Design Aspects of Additive Manufacturing at Microscale: A Review

A self-stiffening compliant intracortical microprobe

Utilising a flexible intracortical microprobe to record/stimulate neurons minimises the incompatibility between the implanted microprobe and the brain, reducing tissue damage due to the brain micromotion. Applying bio-dissolvable coating materials temporarily makes a flexible microprobe stiff to tolerate the penetration force during insertion. However, the inability to adjust the dissolving time after the microprobe contact with the cerebrospinal fluid may lead to inaccuracy in the microprobe positioning. Furthermore, since the dissolving process is irreversible, any subsequent positioning error cannot be corrected by re-stiffening the microprobe. The purpose of this study is to propose an intracortical microprobe that incorporates two compressible structures to make the microprobe both adaptive to the brain during operation and stiff during insertion. Applying a compressive force by an inserter compresses the two compressible structures completely, resulting in increasing the equivalent elastic modulus. Thus, instant switching between stiff and soft modes can be accomplished as many times as necessary to ensure high-accuracy positioning while causing minimal tissue damage. The equivalent elastic modulus of the microprobe during operation is ≈ 23 kPa, which is ≈ 42% less than the existing counterpart, resulting in ≈ 46% less maximum strain generated on the surrounding tissue under brain longitudinal motion. The self-stiffening microprobe and surrounding neural tissue are simulated during insertion and operation to confirm the efficiency of the design. Two-photon polymerisation technology is utilised to 3D print the proposed microprobe, which is experimentally validated and inserted into a lamb's brain without buckling.

Composites in Aerospace and Mechanical Engineering

An important step towards improving performance while reducing weight and maintenance needs is the integration of composite materials into mechanical and aerospace engineering. This subject explores the many aspects of composite application, from basic material characterization to state-of-the-art advances in manufacturing and design processes. The major goal is to present the most recent developments in composite science and technology while highlighting their critical significance in the industrial sector-most notably in the wind energy, automotive, aerospace, and marine domains. The foundation of this investigation is material characterization, which offers insights into the mechanical, chemical, and physical characteristics that determine composite performance. The papers in this collection discuss the difficulties of gaining an in-depth understanding of composites, which is necessary to maximize their overall performance and design. The collection of articles within this topic addresses the challenges of achieving a profound understanding of composites, which is essential for optimizing design and overall functionality. This includes the application of complicated material modeling together with cutting-edge simulation tools that integrate multiscale methods and multiphysics, the creation of novel characterization techniques, and the integration of nanotechnology and additive manufacturing. This topic offers a detailed overview of the current state and future directions of composite research, covering experimental studies, theoretical evaluations, and numerical simulations. This subject provides a platform for interdisciplinary cooperation and creativity in everything from the processing and testing of innovative composite structures to the inspection and repair procedures. In order to support the development of more effective, durable, and sustainable materials for the mechanical and aerospace engineering industries, we seek to promote a greater understanding of composites.

Design, Simulation and Multi-Objective Optimization of a Micro-Scale Gearbox for a Novel Rotary Peristaltic Pump

Peristaltic pumps are widely used in biomedical applications to ensure the safe flow of sterile or medical fluids. They are commonly employed for drug injections, IV fluids, and blood separation (apheresis). These pumps operate through a progressive contraction or expansion along a flexible tube, enabling fluid flow. They are also utilized in industrial applications for sanitary fluid transport, corrosive fluid handling, and novel pharmacological delivery systems. This research provides valuable insights into the selection and optimal design of the powertrain stages for peristaltic pumps implemented in drug delivery systems. The focus of this paper lies in the simulation and optimization of the performance of a power transmission gearbox by examining the energy consumption, sound levels, reliability, and volume as output metrics. The components of the powertrain consist of a helical gear pair for the first stage, a bevel gear pair for the second one, and finally a planetary transmission. Through extensive simulations, the model exhibits promising results, achieving an efficiency of up to 90%. Furthermore, alternative configurations were investigated to optimize the overall performance of the powertrain. This process has been simulated by employing the KISSsoft/KISSsys software package. The findings of this investigation contribute to advancements in the field of biomedical engineering and hold significant potential for improving the efficiency, reliability, and performance of drug delivery mechanisms.

Characterization of Photocurable IP-PDMS for Soft Micro Systems Fabricated by Two-Photon Polymerization 3D Printing

Recent developments in micro-scale additive manufacturing (AM) have opened new possibilities in state-of-the-art areas, including microelectromechanical systems (MEMS) with intrinsically soft and compliant components. While fabrication with soft materials further complicates micro-scale AM, a soft photocurable polydimethylsiloxane (PDMS) resin, IP-PDMS, has recently entered the market of two-photon polymerization (2PP) AM. To facilitate the development of microdevices with soft components through the application of 2PP technique and IP-PDMS material, this research paper presents a comprehensive material characterization of IP-PDMS. The significance of this study lies in the scarcity of existing research on this material and the thorough investigation of its properties, many of which are reported here for the first time. Particularly, for uncured IP-PDMS resin, this work evaluates a surface tension of 26.7 ± 4.2 mN/m, a contact angle with glass of 11.5 ± 0.6°, spin-coating behavior, a transmittance of more than 90% above 440 nm wavelength, and FTIR with all the properties reported for the first time. For cured IP-PDMS, novel characterizations include a small mechanical creep, a velocity-dependent friction coefficient with glass, a typical dielectric permittivity value of 2.63 ± 0.02, a high dielectric/breakdown strength for 3D-printed elastomers of up to 73.3 ± 13.3 V/µm and typical values for a spin coated elastomer of 85.7 ± 12.4 V/µm, while the measured contact angle with water of 103.7 ± 0.5°, Young's modulus of 5.96 ± 0.2 MPa, and viscoelastic DMA mechanical characterization are compared with the previously reported values. Friction, permittivity, contact angle with water, and some of the breakdown strength measurements were performed with spin-coated cured IP-PDMS samples. Based on the performed characterization, IP-PDMS shows itself to be a promising material for micro-scale soft MEMS, including microfluidics, storage devices, and micro-scale smart material technologies.

Editorial for the Special Issue on Micro/Nano Structures and Systems: Analysis, Design, Manufacturing, and Reliability

The advancement of fundamental sciences in recent decades has led to an increased focus on the prediction of phenomena occurring at the micro and nano scales. Micro- and nanostructures have a wide range of applications in various fields, such as aerospace and automobiles, and are widely used in nano- and micro-sized systems and devices, such as biosensors, nanoactuators, and nanoprobes. The design of these structures relies on a complete understanding of their physical and mechanical behaviors. Mechanics plays a crucial role at the micro- and nanoscales, from the generation of nanostructures to the properties of nanocomposite materials and the manufacturing and design of machines, structures, sensors, actuators, fluidics, and more. This Special Issue aims to bring together high-quality papers that advance the field of micro- and nanostructures and systems through the use of modern computational and analytical methods, in conjunction with experimental techniques, for their analysis, design, manufacture, maintenance, quality, and reliability.

Microneedles: One-Plane Bevel-Tipped Fabrication by 3D-Printing Processes

This article presents microneedles analyses where the design parameters studied included length and inner and outer diameter ranges. A mathematical model was also used to generalize outer and inner diameter ratios in the obtained ranges. Following this, the range of inner and outer diameters was completed by mechanical simulations, ranging from 30 μm to 134 μm as the inner diameter range and 208 μm to 250 μm as the outer diameter range. With these ranges, a mathematical model was made using fourth-order polynomial regressions with a correlation of 0.9993, ensuring a safety factor of four in which von Misses forces of the microneedle are around 17.931 MPa; the ANSYS software was used to analyze the mechanical behavior of the microneedles. In addition, the microneedle concept was made by 3D printing using a bio-compatible resin of class 1. The features presented by the microneedle designed in this study make it a promising option for implementation in a transdermal drug-delivery device.

Topological and Mechanical Properties of Different Lattice Structures Based on Additive Manufacturing

The appearance and development of additive manufacturing technology promotes the production and manufacture of parts with more complex designs and smaller sizes and realizes the complex topology that cannot be made by equal-material manufacturing and submanufacturing. Nowadays, the application of tri-periodic minimal surface (TPMS) in topology optimization design has become a new choice, and, because of its excellent structure and properties, has gradually become mainstream. In this paper, the mechanical properties of four different topologies prepared by selective laser melting (SLM) using 316L stainless steel powder were investigated, including two TPMS sheet structures (Primitive surface, Gyroid surface) and two common lattice structures (Bcc lattice, truss lattice). The mechanical properties (Young’s modulus, yield stress, plateau stress, and toughness) were compared by numerical simulation and compression experiment. It can be concluded from the results that the mechanical properties and deformation mechanism of the specimen are mainly related to the type of lattice, though have little relationship with unit thickness at the same relative density. The Gyroid curved structure showed the best mechanical properties and energy absorption capacity, followed by the truss lattice structure. By comparison, the mechanical properties of the traditional Bcc lattice structure and the Primitive surface structure are poor, and the deformation mechanism of these two structures is uncertain and difficult to control.