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Xu H, Chen S, Hu R, Hu M, Xu Y, Yoon Y, Chen Y. Continuous Vat Photopolymerization for Optical Lens Fabrication. Small 2023; 19:e2300517. [PMID: 37246277 DOI: 10.1002/smll.202300517] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/17/2023] [Revised: 05/04/2023] [Indexed: 05/30/2023]
Abstract
Optical lenses require feature resolution and surface roughness that are beyond most (3D) printing methods. A new continuous projection-based vat photopolymerization process is reported that can directly shape polymer materials into optical lenses with microscale dimensional accuracy (< 14.7 µm) and nanoscale surface roughness (< 20 nm) without post-processing. The main idea is to utilize frustum layer stacking, instead of the conventional 2.5D layer stacking, to eliminate staircase aliasing. A continuous change of mask images is achieved using a zooming-focused projection system to generate the desired frustum layer stacking with controlled slant angles. The dynamic control of image size, objective and imaging distances, and light intensity involved in the zooming-focused continuous vat photopolymerization are systematically investigated. The experimental results reveal the effectiveness of the proposed process. The 3D-printed optical lenses with various designs, including parabolic lenses, fisheye lenses, and a laser beam expander, are fabricated with a surface roughness of 3.4 nm without post-processing. The dimensional accuracy and optical performance of the 3D-printed compound parabolic concentrators and fisheye lenses within a few millimeters are investiagted. These results highlight the rapid and precise nature of this novel manufacturing process, demonstrating a promising avenue for future optical component and device fabrication.
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Affiliation(s)
- Han Xu
- Center for Advanced Manufacturing, University of Southern California, Los Angeles, CA, 90007, USA
- Daniel J. Epstein Department of Industrial and Systems Engineering, University of Southern California, Los Angeles, CA, 90089, USA
| | - Shuai Chen
- Center for Advanced Manufacturing, University of Southern California, Los Angeles, CA, 90007, USA
- Department of Aerospace and Mechanical Engineering, University of Southern California, Los Angeles, CA, 90089, USA
| | - Renzhi Hu
- Center for Advanced Manufacturing, University of Southern California, Los Angeles, CA, 90007, USA
- Department of Aerospace and Mechanical Engineering, University of Southern California, Los Angeles, CA, 90089, USA
| | - Muqun Hu
- Department of Aerospace and Mechanical Engineering, University of Southern California, Los Angeles, CA, 90089, USA
| | - Yang Xu
- Center for Advanced Manufacturing, University of Southern California, Los Angeles, CA, 90007, USA
- Daniel J. Epstein Department of Industrial and Systems Engineering, University of Southern California, Los Angeles, CA, 90089, USA
| | - Yeowon Yoon
- Center for Advanced Manufacturing, University of Southern California, Los Angeles, CA, 90007, USA
- Department of Aerospace and Mechanical Engineering, University of Southern California, Los Angeles, CA, 90089, USA
| | - Yong Chen
- Center for Advanced Manufacturing, University of Southern California, Los Angeles, CA, 90007, USA
- Daniel J. Epstein Department of Industrial and Systems Engineering, University of Southern California, Los Angeles, CA, 90089, USA
- Department of Aerospace and Mechanical Engineering, University of Southern California, Los Angeles, CA, 90089, USA
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2
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Arora P, Mostafa KG, Russell E, Dehgahi S, Butt SU, Talamona D, Qureshi AJ. Shrinkage Compensation and Effect of Building Orientation on Mechanical Properties of Ceramic Stereolithography Parts. Polymers (Basel) 2023; 15:3877. [PMID: 37835926 PMCID: PMC10575243 DOI: 10.3390/polym15193877] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/31/2023] [Revised: 08/31/2023] [Accepted: 09/05/2023] [Indexed: 10/15/2023] Open
Abstract
Stereolithography additive manufacturing (SLA-AM) can be used to produce ceramic structures by selectively curing a photosensitive resin that has ceramic powder in it. The photosensitive resin acts as a ceramic powder binder, which is burned, and the remaining ceramic part is sintered during post-processing using a temperature-time-controlled furnace. Due to this process, the ceramic part shrinks and becomes porous. Moreover, additive manufacturing leads to the orthotropic behavior of the manufactured parts. This article studies the effect of the manufacturing orientation of ceramic parts produced via SLA-AM on dimensional accuracy. Scaled CAD models were created by including the calculated shrinkage factor. The dimensions of the final sintered specimens were very close to the desired dimensions. As sintering induces porosity and reduces the mechanical strength, in this study, the effect of orientation on strength was investigated, and it was concluded that the on-edge specimen possessed by far the highest strength in terms of both compression and tension.
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Affiliation(s)
- Piyush Arora
- Additive Design and Manufacturing Systems Laboratory, Department of Mechanical Engineering, University of Alberta, Edmonton, AB T6G 2R3, Canada; (P.A.); (K.G.M.); (S.D.); (S.U.B.); (A.J.Q.)
| | - Khaled G. Mostafa
- Additive Design and Manufacturing Systems Laboratory, Department of Mechanical Engineering, University of Alberta, Edmonton, AB T6G 2R3, Canada; (P.A.); (K.G.M.); (S.D.); (S.U.B.); (A.J.Q.)
| | - Emmanuel Russell
- Fraunhofer Institute of Production Technology IPT, RWTH Aachen, 52062 Aachen, Germany;
| | - Shirin Dehgahi
- Additive Design and Manufacturing Systems Laboratory, Department of Mechanical Engineering, University of Alberta, Edmonton, AB T6G 2R3, Canada; (P.A.); (K.G.M.); (S.D.); (S.U.B.); (A.J.Q.)
| | - Sajid Ullah Butt
- Additive Design and Manufacturing Systems Laboratory, Department of Mechanical Engineering, University of Alberta, Edmonton, AB T6G 2R3, Canada; (P.A.); (K.G.M.); (S.D.); (S.U.B.); (A.J.Q.)
- Department of Mechanical Engineering (CEME), National University of Sciences and Technology (NUST), Islamabad 46000, Pakistan
| | - Didier Talamona
- School of Engineering and Digital Sciences, Nazarbayev University, Astana 010000, Kazakhstan
| | - Ahmed Jawad Qureshi
- Additive Design and Manufacturing Systems Laboratory, Department of Mechanical Engineering, University of Alberta, Edmonton, AB T6G 2R3, Canada; (P.A.); (K.G.M.); (S.D.); (S.U.B.); (A.J.Q.)
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Liz-Basteiro P, Reviriego F, Martínez-Campos E, Reinecke H, Elvira C, Rodríguez-Hernández J, Gallardo A. Vat Photopolymerization 3D Printing of Hydrogels with Re-Adjustable Swelling. Gels 2023; 9:600. [PMID: 37623055 PMCID: PMC10452991 DOI: 10.3390/gels9080600] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/23/2023] [Revised: 07/19/2023] [Accepted: 07/24/2023] [Indexed: 08/26/2023] Open
Abstract
Vat photopolymerization typically prints highly crosslinked networks. Printing hydrogels, which are also networks but with a high swelling capacity in water and therefore with low crosslinking density, is a challenge for this technique. However, it may be of interest in medicine and in other areas, since it would allow for the preparation of this type of 3D-shaped material. In this work, an approach for printing hydrogels via vat photopolymerization that uses a mixture of stable and hydrolysable crosslinkers has been evaluated so that an initial highly crosslinked network can be printed, although after hydrolysis it becomes a network with low crosslinking. This approach has been studied with PEO/PEG-related formulations, that is, with a PEG-dimethacrylate as a stable crosslinker, a PEO-related derivative carrying β-aminoesters as a degradable crosslinker, and PEG-methyl ether acrylate and hydroxyethyl acrylate as monofunctional monomers. A wide family of formulations has been studied, maintaining the weight percentage of the crosslinkers at 15%. Resins have been studied in terms of viscosity, and the printing process has been evaluated through the generation of Jacobs working curves. It has been shown that this approach allows for the printing of pieces of different shapes and sizes via vat photopolymerization, and that these pieces can re-ajust their water content in a tailored fashion through treatments in different media (PBS or pH 10 buffer).
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Affiliation(s)
- Pedro Liz-Basteiro
- Instituto de Ciencia y Tecnología de Polímeros (ICTP), CSIC, C/Juan de la Cierva 3, 28006 Madrid, Spain; (P.L.-B.); (F.R.); (E.M.-C.); (H.R.); (C.E.)
| | - Felipe Reviriego
- Instituto de Ciencia y Tecnología de Polímeros (ICTP), CSIC, C/Juan de la Cierva 3, 28006 Madrid, Spain; (P.L.-B.); (F.R.); (E.M.-C.); (H.R.); (C.E.)
| | - Enrique Martínez-Campos
- Instituto de Ciencia y Tecnología de Polímeros (ICTP), CSIC, C/Juan de la Cierva 3, 28006 Madrid, Spain; (P.L.-B.); (F.R.); (E.M.-C.); (H.R.); (C.E.)
- Grupo de Síntesis Orgánica y Bioevaluación, Instituto Pluridisciplinar (IP), UCM, Unidad Asociada al CSIC por el ICTP y el IQM, Paseo de Juan XXIII 1, 28040 Madrid, Spain
| | - Helmut Reinecke
- Instituto de Ciencia y Tecnología de Polímeros (ICTP), CSIC, C/Juan de la Cierva 3, 28006 Madrid, Spain; (P.L.-B.); (F.R.); (E.M.-C.); (H.R.); (C.E.)
| | - Carlos Elvira
- Instituto de Ciencia y Tecnología de Polímeros (ICTP), CSIC, C/Juan de la Cierva 3, 28006 Madrid, Spain; (P.L.-B.); (F.R.); (E.M.-C.); (H.R.); (C.E.)
| | - Juan Rodríguez-Hernández
- Instituto de Ciencia y Tecnología de Polímeros (ICTP), CSIC, C/Juan de la Cierva 3, 28006 Madrid, Spain; (P.L.-B.); (F.R.); (E.M.-C.); (H.R.); (C.E.)
| | - Alberto Gallardo
- Instituto de Ciencia y Tecnología de Polímeros (ICTP), CSIC, C/Juan de la Cierva 3, 28006 Madrid, Spain; (P.L.-B.); (F.R.); (E.M.-C.); (H.R.); (C.E.)
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Wu Y, Su H, Li M, Xing H. Digital light processing-based multi-material bioprinting: Processes, applications, and perspectives. J Biomed Mater Res A 2023; 111:527-542. [PMID: 36436142 DOI: 10.1002/jbm.a.37473] [Citation(s) in RCA: 7] [Impact Index Per Article: 7.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/26/2022] [Revised: 11/08/2022] [Accepted: 11/15/2022] [Indexed: 11/29/2022]
Abstract
In the past decade, three-dimensional (3D) printing technology based on digital light processing (DLP) has developed rapidly and shown application prospects in several fields such as pneumatic robotics, flexible electronics, and tissue engineering. In particular, DLP-based multi-material printing has been capable of constructing heterogeneous 3D structures with characteristic gradients. DLP 3D printing technology has a wide range of applications in the field of bioprinting due to its high precision and mild printing conditions, including functionalized artificial tissues, medical models, and bioreactors. This paper focuses on the development of DLP-based multi-material 3D printing technology and its applications in the field of bioprinting, followed by giving an outlook on future efforts on overcoming the challenges and obstacles of this promising technique.
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Affiliation(s)
- Yang Wu
- School of Mechanical Engineering and Automation, Harbin Institute of Technology, Shenzhen, China.,State Key Laboratory of Fluid Power and Mechatronic Systems, Zhejiang University, Hangzhou, China
| | - Hao Su
- School of Mechanical Engineering and Automation, Harbin Institute of Technology, Shenzhen, China
| | - Ming Li
- School of Mechanical Engineering and Automation, Harbin Institute of Technology, Shenzhen, China
| | - Huayang Xing
- Hangzhou AimingMed Technologies, Hangzhou, China
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Muenks D, Kyosev Y. Productivity Comparison Between Vat Polymerization and Fused Filament Fabrication Methods for Additive Manufacturing of Polymers. 3D Print Addit Manuf 2023; 10:40-49. [PMID: 36998801 PMCID: PMC10049869 DOI: 10.1089/3dp.2021.0009] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/19/2023]
Abstract
Many users relate additive manufacturing (AM) directly with fast and high-quality prototyping and manufacturing. Nevertheless, already within the different printing techniques there are significant printing time differences for the same polymer printed objects. For AM, there are currently two main known methods to three-dimensional (3D) print objects: One is the vat polymerization process using liquid crystal display (LCD) polymerization, also known as masked stereolithography (MSLA). The other is material extrusion, known as fused filament fabrication (FFF) or fused deposition modeling. Both processes can be found in the private sector (desktop printers) or in industry. The FFF and MSLA processes apply material layer by layer to 3D print objects, but both processes are different in their printing techniques. The different printing methods result in different printing speeds for the same 3D printed object. Geometry models are used to investigate which design elements affect the printing speed without changing the actual printing parameters. Support and infill are also taken into account. The influencing factors will be shown to optimize the printing time. With the assistance of the different slicer software, the influence factors were calculated and the different variants are pointed out. The determined correlations help to find the suitable printing technique to make optimum use of the printing performance of both technologies.
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Affiliation(s)
- Dominik Muenks
- Chair of Assembly Technology for Textile Products, Institute of Textile Machinery and High Performance Material Technology (ITM), Technische Universität Dresden, Dresden, Germany
| | - Yordan Kyosev
- Chair of Assembly Technology for Textile Products, Institute of Textile Machinery and High Performance Material Technology (ITM), Technische Universität Dresden, Dresden, Germany
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Unkovskiy A, Beuer F, Metin DS, Bomze D, Hey J, Schmidt F. Additive Manufacturing of Lithium Disilicate with the LCM Process for Classic and Non-Prep Veneers: Preliminary Technical and Clinical Case Experience. Materials (Basel) 2022; 15:ma15176034. [PMID: 36079415 PMCID: PMC9457325 DOI: 10.3390/ma15176034] [Citation(s) in RCA: 10] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/26/2022] [Revised: 08/23/2022] [Accepted: 08/30/2022] [Indexed: 05/02/2023]
Abstract
BACKGROUND ceramic veneers, crowns, and other types of restorations are often made using either the press heating technique or the subtractive method. The advent of lithography-based ceramic manufacturing (LCM) allows for the manufacturing of such restorations in an additive way. METHODS this concept paper describes the first clinical experience in the application of LCM lithium disilicate restorations in vivo for the manufacturing of classic veneers for a patient with severe tooth wear. The applied restorations were analyzed in terms of their marginal fit in metrology software (Geomagic Control X, 3D Systems). Furthermore, the feasibility of 3D printing of non-prep veneers with a 0.1 mm thickness was tested. RESULTS the classic LCM lithium disilicate veneers were tried in the mouth cavity and demonstrated adequate esthetics and a sufficient marginal fit of 100 µm. Furthermore, the non-prep veneers with a 0.1 mm thickness could be successfully printed using LCM technology and also demonstrated an adequate fit on the model in vitro. CONCLUSIONS the described technical approach of lithium disilicate 3D printing with LCM technology may pose a valid alternative to subtractive and analog manufacturing and be a game-changing option with the use of additive chairside ceramic fabrication.
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Affiliation(s)
- Alexey Unkovskiy
- Department of Prosthodontics, Geriatric Dentistry and Craniomandibular Disorders, Charité-Universitätsmedizin Berlin, Corporate Member of Freie Universität Berlin, Humboldt-Universität zu Berlin, Aßmannshauser Str. 4–6, 14197 Berlin, Germany
- Department of Prosthodontics, Peoples’ Friendship University of Russia (RUDN University), 117198 Moscow, Russia
- Correspondence:
| | - Florian Beuer
- Department of Prosthodontics, Geriatric Dentistry and Craniomandibular Disorders, Charité-Universitätsmedizin Berlin, Corporate Member of Freie Universität Berlin, Humboldt-Universität zu Berlin, Aßmannshauser Str. 4–6, 14197 Berlin, Germany
| | - Dilan Seda Metin
- Department of Prosthodontics, Geriatric Dentistry and Craniomandibular Disorders, Charité-Universitätsmedizin Berlin, Corporate Member of Freie Universität Berlin, Humboldt-Universität zu Berlin, Aßmannshauser Str. 4–6, 14197 Berlin, Germany
| | - Daniel Bomze
- Lithoz GmbH, Mollardgasse 85a/2/64-69, 1060 Vienna, Austria
| | - Jeremias Hey
- Department of Prosthodontics, Geriatric Dentistry and Craniomandibular Disorders, Charité-Universitätsmedizin Berlin, Corporate Member of Freie Universität Berlin, Humboldt-Universität zu Berlin, Aßmannshauser Str. 4–6, 14197 Berlin, Germany
| | - Franziska Schmidt
- Department of Prosthodontics, Geriatric Dentistry and Craniomandibular Disorders, Charité-Universitätsmedizin Berlin, Corporate Member of Freie Universität Berlin, Humboldt-Universität zu Berlin, Aßmannshauser Str. 4–6, 14197 Berlin, Germany
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Murphy CA, Lim KS, Woodfield TBF. Next Evolution in Organ-Scale Biofabrication: Bioresin Design for Rapid High-Resolution Vat Polymerization. Adv Mater 2022; 34:e2107759. [PMID: 35128736 DOI: 10.1002/adma.202107759] [Citation(s) in RCA: 8] [Impact Index Per Article: 4.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 09/28/2021] [Revised: 01/30/2022] [Indexed: 06/14/2023]
Abstract
The field of bioprinting has made significant advancements in recent years and allowed for the precise deposition of biomaterials and cells. However, within this field lies a major challenge, which is developing high resolution constructs, with complex architectures. In an effort to overcome these challenges a biofabrication technique known as vat polymerization is being increasingly investigated due to its high fabrication accuracy and control of resolution (µm scale). Despite the progress made in developing hydrogel precursors for bioprinting techniques, such as extrusion-based bioprinting, there is a major lack in developing hydrogel precursor bioresins for vat polymerization. This is due to the specific unique properties and characteristics required for vat polymerization, from lithography to the latest volumetric printing. This is of major concern as the shortage of bioresins available has a significant impact on progressing this technology and exploring its full potential, including speed, resolution, and scale. Therefore, this review discusses the key requirements that need to be addressed in successfully developing a bioresin. The influence of monomer architecture and bioresin composition on printability is described, along with key fundamental parameters that can be altered to increase printing accuracy. Finally, recent advancements in bioresins are discussed together with future directions.
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Affiliation(s)
- Caroline A Murphy
- Christchurch Regenerative Medicine and Tissue Engineering (CReaTE) Group, Department of Orthopaedic Surgery and Musculoskeletal Medicine, Centre for Bioengineering and Nanomedicine, University of Otago, Christchurch, 8011, New Zealand
| | - Khoon S Lim
- Christchurch Regenerative Medicine and Tissue Engineering (CReaTE) Group, Department of Orthopaedic Surgery and Musculoskeletal Medicine, Centre for Bioengineering and Nanomedicine, University of Otago, Christchurch, 8011, New Zealand
- Light Activated Biomaterials (LAB) Group, Department of Orthopaedic Surgery and Musculoskeletal Medicine, Centre for Bioengineering and Nanomedicine, University of Otago, Christchurch, 8011, New Zealand
| | - Tim B F Woodfield
- Christchurch Regenerative Medicine and Tissue Engineering (CReaTE) Group, Department of Orthopaedic Surgery and Musculoskeletal Medicine, Centre for Bioengineering and Nanomedicine, University of Otago, Christchurch, 8011, New Zealand
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Wang M, Li W, Mille LS, Ching T, Luo Z, Tang G, Garciamendez CE, Lesha A, Hashimoto M, Zhang YS. Digital Light Processing Based Bioprinting with Composable Gradients. Adv Mater 2022; 34:e2107038. [PMID: 34609032 PMCID: PMC8741743 DOI: 10.1002/adma.202107038] [Citation(s) in RCA: 51] [Impact Index Per Article: 25.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 09/05/2021] [Indexed: 05/23/2023]
Abstract
Recapitulation of complex tissues signifies a remarkable challenge and, to date, only a few approaches have emerged that can efficiently reconstruct necessary gradients in 3D constructs. This is true even though mimicry of these gradients is of great importance to establish the functionality of engineered tissues and devices. Here, a composable-gradient Digital Light Processing (DLP)-based (bio)printing system is developed, utilizing the unprecedented integration of a microfluidic mixer for the generation of either continual or discrete gradients of desired (bio)inks in real time. Notably, the precisely controlled gradients are composable on-the-fly by facilely by adjusting the (bio)ink flow ratios. In addition, this setup is designed in such a way that (bio)ink waste is minimized when exchanging the gradient (bio)inks, further enhancing this time- and (bio)ink-saving strategy. Various planar and 3D structures exhibiting continual gradients of materials, of cell densities, of growth factor concentrations, of hydrogel stiffness, and of porosities in horizontal and/or vertical direction, are exemplified. The composable fabrication of multifunctional gradients strongly supports the potential of the unique bioprinting system in numerous biomedical applications.
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Affiliation(s)
- Mian Wang
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women’s Hospital, Harvard Medical School, Cambridge, MA 02139, USA
| | - Wanlu Li
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women’s Hospital, Harvard Medical School, Cambridge, MA 02139, USA
| | - Luis S. Mille
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women’s Hospital, Harvard Medical School, Cambridge, MA 02139, USA
| | - Terry Ching
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women’s Hospital, Harvard Medical School, Cambridge, MA 02139, USA
- Pillar of Engineering Product Development, Singapore University of Technology and Design, Singapore 48737
- Digital Manufacturing and Design Centre, Singapore University of Technology and Design, Singapore 487372
- Department of Biomedical Engineering, National University of Singapore, Singapore 117583
| | - Zeyu Luo
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women’s Hospital, Harvard Medical School, Cambridge, MA 02139, USA
| | - Guosheng Tang
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women’s Hospital, Harvard Medical School, Cambridge, MA 02139, USA
| | - Carlos Ezio Garciamendez
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women’s Hospital, Harvard Medical School, Cambridge, MA 02139, USA
| | - Ami Lesha
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women’s Hospital, Harvard Medical School, Cambridge, MA 02139, USA
| | - Michinao Hashimoto
- Pillar of Engineering Product Development, Singapore University of Technology and Design, Singapore 48737
- Digital Manufacturing and Design Centre, Singapore University of Technology and Design, Singapore 487372
| | - Yu Shrike Zhang
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women’s Hospital, Harvard Medical School, Cambridge, MA 02139, USA
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Hata K, Ikeda H, Nagamatsu Y, Masaki C, Hosokawa R, Shimizu H. Development of Dental Poly(methyl methacrylate)-Based Resin for Stereolithography Additive Manufacturing. Polymers (Basel) 2021; 13:polym13244435. [PMID: 34960985 PMCID: PMC8706392 DOI: 10.3390/polym13244435] [Citation(s) in RCA: 17] [Impact Index Per Article: 5.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/25/2021] [Revised: 12/14/2021] [Accepted: 12/15/2021] [Indexed: 11/16/2022] Open
Abstract
Poly(methyl methacrylate) (PMMA) is widely used in dental applications. However, PMMA specialized for stereolithography (SLA) additive manufacturing (3D-printing) has not been developed yet. This study aims to develop a novel PMMA-based resin for SLA 3D-printing by mixing methyl methacrylate (MMA), ethylene glycol dimethacrylate (EGDMA), and PMMA powder in various mixing ratios. The printability and the viscosity of the PMMA-based resins were examined to determine their suitability for 3D-printing. The mechanical properties (flexural strength and Vickers hardness), shear bond strength, degree of conversion, physicochemical properties (water sorption and solubility), and cytotoxicity for L929 cells of the resulting resins were compared with those of three commercial resins: one self-cured resin and two 3D-print resins. EGDMA and PMMA were found to be essential components for SLA 3D-printing. The viscosity increased with PMMA content, while the mechanical properties improved as EGDMA content increased. The shear bond strength tended to decrease as EGDMA increased. Based on these characteristics, the optimal composition was determined to be 30% PMMA, 56% EGDMA, 14% MMA with flexural strength (84.6 ± 7.1 MPa), Vickers hardness (21.6 ± 1.9), and shear bond strength (10.5 ± 1.8 MPa) which were comparable to or higher than those of commercial resins. The resin’s degree of conversion (71.5 ± 0.7%), water sorption (19.7 ± 0.6 μg/mm3), solubility (below detection limit), and cell viability (80.7 ± 6.2% at day 10) were all acceptable for use in an oral environment. The printable PMMA-based resin is a potential candidate material for dental applications.
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Affiliation(s)
- Kentaro Hata
- Division of Oral Reconstruction and Rehabilitation, Department of Oral Functions, Kyushu Dental University, Fukuoka 803-8580, Japan; (K.H.); (C.M.); (R.H.)
- Division of Biomaterials, Department of Oral Functions, Kyushu Dental University, Fukuoka 803-8580, Japan; (Y.N.); (H.S.)
| | - Hiroshi Ikeda
- Division of Biomaterials, Department of Oral Functions, Kyushu Dental University, Fukuoka 803-8580, Japan; (Y.N.); (H.S.)
- Correspondence: ; Tel.: +81-93-582-1131; Fax: +81-93-592-1699
| | - Yuki Nagamatsu
- Division of Biomaterials, Department of Oral Functions, Kyushu Dental University, Fukuoka 803-8580, Japan; (Y.N.); (H.S.)
| | - Chihiro Masaki
- Division of Oral Reconstruction and Rehabilitation, Department of Oral Functions, Kyushu Dental University, Fukuoka 803-8580, Japan; (K.H.); (C.M.); (R.H.)
| | - Ryuji Hosokawa
- Division of Oral Reconstruction and Rehabilitation, Department of Oral Functions, Kyushu Dental University, Fukuoka 803-8580, Japan; (K.H.); (C.M.); (R.H.)
| | - Hiroshi Shimizu
- Division of Biomaterials, Department of Oral Functions, Kyushu Dental University, Fukuoka 803-8580, Japan; (Y.N.); (H.S.)
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Abstract
Three-dimensional printing (3DP) technology is an innovative tool used in manufacturing medical devices, producing alloys, replacing biological tissues, producing customized dosage forms and so on. Stereolithography (SLA), a 3D printing technique, is very rapid and highly accurate and produces finished products of uniform quality. 3D formulations have been optimized with a perfect tool of artificial intelligence learning techniques. Complex designs/shapes can be fabricated through SLA using the photopolymerization principle. Different 3DP technologies are introduced and the most promising of these, SLA, and its commercial applications, are focused on. The high speed and effectiveness of SLA are highlighted. The working principle of SLA, the materials used and applications of the technique in a wide range of different sectors are highlighted in this review. An innovative idea of 3D printing customized pharmaceutical dosage forms is also presented. SLA compromises several advantages over other methods, such as cost effectiveness, controlled integrity of materials and greater speed. The development of SLA has allowed the development of printed pharmaceutical devices. Considering the present trends, it is expected that SLA will be used along with conventional methods of manufacturing of 3D model. This 3D printing technology may be utilized as a novel tool for delivering drugs on demand. This review will be useful for researchers working on 3D printing technologies.
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Affiliation(s)
- Subhash Deshmane
- Department of Pharmaceutics, Rajarshi Shahu College of Pharmacy, Malvihir, India
| | - Prakash Kendre
- Department of Pharmaceutics, Rajarshi Shahu College of Pharmacy, Malvihir, India
| | - Hitendra Mahajan
- Department of Pharmaceutics, R. C. Patel Institute of Pharmaceutical Education and Research, Shirpur, India
| | - Shirish Jain
- Department of Pharmaceutics, Rajarshi Shahu College of Pharmacy, Malvihir, India
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Arias-Ferreiro G, Ares-Pernas A, Lasagabáster-Latorre A, Aranburu N, Guerrica-Echevarria G, Dopico-García MS, Abad MJ. Printability Study of a Conductive Polyaniline/Acrylic Formulation for 3D Printing. Polymers (Basel) 2021; 13:polym13132068. [PMID: 34201892 PMCID: PMC8272001 DOI: 10.3390/polym13132068] [Citation(s) in RCA: 9] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/25/2021] [Revised: 06/15/2021] [Accepted: 06/19/2021] [Indexed: 11/16/2022] Open
Abstract
There is need for developing novel conductive polymers for Digital Light Processing (DLP) 3D printing. In this work, photorheology, in combination with Jacobs working curves, efficaciously predict the printability of polyaniline (PANI)/acrylate formulations with different contents of PANI and photoinitiator. The adjustment of the layer thickness according to cure depth values (Cd) allows printing of most formulations, except those with the highest gel point times determined by photorheology. In the working conditions, the maximum amount of PANI embedded within the resin was ≃3 wt% with a conductivity of 10-5 S cm-1, three orders of magnitude higher than the pure resin. Higher PANI loadings hinder printing quality without improving electrical conductivity. The optimal photoinitiator concentration was found between 6 and 7 wt%. The mechanical properties of the acrylic matrix are maintained in the composites, confirming the viability of these simple, low-cost, conductive composites for applications in flexible electronic devices.
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Affiliation(s)
- Goretti Arias-Ferreiro
- Grupo de Polímeros, Centro de Investigacións Tecnolóxicas, Universidade da Coruña, Campus de Ferrol, 15471 Ferrol, Spain; (G.A.-F.); (A.A.-P.); (M.S.D.-G.)
| | - Ana Ares-Pernas
- Grupo de Polímeros, Centro de Investigacións Tecnolóxicas, Universidade da Coruña, Campus de Ferrol, 15471 Ferrol, Spain; (G.A.-F.); (A.A.-P.); (M.S.D.-G.)
| | - Aurora Lasagabáster-Latorre
- Departemento Química Orgánica I, Facultad de Óptica y Optometría, Universidad Complutense de Madrid, Arcos de Jalón 118, 28037 Madrid, Spain;
| | - Nora Aranburu
- POLYMAT and Department of Advanced Polymers and Materials, Physics, Chemistry and Technology, Faculty of Chemistry, University of the Basque Country UPV/EHU, 20018 San Sebastián, Spain; (N.A.); (G.G.-E.)
| | - Gonzalo Guerrica-Echevarria
- POLYMAT and Department of Advanced Polymers and Materials, Physics, Chemistry and Technology, Faculty of Chemistry, University of the Basque Country UPV/EHU, 20018 San Sebastián, Spain; (N.A.); (G.G.-E.)
| | - M. Sonia Dopico-García
- Grupo de Polímeros, Centro de Investigacións Tecnolóxicas, Universidade da Coruña, Campus de Ferrol, 15471 Ferrol, Spain; (G.A.-F.); (A.A.-P.); (M.S.D.-G.)
| | - María-José Abad
- Grupo de Polímeros, Centro de Investigacións Tecnolóxicas, Universidade da Coruña, Campus de Ferrol, 15471 Ferrol, Spain; (G.A.-F.); (A.A.-P.); (M.S.D.-G.)
- Correspondence:
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Aretxabaleta M, Xepapadeas AB, Poets CF, Koos B, Spintzyk S. Fracture Load of an Orthodontic Appliance for Robin Sequence Treatment in a Digital Workflow. Materials (Basel) 2021; 14:E344. [PMID: 33445670 DOI: 10.3390/ma14020344] [Citation(s) in RCA: 7] [Impact Index Per Article: 2.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/10/2020] [Revised: 01/06/2021] [Accepted: 01/07/2021] [Indexed: 11/17/2022]
Abstract
CAD/CAM technologies and materials have the potential to improve the treatment of Robin Sequence with orthodontic appliances (Tübingen palatal plate, TPP). However, studies on the provided suitability and safety are lacking. The present study evaluates CAD/CAM technologies and materials for implementation into the workflow for producing these orthodontic appliances (TPPs), manufactured by different techniques and materials: additive manufacturing (AM) and subtractive manufacturing (SM) technologies vs. conventional manufacturing. The fracture load was obtained in a universal testing machine, and the breaking behavior of each bunch, as well as the necessity of adding a safety wire, was evaluated. The minimum fracture load was used to calculate the safety factor (SF) provided by each material. Secondary factors included manufacturing time, material cost and reproducibility. Dental LT clear showed the highest fracture load and best breaking behavior among AM materials. The highest fracture load and safety factor were obtained with Smile polyether ether ketone (PEEK). For the prototyping stage, the use of a Freeprint tray (SF = 114.145) is recommended. For final manufacturing, either the cost-effective approach, Dental LT clear (SF = 232.13%), or the safest but most expensive approach, Smile PEEK (SF = 491.48%), can be recommended.
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Li W, Mille LS, Robledo JA, Uribe T, Huerta V, Zhang YS. Recent Advances in Formulating and Processing Biomaterial Inks for Vat Polymerization-Based 3D Printing. Adv Healthc Mater 2020; 9:e2000156. [PMID: 32529775 PMCID: PMC7473482 DOI: 10.1002/adhm.202000156] [Citation(s) in RCA: 71] [Impact Index Per Article: 17.8] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 02/01/2020] [Revised: 04/21/2020] [Accepted: 04/23/2020] [Indexed: 12/15/2022]
Abstract
3D printing and bioprinting have become a key component in precision medicine. They have been used toward the fabrication of medical devices with patient-specific shapes, production of engineered tissues for in vivo regeneration, and preparation of in vitro tissue models used for screening therapeutics. In particular, vat polymerization-based 3D (bio)printing as a unique strategy enables more sophisticated architectures to be rapidly built. This progress report aims to emphasize the recent advances made in vat polymerization-based 3D printing and bioprinting, including new biomaterial ink formulations and novel vat polymerization system designs. While some of these approaches have not been utilized toward the combination with biomaterial inks, it is anticipated their rapid translation into biomedical applications.
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Affiliation(s)
- Wanlu Li
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women's Hospital, Harvard Medical School, Cambridge, MA, 02139, USA
| | - Luis S Mille
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women's Hospital, Harvard Medical School, Cambridge, MA, 02139, USA
| | - Juan A Robledo
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women's Hospital, Harvard Medical School, Cambridge, MA, 02139, USA
| | - Tlalli Uribe
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women's Hospital, Harvard Medical School, Cambridge, MA, 02139, USA
| | - Valentin Huerta
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women's Hospital, Harvard Medical School, Cambridge, MA, 02139, USA
| | - Yu Shrike Zhang
- Division of Engineering in Medicine, Department of Medicine, Brigham and Women's Hospital, Harvard Medical School, Cambridge, MA, 02139, USA
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Stefaniak AB, Bowers LN, Knepp AK, Luxton TP, Peloquin DM, Baumann EJ, Ham JE, Wells JR, Johnson AR, LeBouf RF, Su FC, Martin SB, Virji MA. Particle and vapor emissions from vat polymerization desktop-scale 3-dimensional printers. J Occup Environ Hyg 2019; 16:519-531. [PMID: 31094667 PMCID: PMC6863047 DOI: 10.1080/15459624.2019.1612068] [Citation(s) in RCA: 25] [Impact Index Per Article: 5.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 05/28/2023]
Abstract
Little is known about emissions and exposure potential from vat polymerization additive manufacturing, a process that uses light-activated polymerization of a resin to build an object. Five vat polymerization printers (three stereolithography (SLA) and two digital light processing (DLP) were evaluated individually in a 12.85 m3 chamber. Aerosols (number, size) and total volatile organic compounds (TVOC) were measured using real-time monitors. Carbonyl vapors and particulate matter were collected for offline analysis using impingers and filters, respectively. During printing, particle emission yields (#/g printed) ranged from 1.3 ± 0.3 to 2.8 ± 2.6 x 108 (SLA printers) and from 3.3 ± 1.5 to 9.2 ± 3.0 x 108 (DLP printers). Yields for number of particles with sizes 5.6 to 560 nm (#/g printed) were 0.8 ± 0.1 to 2.1 ± 0.9 x 1010 and from 1.1 ± 0.3 to 4.0 ± 1.2 x 1010 for SLA and DLP printers, respectively. TVOC yield values (µg/g printed) ranged from 161 ± 47 to 322 ± 229 (SLA printers) and from 1281 ± 313 to 1931 ± 234 (DLP printers). Geometric mean mobility particle sizes were 41.1-45.1 nm for SLA printers and 15.3-28.8 nm for DLP printers. Mean particle and TVOC yields were statistically significantly higher and mean particle sizes were significantly smaller for DLP printers compared with SLA printers (p < 0.05). Energy dispersive X-ray analysis of individual particles qualitatively identified potential occupational carcinogens (chromium, nickel) as well as reactive metals implicated in generation of reactive oxygen species (iron, zinc). Lung deposition modeling indicates that about 15-37% of emitted particles would deposit in the pulmonary region (alveoli). Benzaldehyde (1.0-2.3 ppb) and acetone (0.7-18.0 ppb) were quantified in emissions from four of the printers and 4-oxopentanal (0.07 ppb) was detectable in the emissions from one printer. Vat polymerization printers emitted nanoscale particles that contained potential carcinogens, sensitizers, and reactive metals as well as carbonyl compound vapors. Differences in emissions between SLA and DLP printers indicate that the underlying technology is an important factor when considering exposure reduction strategies such as engineering controls.
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Affiliation(s)
- A. B. Stefaniak
- National Institute for Occupational Safety and Health, Morgantown, West Virginia
| | - L. N. Bowers
- National Institute for Occupational Safety and Health, Morgantown, West Virginia
| | - A. K. Knepp
- National Institute for Occupational Safety and Health, Morgantown, West Virginia
| | - T. P. Luxton
- U.S. Environmental Protection Agency, Office of Research and Development, National Risk Management Research Laboratory, Cincinnati, Ohio
| | - D. M. Peloquin
- Oak Ridge Institute for Science and Education, Oak Ridge, Tennessee
| | | | - J. E. Ham
- National Institute for Occupational Safety and Health, Morgantown, West Virginia
| | - J. R. Wells
- National Institute for Occupational Safety and Health, Morgantown, West Virginia
| | - A. R. Johnson
- National Institute for Occupational Safety and Health, Morgantown, West Virginia
| | - R. F. LeBouf
- National Institute for Occupational Safety and Health, Morgantown, West Virginia
| | - F.-C. Su
- National Institute for Occupational Safety and Health, Morgantown, West Virginia
| | - S. B. Martin
- National Institute for Occupational Safety and Health, Morgantown, West Virginia
| | - M. A. Virji
- National Institute for Occupational Safety and Health, Morgantown, West Virginia
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