the printing technology and promoting its application was proposed to be the main developing directions of biomass 3D printing in the future. It is believed that the combination of abundant biomass feedstocks and advanced 3D printing technology will provide a green, low-carbon and efficient way for the sustainable development of materials manufacturing industry.

A Review on Manufacturing Processes of Biocomposites Based on Poly(α-Esters) and Bioactive Glass Fillers for Bone Regeneration

The incorporation of bioactive and biocompatible fillers improve the bone cell adhesion, proliferation and differentiation, thus facilitating new bone tissue formation upon implantation. During these last 20 years, those biocomposites have been explored for making complex geometry devices likes screws or 3D porous scaffolds for the repair of bone defects. This review provides an overview of the current development of manufacturing process with synthetic biodegradable poly(α-ester)s reinforced with bioactive fillers for bone tissue engineering applications. Firstly, the properties of poly(α-ester), bioactive fillers, as well as their composites will be defined. Then, the different works based on these biocomposites will be classified according to their manufacturing process. New processing techniques, particularly additive manufacturing processes, open up a new range of possibilities. These techniques have shown the possibility to customize bone implants for each patient and even create scaffolds with a complex structure similar to bone. At the end of this manuscript, a contextualization exercise will be performed to identify the main issues of process/resorbable biocomposites combination identified in the literature and especially for resorbable load-bearing applications.

Additive Manufacturing of Polyolefins

Polyolefins are semi-crystalline thermoplastic polymers known for their good mechanical properties, low production cost, and chemical resistance. They are amongst the most commonly used plastics, and many polyolefin grades are regarded as engineering polymers. The two main additive manufacturing techniques that can be used to fabricate 3D-printed parts are fused filament fabrication and selective laser sintering. Polyolefins, like polypropylene and polyethylene, can, in principle, be processed with both these techniques. However, the semi-crystalline nature of polyolefins adds complexity to the use of additive manufacturing methods compared to amorphous polymers. First, the crystallization process results in severe shrinkage upon cooling, while the processing temperature and cooling rate affect the mechanical properties and mesoscopic structure of the fabricated parts. In addition, for ultra-high-molecular weight polyolefins, limited chain diffusion is a major obstacle to achieving proper adhesion between adjunct layers. Finally, polyolefins are typically apolar polymers, which reduces the adhesion of the 3D-printed part to the substrate. Notwithstanding these difficulties, it is clear that the successful processing of polyolefins via additive manufacturing techniques would enable the fabrication of high-end engineering products with enormous design flexibility. In addition, additive manufacturing could be utilized for the increased recycling of plastics. This manuscript reviews the work that has been conducted in developing experimental protocols for the additive manufacturing of polyolefins, presenting a comparison between the different approaches with a focus on the use of polyethylene and polypropylene grades. This review is concluded with an outlook for future research to overcome the current challenges that impede the addition of polyolefins to the standard palette of materials processed through additive manufacturing.

Partial Biodegradable Blend with High Stability against Biodegradation for Fused Deposition Modeling

This research presents a partial biodegradable polymeric blend aimed for large-scale fused deposition modeling (FDM). The literature reports partial biodegradable blends with high contents of fossil fuel-based polymers (>20%) that make them unfriendly to the ecosystem. Furthermore, the reported polymer systems neither present good mechanical strength nor have been investigated in vulnerable environments that results in biodegradation. This research, as a continuity of previous work, presents the stability against biodegradability of a partial biodegradable blend prepared with polylactic acid (PLA) and polypropylene (PP). The blend is designed with intended excess physical interlocking and sufficient chemical grafting, which has only been investigated for thermal and hydrolytic degradation before by the same authors. The research presents, for the first time, ANOVA analysis for the statistical evaluation of endurance against biodegradability. The statistical results are complemented with thermochemical and visual analysis. Fourier transform infrared spectroscopy (FTIR) determines the signs of intermolecular interactions that are further confirmed by differential scanning calorimetry (DSC). The thermochemical interactions observed in FTIR and DSC are validated with thermogravimetric analysis (TGA). Scanning electron microscopy (SEM) is also used as a visual technique to affirm the physical interlocking. It is concluded that the blend exhibits high stability against soil biodegradation in terms of high mechanical strength and high mass retention percentage.

Affordable Biocidal Ultraviolet Cured Cuprous Oxide Filled Vat Photopolymerization Resin Nanocomposites with Enhanced Mechanical Properties

In this study, Cuprous Oxide (Cu2O), known for its mechanism against bacteria, was used as filler to induce biocidal properties on a common commercial resin stereolithography (SLA) 3D printing resin. The aim was to develop nanocomposites suitable for the SLA process with a low-cost process that mimic host defense peptides (HDPs). Such materials have a huge economic and societal influence on the global technological war on illness and exploiting 3D printing characteristics is an additional asset for these materials. Their mechanical performance was also investigated with tensile, flexural, Charpy's impact, and Vickers microhardness tests. Morphological analysis was performed through scanning electron microscopy (SEM), atomic force microscopy (AFM), and energy-dispersive X-ray spectroscopy (EDS) analysis, while the thermal behavior was studied through Thermogravimetric Analysis (TGA). The antibacterial activity of the fabricated nanocomposites was investigated using a screening agar well diffusion method, for a gram-negative and a gram-positive bacterium. Three-dimensional printed nanocomposites exhibited antibacterial performance in all loadings studied, while their mechanical enhancement was approximately 20% even at low filler loadings, revealing a multi-functional performance and a potential of Cuprous Oxide implementation in SLA resin matrices for engineering and medical applications.