Early Radiographic and Clinical Outcomes of an Additive-Manufactured Acetabular Component

Background

Additive manufacturing has recently gained popularity and is widely adopted in the orthopaedic industry. However, there is a paucity of literature on the radiographic and clinical outcomes of these relatively novel components. The aim of this study was to assess the 2-year clinical and radiographic outcomes of a specific additive-manufactured acetabular component in primary total hip arthroplasty.

Methods

We performed a retrospective review of 60 patients who underwent primary total hip arthroplasty with the use of the Stryker's TRIDENT II acetabular component. Evaluation of radiographs was performed at 6 weeks, 1 year, and 2 years postoperatively. Radiographs were evaluated for radiolucencies in Charnley and DeLee zones, signs of biologic fixation, and acetabular inclination and anteversion measurements. Patient-reported outcomes and complications were also obtained.

Results

There were no cases of component loosening or changes in component position during follow-up, with an average follow-up time of 1.7 years. A radiolucent line was identified in one patient in zone 1 at 6 weeks; this was absent at 1 year. Radiographic signs of cup biologic fixation were present in 85% of cases by final follow-up. The average inclination was 45.1 (SD = 4.0), and the average anteversion was 26.9 (SD = 5.2). Patient-Reported Outcomes Measurement Information System scores significantly increased at the final follow-up, and there were no complications in this cohort.

Conclusions

This study demonstrated excellent radiographic and clinical outcomes with this novel additive-manufactured acetabular component at early follow-up. Although longer-term follow-up is warranted, this additively manufactured highly porous titanium acetabular component demonstrated excellent biologic fixation and reliable fixation at mid-term follow-up.

3D-printed electrodes using graphite/carbon nitride/polylactic acid composite material: A greener platform for detection of amaranth dye in food samples

The production of sustainable materials with properties aimed at the additive manufacturing of electrochemical sensors has gained prestige in the scientific scenario. Here, a novel lab-made composite material using graphite (G) and carbon nitride (C3N4) embedded into polylactic acid (PLA) biopolymer is proposed to produce 3D-printed electrodes. PLA offers printability and mechanical stability in this composition, while G and C3N4 provide electrical properties and electrocatalytic sites, respectively. Characterizations by Raman and infrared spectroscopies and Energy Dispersive X-rays indicated that the G/C3N4/PLA composite was successfully obtained, while electron microscopy images revealed non-homogeneous rough surfaces. Better electrochemical properties were achieved when the G/C3N4/PLA proportion (35:5:60) was used. As a proof of concept, amaranth (AMR), a synthetic dye, was selected as an analyte, and a fast method using square wave voltammetry was developed. Utilizing the 3D-printed G/C3N4/PLA electrode, a more comprehensive linear range (0.2 to 4.2 μmol/L), a 5-fold increase in sensitivity (9.83 μmol-1 L μA), and better limits of detection (LOD = 0.06 μmol/L) and quantification (LOQ = 0.18 μmol/L) were achieved compared to the G/PLA electrode. Samples of jelly, popsicles, isotonic drinks, and food flavoring samples were analyzed, and similar results to those obtained by UV-vis spectrometry confirmed the method's reliability. Therefore, the described sensor is a simple, cost-effective alternative for assessing AMR in routine food analysis.

Finite element validation dataset of additively manufactured equal angle section stub columns

This article provides experimental and numerical data pertaining to the compressive testing and model calibration for a novel design of 316 L stainless steel equal angle sections (EAS) produced through additive manufacturing, wherein each leg of the EAS is replaced by a wavy surface resembling high order buckling modes of the flat plate. The experimental data were acquired from testing 9 unique stub column sections, in all combinations of 3 different thicknesses and 2 wave magnitudes, with a control section provided for each thickness. The provided numerical data was produced to calibrate a finite element model of the tested sections by varying imperfection magnitudes, and selected values fit strongly to the physical tests. Both physical and numerical tests data herein are given in two parts each, one summary spreadsheet describing section geometry and peak load, and one more detailed spreadsheet providing load-displacement history for all physical sections and selected finite element sections. This data provides insight into finite element analysis of additively manufactured stainless steel sections, making it valuable for the validation of numerical models and stainless steel material behaviour.

Electrochemical polishing, characterisation and in vitro evaluation of additively manufactured CoCr stents with personalised designs

Additive manufacturing (AM) technology has paved the way for manufacturing personalised stents. However, there is a notable gap in comprehensive microstructure analyses and in vitro evaluations of the AM CoCr stents using advanced methodologies. To address this gap, this study focuses on investigating the microstructure and in vitro performance of personalised CoCr stents manufactured through micro-laser powder bed fusion (μ-LPBF). The evaluation process begins with the measurements of dimensions and surface roughness, followed by in-depth microstructural analyses. To improve surface roughness and reduce excessive strut size, the μ-LPBF stents undergo electrochemical polishing. Importantly, in vitro stent deployments are carried out in artificial arteries manufactured based on actual patients' data. Compared to the commercial MULTI-LINK VISION CoCr stent, the μ-LPBF personalised stents have rough surface finish (average roughness: 1.55 μm for μ-LPBF vs. 1.09 μm for commercial) and compromised grain microstructures (elongated for μ-LPBF vs. equiaxed for commercial). However, the personalised stents demonstrate better performances in in vitro tests. Notably, compared to the commercial stent in the two studied cases, they deliver larger lumen gains (up to 11.24 %) and reduced recoils (up to 4 times). This study validates the merit of the lesion-specific designs and the feasibility of using AM technology for stent fabrication.

Accuracy of the intaglio surface of 3D-printed hybrid resin-ceramic crowns, veneers and table-tops: An in vitro study

OBJECTIVES

The present study aims to examine the influence of the build angle on the accuracy (trueness and precision) of 3D printed crowns, table-tops and veneers with a hybrid resin-ceramic material.

METHODS

One crown, on table-top and one veneer were printed in five different build angles (0°, 30°, 45°, 60°, 90°) (n = 50) with the digital light processing (DLP) system (Varseo XS, Bego) using hybrid resin (Varseo Smile Crownplus A3, Bego). All printed restorations were scanned using the laboratory scanner (D2000, 3Shape) and matched onto the initial reference design in metrology software (Geomagic Control X, 3D Systems). The root mean square error (RMSE) was calculated between the scanned and reference data. The data was statistically analyzed using the Tukey multiple comparison test and Wilcoxon multiple comparison test.

RESULTS

The crown group showed higher trueness at 30° (0.021 ± 0.002) and 45° (0.020 ± 0.002), and table-tops at 0° (0.015 ± 0.001) and 30° (0.014 ± 0.001) (p < 0.0001). Veneers demonstrated higher trueness at 30° (0.016 ± 0.002) (p < 0.0001). All three restoration types demonstrated the lowest trueness at a 90° build angle and portrayed deviations along the z axis. The veneer and table-top groups showed the lowest precision at 90° (veneers: 0.021 ± 0.008; table-tops: 0.013 ± 0.003). The crown group portrayed the lowest precision at 45° (0.017 ± 0.005) (p < 0.0001).

CONCLUSION

The build angle of DLP-printed hybrid resin-ceramic restorations influences their accuracy.

CLINICAL SIGNIFICANCE

Considering the build angle is important to achieve a better accuracy of 3D-printed resin-ceramic hybrid restorations. This may help predict or avoid the interference points between a restoration and a die and minimize the clinical adjustments.

Biodegradable and 3D printable lysine functionalized polycaprolactone scaffolds for tissue engineering applications

Tissue engineering (TE) has sparked interest in creating scaffolds with customizable properties and functional bioactive sites. However, due to limitations in medical practices and manufacturing technologies, it is challenging to replicate complex porous frameworks with appropriate architectures and bioactivity in vitro. To address these challenges, herein, we present a green approach that involves the amino acid (l-lysine) initiated polymerization of ɛ-caprolactone (CL) to produce modified polycaprolactone (PCL) with favorable active sites for TE applications. Further, to better understand the effect of morphology and porosity on cell attachment and proliferation, scaffolds of different geometries with uniform and interconnected pores are designed and fabricated, and their properties are evaluated in comparison with commercial PCL. The scaffold morphology and complex internal micro-architecture are imaged by micro-computed tomography (micro-CT), revealing pore size in the range of ~300-900 μm and porosity ranging from 30 to 70 %, while based on the geometry of scaffolds the compressive strength varied from 143 ± 19 to 214 ± 10 MPa. Additionally, the degradation profiles of fabricated scaffolds are found to be influenced by both the chemical nature and product design, where Lys-PCL-based scaffolds with better porosity and lower crystallinity degraded faster than commercial PCL scaffolds. According to in vitro studies, Lys-PCL scaffolds have produced an environment that is better for cell adhesion and proliferation. Moreover, the scaffold design affects the way cells interact; Lys-PCL with zigzag geometry has demonstrated superior in vitro vitality (>90 %) and proliferation in comparison to other designs. This study emphasizes the importance of enhancing bioactivity while meeting morphology and porosity requirements in the design of scaffolds for tissue engineering applications.

Prolonged post-washing in ethanol decreases bond strength of additively manufactured crown materials

OBJECTIVES

This study aimed to investigate the effect of post-washing duration and crown thickness on the bond strength between additively manufactured crown materials and dental cement in vitro.

METHODS

Rectangular-shaped specimens of two thicknesses (1.5 and 2.0 mm) were additively manufactured from permanent VarseoSmile Crown (VC) and long-term temporary NextDent (ND) materials. The specimens were post-washed (n = 160) in ethanol for 5 min, 10 min, 1 h, and 8 h then cemented with dual-cure resin cement. Twenty PMMA (TC) were milled as a control. A chevron-notch test was performed to measure the maximum load until failure (N). Interfacial bond strength (J/m2) was calculated and statistically analysed. The mode of failure was analysed by scanning electron microscopy (SEM).

RESULTS

There was a significant difference in the bond strength between all groups (p < 0.01). VC at 1.5mm thickness post-washed for 10 min showed the highest mean bond strength (1.77 ±0.96 J/m2) while VC at 2.0mm thickness post-washed for 8 h showed the lowest (0.22 ±0.10 J/m2). Exposure to ethanol for 8 h resulted in lower bond strength. Within the type of material, there were no differences in bond strength between the thicknesses when post-washed for the same duration.

CONCLUSIONS

Prolonged post-washing of AM crown materials can significantly decrease the bond strength to resin cement. There were no differences between the permanent and long-term temporary AM materials. When post-washed for 5 min, AM materials observed comparable or higher bond strength values compared to PMMA.

CLINICAL SIGNIFICANCE

The output of this research serves as a guide for dental practitioners, emphasising the importance of adhering to correct post-washing procedures for optimal bond strength of additively manufactured crown materials.

Additively-manufactured Mg wire-reinforced PLDL-matrix composites for biomedical applications

Coupons of a medical grade PLDL polymer matrix uniaxially reinforced with a 15% volume fraction of Mg wires have been manufactured by fused filament fabrication for the first time. Two different types of Mg wires, without and with a surface treatment by plasma electrolytic oxidation were used. Both composite materials were subjected to degradation in phosphate buffer solution over a 3-week period, and their degradation and deformation micromechanisms were analysed in detail. Additionally, the materials were subjected to extensive mechanical testing under various loading conditions, and the interface strength was also analysed. It was found that the presence of the Mg wires improves the mechanical behaviour and accelerates the corrosion rate of the composite with respect that of the polymer matrix and these properties can be further tailored through the surface-modification of Mg wires by plasma electrolytic oxidation. The additive manufacturing strategy presented opens the path to fabricate multimaterial implants and scaffolds with complex shape and tailored properties provided by biodegradable polymers reinforced with either Mg and Zn particles and/or wires.

Dynamic topology optimization of 3D-Printed transtibial orthopedic implant using tunable isotropic porous metamaterials

In this paper, we introduce the design and manufacturing process of a transtibial orthopedic implant. We used medical-grade polyurethane polymer resin to fabricate a 3D porous architected implant with tunable isotropy, employing a high-speed printing method known as Continuous Liquid Interface Production (CLIP). Our objective is to enhance the weight-bearing capabilities of the bone structures in the residual limb, thereby circumventing the traditional reliance on a natural bridge. To achieve a custom-made design, we acquire the topology and morphology of the residual limb as well as the bone structure of the tibia and fibula, utilizing computed tomography (CT) and high-resolution 3D scanning. We employed a dynamic topological optimization method, informed by gait cycle data, to effectively reduce the mass of the implant. This approach, which differs from conventional static methods, enables the quantification of variations in applied forces over time. Using the Euler-Lagrange energy approach, we propose the equations of motion for a homologous multibody model with three degrees of freedom. The versatility of the Solid Isotropic Material with Penalization (SIMP) method facilitates the integration of homogenization methods for microscale porous architectures into the optimized domain. The design of these porous architectures is based on a bias-driven tuning symmetry isotropy of a Triply Periodic Minimal Surface (Schwarz Primitive surface). The internal porosity of the structure significantly reduces weight without compromising the isotropic behavior of the implant.

EBSD investigation of microstructure and microtexture evolution on additively manufactured TiC-Fe based cermets-Influence of multiple laser scanning

Sustainable TiC-Fe-based cermets have been fabricated by adopting an Additive Manufacturing route based on laser powder bed fusion technology (L-PBF). The objective is to produce crack-free cermet components by employing novel multiple laser scanning techniques with variations in laser process parameters. Electron backscatter diffraction analysis (EBSD) was used to study the microstructure and microtexture evolution with variations in laser process parameters. The investigation revealed that adjusting the preheating scan speed (PHS) and melting scan speed (MS) influenced the growth and nucleation of TiC phases. Lowering these speeds resulted in grain coarsening, while higher scan speeds led to grain refinement with larger sub-grain boundaries. Moreover, a high scanning speed increases the degree of dislocation density and internal stress in the fabricated cermet parts. Notably, it is revealed that decreasing the laser scan speed enhanced the proportion of high-angle grain boundaries in the cermet components, signifying an increase in material ductility.

Dimensional accuracy and simulation-based optimization of polyolefins and biocopolyesters for extrusion-based additive manufacturing and steam sterilization

Polyolefins exhibit robust mechanical and chemical properties and can be applied in the medical field, e.g. for the manufacturing of dentures. Despite their wide range of applications, they are rarely used in extrusion-based printing due to their warpage tendency. The aim of this study was to investigate and reduce the warpage of polyolefins compared to commonly used filaments after additive manufacturing (AM) and sterilization using finite element simulation. Three types of filaments were investigated: a medical-grade polypropylene (PP), a glass-fiber reinforced polypropylene (PP-GF), and a biocopolyester (BE) filament, and they were compared to an acrylic resin (AR) for material jetting. Square specimens, standardized samples prone to warpage, and denture bases (n = 10 of each group), as clinically relevant and anatomically shaped reference, were digitized after AM and steam sterilization (134 °C). To determine warpage, the volume underneath the square specimens was calculated, while the deviations of the denture bases from the printing file were measured using root mean square (RMS) values. To reduce the warpage of the PP denture base, a simulation of the printing file based on thermomechanical calculations was performed. Statistical analysis was conducted using the Kruskal-Wallis test, followed by Dunn's test for multiple comparisons. The results showed that PP exhibited the greatest warpage of the square specimens after AM, while PP-GF, BE, and AR showed minimal warpage before sterilization. However, warpage increased for PP-GF, BE and AR during sterilization, whereas PP remained more stable. After AM, denture bases made of PP showed the highest warpage. Through simulation-based optimization, warpage of the PP denture base was successfully reduced by 25%. In contrast to the reference materials, PP demonstrated greater dimensional stability during sterilization, making it a potential alternative for medical applications. Nevertheless, reducing warpage during the cooling process after AM remains necessary, and simulation-based optimization holds promise in addressing this issue.

Characterization of degradation kinetics of additively manufactured PLGA under variable mechanical loading paradigms

Controlled degradation of biodegradable poly-lactic-co-glycolic acid (PLGA) trauma implants may increase interfragmentary loading which is known to accelerate fracture healing. Additive manufacturing allows us to tune the mechanical properties of PLGA scaffolds; however, little is known about this novel approach. The purpose of this study was to use in vitro and in vivo models to determine the degradative kinetics of additively manufactured test coupons fabricated with PLGA. We hypothesized that 1) increases in infill density would lead to improved initial mechanical properties, and 2) loss of mechanical properties would be constant as a function of time, regardless of implant design. Porous and solid test coupons were fabricated using 85:15 PLGA filament. Coupons were either incubated in serum or implanted subcutaneously in rats for up to 16 weeks. Samples were tested in tension, compression, torsion, and bending on a universal test frame. Variables of interest included, but were not limited to: stiffness, and ultimate force for each unique test. Infill density was the driving factor in test coupon mechanical properties, whereas differences in lattice architecture led to minimal changes. We observed moderate levels of degradation after 8 weeks, and significant decreases for all specimens after 16 weeks. Results from this study suggest substantial degradation of 3-D printed PLGA implants occurs during the 8- to 16-week window, which may be desirable for bone fracture repair applications. This study represents initial findings that will help us better understand the complicated interactions between overall implant design, porosity, and implant biodegradation.

Fabrication trueness and marginal quality of additively manufactured resin-based definitive laminate veneers with different restoration thicknesses

OBJECTIVES

To evaluate how restoration thickness (0.5 mm and 0.7 mm) affects the fabrication trueness of additively manufactured definitive resin-based laminate veneers, and to analyze the effect of restoration thickness and margin location on margin quality.

METHODS

Two maxillary central incisors were prepared either for a 0.5 mm- or 0.7 mm-thick laminate veneer. After acquiring the partial-arch scans of each preparation, laminate veneers were designed and stored as reference data. By using these reference data, a total of 30 resin-based laminate veneers were additively manufactured (n = 15 per thickness). All veneers were digitized and stored as test data. The reference and test data were superimposed to calculate the root mean square values at overall, external, intaglio, and marginal surfaces. The margin quality at labial, incisal, mesial, and distal surfaces was evaluated. Fabrication trueness at each surface was analyzed with independent t-tests, while 2-way analysis of variance was used to analyze the effect of thickness and margin location on margin quality (α = 0.05).

RESULTS

Regardless of the evaluated surface, 0.7 mm-thick veneers had lower deviations (P < 0.001). Only the margin location (P < 0.001) affected the margin quality as labial margins had the lowest quality (P < 0.001).

CONCLUSION

Restoration thickness affected the fabrication trueness of resin-based laminate veneers as 0.7 mm-thick veneers had significantly higher trueness. However, restoration thickness did not affect the margin quality and labial margins had the lowest quality.

CLINICAL SIGNIFICANCE

Laminate veneers fabricated by using tested urethane-based acrylic resin may require less adjustment when fabricated in 0.7 mm thickness. However, marginal integrity issues may be encountered at the labial surface.

Factors influencing the bond strength of additively manufactured crown materials in dentistry: A systematic review of in vitro studies

OBJECTIVE

The purpose of this systematic review was to investigate how different interventions can impact the bond strength of additively manufactured crown materials after cementation.

DATA/SOURCES

Four online databases Ovid MEDLINE, Scopus, Web of Science and Google Scholar were searched up to January 2023. Inclusion criteria were English-language publications, full-text, and in vitro studies only. Exclusion criteria were studies that did not assess the bonding of an additively manufactured crown material to cement or did not conduct any bond strength tests. An assessment of risk of bias was done in accordance with a modified Consolidated Standards of Reporting Trials (CONSORT) checklist. Each study was analysed and compared based on the interventions and bond strength results.

STUDY SELECTION

Six studies satisfied the inclusion and exclusion criteria, five of which evaluated photopolymerised resin and one that tested zirconia manufacturing via 3D printing. All studies observed a low risk of bias. The interventions applied included the type of surface pretreatments, airborne-particle abrasion pressure, cement type, taper of crown, and artificial aging. Three studies compared the bonding performance to milled materials.

CONCLUSIONS

The bond strength of crown materials additively manufactured from photopolymers presented high values and are comparable to milled materials. The systematic review demonstrated there was no definite superior cement type, but airborne-particle abrasion with alumina was generally recommended. There is a clear gap in the literature regarding the bond strength of additively manufactured crowns. Therefore, further research is necessary to evaluate its clinical applicability for permanent restorations.

CLINICAL SIGNIFICANCE

Factors influencing the bond strength of additively manufactured crown materials should be evaluated so dental professionals can adopt procedures that promote the strongest bond.

Assessment of the trueness of additively manufactured mol3% zirconia crowns at different printing orientations with an industrial and desktop 3D printer compared to subtractive manufacturing

OBJECTIVES

This study endeavours to investigate the effect of printing orientation on the trueness of additively manufactured molar zirconia crowns. The areal surface roughness and the characteristics of the marginal regions of the crowns were also considered.

METHODS

Twelve molar crowns were manufactured at 0°, 45°, and, 90° printing orientations in a Lithoz and AON zirconia printer, respectively. Twelve milled crowns were used as a comparison. Samples were scanned and analysed in metrology software to determine the trueness of the groups. Regions of interest were defined as the margins, intaglio surface and contact points. Areal surface roughness and print layer thickness were further analysed using a confocal laser scanning microscope.

RESULTS

The results indicate that there are clear differences between the investigated desktop (AON) and industrial (Lithoz) 3D printer. The 45° Lithoz group is the only sample group showing no significantly different results in trueness for all regions analysed compared to the milled group. Areal surface roughness analysis indicates that the print layers in the marginal regions are within clinically tolerable limits and surface characteristics.

CONCLUSIONS

The printing orientation for zirconia crowns is critical to trueness, and differences are evident between different AM apparatuses. Considerations for design and orientation between different apparatuses should therefore be considered when utilising direct additive manufacturing processes. The areal surface roughness of the marginal regions is within acceptable clinical limits for all manufacturing processes and print orientations considered.

CLINICAL SIGNIFICANCE

The materials and apparatuses for additive manufacturing of zirconia crowns are now clinically acceptable from the perspective of the trueness of a final crown for critical functional surfaces and areal surface roughness of the marginal regions.

Development of a simple paste for 3D printing of drug formulations containing a mesoporous material loaded with a poorly water-soluble drug

Poorly soluble drugs represent a substantial portion of emerging drug candidates, posing significant challenges for pharmaceutical formulators. One promising method to enhance the drug's dissolution rate and, consequently, bioavailability involves transforming them into an amorphous state within mesoporous materials. These materials can then be seamlessly integrated into personalized drug formulations using Additive Manufacturing (AM) techniques, most commonly via Fused Deposition Modeling. Another innovative approach within the realm of AM for mesoporous material-based formulations is semi-solid extrusion (SSE). This study showcases the feasibility of a straightforward yet groundbreaking hybrid 3D printing system employing SSE to incorporate drug-loaded mesoporous magnesium carbonate (MMC) into two different drug formulations, each designed for distinct administration routes. MMC was loaded with the poorly water-soluble drug ibuprofen via a solvent evaporation method and mixed with PEG 400 as a binder and lubricant, facilitating subsequent SSE. The formulation is non-aqueous, unlike most pastes which are used for SSE, and thus is beneficial for the incorporation of poorly water-soluble drugs. The 3D printing process yielded tablets for oral administration and suppositories for rectal administration, which were then analyzed for their dissolution behavior in biorelevant media. These investigations revealed enhancements in the dissolution kinetics of the amorphous drug-loaded MMC formulations. Furthermore, an impressive drug loading of 15.3 % w/w of the total formulation was achieved, marking the highest reported loading for SSE formulations incorporating mesoporous materials to stabilize drugs in their amorphous state by a wide margin. This simple formulation containing PEG 400 also showed advantages over other aqueous formulations for SSE in that the formulations did not exhibit weight loss or changes in size or form during the curing process post-printing. These results underscore the substantial potential of this innovative hybrid 3D printing system for the development of drug dosage forms, particularly for improving the release profile of poorly water-soluble drugs.

A review of the recent achievements and future trends on 3D printed microfluidic devices for bioanalytical applications

3D printing has revolutionized the manufacturing process of microanalytical devices by enabling the automated production of customized objects. This technology promises to become a fundamental tool, accelerating investigations in critical areas of health, food, and environmental sciences. This microfabrication technology can be easily disseminated among users to produce further and provide analytical data to an interconnected network towards the Internet of Things, as 3D printers enable automated, reproducible, low-cost, and easy fabrication of microanalytical devices in a single step. New functional materials are being investigated for one-step fabrication of highly complex 3D printed parts using photocurable resins. However, they are not yet widely used to fabricate microfluidic devices. This is likely the critical step towards easy and automated fabrication of sophisticated, complex, and functional 3D-printed microchips. Accordingly, this review covers recent advances in the development of 3D-printed microfluidic devices for point-of-care (POC) or bioanalytical applications such as nucleic acid amplification assays, immunoassays, cell and biomarker analysis and organs-on-a-chip. Finally, we discuss the future implications of this technology and highlight the challenges in researching and developing appropriate materials and manufacturing techniques to enable the production of 3D-printed microfluidic analytical devices in a single step.

A 3D printed ultra-short dental implant based on lattice structures and ZIRCONIA/Ca2SiO4 combination

Additive Manufacturing (AM) enables the generation of complex geometries and controlled internal cavities that are so interesting for the biomedical industry due to the benefits they provide in terms of osseointegration and bone growth. These technologies enable the manufacturing of the so-called lattice structures that are cells with different geometries and internal pores joint together for the formation of scaffold-type structures. In this context, the present paper analyses the feasibility of using diamond-type lattice structures and topology optimisation for the re-design of a dental implant. Concretely, a new ultra-short implant design is proposed in this work. For the manufacturing of the implant, digital light processing additive manufacturing technique technology is considered. The implant was made out of Nano-zirconia and Nano-Calcium Silicate as an alternative material to the more common Ti6Al4V. This material combination was selected due to the properties of the calcium-silicate that enhance bone ingrowth. The influence of different material combination ratios and lattice pore sizes were analysed by means of FEM simulation. For those simulations, a bio-material bone-nanozirconia model was considered that represents the final status after the bone is integrated in the implant. Results shows that the mechanical properties of the biocompatible composite employed were suitable for dental implant applications in dentistry. Based on the obtained results it was seen that those designs with 400 μm and 500 μm pore sizes showed best performance and led to the required factor of safety.

High-precision 3D printing of multi-branch vascular scaffold with plasticized PLCL thermoplastic elastomer

Three-dimensional (3D) printing has emerged as a transformative technology for tissue engineering, enabling the production of structures that closely emulate the intricate architecture and mechanical properties of native biological tissues. However, the fabrication of complex microstructures with high accuracy using biocompatible, degradable thermoplastic elastomers poses significant technical obstacles. This is primarily due to the inherent soft-matter nature of such materials, which complicates real-time control of micro-squeezing, resulting in low fidelity or even failure. In this study, we employ Poly (L-lactide-co-ε-caprolactone) (PLCL) as a model material and introduce a novel framework for high-precision 3D printing based on the material plasticization process. This approach significantly enhances the dynamic responsiveness of the start-stop transition during printing, thereby reducing harmful errors by up to 93%. Leveraging this enhanced material, we have efficiently fabricated arrays of multi-branched vascular scaffolds that exhibit exceptional morphological fidelity and possess elastic moduli that faithfully approximate the physiological modulus spectrum of native blood vessels, ranging from 2.5 to 45 MPa. The methodology we propose for the compatibilization and modification of elastomeric materials addresses the challenge of real-time precision control, representing a significant advancement in the domain of melt polymer 3D printing. This innovation holds considerable promise for the creation of detailed multi-branch vascular scaffolds and other sophisticated organotypic structures critical to advancing tissue engineering and regenerative medicine. .

Optimizing metal part distortion in the material extrusion-thermal debinding-sintering process: An experimental and numerical study

The thermal debinding-sintering process plays an essential role in the context of material extrusion-based additive manufacturing (AM) for producing parts using metal injection molding (MIM). During thermal debinding, metal parts often experience material distortion and porosity, which negatively impacts their mechanical properties. Slowing down the debinding speed is a common approach to mitigate material distortion and porosity. However, this leads to a significant increase in the debinding time. In this study, we carried out debinding-sintering experiments to optimize the distortion and porosity in metal parts. These metal parts were manufactured utilizing bronze/polylactide (PLA) blend filaments and placed in crucibles of different sizes (small, medium, and large), with different heating rates and holding times. The results revealed that the small crucible yielded higher porosity levels in the metal parts, which could be reduced from 23% to 12% by extending both the heating and holding times. In contrast, the medium crucible managed to reduce porosity to approximately 15% without requiring an extension of the processing time. The large crucible, on the other hand, couldn't achieve further porosity reduction due to challenges in reaching the desired temperature. To gain a deeper insight into temperature distribution during the debinding process, we performed numerical simulations using the computational fluid dynamics (CFD) technique and obtained temperature profiles within the kiln using the three crucibles. Ultimately, we carried out standard mechanical tests on the resulting metal parts and evaluated the thermal debinding procedure under various conditions. The approach we employed, combining experiments and numerical simulations, demonstrated significant promise for enhancing the quality of metal parts in the thermal debinding-sintering process.

Size effect characteristics and influences on fatigue behavior of laser powder bed fusion of thin wall GRCop-42 copper alloy

Size effects, influencing a material's strength, elongation, fatigue limit, and longevity, depend on the operative and dominant deformation and failure mechanisms. This study explores the size effects in additive manufactured (AM) GRCop-42 (Cu-4at%Cr-2at%Nb) thin wall structures fabricated via laser-powder bed fusion (L-PBF) and their impact on fatigue life. The influence of internal defects and surface topography on the fatigue life of specimens in both as-built and hot isostatic pressed (HIP) conditions across different thicknesses is investigated. Where micro-computed tomography (μCT) was used to quantify the internal porosity of as-built, pristine HIP'd, and fatigued HIP'd specimens, and laser microscopy was employed to quantify the surface topography of specimens prior to fatigue. Additionally, quasi-static tests were used to establish baseline mechanical properties (i.e. yield strength (YS), ultimate tensile strength (UTS), and elongation) to frame fatigue testing conditions. Results indicate a significant enhancement in fatigue life for HIP'd specimens for both thicknesses, with internal defects depicting a greater impact than surface topography. Furthermore, fractographic analysis suggests that thicker specimens exhibit higher resistance to crack propagation during fatigue testing in the absence of substantial porosity. Thus, the size effects observed on the fatigue life of L-PBF GRCop-42 appears to be dominated by internal defects.

Medical, pharmaceutical, and nutritional applications of 3D-printing technology in diabetes

AIMS

Despite numerous studies covering the various features of three-dimensional printing (3D printing) technology, and its applications in food science and disease treatment, no study has yet been conducted to investigate applying 3D printing in diabetes. Therefore, the present study centers on the utilization and impact of 3D printing technology in relation to the nutritional, pharmaceutical, and medicinal facets of diabetes management. It highlights the latest advancements, and challenges in this field.

METHODS

In this review, the articles focusing on the application and effect of 3D printing technology on medical, pharmaceutical, and nutritional aspects of diabetes management were collected from different databases.

RESULT

High precision of 3D printing in the placement of cells led to accurate anatomic control, and the possibility of bio-printing pancreas and β-cells. Transdermal drug delivery via 3D-printed microneedle (MN) patches was beneficial for the management of diabetes disease. 3D printing supported personalized medicine for Diabetes Mellitus (DM). For instance, it made it possible for pharmaceutical companies to manufacture unique doses of medications for every diabetic patient. Moreover, 3D printing allowed the food industry to produce high-fiber and sugar-free products for the individuals with DM.

CONCLUSIONS

In summary, applying 3D printing technology for diabetes management is in its early stages, and needs to be matured and developed to be safely used for humans. However, its rapid progress in recent years showed a bright future for the treatment of diabetes.

Empowering powdered activated carbon (PAC) with 3D printing: Achieving highly efficient and reusable cationic dye removal

Powdered activated carbon (PAC) has been extensively used as an effective adsorbent. Despite its excellent adsorption ability, PAC has drawbacks, including difficulty in filtration and reactivation after use, limitations of mass transfer in deeper areas because of its aggregated powder form, and limited applicability in high-flow systems. To overcome these limitations, we used a three-dimensional (3D) printing system to fabricate PAC into a 3D structure. Spectral and microscopic analyses indicated that PAC was embedded into 3D monolith and exhibited high porosity suitable for facile mass transfer. The designed 3D PAC filter effectively removed 200 ppm-methylene blue (MB) within 8 h and showed an adsorption efficiency of 93.4 ± 0.9%. The adsorption of MB onto the 3D PAC filter was described by the pseudo-first-order kinetic and Freundlich isotherm models. The negatively charged 3D PAC filter might attract the positively charged MB, thus favoring the physical adsorption of MB onto the 3D PAC filter. The adsorption performance of the 3D PAC filter was tested at various pH levels of 4-10 and against MB spiked in seawaters and freshwaters to evaluate its feasibility for use in real environments. Finally, the reproducibility and reusability of the 3D PAC filter were demonstrated through repeated adsorption and desorption processes against MB.

Fatigue life prediction considering variability for additively manufactured pure titanium clasps

PURPOSE

This study aims to develop a numerical prediction method for the average and standard deviation values of the largely varied fatigue life of additively manufactured commercially pure titanium (CPTi grade 2) clasps. Accordingly, the proposed method is validated by applying it to clasps of different shapes.

METHODS

The Smith-Watson-Topper (SWT) equation and finite element analysis (FEA) were used to predict the average fatigue life. The variability was expressed by a 95% reliability range envelope based on the experimentally determined standard deviation.

RESULTS

When predicting the average fatigue life, the previously determined fatigue parameters implemented in the SWT equation were found to be useful after conducting fatigue tests using a displacement-controlled fatigue testing machine. The standard deviation with respect to stroke and fatigue life was determined for each clasp type to predict variability. The proposed prediction method effectively covered the experimental data. Subsequently, the prediction method was applied to clasps of different shapes and validated through fatigue tests using 22 specimens. Finally, the fracture surface was observed using scanning electron microscopy (SEM). Many manufacturing process-induced defects were observed; however, only the surface defects where the maximum tensile stress occurred were crucial.

CONCLUSIONS

It was confirmed that the fatigue life of additively manufactured pure titanium parts is predictable before the manufacturing process considering its variability by performing only static elasto-plastic FEA. This outcome contributes to the quality assurance of patient-specific clasps without any experimental investigation, reducing total costs and response time.

Effects of surface glazing on the mechanical and biological properties of 3D printed permanent dental resin materials

Purpose This study aimed to determine the surface glazing effect on the mechanical and biological properties of three-dimensional printed dental permanent resins.Methods Specimens were prepared using Formlabs, Graphy Tera Harz permanent, and NextDent C&B temporary crown resins. Specimens were divided into three groups: samples with untreated surfaces, glazed surfaces, and sand-glazed surfaces. The flexural strength, Vickers hardness, color stability, and surface roughness of the samples were analyzed to identify their mechanical properties. Their cell viability and protein adsorption were analyzed to identify their biological properties.Results The flexural strength and Vickers hardness of the samples with sand glazed and glazed surfaces were significantly increased. The color change was higher for surface untreated samples than that for the samples with sand-glazed and glazed surfaces. The surface roughness of the samples with sand-glazed and glazed surfaces was low. The samples with sand-glazed and glazed surfaces have low protein adsorption ability and high cell viability.Conclusions Surface glazing increased the mechanical strength, color stability, and cell compatibility, while reducing the Ra and protein adsorption of 3D-printed dental resins. Thus, a glazed surface exhibited a positive effect on the mechanical and biological properties of 3D-printed resins.

Additive manufacturing-derived free-standing 3D pyrolytic carbon electrodes for sustainable microbial electrochemical production of H2O2

Producing H2O2 via microbial electrosynthesis is a cost-effective and environmentally favorable alternative to the costly and environmentally hazardous anthraquinone method. However, most studies have relied on carbon electrodes with two-dimensional (2D) surfaces (e.g., graphite), which have limited surface area and active sites, resulting in suboptimal H2O2 production. In this study, we demonstrate the enhanced efficiency of microbial H2O2 synthesis using three-dimensional (3D) electrodes produced through additive manufacturing technology due to their larger surface area than conventional carbon electrodes with 2D surfaces. This work innovatively combines 3D printed pyrolytic carbon (3D PyrC) electrodes with highly defined outer geometry and internal mesh structures derived from additive manufacturing with high-temperature resin precursors followed by pyrolysis with microbial electrochemical platform technology to achieve efficient H2O2 synthesis. The 3D PyrC electrode produced a maximum of 129.2 mg L-1 of H2O2 in 12 h, which was 2.3-6.9 times greater than conventional electrodes (e.g., graphite and carbon felt). Furthermore, the scalability, reusability and mechanical properties of the 3D PyrC electrode were exemplary, showcasing its practical viability for large-scale applications. Beyond H2O2 synthesis, the study explored the application of the 3D PyrC electrode in the bio-electro-Fenton process, demonstrating its efficacy as a tertiary treatment technology for the removal of micropollutants. This dual functionality underscores the versatility of the 3D PyrC electrode in addressing both the synthesis of valuable chemicals and environmental remediation. This study shows a novel electrode design for efficient, sustainable synthesis of H2O2 and subsequent environmental remediation.

Additive manufacturing of wet-spun chitosan/hyaluronic acid scaffolds for biomedical applications

Additive manufacturing (AM) holds great potential for processing natural polymer hydrogels into 3D scaffolds exploitable for tissue engineering and in vitro tissue modelling. The aim of this research activity was to assess the suitability of computer-aided wet-spinning (CAWS) for AM of hyaluronic acid (HA)/chitosan (Cs) polyelectrolyte complex (PEC) hydrogels. A post-printing treatment based on HA chemical cross-linking via transesterification with poly(methyl vinyl ether-alt-maleic acid) (PMVEMA) was investigated to enhance the structural stability of the developed scaffolds in physiological conditions. PEC formation and the esterification reaction were investigated by infrared spectroscopy, thermogravimetric analysis, evolved gas analysis-mass spectrometry, and differential scanning calorimetry measurements. In addition, variation of PMVEMA concentration in the cross-linking medium was demonstrated to strongly influence scaffold water uptake and its stability in phosphate buffer saline at 37 °C. The in vitro cytocompatibility of the developed hydrogels was demonstrated by employing the murine embryo fibroblast Balb/3T3 clone A31 cell line, highlighting that PMVEMA cross-linking improved scaffold cell colonization. The results achieved demonstrated that the developed hydrogels represent suitable 3D scaffolds for long term cell culture experiments.

Tailoring mechanical properties in 3D printed multimaterial architected structures

In recent years, significant advancements have been made in developing architected materials, known for their benefits like being lightweight, customizable mechanical performance, and excellent energy absorption. The capabilities of 3D printing technology have facilitated the emergence of a diverse range of architected structures, featuring various unit cell types and geometries for different applications. This study explores the unique opportunity offered by multimaterial 3D printing in fine-tuning the mechanical performance of architected structures. The exploration of the programmability of these structures involves a systematic assessment of various material candidates. After careful evaluation, the selection process led to the choice of PLA and PCL biopolymers for the multimaterial structure. Experimental results emphasize the key role of design configurations in influencing mechanical characteristics, particularly in enhancing the energy absorption capacity of architected structures. By skillfully manipulating the local structure and composition through the synergistic combination of soft and hard materials, the study demonstrates the ability to achieve a diverse range of mechanical responses. The discovered insights present a promising approach that holds applicability in the design and development of multifunctional devices. This is especially significant in the biomedical field, where there is a growing demand for versatile devices.

Surface modification of additive manufactured Ti6Al4V scaffolds with gelatin/alginate- IGF-1 carrier: An effective approach for healing bone defects

The study investigates the potential of porous scaffolds with Gel/Alg-IGF-1 coatings as a viable candidate for orthopaedic implants. The scaffolds are composed of additively manufactured Ti6Al4V lattices, which were treated in an alkali solution to obtain the anatase and rutile phases. The treated surface exhibited hydrophilicity of <11.5°. A biopolymer carrier containing Insulin-like growth factor 1 was coated on the samples using immersion treatment. This study showed that the surface-modified porous Ti6Al4V scaffolds increased cell viability and proliferation, indicating potential for bone regeneration. The results demonstrate that surface modifications can enhance the osteoconduction and osteoinduction of Ti6Al4V implants, leading to improved bone regeneration and faster recovery. The porous Ti6Al4V scaffolds modified with surface coating of Gel/Alg-IGF-1 exhibited a noteworthy increase in cell viability (from 80.7 to 104.1%viability) and proliferation. These results suggest that the surface modified scaffolds have potential for use in treating bone defects.

Current update and trend of 3D printing in spinal surgery: A bibliometric analysis and review of literature

Incorporation of three-dimensional (3D) printing technology into the field of spinal surgery is on the rise. A bibliometric analysis of the current topic was carried out to elaborate the trend and to navigate future research. A Scopus database search was conducted with keywords related to 3D printing, spine, and surgery. The final 792 articles were extracted and further analyzed with VOSviewer 1.6.19 and Biblioshiny. The first published article was in 2002. A notable increase in articles in 2014 might be attributable to the availability of cheaper 3D printers which rose significantly on a global scale in 2011. China leads in terms of published research on 3D printing in spinal surgery, followed by the US, Australia, and India. The author's keyword co-occurrence analysis reveals 8 theme clusters, including preoperative and intraoperative measures, biomodelling, spinal neoplasms, biomechanics of 3D-printed materials, degenerative spinal diseases, minimally invasive surgery, and bioprinting. The top 15 of the most recently cited keywords are listed to provide future researchers to produce impactful articles. Two strategic diagrams of 2 periods (2002-2018 and 2018-2023) show the theme's evolution. We found 6 consistent themes in keyword co-occurrence analysis and the strategic diagram analysis, that are promising subjects for future research. Overall, this bibliographic study indicates the expanding importance of 3D printing in spinal surgery and suggests several critical themes and impactful keywords for future researchers.

Dataset of process-structure-property feature relationships for AlSi10Mg material fabricated using laser powder bed fusion additive manufacturing

This dataset reports microstructure and mechanical property features of AlSi10Mg manufactured using laser powder bed fusion over a wide range of processing conditions. Samples were fabricated with different combinations of laser power, scan speed, and hatch spacing to probe dense regimes as well as porous samples resulting from keyholing and lack of fusion. Pore and grain/sub-grain features for each processing set were quantified. Sample porosity was measured using Archimedes density measurements and X-ray computed tomography (XCT). XCT was also used to characterize the surface roughness of samples along with pore size and morphology. Electron backscatter diffraction (EBSD) was used to characterize the grain size and morphology while scanning electron microscope (SEM) imaging and was used to measure solidification cell size. Uniaxial tension tests were performed to ascertain yield and ultimate tensile strengths, elongation, and elastic modulus, and microhardness was measured using Vickers indentation.

Accuracy of additively manufactured and steam sterilized surgical guides by means of continuous liquid interface production, stereolithography, digital light processing, and fused filament fabrication

Different printing technologies can be used for prosthetically oriented implant placement, however the influence of different printing orientations and steam sterilization remains unclear. In particular, no data is available for the novel technology Continuous Liquid Interface Production. The objective was to evaluate the dimensional accuracy of surgical guides manufactured with different printing techniques in vertical and horizontal printing orientation before and after steam sterilization. A total of 80 surgical guides were manufactured by means of continuous liquid interface production (CLIP; material: Keyguide, Keyprint), digital light processing (DLP; material: Luxaprint Ortho, DMG), stereolithography (SLA; Surgical guide, Formlabs), and fused filament fabrication (FFF; material: Clear Base Support, Arfona) in vertical and horizontal printing orientation (n = 10 per subgroup). Spheres were included in the design to determine the coordinates of 17 reference points. Each specimen was digitized with a laboratory scanner after additive manufacturing (AM) and after steam sterilization (134 °C). To determine the accuracy, root mean square values (RMS) were calculated and coordinates of the reference points were recorded. Based on the measured coordinates, deviations of the reference points and relevant distances were calculated. Paired t-tests and one-way ANOVA were applied for statistical analysis (significance p < 0.05). After AM, all printing technologies showed comparable high accuracy, with an increased deviation in z-axis when printed horizontally. After sterilization, FFF printed surgical guides showed distinct warpage. The other subgroups showed no significant differences regarding the RMS of the corpus after steam sterilization (p > 0.05). Regarding reference points and distances, CLIP showed larger deviations compared to SLA in both printing orientations after steam sterilization, while DLP manufactured guides were the most dimensionally stable. In conclusion, the different printing technologies and orientations had little effect on the manufacturing accuracy of the surgical guides before sterilization. However, after sterilization, FFF surgical guides exhibited significant deformation making their clinical use impossible. CLIP showed larger deformations due to steam sterilization than the other photopolymerizing techniques, however, discrepancies may be considered within the range of clinical acceptance. The influence on the implant position remains to be evaluated.

The design and characterisation of sinusoidal toolpaths using sub-zero bioprinting of polyvinyl alcohol

Sub-zero (°C) additive manufacturing (AM) systems present a promising solution for the fabrication of hydrogel structures with complex external geometry or a heterogeneous internal structure. Polyvinyl alcohol cryogels (PVA-C) are promising tissue-mimicking materials, with mechanical properties that can be designed to satisfy a wide variety of soft tissues. However, the design of more complex mechanical properties into additively manufactured PVA-C samples, which can be enabled using the toolpath, is a largely unstudied area. This research project will investigate the effect of toolpath variation on the elastic and viscoelastic properties of PVA-C samples fabricated using a sinusoidal toolpath. Samples were fabricated using parametric variation of a sinusoidal toolpath, whilst retaining the same overall cross-sectional area, using a sub-zero AM system. To mechanically characterise the samples, they were tested under tension in uniaxial ramp tests, and through dynamic mechanical analysis (DMA). The elastic and viscoelastic moduli of the samples are presented. No correlations between the parametric variation of the design and the Young's modulus were observed. Analysis of the data shows high intra-sample repeatability, demonstrated robust testing protocols, and variable inter-sample repeatability, indicating differences in the printability and consistency of fabrication between sample sets. DMA of the wavelength samples, show a frequency-dependent loss moduli. The storage modulus demonstrates frequency independence, and a large increase in magnitude as the sample increases to 3 wavelengths.

An innovative 3D hydroxyapatite patient-specific implant for maxillofacial bone reconstruction: A case series of 13 patients

The study aimed to evaluate and discuss the use of an innovative PSI made of porous hydroxyapatite, with interconnected porosity promoting osteointegration, called MyBone Custom® implant (MBCI), for maxillofacial bone reconstruction. A multicentric cohort of 13 patients underwent maxillofacial bone reconstruction surgery using MBCIs for various applications, from genioplasty to orbital floor reconstruction, including zygomatic and mandibular bone reconstruction, both for segmental defects and bone augmentation. The mean follow-up period was 9 months (1-22 months). No infections, displacements, or postoperative fractures were reported. Perioperative modifications of the MBCIs were possible when necessary. Additionally, surgeons reported significant time saved during surgery. For patients with postoperative CT scans, osteointegration signs were visible at the 6-month postoperative follow-up control, and continuous osteointegration was observed after 1 year. The advantages and disadvantages compared with current techniques used are discussed. MBCIs offer new bone reconstruction possibilities with long-term perspectives, while precluding the drawbacks of titanium and PEEK. The low level of postoperative complications associated with the high osteointegration potential of MBCIs paves the way to more extensive use of this new hydroxyapatite PSI in maxillofacial bone reconstruction.

Dataset on sinusoidally stiffened 3D printed steel plated structures

The paper reports a series of experimental and numerical data of destructive stub column tests on additively manufactured steel parts stiffened by surface sinusoidal wave patterns. The specimens were made in 316L stainless steel and manufactured by selective laser melting (SLM). The experimental tests covered five tensile coupon tests, fourteen square hollow section (SHS) stub column tests and measurements of geometric imperfections of the stub columns. Numerical models incorporating the measured material and geometric properties were developed and analysed via GMNIA approach. The validity of the numerical models is demonstrated by their accurate replications of the load-end shortening responses of the tested specimens. The reported dataset will contribute to the stability design and characterisation of thin-walled steel plated structures with advanced stiffening patterns.

Personalized lattice-structured prosthesis as a graftless solution for mandible reconstruction and prosthetic restoration: A finite element analysis

Oral cavity tumors are a prevalent cause of mandible reconstruction surgeries. The mandible is vital for functions like oralization, respiration, mastication, and deglutition. Current mandible reconstruction methods have low success rates due to complications like plate fracture or exposure, infections, and screw loosening. Autogenous bone grafts are commonly used but carry the risk of donor region morbidity. Despite technological advances, an ideal solution for mandible reconstruction remains elusive. Additive manufacturing in medicine offers personalized prosthetics from patient-specific medical images, allowing for the creation of porous structures with tailored mechanical properties that mimic bone properties. This study compared a commercial reconstruction plate with a lattice-structured personalized prosthesis under different biting and osseointegration conditions using Finite Element Analysis. Patient-specific images were obtained from an individual who underwent mandible reconstruction with a commercial plate and suffered from plate fracture by fatigue after 26 months. Compared to the commercial plate, the maximum von Mises equivalent stress was significantly lowered for the personalized prosthesis, hindering a possible fatigue fracture. The equivalent von Mises strains found in bone were within bone maintenance and remodeling intervals. This work introduces a design that doesn't require grafts for large bone defects and allows for dental prosthesis addition without the need for implants.

Biodegradation-affected fatigue behavior of extrusion-based additively manufactured porous iron-manganese scaffolds

Additively manufactured (AM) biodegradable porous iron-manganese (FeMn) alloys have recently been developed as promising bone-substituting biomaterials. However, their corrosion fatigue behavior has not yet been studied. Here, we present the first study on the corrosion fatigue behavior of an extrusion-based AM porous Fe35Mn alloy under cyclic loading in air and in the revised simulated body fluid (r-SBF), including the fatigue crack morphology and distribution in the porous structure. We hypothesized that the fatigue behavior of the architected AM Fe35Mn alloy would be strongly affected by the simultaneous biodegradation process. We defined the endurance limit as the maximum stress at which the scaffolds could undergo 3 million loading cycles without failure. The endurance limit of the scaffolds was determined to be 90 % of their yield strength in air, but only 60 % in r-SBF. No notable crack formation in the specimens tested in air was observed even after loading up to 90 % of their yield strength. As for the specimens tested in r-SBF, however, cracks formed in the specimens subjected to loads exceeding 60 % of their yield strength appeared to initiate on the periphery and propagate toward the internal struts. Altogether, the results show that the extrusion-based AM porous Fe35Mn alloy is capable of tolerating up to 60 % of its yield strength for up to 3 million cycles, which corresponds to 1.5 years of use of load-bearing implants subjected to repetitive gait cycles. The fatigue performance of the alloy thus further enhances its potential for trabecular bone substitution subjected to cyclic compressive loading. STATEMENT OF SIGNIFICANCE: Fatigue behavior of extrusion-based AM porous Fe35Mn alloy scaffolds in air and revised simulated body fluid was studied. The Fe35Mn alloy scaffolds endured 90 % of their yield strength for up to 3 × 106 loading cycles in air. Moreover, the scaffolds tolerated 3 × 106 loading cycles at 60 % of their yield strength in revised simulated body fluid. The Fe35Mn alloy scaffolds exhibited a capacity of withstanding 1.5-year physiological loading when used as bone implants.

The emergence of 3D-printed firearms: An analysis of media and law enforcement reports

3D-printed firearms, an emerging category of privately made firearms (PMF) produced beyond government control, have become increasingly prevalent due to technological advancements. They are now emerging as a cost-effective and reliable alternative to conventional firearms. Raised to public awareness following the 2013 release of the 3D-printed Liberator, these firearms are now more commonly encountered by police forces. This article analyses various reports involving 3D-printed firearms, reflecting the increasing encounters by law enforcement agencies. It examines 186 cases involving 3D-printed firearms, primarily from North America, Europe, and Oceania, highlighting a significant rise in incidents since 2021. These incidents include seizures, illicit uses, and online sales, with the firearms typically being hybrid models, Parts Kit Completions/Conversions (PKC), or firearm components such as auto sears. The study underscores the use of affordable equipment and materials for production, emphasizing the accessibility and potential risks of these firearms.

Tailoring drug release in bilayer tablets through droplet deposition modeling and injection molding

This study explores the innovative production of personalized bilayer tablets, integrating two advanced manufacturing techniques: Droplet Deposition Modeling (DDM) and Injection Molding (IM). Unlike traditional methods limited to customizing dense bilayer medicines, our approach uses Additive Manufacturing (AM) to effectively adjust drug release profiles. Focusing on Caffeine and Paracetamol, we found successful processing for both DDM and IM using Caffeine formulation. The high viscosity of Paracetamol formulation posed challenges during DDM processing. Integrating Paracetamol formulation for the over-molding process proved effective, demonstrating IM's versatility in handling complex formulations. Varying infill percentages in DDM tablets led to distinct porosities affecting diverse drug release profiles in DDM-fabricated tablets. In contrast, tablets with high-density structures formed through the over-molding process displayed slower and more uniform release patterns. Combining DDM and IM techniques allows for overcoming the inherent limitations of each technique independently, enabling the production of bilayer tablets with customizable drug release profiles. The study's results offer promising insights into the future of personalized medicine, suggesting new pathways for the development of customized oral dosage forms.

Optimising the manufacturing of a β-Ti alloy produced via direct energy deposition using small dataset machine learning

Successful additive manufacturing involves the optimisation of numerous process parameters that significantly influence product quality and manufacturing success. One commonly used criteria based on a collection of parameters is the global energy distribution (GED). This parameter encapsulates the energy input onto the surface of a build, and is a function of the laser power, laser scanning speed and laser spot size. This study uses machine learning to develop a model for predicting manufacturing layer height and grain size based on GED constituent process parameters. For both layer height and grain size, an artificial neural network (ANN) reduced error over the data set compared with multi linear regression. Layer height predictions using ANN achieved an R2 of 0.97 and a root mean square error (RMSE) of 0.03 mm, while grain size predictions resulted in an R2 of 0.85 and an RMSE of 9.68 μm. Grain refinement was observed when reducing laser power and increasing laser scanning speed. This observation was successfully replicated in another α + β Ti alloy. The findings and developed models show why reproducibility is difficult when solely considering GED, as each of the constituent parameters influence these individual responses to varying magnitudes.

Defect detection in additively manufactured AlSi10Mg and Ti6Al4V samples using laser ultrasonics and phase shift migration

Laser ultrasonics (LU) is a non-contact and non-destructive method with a high data acquisition rate, making it a promising candidate for in-situ monitoring of defects in different additive manufacturing (AM) processes, including laser powder bed fusion (LPBF) and directed energy deposition, as well as final part inspection. In order to see the effect of various artificial defect types on an LU sub-surface reconstruction, AlSi10Mg samples with side through-holes, as well as Ti6Al4V samples with bottom blind holes and trapped powder were printed using LPBF, and then ultrasound B-scans of the samples were obtained using an LU system. The resulting scan data was processed using a custom frequency domain phase shift migration (PSM) algorithm, to reconstruct the defects and their locations. Novel ways of pre-processing the B-scan, used as an input to PSM, and taking advantage of its frequency representation, are demonstrated. Newton's method was used to find a stationary phase approximation, used to account in the frequency domain for the fixed offset emitter-receiver arrangement within the PSM calculation. The Newton's method calculation time was reduced by 33%, by using an approximation of the phase function to find an initial guess. The smallest defects that were detected using this method were in the size range between 200 to 300μm for the bottom hole defects, using an 8 ns laser pulse duration. The effect of the laser on the surface of a part being built, and the challenges and further work needed to integrate LU in a LPBF machine for in-situ inspection are discussed.

Alkali activated materials applied in 3D printing construction: A review

This study aims to contribute to the promising field of alkali-activated materials (AAM) used in 3D printing for construction. Presented as a comprehensive review, the research provides valuable insights for researchers within and beyond the field. The study focuses on identifying prevalent research trends and accessing pertinent information on materials, methodologies, and parameters of interest. The study commenced with a bibliometric analysis of 55 carefully selected publications, followed by an in-depth review of these articles categorized into extrusion-based and powder-based systems. Emphasis was placed on the materials used, methodologies employed, and key findings from these studies. The bibliometric analysis unveiled prevalent keywords, their relevance in the field, highly cited articles, and collaborative networks among researchers. The most influential countries in terms of publications are Australia, China, and Singapore. The review highlighted commonly used materials and their potential impacts on large-scale applications of AAM, exploring how various precursors, activators, additives, aggregates, and reinforcements shape the properties of printed AAM, featuring innovative approaches with alternative materials. The methodologies employed in these studies and trends in characterization were outlined, due to the absence of standardized tests for materials in 3D printing applications. The study emphasized how material properties vary concerning production processes, printing parameters, curing methods, and post-treatment, outlining advancements in material characterization necessary for achieving a printable mix design. Through the analysis of these 55 articles, key scientific challenges and hurdles in large-scale applications were identified, suggesting potential focal points for further studies. In summary, AAMs exhibit substantial uniqueness and complexity due to their diverse material composition, resulting in varying properties in both fresh and hardened states. However, this diversity also signifies the adaptability of AAMs to diverse equipment, construction techniques, and desired specifications, showcasing their potential to revolutionize traditional construction by integrating technology and sustainability.

3D-printing allows for fluid-controlled linear actuators with unconventional shapes

Background

Pneumatic actuators are widely used in applications like (medical) robots, or prostheses. Pneumatic actuators require a complex manufacturing process and are produced in standardized dimensions to reduce costs. Over the last decade 3D-printing has emerged as a cost-effective and efficient production method in medical applications. 3D-printing can also function as a cost-efficient alternative production method for pneumatic actuators.

Objective

The goal of this research is to study the possibility of creating a pneumatic linear actuator with 3D-printing. Furthermore, the aim is to use the advantage of 3D-printing to create pneumatic actuators with non-circular cross-sections.

Methodology

To evaluate the performance of a 3D-printed pneumatic actuator, a test setup was designed and built to measure the leakage and sliding friction force. Furthermore, two pneumatic actuators with a non-conventional cross-sectional shape were designed and their performance was tested and compared with a 3D-printed cylindrical pneumatic actuator, since these tests only ran once, the results are more a guideline. During the manufacturing of the cylinders, no post-processing techniques were used.

Results

The functioning of a 3D-printed circular pneumatic actuator was proven with low static leakage rates of 2.5%, low dynamic leakage rates of approximately 1%, and a maximum friction force of Image 1. Furthermore, the results show that it is possible to print functioning pneumatic cylinders with a non-cylindrical concave cross-section. The non-conventional cylinders were tested up to Image 2 with maximum dynamic leakage of Image 3.

Conclusion

This study demonstrates a method to create functional pneumatic linear actuators with 3D-printing. It was possible to create 3D-printed actuators with a conventional shape, e.g. circular and unconventional shapes e.g. stadium/oval shape and a kidney shape. The leak rates for conventional and unconventional shapes were in the same range. This opens up the world for more design freedom in pneumatic actuators.

Future trends of additive manufacturing in medical applications: An overview

Additive Manufacturing (AM) has recently demonstrated significant medical progress. Due to advancements in materials and methodologies, various processes have been developed to cater to the medical sector's requirements, including bioprinting and 4D, 5D, and 6D printing. However, only a few studies have captured these emerging trends and their medical applications. Therefore, this overview presents an analysis of the advancements and achievements obtained in AM for the medical industry, focusing on the principal trends identified in the annual report of AM3DP.

Recycled aluminium feedstock in metal additive manufacturing: A state of the art review

Additive manufacturing has revolutionised the production of functional components and assemblies, offering a high degree of manufacturing flexibility. This review explores the latest advancements in additive manufacturing, focusing on its fusion-based and solid-state based technologies, and highlights the use of recycled aluminium as feedstock in these processes. The advantages and limitations of incorporating recycled materials are thoroughly analysed, considering factors such as material properties, sustainability, and process acceptance. While up to 14.4 kg CO2 per kg of aluminium is released during primary aluminium ingot production, solid-state based additive manufacturing, which is tolerant of feedstock contamination, can directly recycle aluminium. Meanwhile, fusion based additive manufacturing can readily utilise recycling pathways such as maintaining grade, upcycling, and downcycling, as well as powder reuse, providing opportunities for significant emissions reduction. The examination of feedstock manufacturing in this review, such as wire for WAAM and powder for PBF, indicates that this step indirectly increases the resource consumption of additive manufacturing. Finally, the alignment of aluminium recycling and additive manufacturing with Circular Economy principles and the UN's sustainable development goals are addressed, highlighting contributions to SDGs 3, 9, and 12.

Unlocking the future of precision manufacturing: A comprehensive exploration of 3D printing with fiber-reinforced composites in aerospace, automotive, medical, and consumer industries

Rapid advancements in the field of 3D printing in the last several decades have made it possible to produce complex and unique parts with remarkable precision and accuracy. Investigating the use of 3D printing to create various high-performance materials is a relatively new field that is expanding exponentially worldwide. Automobile, biomedical, construction, aerospace, electronics, and metal and alloy industries are among the most prolific users of 3D printing technology. Modern 3D printing technologies, such as polymer matrices that use fiber-reinforced composites (FRCs) to enhance the mechanical qualities of printed components greatly, have been useful to several industries. High stiffness and tensile strength lightweight components are developed from these materials. Fiber-reinforced composites have a wide range of applications, such as military vehicles, fighter aircraft, underwater structures, shelters, and warfare equipment. Fabricating FRCs using fused deposition modeling (FDM) is also advantageous over other 3D printing methods due to its low cost and ease of operation. The impact of different continuous fiber and matrix polymer selections on FRC performance is covered in this review paper. We will also evaluate the important parameters influencing FRC characteristics and review the most recent equipment and methods for fabricating FRCs. Furthermore, the challenges associated with 3D printing fiber-reinforced composites are covered. The constraints of present technology have also been used to identify future research areas.

Development of a density-based topology optimization of homogenized lattice structures for individualized hip endoprostheses and validation using micro-FE

Prosthetic implants, particularly hip endoprostheses, often lead to stress shielding because of a mismatch in compliance between the bone and the implant material, adversely affecting the implant's longevity and effectiveness. Therefore, this work aimed to demonstrate a computationally efficient method for density-based topology optimization of homogenized lattice structures in a patient-specific hip endoprosthesis. Thus, the root mean square error (RMSE) of the stress deviations between the physiological femur model and the optimized total hip arthroplasty (THA) model compared to an unoptimized-THA model could be reduced by 81 % and 66 % in Gruen zone (GZ) 6 and 7. However, the method relies on homogenized finite element (FE) models that only use a simplified representation of the microstructural geometry of the bone and implant. The topology-optimized hip endoprosthesis with graded lattice structures was synthesized using algorithmic design and analyzed in a virtual implanted state using micro-finite element (micro-FE) analysis to validate the optimization method. Homogenized FE and micro-FE models were compared based on averaged von Mises stresses in multiple regions of interest. A strong correlation (CCC > 0.97) was observed, indicating that optimizing homogenized lattice structures yields reliable outcomes. The graded implant was additively manufactured to ensure the topology-optimized result's feasibility.

Design of robot grippers for binder jet products handling

Dimension accuracy, damage minimization, and defect detection are essential in manufacturing processes, especially additive manufacturing. These types of challenges may arise either during the manufacture of a product or its use. The repeatability of the process is vital in additive manufacturing systems. However, human users may lose concentration and, thus, would be a great alternative as an assistant. Depending on the nature of work, a robot's fingers might vary, for example, mechanical, electrical, vacuum, two-fingers, and three-fingers. In addition, the end effector plays a vital role in picking up an object in the advanced manufacturing process. However, inbuilt robotic fingers may not be appropriate in different production environments. In this research presented here considering metal binder jet additive manufacturing, the two-finger end- effectors are proposed design, analysis, and experiment to pick up an object after completing the production process from a specific location. The final designs were further printed by using a 3D metal printer and installed in the existing robotic systems. These new designs are used successfully to hold the object from the specific location by reducing the contact force that was not possible with the previously installed end effector's finger. In addition, a numerical study was conducted in order to compare the flowability of the geometric shape of finger's free areas.

Influence of build orientation and support structure on additive manufacturing of human knee replacements: a computational study

Developing patient-specific implants has an increasing interest in the application of emerging additive manufacturing (AM) technologies. On the other hand, despite advances in total knee replacement (TKR), studies suggest that up to 20% of patients with elective TKR are dissatisfied with the outcome. By creating 3D objects from digital models, AM enables the production of patient-specific implants with complex geometries, such as those required for knee replacements. Previous studies have highlighted concerns regarding the risk of residual stresses and shape distortions in AM parts, which could lead to structural failure or other complications. This article presents a computational framework that uses CT images to create patient-specific finite element models for optimizing AM knee replacements. The workflow includes image processing in the open-source software 3DSlicer and MeshLab and AM process simulations in the commercial platform 3DEXPERIENCE. The approach is demonstrated on a distal femur replacement for a 50-year-old male patient from the open-access Natural Knee Data. The results show that build orientations have a significant impact on both shape distortions and residual stresses. Support structures have a marginal effect on residual stresses but strongly influence shape distortions, whereas conical support exhibits a maximum distortion of 18.5 mm. Future research can explore how these factors affect the functionality of AM knee replacements under in-service loading.

Novel disposable and portable 3D-printed electrochemical apparatus for fast and selective screening of 25E-NBOH in forensic samples

The advent of new psychoactive substances (NPS) has caused enormous difficulty for legal control since they are rapidly commercialized, and their chemical structures are routinely altered. In this aspect, derivatives phenethylamines, such as 25E-NBOH, have received great attention in the forensic scenario. Hence, we propose portable and cost-effective (U$ 5.00) 3D-printed devices for the electrochemical screening of 25E-NBOH for the first time. The cell and all electrodes were printed using acrylonitrile butadiene styrene filament (insulating material) and conductive filament (graphite embedded in a polylactic acid matrix), respectively, both by the fused deposition modeling (FDM) 3D printing technique. The electrochemical apparatus enables micro-volume analysis (50-2000 μL), especially important for low sample volumes. A mechanistic route for the electrochemical oxidation of 25E-NBOH is proposed based on cyclic voltammetric data, which showed two oxidation processes around +0.75 V and +1.00 V and a redox pair between +0.2 and -0.2 V (vs. graphite ink pseudo-reference). A fast and sensitive square-wave voltammetry method was developed, which exhibited a linear working range from 0.85 to 5.1 μmoL-1, detection limit of 0.2 μmol L-1, and good intra-electrode precision (n = 10, RSD <5.3 %). Inter-electrode measurements (n = 3, RSD <9.8 %) also attested that the electrode production process is reproducible. Interference tests in the presence of other drugs frequently found in blotting paper indicated high selectivity of the electrochemical method for screening of 25E-NBOH. Screening analysis of blotting paper confirmed the presence of 25E-NBOH in the seized samples. Moreover, a recovery percentage close to 100 % was found for a spiked saliva sample, suggesting the method's usefulness for quantitative purposes aimed at information on recent drug use.