Nondestructive quantification of internal raster path for additively manufactured components via ultrasonic testing

This work investigates the viability of discerning the raster pattern of additively manufactured components using high frequency ultrasonic nondestructive testing. Test coupons were fabricated from poly cyclohexylenedimethylene terephthalate glycol using the fused filament fabrication process, in which layers were deposited at various predetermined raster angles. Each printed part was scanned using spherically focused, high-resolution, ultrasonic transducers of various peak frequencies between 7.5 and 15 MHz. From the captured waveform data, images are extracted to observe the raster pattern in a layer-by-layer manner, with the results from the 10 MHz element yielding the best performance. An in-house MATLAB script was developed to analyze the transducer signal to investigate C-scan images at various depths throughout the component. From the resulting C-scan images, one can consistently identify the proper raster orientation within 2°-4° in each of the first 10 deposited layers, with the accuracy decreasing as a function of depth into the component. Due to signal attenuation, there is insufficient data at depths beyond the 11th and 12th layer, to properly analyze the present data sets accurately. Validation was performed using X-ray computed tomography scans to demonstrate the accuracy of the ultrasonic inspection method.

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.

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.

Influence of post-processing on the adhesion of dual-species biofilm on polylactic acid obtained by additive manufacturing

Introduction

Post-processing (PP) is performed to improve the surface, which can favor microbial adhesion and consequent pathological manifestations that impair the indication of polylactic acid (PLA) obtained by fused filament fabrication (FFF) for biomedical applications. This aims to evaluate the influence of chemical, thermal, and mechanical PP on the adhesion of Streptococcus mutants and Candida albicans, roughness, and wettability of the PLA obtained by FFF with and without thermal aging.

Methods

The specimens were designed in the 3D modeling program and printed. The chemical PP was performed by immersion in chloroform, the thermal by the annealing method, and the mechanical by polishing. Thermal aging was performed by alternating the temperature from 5 °C to 55 °C with 5000 cycles. Colony-forming unit (CFU/mL) counting was performed on dual-species biofilm of C. albicans and S. mutans. Roughness was analyzed by rugosimeter and wettability by the sessile drop technique. Data were verified for normality using the Shapiro-Wilk test, two-way ANOVA (α = 0.05) applied for CFU and wettability, and Kruskal-Wallis (α = 0.05) for roughness.

Results

Chemical, thermal, and mechanical PP methods showed no influence on CFU/mL of C. albicans (p = 0.296) and S. mutans (p = 0.055). Thermal aging did not influence microbial adhesion. Chemical PP had lower roughness, which had increased after aging. Wettability of the mechanical PP was lower.

Conclusions

Post-processing techniques, do not present an influence on the adhesion of S. mutans and C. albicans in PLA obtained by FFF, chemical PP reduced roughness, and mechanical reduced wettability. Thermal aging did not alter the microbial adhesion and altered the roughness and wettability.

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.

Semi-crystalline materials for pharmaceutical fused filament fabrication: Dissolution and porosity

A better understanding of crystallization kinetics and the effect on drug product quality characteristics is needed to exploit the use of semi-crystalline polymers in pharmaceutical fused filament fabrication. Filaments were prepared from polycaprolactone or polyethylene oxide loaded with a crystallization inhibitor or inducer, which was either 10% (w/w) ibuprofen or theophylline. A design-of-experiments approach was conducted to investigate the effect of nozzle temperature, bed temperature and print speed on the printed tablets' microstructure and dissolution kinetics. Helium pycnometry derived porosity proved an ideal technique to capture significant distortions in the tablets' microstructure. On the other hand, terahertz time domain spectroscopy (THz-TDS) analysis proved valuable to investigate additional enclosed pores of the tablets' microstructure. The surface roughness was analyzed using optical coherence tomography, showing the importance of extensional viscosity for printed drug products. Drug release occurred via erosion for tablets consisting of polyethylene oxide, which partly reduced the effect of the inner microstructure on the drug release kinetics. An initial burst release effect was noted for polycaprolactone tablets, after which drug release continued via diffusion. Both the pore and crystalline microstructure were deemed essential to steer drug release. In conclusion, this research provided guidelines for material and process choice when a specific microstructure has to be constructed from semi-crystalline materials. In addition, non-destructive tests for the characterization of printed products were evaluated.

Maximizing performance and efficiency in 3D printing of polylactic acid biomaterials: Unveiling of microstructural morphology, and implications of process parameters and modeling of the mechanical strength, surface roughness, print time, and print energy for fused filament fabricated (FFF) bioparts

Medical stents, artificial teeth, and grafts are just some of the many applications for additive manufacturing techniques like bio-degradable polylactic acid 3D printing. However, there are drawbacks associated with fused filament fabrication-fabricated objects, including poor surface quality, insufficient mechanical strength, and a lengthy construction time for even a relatively small object. Thus, this study aims to identify the finest polylactic acid 3D printing parameters to maximize print quality while minimizing energy use, print time, flexural and tensile strengths, average surface roughness, and print time, respectively. Specifically, the infill density, printing speed, and layer thickness are all variables that were selected. A full-central-composite design generated 20 samples to test the prediction models' experimental procedures. Validation trial tests were used to show that the experimental findings agreed with the predictions, and analysis of variance was used to verify the importance of the performance characteristics (ANOVA). At layer thickness = 0.26 mm, infill density = 84 %, and print speed = 68.87 mm/s, the following optimized values were measured for PLA: flexural strength = 70.1 MPa, tensile strength = 39.2 MPa, minimum surface roughness = 7.8 μm, print time = 47 min, and print energy = 0.18 kwh. Firms and clinicians may benefit from utilizing the developed, model to better predict the required surface characteristic for various aspects afore trials.

Investigating environmentally persistent free radicals (EPFRs) emissions of 3D printing process

In recent years, the emission of particles and gaseous pollutants from 3D printing has attracted much attention due to potential health risks. This study investigated the generation of environmentally persistent free radicals (EPFRs, organic free radicals stabilized on or inside particles) in total particulate matter (TPM) released during the 3D printing process. Commercially available 3D printer filaments, made of acrylonitrile-butadiene-styrene (ABS) in two different colors and metal content, ABS-blue (19.66 μg/g Cu) and ABS-black (3.69 μg/g Fe), were used for printing. We hypothesized that the metal content/composition of the filaments contributes not only to the type and number of EPFRs in TPM emissions, but also impacts the overall yield of TPM emissions. TPM emissions during printing with ABS-blue (11.28 μg/g of printed material) were higher than with ABS-black (7.29 μg/g). Electron paramagnetic resonance (EPR) spectroscopy, employed to measure EPFRs in TPM emissions of both filaments, revealed higher EPFR concentrations in ABS-blue TPM (6.23 × 1017 spins/g) than in ABS-black TPM (9.72 × 1016 spins/g). The presence of copper in the ABS-blue contributed to the formation of mostly oxygen-centered EPFR species with a g-factor of ~2.0041 and a lifetime of 98 days. The ABS-black EPFR signal had a lower g-factor of ~2.0011, reflecting the formation of superoxide radicals during the printing process, which were shown to have an "estimated tentative" lifetime of 26 days. Both radical species (EPFRs and superoxides) translate to a potential health risk through inhalation of emitted particles.

Exposure hazards of particles and volatile organic compounds emitted from material extrusion 3D printing: Consolidation of chamber study data

Ultrafine particles and volatile organic compounds (VOCs) have been detected from material extrusion 3D printing, which is widely used in non-industrial environments. This study consolidates data of 447 particle emission and 58 VOC emission evaluations from a chamber study using a standardized testing method with various 3D printing scenarios. The interquartile ranges of the observed emission rates were 109-1011 #/h for particles and 0.2-1.0 mg/h for total VOC. Print material contributed largely to the variations of particle and total VOC emissions and determined the most abundantly emitted VOCs. Printing conditions and filament specifications, included printer brand, print temperature and speed, build plate heating setup, filament brand, color and composite, also affected emissions and resulted in large variations observed in emission profiles. Multiple regression showed that particle emissions were more impacted by various print conditions than VOC emissions. According to indoor exposure modeling, personal and residential exposure scenarios were more likely to result in high exposure levels, often exceeding recommended exposure limits. Hazardous VOCs commonly emitted from 3D printing included aromatics, aldehydes, alcohols, ketones, esters and siloxanes, among which were various carcinogens, irritants and developmental and reproductive toxins. Therefore, 3D printing emits a complex mixture of ultrafine particles and various hazardous chemicals, exposure to which may exceed recommended exposure limits and potentially induce acute, chronic, or developmental health effects for users depending on exposure scenarios.

Waveform load analysis for fatigue in the printed PLA

Additive manufacturing is fast becoming a key process to manufacture a customized design with complex geometry and one process usually employed is based on the fused filament fabrication. Up to now this method is typically employed for rapid prototyping, it is therefore their mechanical strength is lower than the components manufactured using conventional casting process. It is well known that most failures are happened under repeated loads; therefore, a functional component mandatory needs to reach endurance strength under cyclic loads. Hence, this study set out to clarify several aspects of filament fused test specimens to determine their effect on accumulated damage to then predict component life under repeated loads. In this study is considered three waveforms such as sinusoidal, triangular and square, where it is observed that the square waveform provides the most severe loads. This study therefore makes a major contribution to research on the fatigue properties of parts manufactured using fused filament by reporting their fatigue behaviour under different fatigue load conditions. It would give a better understanding to improve the mechanical prediction of PLA, thereby it might be used to manufacture a functional component instead of only a prototype or spare part.

Optimization and manufacture of polyetheretherketone patient specific cranial implants by material extrusion - A clinical perspective

Polyetheretherketone (PEEK) is a high performing thermoplastic that has established itself as a 'gold-standard' material for cranial reconstruction. Traditionally, milled PEEK patient specific cranial implants (PSCIs) exhibit uniform levels of smoothness (excusing suture/drainage holes) to the touch (<1 μm) and homogenous coloration throughout. They also demonstrate predictable and repeatable levels of mechanical performance, as they are machined from isotropic material blocks. The combination of such factors inspires confidence from the surgeon and in turn, approval for implantation. However, manufacturing lead-times and affiliated costs to fabricate a PSCI are high. To simplify their production and reduce expenditure, hospitals are exploring the production of in-house PEEK PSCIs by material extrusion-based additive manufacturing. From a geometrical and morphological perspective, such implants have been produced with good-to-satisfactory clinical results. However, lack of clinical adoption persists. To determine the reasoning behind this, it was necessary to assess the benefits and limitations of current printed PEEK PSCIs in order to establish the status quo. Afterwards, a review on individual PEEK printing variables was performed in order to identify a combination of parameters that could enhance the aesthetics and performance of the PSCIs to that of milled implants/cranial bone. The findings from this review could be used as a baseline to help standardize the production of PEEK PSCIs by material extrusion in the hospital.

Investigating the thermal and mechanical properties of novel LDPE/TiO2 and LDPE/TiO2/CNT composites for 3D printing applications

The development of new materials is essential for advancing technology and improving the quality of life. With new materials, we can create products that are stronger, more durable, and more efficient. The ongoing research and development of new materials for 3D printing applications continue to drive innovation in various fields, leading to improved products and processes with great benefits. The main goal of this work was to produce a functional filament with a 1.75-mm diameter that may be used for 3D printing. Composite materials were prepared using a low-density polyethylene (LDPE) resin as polymer matrix, and titanium dioxide (TiO₂) and carbon nanotubes (CNT) as fillers in various ratios. Up to 15 wt% of TiO₂ and 0.25 wt% of CNT were added. Some of the greatest difficulties with high filler content composites are achieving good homogeneity, and in the case of the 3D printing, greatest difficulties are producing the filament with a specific and stable filament diameter. During the 3D printing itself, the fillers can also often cause the nozzle clogging. This paper reports findings of thermal and mechanical properties of the LDPE/TiO₂/CNT composites which are significant for the 3D printing process and the applicability of the composite materials. All of the planed composite materials are successfully prepared and 3D printed into the tensile test specimens. The melting point shift caused by the addition of fillers did not show consistent pattern at differential scanning calorimetry, as all of the samples had melting temperatures around 113.5 ± 1.4 °C. The addition of filler, according to the TGA, increased the threshold temperature for the material decomposition, in case of TiO₂ 5.4 °C increase, while TiO₂ and CNT combination increased the threshold temperature for 6.8 °C. The results of the tensile test show a general increase trend with addition of TiO₂ filler but do not show to a trend for the tensile strength as a result of the addition of CNT filler. The sample with highest TiO₂ filler ratio of 15% (LDPE 15T0C) showed the greatest tensile strength of 14.5 MPa, compared to the 13.0 MPa of pure LDPE. The sample with 5% of TiO₂ filler and 0.1% of CNT filler (LDPE 5T0.1C) showed the greatest elongation of 73.9%, compared to the 68.9% of pure LDPE.

A facile, semi-automatic protocol for the design and production of 3D printed, anatomical customized orthopedic casts for forearm fractures

Closed fractures of distal radius and ulna are one of the most common skeletal injuries, occurring at all ages. Temporary arm immobilization through cast is part of the standard treatments. However, traditional casting procedures are time consuming, operator's skill dependent and do not always guarantee a satisfactory outcome. From a clinical perspective, casts are often considered uncomfortable and can be associated to skin lesions. To overcome these limitations, the recent growth of 3D technologies has enabled new standardized casting procedures: additive manufacturing (AM) is a technique that creates highly customized cast models from anatomical 3D data by using digitally controlled and operated material laying tools. Compared with conventional casts, those produced with AM technique could potentially reduce skin complications and satisfy both mechanical and clinical requirements of functionality, comfort, and aesthetics. The objective of this study is to describe the new practical methodology to produce a 3D printable cast for upper arm immobilization. The parametric modelling tool, employed to develop a semi-automatic design system for generating the printable cast model, reduces the complex process of orthosis design to a few minutes and all the manufacturing operations remain unaffected by CAD skills of the operator. Specific hardware and software tools (3D scanner, modelling software and FDM technology) were chosen to mitigate design and production costs while guaranteeing suitable levels of data accuracy, process efficiency and design versatility. To highlight the effectiveness of the proposed solution, a finite element analysis simulation was performed on models with different geometry, highlighting the mechanical strength of generated structures. The final result is a personalized 3D printed cast with a highly ventilated structure that is lightweight but still maintains a high level of strength and provides hygienic benefits, reducing the risk of cutaneous complications, potentially improving treatment efficacy and increasing patient satisfaction.

An investigation of combined effect of infill pattern, density, and layer thickness on mechanical properties of 3D printed ABS by fused filament fabrication

Additive manufacturing technology and its benefits have a significant impact on different industrial applications. The 3D printing technologies help manufacture lightweight intricate geometrical designs with enhanced strengths. The present study investigates the blended effects of previously recommended parameters of different infill patterns (line, triangle, and concentric) and infill densities (75, 80, and 85%) with varying thicknesses of layers (100, 200, and 300 μm). The test samples were created through Fused Filament Fabrication (FFF) technology using Acrylonitrile Butadiene Styrene (ABS) 3D printing. Mechanical properties were evaluated through tensile and impact strength tests conducted in accordance with ASTM standards. The experimental investigation reveals that the infill pattern greatly affected both tensile and impact strength. The best results were obtained with a concentric infill pattern, along with 80% infill density and 100 μm layer thickness. These conditions resulted in 123% and 115% higher tensile strength and 168% and 80% higher impact strength compared to line and triangle patterns, respectively.

Fused filament fabrication (FFF): influence of layer height on forces and moments delivered by aligners-an in vitro study

OBJECTIVES

To investigate the effect of layer height of FFF-printed models on aligner force transmission to a second maxillary premolar during buccal torquing, distalization, extrusion, and rotation using differing foil thicknesses.

MATERIALS AND METHODS

Utilizing OnyxCeph3™ Lab (Image Instruments GmbH, Chemnitz, Germany, Release Version 3.2.185), the following movements were programmed for the second premolar: buccal torque (0.1-0.5 mm), distalization (0.1-0.4 mm), extrusion (0.1-0.4 mm), rotation (0.1-0.5 mm), and staging 0.1 mm. Via FFF, 91 maxillary models were printed for each staging at different layer heights (100 µm, 150 µm, 200 µm, 250 µm, 300 µm). Hence, 182 aligners, made of polyethylene terephthalate glycol (PET-G) with two thicknesses (0.5 mm and 0.75 mm), were prepared. The test setup comprised an acrylic maxillary model with the second premolar separated and mounted on a sensor, measuring initial forces and moments exerted by the aligners. A generalized linear model for the gamma distribution was applied, evaluating the significance of the factors layer height, type of movement, aligner thickness, and staging on aligner force transmission.

RESULTS

Foil thickness and staging were found to have a significant influence on forces delivered by aligners, whereas no significance was determined for layer height and type of movement. Nevertheless, at a layer height of 150 µm, the most appropriate force transmission was observed.

CONCLUSIONS

Printing aligner models at particularly low layer heights leads to uneconomically high print time without perceptible better force delivery properties, whereas higher layer heights provoke higher unpredictability of forces due to scattering. A z-resolution of 150 µm appears ideal for in-office aligner production combining advantages of economic print time and optimal force transmission.

Optimizing fused filament fabrication process parameters for quality enhancement of PA12 parts using numerical modeling and taguchi method

Fused Filament Fabrication (FFF) is an Additive Manufacturing (AM) technique implemented in widespread applications and several components. Despite its benefits, the physics behind the FFF process is quite complicated and requires fast heating and cooling rate of the extruded material. Consequently, the component experiences extremely non-uniform internal stresses that might lead to warpage deformation. It is necessary to optimize the printing parameters as they are associated with the warpage deformation of printed components. One method for achieving this target is conducting physical tests that offer precise findings, but it is an expensive strategy. Another approach is to simulate the printing parameters with special software. In this work, Digimat-AM was employed to develop a thermomechanical Finite Element Model of the FFF to simulate parts made of Polyamide12 (PA12). An L27 orthogonal array, a tool of the Taguchi orthogonal array, and an analysis of variance (ANOVA) were used to estimate the impact of five printing parameters and their ultimate levels to improve the dimension's quality by minimizing the warpage deformation. Results showed a significant impact of the bed temperature on the warpage deformation values. The infill density contributed 2.84% in reducing the warpage deformation, and the rest of the parameters' contribution was less than 1% for each.

Influence of 3D printing properties on relative dielectric constant in PLA and ABS materials

Nowadays, it is well known that on the ship, free space is at a premium. Unfortunately, every part on the ship has its duration before the failure, and the spare parts occupy the space. The broken part must be replaced when the failure occurs to maintain the ship's operation. Developing 3D printer technology and particular material technology, it has become possible to print a spare part that can replace broken. However, due to hazardous environments (salt, humidity, vibrations, etc.), printed parts change their properties. Electrical capacity and further dielectric permittivity is a parameter or metric that has to be monitored since it directly influences the printed part material structure. Therefore, this paper aims to research the impact of relative dielectric constant in additive manufacturing on printed ship's spare parts since infill patterns and density were changed due to a hazardous environment. The experiment, in which the three shaped material samples are created, consists of the following equipment, the Ultimaker S5 3D printer, Polylactic Acid (PLA) and Acrylonitrile-Butadiene-Styrene (ABS) materials, and LC HM 8018 m. Results show relative dielectric constant changes between 1.7778 and 2.8141 for PLA and between 2.1979 and 2.9989 for ABS, depending on infill density and pattern. ANOVA test for ABS is performed to investigate how the calculated dielectric constant relates to the infill density for various infill shapes. Scores are: F = 154.3773, Fcrit = 5.1432, and p = 6.9269·10-6. ANOVA test for PLA resulted in scores F = 18.911, Fcrit = 5.1432, and p = 0.0022.

Osteoconductivity of bone substitutes with filament-based microarchitectures: Influence of directionality, filament dimension, and distance

63Additive manufacturing can be applied to produce personalized bone substitutes. At present, the major three-dimensional (3D) printing methodology relies on filament extrusion. In bioprinting, the extruded filament consists mainly of hydrogels, in which growth factors and cells are embedded. In this study, we used a lithography-based 3D printing methodology to mimic filament-based microarchitectures by varying the filament dimension and the distance between the filaments. In the first set of scaffolds, all filaments were aligned toward bone ingrowth direction. In a second set of scaffolds, which were derived from the identical microarchitecture but tilted by 90°, only 50% of the filaments were in line with the bone ingrowth direction. Testing of all tricalcium phosphate-based constructs for osteoconduction and bone regeneration was performed in a rabbit calvarial defect model. The results revealed that if all filaments are in line with the direction of bone ingrowth, filament size and distance (0.40-1.25 mm) had no significant influence on defect bridging. However, with 50% of filaments aligned, osteoconductivity declined significantly with an increase in filament dimension and distance. Therefore, for filament-based 3D- or bio-printed bone substitutes, the distance between the filaments should be 0.40 to 0.50 mm irrespective of the direction of bone ingrowth or up to 0.83 mm if perfectly aligned to it.

Heat Transfer-Based Non-isothermal Healing Model for the Interfacial Bonding Strength of Fused Filament Fabricated Polyetheretherketone

Fused Filament Fabrication (FFF) as an Additive Manufacturing (AM) method for Polyetheretherketone (PEEK) has established a promising future for medical applications so far, however interlayer delamination as a failure mechanism for FFF implants has raised critical concerns. A one-dimensional (1D) heat transfer model (HTM) was developed to compute the layer and interlayer temperatures by considering the nature of 3D printing for FFF PEEK builds. The HTM was then coupled with a non-isothermal healing model to predict the interlayer strength through thickness of a FFF PEEK part. We then conducted a parametric study of the primary temperature effects of the FFF system, including the print bed, nozzle, and chamber temperatures, on layer healing. The heat transfer component of the model for the FFF PEEK layer healing assessment was validated separately. An idealized PEEK cube design (10x10x10 mm3) was used for model development and 3D printed in commercially available industrial and medical FFF machines. During the printing and cooling processes of FFF, thermal videos were recorded in both printers using a calibrated infrared camera. Thermal images were then processed to obtain time-dependent layer temperature profiles of FFF PEEK prints. Both the theoretical model and experiments confirmed that the upper layers in reference to the print bed exhibited higher temperatures, thus higher healing degrees than the lower layers. Increasing the print bed temperature increased the healing of the layers allowing more layers to heal 100%. The nozzle temperature showed the most significant effect on the layer healing, and under certain nozzle temperature, none of the layers healed adequately. Although environment temperature had less impact on the lower layers closer to the print bed, 100% healed layer number increased when the chamber temperature increased. The model predictions were in good agreement with the experimental data, particularly for the mid-part of FFF PEEK cubes printed in both FFF machines.

Additively manufactured electrodes for the electrochemical detection of hydroxychloroquine

Although studies have demonstrated the inactivity of hydroxychloroquine (HCQ) towards SARS-CoV-2, this compound was one of the most prescribed by medical organizations for the treatment of hospitalized patients during the coronavirus pandemic. As a result of it, HCQ has been considered as a potential emerging contaminant in aquatic environments. In this context, we propose a complete electrochemical device comprising cell and working electrode fabricated by the additive manufacture (3D-printing) technology for HCQ monitoring. For this, a 3D-printed working electrode made of a conductive PLA containing carbon black assembled in a 3D-printed cell was associated with square wave voltammetry (SWV) for the fast and sensitive determination of HCQ. After a simple surface activation procedure, the proposed 3D-printed sensor showed a linear response towards HCQ detection (0.4-7.5 μmol L^-1) with a limit of detection of 0.04 μmol L^-1 and precision of 2.4% (n = 10). The applicability of this device was shown to the analysis of pharmaceutical and water samples. Recovery values between 99 and 112% were achieved for tap water samples and, in addition, the obtained concentration values for pharmaceutical tablets agreed with the values obtained by spectrophotometry (UV region) at a 95% confidence level. The proposed device combined with portable instrumentation is promising for on-site HCQ detection.

Processing and mechanical properties of novel biodegradable poly-lactic acid/Zn 3D printed scaffolds for application in tissue regeneration

The feasibility to manufacture scaffolds of poly-lactic acid reinforced with Zn particles by fused filament fabrication is demonstrated for the first time. Filaments of 2.85 mm in diameter of PLA reinforced with different weight fractions of μm-sized Zn - 1 wt.% Mg alloy particles (in the range 3.5 to 17.5 wt.%) were manufactured by a double extrusion method in which standard extrusion is followed by precision extrusion in a filament-maker machine. Filaments with constant diameter, negligible porosity and a homogeneous reinforcement distribution were obtained for Zn weight fractions of up to 10.5%. It was found that the presence of Zn particles led to limited changes in the physico-chemical properties of the PLA that did not affect the window temperature for 3D printing nor the melt flow index. Thus, porous scaffolds could be manufactured by fused filament fabrication at 190 °C with poly-lactic acid/Zn composites containing 3.5 and 7 wt.% of Zn and at 170 °C when the Zn content was 10.5 wt.% with excellent dimensional accuracy and mechanical properties.

Device for measuring part adhesion in FFF process

The adhesion of parts to the build surface plays a central role in the Fused Filament Fabrication (FFF) process. Without sufficient adhesion, the part will deform (so called warping) due to thermal shrinkage, so that no defined geometries can be created. Nevertheless, there is no established method to measure the adhesion of printed parts and therefore it is not possible to targeted improve it. This article presents a measurement method based on the DIN EN 28510-1 standard and a corresponding test device which makes it possible to identify the optimum build surface for a filament and also to improve the process parameters in a targeted manner. The test device combines a FFF printer with a measuring unit so that all common filaments can be tested close to the process up to a processing temperature of 400 °C in the nozzle and around 150 °C on the build platform. The test device uses only open-source parts and software and costs about 1700€.

Size and print path effects on mechanical properties of material extrusion 3D printed plastics

Print conditions for thermoplastics by filament-based material extrusion (MatEx) are commonly optimized to maximize the elastic modulus. However, these optimizations tend to ignore the impact of thermal history that depends on the specimen size and print path selection. Here, we investigate the effect of size print path (raster angle and build orientation) and print sequence on the mechanical properties of polycarbonate (PC) and polypropylene (PP). Examination of parallel and series printing of flat (XY) and stand-on (YZ) orientation of Type V specimens demonstrated that to observe statistical differences in the mechanical response that the interlayer time between printed roads should be approximately 5 s or less. The print time for a single layer in XY orientation is much longer than that for a single layer in YZ orientation, so print sequence only impacts the mechanical response in the YZ orientation. However, the specimen size and raster angle did influence the mechanical properties in XY orientation due to the differences in thermal history associated with intralayer time between adjacent roads. Moreover, all of these effects are significantly larger when printing PC than PP. These differences between PP and PC are mostly attributed to the mechanism of interface consolidation (crystallization vs. glass formation), which changes the requirements for a strong interface between roads (crystals vs. entanglements). These results illustrate how the print times dictated by the print path layout impact observed mechanical properties. This work also demonstrated that the options available in some standards developed for traditional manufacturing will change the quantitative results when applied to 3D printed parts.

Supplementary Information

The online version contains supplementary material available at 10.1007/s40964-022-00275-w.

How do the printing parameters of fused filament fabrication and structural voids influence the degradation of biodegradable devices?

Fused Filament Fabrication (FFF), a commonly used additive manufacturing technology, is now employed widely in biomedical fields for fabricating geometrically complex biodegradable devices. Structural voids arising from the printing process exist within the objects manufactured by FFF. This paper reveals the underlying mechanism of how the printing parameters and voids affect the degradation behaviours of devices made of biodegradable polyesters. It was found that both voids and internal architecture (layer height, for instance) affect the degradation rate by interacting with the reaction-diffusion process. Large suppression of the degradation rate was found when auto-catalytic hydrolysis and diffusion are significant. Degradation rate reduced in an approximately logarithmic manner as void size increased. The extent this effect depended on the strength of auto-catalytic hydrolysis and diffusion, void size and overall device size. The internal architecture of FFF products (regulated by printing parameters) influences the degradation rate by altering the diffusion speed of acid catalysts (regulated by diffusion path length). Both void size and internal architecture should be considered in fabricating biodegradable devices using FFF. STATEMENT OF SIGNIFICANCE: A geometric model that relates printing parameters with voids of FFF is developed to characterise the structure of FFF components. Such a model, when coupled with a degradation model, offers end-to-end simulation capability (e.g. from printing parameters to degradation rate) for predicting degradation properties. The model is validated against the in vitro degradation data obtained in this study. To our knowledge, the impact of printing parameters and voids on degradation is investigated here for the first time. It is found that both the void size and the internal architecture determined by the printing parameters play an essential role in regulating degradation behaviours.

Reusability of autoclaved 3D printed polypropylene compared to a glass filled polypropylene composite

Health care waste can be a costly expenditure for facilities as specific disposal methods must be used to prevent the spread of pathogens. If more multi-use medical devices were available, it could potentially relieve some of this burden; however, sterilization between uses is important in preventing disease transmission. 3D printing has the ability to easily create custom medical devices at a low cost, but the majority of filaments utilized cannot survive steam sterilization. Polypropylene (PP) can withstand autoclave temperatures, but is difficult to print as it warps and shrinks during printing; however, a composite PP filament reduces these effects. Commercially available PP and glass filled PP (GFPP) filaments were successfully 3D printed into 30 × 30 × 30 mm cubes with no shrinking or warping and were autoclaved. The 134 °C autoclave temperature was too high as several cubes melted after two to three rounds, but both PP and GFPP cubes displayed minimal changes in mass and volume after one, four, seven, and ten rounds of autoclaving at 121 °C. GFPP cubes autoclaved zero, four, seven, and ten times had significantly smaller average compressive stress values compared to all PP groups, but the GFPP cubes autoclaved once were only less than PP cubes autoclaved zero, seven and ten times. GFPP cubes autoclaved zero, one, four, and seven times also deformed less indicating that the embedded glass fibers provided additional strength. While a single method was found that successfully printed PP and GFPP cubes that were able to survive up to ten rounds of autoclaving, future work should include further investigation into the mechanical properties and increasing the number of autoclave rounds.

Can filaments, pellets and powder be used as feedstock to produce highly drug-loaded ethylene-vinyl acetate 3D printed tablets using extrusion-based additive manufacturing?

Personalized medicine, produced through 3D printing, is a promising approach for delivering the required drug dose based on the patient's profile. The primary purpose of this study was to investigate the potential of two different extrusion-based additive manufacturing techniques - fused filament fabrication (FFF) and screw-based 3D printing, also known as direct extrusion additive manufacturing (DEAM). Different ethylene-vinyl acetate (EVA) copolymers (9 %VA, 12 %VA, 16 %VA, 18 %VA, 25 %VA, 28 %VA, and 40 %VA) were selected and loaded with 50% (w/w) metoprolol tartrate (MPT). Hot-melt extrusion was performed to produce the drug-loaded filaments. These filaments were used for FFF in which the mechanical and rheological properties were rate-limiting steps. The drug-loaded filament based on the 18 %VA polymer was the only printable formulation due to its appropriate mechanical and rheological properties. As for the highest VA content (40 %VA), the feeding pinch rolls cause buckling of the filaments due to insufficient stiffness, while other filaments were successfully feedable towards the extrusion nozzle. However, poor flowability out of the extrusion nozzle due to the rheological limitation excluded these formulations from the initial printing trials. Filaments were also pelletized and used for pellets-DEAM. This method showed freedom in formulation selection because the screw rotation drives the material flow with less dependence on their mechanical properties. All drug-loaded pellets were successfully printed via DEAM, as sufficient pressure was built up towards the nozzle due to single screw extrusion processing method. In contrast, filaments were used as a piston to build up the pressure required for extrusion in filament-based printing, which highly depends on the filament's mechanical properties. Moreover, printing trials using a physical mixture in powder form were also investigated and showed promising results. In vitro drug release showed similar release patterns for MPT-loaded 3D printed tablets regardless of the printing technique. Additionally, pellets-DEAM enabled the production of tablets with the highest VA content, which failed in FFF 3D printing but showed an interesting delayed release profile.

Estimations of the effective Young's modulus of specimens prepared by fused filament fabrication

The elastic response of homogeneous isotropic materials is most commonly represented by their Young's modulus (E), but geometric variability associated with additive manufacturing results in materials that are neither homogeneous nor isotropic. Here we investigated methods to estimate the effective elastic modulus ( E eff ) of samples fabricated by fused filament fabrication. We conducted finite element analysis (FEA) on printed samples based on material properties and CT-scanned geometries. The analysis revealed how the layer structure of a specimen altered the internal stress distribution and the resulting E eff . We also investigated different empirical methods to estimate E eff as guides. We envision the findings from our study can provide guidelines for modulus estimation of as-printed specimens, with the potential of applying to other extrusion-based additive manufacturing technologies.

Fully integrated 3D-printed electrochemical cell with a modified inkjet-printed Ag electrode for voltammetric nitrate analysis

To address the need for low-cost analytical tools for on-site aquaculture water quality monitoring, miniaturized electrochemical sensor systems can be readily fabricated using additive manufacturing technologies such as 3D printing and inkjet printing. In this work, we report the design and fabrication of an additively manufactured electrochemical platform featuring a reusable 3D-printed electrochemical cell with integrated reference and counter electrodes, and a replaceable inkjet-printed Ag (IJP-Ag) working electrode. The electrochemical cell was 3D-printed with acrylonitrile butadiene styrene (ABS) filament and features a 3D-printed ABS-carbon counter electrode and a Ag|AgCl|gel-KCl reference electrode with a 3D-printed porous junction directly integrated along the sides of the sample compartment. The application of the integrated cell is demonstrated with the analysis of nitrate ions on the IJP-Ag electrode, which was modified with electrodeposited nanostructured Ag to enhance sensitivity to nitrate reduction. Linear sweep voltammetry (LSV) was successfully applied to detect nitrate with a LOD of 1.40 ppm and a sensitivity of 0.2086 μA ppm^-1 in a background of artificial brackish aquaculture water (pH 8.0). The sensor response showed intra- and inter-electrode reproducibility and no significant interferences to most of the commonly encountered cations and anions in brackish water. The electrochemical sensor system was also applied to nitrate determination in real aquaculture water samples and demonstrated no significant differences with the results obtained using the standard spectrophotometric method at a 95% confidence level. Our results show how additive manufacturing is a promising approach to readily fabricate fit-for-purpose, low-cost miniaturized electrochemical sensor systems for point-of-use applications.

Structure-function assessment of 3D-printed porous scaffolds by a low-cost/open source fused filament fabrication printer

Additive manufacturing encompasses a plethora of techniques to manufacture structures from a computational model. Among them, fused filament fabrication (FFF) relies on heating thermoplastics to their fusion point and extruding the material through a nozzle in a controlled pattern. FFF is a suitable technique for tissue engineering, given that allows the fabrication of 3D-scaffolds, which are utilized for tissue regeneration purposes. The objective of this study is to assess a low-cost/open-source 3D printer (In-House), by manufacturing both solid and porous samples with relevant microarchitecture in the physiological range (100-500 μm pore size), using an equivalent commercial counterpart for comparison. For this, compressive tests in solid and porous scaffolds manufactured in both printers were performed, comparing the results with finite element analysis (FEA) models. Additionally, a microarchitectural analysis was done in samples from both printers, comparing the measurements of both pore size and porosity to their corresponding computer-aided design (CAD) models. Moreover, a preliminary biological assessment was performed using scaffolds from our In-House printer, measuring cell adhesion efficiency. Finally, Fourier transform infrared spectroscopy - attenuated total reflectance (FTIR-ATR) was performed to evaluate chemical changes in the material (polylactic acid) after fabrication in each printer. The results show that the In-House printer achieved generally better mechanical behavior and resolution capacity than its commercial counterpart, by comparing with their FEA and CAD models, respectively. Moreover, a preliminary biological assessment indicates the feasibility of the In-House printer to be used in tissue engineering applications. The results also show the influence of pore geometry on mechanical properties of 3D-scaffolds and demonstrate that properties such as the apparent elastic modulus (E_app) can be controlled in 3D-printed scaffolds.

Mechanical and hydrolytic properties of thin polylactic acid films by fused filament fabrication

Thin polymeric films are widely used as medical applications such as cell culture, stent, drug delivery and mechanical fixation. One of the most commonly used materials is polylactic acid (PLA) - a material, which is non-toxic, biodegradable and biocompatible. Fused filament fabrication (FFF) is a preferable additive manufacturing technique to manufacture polymers, where PLA is one of the most common materials. FFF is a promising technique for customised biomedical applications due to its relatively low cost and geometrical flexibility where biomedical applications are patient tailored. This study is the first to consider FFF monolayered thin films of PLA in terms of mechanical and hydrolytic properties at 37 °C in vitro degradation. Throughout degradation, the reduction in mechanical properties was examined by analysing molecular weight and thermal properties. FFF monolayered PLA underwent autocatalytic bulk degradation with no proof of significant mass loss. Young's modulus, ultimate tensile strength and molecular weight reduced by approximately 60%, 86%, and 80% after 280 days, respectively, while the degree of crystallinity increased by 143% in comparison to benchmark thin films at day 0. It was found that the decrease in mechanical properties was more sensitive to the increase in crystallinity in the early stage of the degradation, while the molecular weight was more dominant in the late stage of the degradation. This study provides practical information in terms of mechanical properties to support medical device designers in a range of potential end-use biomedical applications to achieve safe functional products over the required degradation lifetime.

M3DISEEN: A novel machine learning approach for predicting the 3D printability of medicines

Artificial intelligence (AI) has the potential to reshape pharmaceutical formulation development through its ability to analyze and continuously monitor large datasets. Fused deposition modeling (FDM) three-dimensional printing (3DP) has made significant advancements in the field of oral drug delivery with personalized drug-loaded formulations being designed, developed and dispensed for the needs of the patient. The FDM 3DP process begins with the production of drug-loaded filaments by hot melt extrusion (HME), followed by the printing of a drug product using a FDM 3D printer. However, the optimization of the fabrication parameters is a time-consuming, empirical trial approach, requiring expert knowledge. Here, M3DISEEN, a web-based pharmaceutical software, was developed to accelerate FDM 3D printing using AI machine learning techniques (MLTs). In total, 614 drug-loaded formulations were designed from a comprehensive list of 145 different pharmaceutical excipients, 3D printed and assessed in-house. To build the predictive tool, a dataset was constructed and models were trained and tested at a ratio of 75:25. Significantly, the AI models predicted key fabrication parameters with accuracies of 76% and 67% for the printability and the filament characteristics, respectively. Furthermore, the AI models predicted the HME and FDM processing temperatures with a mean absolute error of 8.9 °C and 8.3 °C, respectively. Strikingly, the AI models achieved high levels of accuracy by solely inputting the pharmaceutical excipient trade names. Therefore, AI provides an effective holistic modeling technology and software to streamline and advance 3DP as a significant technology within drug development. M3DISEEN is available at (http://m3diseen.com/predictions/).

Optimization of fused filament fabrication process parameters under uncertainty to maximize part geometry accuracy

This work presents a novel process design optimization framework for additive manufacturing (AM) by integrating physics-informed computational simulation models with experimental observations. The proposed framework is implemented to optimize the process parameters such as extrusion temperature, extrusion velocity, and layer thickness in the fused filament fabrication (FFF) AM process, in order to reduce the variability in the geometry of the manufactured part. A coupled thermo-mechanical model is first developed to simulate the FFF process. The temperature history obtained from the heat transfer analysis is then used as input for the mechanical deformation analysis to predict the dimensional inaccuracy of the additively manufactured part. The simulation model is then corrected based on experimental observations through Bayesian calibration of the model discrepancy to make it more accurately represent the actual manufacturing process. Based on the corrected prediction model, a robustness-based design optimization problem is formulated to optimize the process parameters, while accounting for multiple sources of uncertainty in the manufacturing process, process models, and measurements. Physical experiments are conducted to verify the effectiveness of the proposed optimization framework.

3D printed medicines: A new branch of digital healthcare

Three-dimensional printing (3DP) is a highly disruptive technology with the potential to change the way pharmaceuticals are designed, prescribed and produced. Owing to its low cost, diversity, portability and simplicity, fused deposition modeling (FDM) is well suited to a multitude of pharmaceutical applications in digital health. Favourably, through the combination of digital and genomic technologies, FDM enables the remote fabrication of drug delivery systems from 3D models having unique shapes, sizes and dosages, enabling greater control over the release characteristics and hence bioavailability of medications. In turn, this system could accelerate the digital healthcare revolution, enabling medicines to be tailored to the individual needs of each patient on demand. To date, a variety of FDM 3D printed medical products (e.g. implants) have been commercialised for clinical use. However, within pharmaceuticals, certain regulatory hurdles still remain. This article reviews the current state-of-the-art in FDM technology for medical and pharmaceutical research, including its use for personalised treatments and interconnection within digital health networks. The outstanding challenges are also discussed, with a focus on the future developments that are required to facilitate its integration within pharmacies and hospitals.

Fabrication of controlled-release budesonide tablets via desktop (FDM) 3D printing

The aim of this work was to explore the feasibility of using fused deposition modelling (FDM) 3D printing (3DP) technology with hot melt extrusion (HME) and fluid bed coating to fabricate modified-release budesonide dosage forms. Budesonide was sucessfully loaded into polyvinyl alcohol filaments using HME. The filaments were engineered into capsule-shaped tablets (caplets) containing 9mg budesonide using a FDM 3D printer; the caplets were then overcoated with a layer of enteric polymer. The final printed formulation was tested in a dynamic dissolution bicarbonate buffer system, and two commercial budesonide products, Cortiment® (Uceris®) and Entocort®, were also investigated for comparison. Budesonide release from the Entocort® formulation was rapid in conditions of the upper small intestine while release from the Cortiment® product was more delayed and very slow. In contrast, the new 3D printed caplet formulation started to release in the mid-small intestine but release then continued in a sustained manner throughout the distal intestine and colon. This work has demonstrated the potential of combining FDM 3DP with established pharmaceutical processes, including HME and film coating, to fabricate modified release oral dosage forms.

A flexible-dose dispenser for immediate and extended release 3D printed tablets

The advances in personalised medicine increased the demand for a fast, accurate and reliable production method of tablets that can be digitally controlled by healthcare staff. A flexible dose tablet system is presented in this study that proved to be suitable for immediate and extended release tablets with a realistic drug loading and an easy-to-swallow tablet design. The method bridges the affordable and digitally controlled Fused Deposition Modelling (FDM) 3D printing with a standard pharmaceutical manufacturing process, Hot Melt Extrusion (HME). The reported method was compatible with three methacrylic polymers (Eudragit RL, RS and E) as well as a cellulose-based one (hydroxypropyl cellulose, HPC SSL). The use of a HME based pharmaceutical filament preserved the linear relationship between the mass and printed volume and was utilized to digitally control the dose via an input from computer software with dose accuracy in the range of 91-95%. Higher resolution printing quality doubled the printing time, but showed a little effect on in vitro release pattern of theophylline and weight accuracy. Physical characterization studies indicated that the majority of the model drug (theophylline) in the 3D printed tablet exists in a crystal form. Owing to the small size, ease of use and the highly adjustable nature of FDM 3D printers, the method holds promise for future individualised treatment.

Fabrication of extended-release patient-tailored prednisolone tablets via fused deposition modelling (FDM) 3D printing

Rapid and reliable tailoring of the dose of controlled release tablets to suit an individual patient is a major challenge for personalized medicine. The aim of this work was to investigate the feasibility of using a fused deposition modelling (FDM) based 3D printer to fabricate extended release tablet using prednisolone loaded poly(vinyl alcohol) (PVA) filaments and to control its dose. Prednisolone was loaded into a PVA-based (1.75 mm) filament at approximately 1.9% w/w via incubation in a saturated methanolic solution of prednisolone. The physical form of the drug was assessed using differential scanning calorimetry (DSC) and X-ray powder diffraction (XRPD). Dose accuracy and in vitro drug release patterns were assessed using HPLC and pH change flow-through dissolution test. Prednisolone loaded PVA filament demonstrated an ability to be fabricated into regular ellipse-shaped solid tablets using the FDM-based 3D printer. It was possible to control the mass of printed tablet through manipulating the volume of the design (R(2) = 0.9983). On printing tablets with target drug contents of 2, 3, 4, 5, 7.5 and 10mg, a good correlation between target and achieved dose was obtained (R(2) = 0.9904) with a dose accuracy range of 88.7-107%. Thermal analysis and XRPD indicated that the majority of prednisolone existed in amorphous form within the tablets. In vitro drug release from 3D printed tablets was extended up to 24h. FDM based 3D printing is a promising method to produce and control the dose of extended release tablets, providing a highly adjustable, affordable, minimally sized, digitally controlled platform for producing patient-tailored medicines.