3D-printed Specimens Research Articles

Flexural Strength Analysis of Different Complete Denture Resin-Based Materials Obtained by Conventional and Digital Manufacturing.

This study compared the flexural strength of different resins fabricated using different technologies (conventional, CAD-CAM-milled, and 3D-printed) and polymerization techniques. A total of 11 different resins were tested: six PMMA conventional (Acrypol R, Acrypol LL, Acrypol HI, Acrypol Fast, Acryself and Acryslef P), two milled obtained from UDMA PMMA disks (Ivotion disk and Aadva disk, control groups), two 3D-printed PMMA resins (NextDent Denture 3D+, and SprintRayEU Denture Base), and one 3D-printed composite resin (GC Temp Print). Flexural strength was measured using a universal testing machine. One-way ANOVA and Bonferroni post hoc tests were performed; the p-value was set at 0.05 to consider statistically significant differences among the groups. Spearman test was used to evaluate the correlation between polymerization technique and the flexural strength of 3D-printed resins. CAD-CAM-milled specimens showed the highest flexural strength (107.87 MPa for UDMA) followed by 3D-printed composite resins (102.96 MPa). Furthermore, 3D-printed resins polymerized for 40 min with the BB cure unit showed no statistically significant differences with conventional resin groups. Moreover, in all the 3D-printed specimens, a high correlation between polymerization technique and flexural strength was found. In terms of flexural strength, the polymerization technique is a determinant for both acrylic and composite resins. Temp Print can be a potential alternative to fabricating removable dentures and showed promising results when used in combination with pink color resin powder.

Advanced additive manufacturing of self-healing composites: Exploiting shape memory alloys for autonomous restoration under mixed-mode loading

Applying Additive Manufacturing (AM) techniques has facilitated the production of innovative self-healing structures that can acclimate to environmental fluctuations by considering their damage response. This paper introduces a novel approach for fabricating AM composites reinforced with Shape Memory Alloys (SMAs) and possessing self-healing capabilities. The self-healing performance of the composites is assessed by subjecting undamaged and repaired samples to mixed mode I/II loading conditions using pre-cracked Semi-Circular Bending (SCB) specimens. Supplementary parameters that impact the self-healing process, including varied pre-strain levels of 1%, 2%, and 4.3% for SMA wires, are investigated. The outcomes of these pre-strain levels are subsequently compared to the repair scenario in the absence of SMAs. The transferred healing agent volume to the damaged region and the remaining crack opening is quantified using a thermography camera and image processing techniques. The study’s results demonstrate that self-healing can be achieved through strategic considerations of pre-strain levels in SMA strings and loading modes. Furthermore, the study suggests that neglecting such concerns may potentially have deleterious effects on layered samples' load-bearing capacity. The proposed methodology holds great promise for producing self-healing 3D-printed composite specimens in the laboratory and scaling them up to real-world applications.

Analyzing the effect of notch geometry on the impact strength of 3D-printed specimens

Abstract Additive manufacturing (AM) using 3D printing techniques such as fused deposition modeling (FDM) has now found much attention, not only in prototyping but also in industrial production. Indeed, the 3D-printed components are now widely used as structural elements in many applications such as biomechanical engineering (dentistry, orthopedics, bio implants, etc.) and therefore, full understanding of their strength, load carrying capacity, improving the mechanical behaviors, and manufacturing process is an important issue. Charpy impact experiments offer information on the strength of a material to sudden failure where a sharp stress raiser or notch is present. In addition to providing information not available from any other simple mechanical experiments, the impact resistance tests are quick and inexpensive, so they are often used. In this research, impact strength experiments were conducted at room temperatures on rectangular samples containing three different notches including V-notch, U-notch, and Keyhole-notch to determine impact resistance of the 3D-printed polylactic acid (PLA) components. The capability of multiple comparison tests for analysis of variance like ANOVA, Tukey, and Fisher methods for prediction of impact resistance in the tested specimens were also investigated. The samples containing Keyhole notch showed highest Charpy impact resistance. In contrary, V-notched sample provided the lowest impact energy. All the employed statistical analyses reveal that the notch type has meaningful influence on the impact energy of 3D-printed parts.

4D-Printed Hydrogel Actuators through Diffusion-Path Architecture Design.

Recently, smart hydrogels have garnered considerable attention as biomedical devices, and several approaches have been introduced for their fabrication, including the incorporation of stimulus-responsive additives, utilization of molecular imprinting techniques, and application of multilayered hydrogels. However, the nonuniform properties resulting from these approaches limit the practical applications of hydrogels by causing inconsistent performance and behavior. In this study, we propose a novel approach to manipulating the swelling kinetics of hydrogels by engineering their diffusion-path architecture. By simply adjusting the diffusion path length within the hydrogel, we achieved a significant change in swelling kinetics. This approach enables precise control over the diffusion and transport processes within the hydrogel, resulting in enhanced swelling kinetics when reducing the diffusion path length. Furthermore, by strategically designing the diffusion-path architecture of a 3D-printed hydrogel specimen, we can fabricate smart hydrogel actuators that exhibit reversible shape transformations during swelling and deswelling through a nonequilibrium differential swelling. The proposed approach eliminates the need to modify the spatial properties of hydrogel structures such as cross-linking density, polymer, or additive compositions, thereby achieving uniform properties throughout the hydrogel and creating new possibilities for the development of advanced 4D-printed biomedical devices.

Optimization of Isotactic Polypropylene Nanocomposite Content of Tungsten Carbide for Material Extrusion 3D Printing

In this study, innovative nanocomposite materials for material extrusion (MEX) 3D printing were developed using a polypropylene (PP) polymer with tungsten carbide (WC) nanopowder. The raw materials were converted into filaments using thermomechanical extrusion. The samples were then fabricated for testing according to the international standards. Extensive mechanical testing was performed on the 3D-printed specimens, including tensile, impact, flexural, and microhardness assessments. In addition, the impact of ceramic additive loading was examined. The thermal and stoichiometric characteristics of the nanocomposites were examined using thermogravimetric analysis, energy-dispersive X-ray spectroscopy, differential scanning calorimetry, and Raman spectroscopy. The 3D-printed shape, quality, and fracture process of the specimens were examined using scanning electron microscopy. The results showed that the filler significantly enhanced the mechanical characteristics of the matrix polymer without reducing its thermal stability or processability. Notably, the highest level of nanocomposite mechanical responsiveness was achieved through the inclusion of 6.0 and 8.0 wt. % fillers. The 10.0 wt. % loading nanocomposite showed significantly increased microhardness, indicating a possible high resistance to wear.

Bond Strength of Reline Materials to 3D-Printed Provisional Crown Resins.

(1) Purpose: The aim of the present study was to compare the bond strength between two 3D-printed resins designed for long-term provisional crowns and three different reline materials. (2) Materials and Methods: Rectangular specimens were prepared from two 3D-printed resins (Envision Tech and NextDent C&B) and a conventional self-cure PMMA. Transparent tubes filled with three different reline materials including composite resin, Bis-acryl, and PMMA were bonded to the 3D-printed specimens (n = 11 per group, total of 6 study groups). Tubes filled with PMMA were bonded to the prepared PMMA specimens which served as the control group (n = 11, control group). The specimens were subjected to a shear bond strength (SBS) test, and mode of failure was recorded using light microscopy. Statistical analysis was performed using a one-way ANOVA and post hoc Tukey's tests (alpha = 0.05). (3) Results: The highest SBS value was achieved to both 3D-printed materials with the PMMA reline material. The bond to both 3D-printed materials was lower with Bis-acrylic or composite resin relines in comparison to that with PMMA (p-value < 0.05). No significant difference was found between the control PMMA group and either 3D-printed material when relined with PMMA (p-value > 0.05). (4) Conclusion: The tested 3D-printed resins achieved a clinically acceptable bond strength when relined with PMMA.

Improved mechanical performance of quasi-cubic lattice metamaterials with asymmetric joints

In this paper, we propose a simple method for the modification of the unit cells in the lattice metamaterials that provides an improvement of their impact strength. The idea is based on the introduction of small mutual offsets of the interconnected struts inside the unit cells. In such way, the joints between the struts become asymmetric and the overall geometry of the unit cells can be defined as the quasi-cubic with the axis of chirality. Considering four types of cubic lattices with BCC, BCT, FCC and octahedron structures, we modified their geometry and investigated the influence of the offsets and the unit cell size on the overall performance in static and dynamic tests. From the experiments we found that the small offsets (less than the strut diameter) can allow to increase the impact strength of 3d-printed polymeric specimens in 1.5–3 times remaining almost the same density and static mechanical properties. Based on the numerical simulations, we show that the explanation of the observed phenomena can be related to the increase of plastic deformations and damage accumulation in the unit-cells with asymmetric joints leading to the transition from the quasi-brittle to the ductile type of fracture in tested specimens.

Biocompatibility characterization of cryogenically treated FDM printed thermoplastic polyurethane

The utilization of Additive Manufacturing (AM) has ushered in a transformative era in healthcare, presenting unprecedented possibilities for medical applications. This trend has escalated the demand for 3D printing of medical-grade materials. Cryogenic treatment, a technique known to influence the structure and morphology of biocompatible thermoplastics like ultra-high molecular weight polyethylene (UHMWPE) and thermoplastic polyurethane (TPU), holds promising potential for revolutionizing biomedical materials. The present study conducted a comprehensive biocompatibility assessment on untreated and deep cryogenically treated 3D printed TPU. Cryogenic treatment induced a roughly 2% decrease in contact angle, enhancing TPU's hydrophilicity. The Deep Cryogenic Treatment (DCT) did not exhibit any deteriorating impact on the 3D-printed TPU specimens. This study shows that the transformative potential of cryogenically treated TPU in biomedical contexts is profound and paves the way for potential breakthroughs in applying DCT on additively manufactured biomedical materials in healthcare.

Multi-Objective Parametric Shape Optimisation of Body-Centred Cubic Lattice Structures for Additive Manufacturing

There has been significant interest in additively manufactured lattice structures in recent years due to their enhanced mechanical and multi-physics properties, making them suitable candidates for various applications. This study presents a multi-parameter implicit equation model for designing body-centred cubic (BCC) lattice structures. The model is used in conjunction with a multi-objective genetic algorithm (MOGA) approach to maximise the stiffness of the BCC lattice structure while minimising von-Mises stress within the structure under a specific loading condition. The selected design from the MOGA at a specific lattice density is compared with the classical BCC lattice structure and the designs generated by a single-objective genetic algorithm, which focuses on maximising stiffness or minimising von-Mises stress alone. By conducting a finite element analysis on the optimised samples and performing mechanical testing on the corresponding 3D-printed specimens, it was observed that the optimised lattice structures exhibited a substantial improvement in mechanical performance compared to the classical BCC model. The suitability of multi-objective and single-objective optimisation approaches for designing lattice structures was further investigated by comparing the corresponding designs in terms of their stiffness and maximum von-Mises stress values. The results from the numerical analysis and experimental testing demonstrate the significance of the application of an appropriate optimisation strategy for designing lattice structures for additive manufacturing.

Investigating a shape memory epoxy resin and its application to engineering shape-morphing devices empowered through kinematic chains and compliant joints

4D printing is the additive manufacturing (3D printing) of objects that can transform their shape in a controlled and predictable way when subjected to external stimuli. A thermo-responsive shape memory polymer (SMP) is a highly suitable material to 4D print smart devices, due to its actuation function and the capability of recovering its original shape from the deformed one upon heating. This study presents the results of employing an epoxy resin in the additive manufacturing of complex-shaped smart devices with shape-morphing properties using laser stereolithography (SLA). To quantify the shape memory behaviour of the shape memory epoxy (SMEp), we first investigate the thermomechanical properties of the 3D-printed specimens in a tensile testing machine coupled with an environmental thermal chamber. This approach allows us to determine the shape fixity and recovery of SMEp. Next, we propose effective designs of complex-shaped devices, with the aim of promoting shape morphing through micro-actuators and compliant joints acting as active regions in combination with multiplying mechanisms or kinematic chains in each of the devices. We manufacture the complex-shaped prototypes by using SLA directly from the computer-aided designs. The shape memory trials of the 3D-printed prototypes reveal quite precise shape recovery of the devices, illustrating their shape-memory. In fact, the inclusion of micro-actuators and compliant joints within the complex-geometry devices allows for local triggering, deformation and recovery, resulting in a prompt response of the devices to heat. Therefore, innovative designs, along with the suitable smart material and high-quality manufacturing process, lead to 4D printed devices with fast actuation and shape-morphing properties. Overall, this research may contribute to the development of smart materials and 4D printing technology for applications in fields such as biomedical engineering, robotics, transport and aerospace engineering.

Experimental and analytical investigation of bio-inspired lattice structures under compressive loading

The main objective of this study is to fabricate a Novel bio-inspired lattice structure for energy absorption. A lattice structure design was proposed based on the microstructure of one of the various butterfly species Papilio Xuthus. Two major parameters are chosen from the structure to make multiple designs which may cause changes in the behavior of the structure among all available parameters. The parametric values required for the designs were calculated with the help of Response Surface Methodology (RSM) using Minitab software. The proposed designs are modeled in Autodesk Fusion 360 and 3D printed specimens of size 40 × 40 × 40 (all are in mm) are fabricated by Stereolithography (SLA) process based on the chosen parameters. The 3D-printed specimens are tested under quasi-static compressive loading using Instron 8801 Universal testing machine (UTM). The test results obtained from the testing are used to construct regression equations for energy absorption (EA) and specific energy absorption (SEA). The developed equations can be used to find out EA and SEA values for any combination of the proposed parameters (x and d) for suitable energy absorption applications.

Design Optimization of DR3AM Vapor Polishing Device for ABS 3D-Printed Parts

3D printing is an additive manufacturing method that turns digital design into an actual product. A 3D-printed part sometimes requires post-processing to enhance its physical and mechanical properties. Acetone vapor polishing is one of those techniques which is highly beneficial in smoothing ABS 3D-printed parts. Previously, an acetone vapor polishing device has been developed which uses a mist maker. However, for a more efficient polishing method, an optimized vapor polishing device using heat has been fabricated in this study. To assess the efficiency of this device, the researchers test the dimensional accuracy, surface roughness, tensile strength, and impact strength of polished and unpolished ABS 3D-printed specimens. The findings showed that the surface smoothness of the polished cube specimens did not significantly alter its physical geometry. The tensile test reveals that the overall elasticity of the polished tensile specimen has increased significantly while the impact test also shows that the polished specimens have the capacity to sustain a resistive impact from a swinging pendulum. Thus, all testing procedures indicated that post-processing using the optimized vapor polishing device has improved the overall physical and mechanical properties of the polished specimens.

Tensile Strength Evaluation of FDM 3D-Printed Polymer Using Taguchi Methodology and Range Analysis

Fused Deposition Modeling (FDM) is an Additive Manufacturing technology where a heated plastic filament will be placed on the bedplate layer by layer until the 3D object is printed. The mechanical properties of the ABS FDM 3D-printed parts are not yet determined or estimated prior printing. Hence, the goal of this study is to identify the optimum 3D printing parameters based on the tensile properties of ABS FDM 3D-printed polymer parts. Taguchi approach and Range Analysis were used in finding the optimum 3D printing parameters in which different parameters were considered to meet the requirements of the orthogonal arrays. Five pieces of 3D-printed dumbbell-shaped tensile specimen were prepared for each parameter. The tests followed the ASTM D638-14 standard. The result for the optimum 3D printing configuration of ABS FDM 3D-printed material were concluded as the values with the highest tensile strength.

Effects of copper additives on load carrying capacity and micro mechanisms of fracture in 3D-printed PLA specimens

This study deals with the effects of employing copper additives on the fracture resistance and fracture micro-mechanisms of 3D-printed Polylactic Acid (PLA) specimens under mixed mode I/II loading. Several comparative fracture tests are conducted on pre-cracked Semi-Circular Bend (SCB) specimens made of pure PLA and particulate copper-reinforced PLA (PLA/Cu) printed using the Fused Deposition Modeling (FDM) technique. The SCB specimens are fabricated in three different layer orientations. The comparison of the experimental results reveals that employing copper additives increases the load carrying capacities (LCCs) of the pre-cracked SCB specimens with the flat, on-edge, and upright layer orientations by 2.9%, 15.5%, and 27.7%, respectively. In addition, to determine the tensile properties of two desired materials, dogbone specimens made of PLA and PLA/Cu in three different layer orientations are fabricated and tested. The experimental results obtained from the characterization tests similarly indicate that the presence of copper additives in 3D printed PLA specimens increases ultimate tensile strength by 15.9%, 14%, and, 10.4% in the three flat, on-edge, and upright layer orientations, respectively. Aside from performing experimental tests, the LCCs of pre-cracked specimens are predicted theoretically by utilizing Equivalent Material Concept (EMC) combined with the well-known Average Strain Energy Density (ASED) criterion. It is shown that the EMC-ASED criterion can estimate accurately the experimental LCCs of both FDM-PLA and FDM-PLA/Cu specimens. Finally, the Scanning Electron Microscope (SEM) technique is employed to provide a better understanding of the effects of copper additives on the micro-mechanisms of fracture.

Corrosion and passivation behavior of Ti-6Al-4V surfaces treated with high-energy pulsed laser: A comparative study of cast and 3D-printed specimens in a NaCl solution

This study explores using high-energy pulsed laser to improve the surface property and corrosion behavior of Ti-6Al-4V, aiming to develop a more eco-friendly and efficient approach. The study comprises conventional cast samples, advanced 3D-printed samples, and their respective laser-treated counterparts, all tested in a 3.5 wt% NaCl solution. The findings showed that sample 3 (as-3D-printed) had a more stable passivation film than sample 1 (as-cast). The laser-treated surface of sample 2 (laser-treated cast) greatly enhances film stability and resistance. Moreover, sample 4 (laser-treated 3D-printed) exhibited significantly better corrosion performance compared to sample 3 (as-3D-printed) due to the increased thickness of the passivation film in the laser-treated samples, resulting in higher film corrosion resistance. The results reveal that laser remelting treatment can eliminate macroscopic defects, reduce grain size, increase grain boundary density, and generate denser and more stable passivation films on the surface of Ti-6Al-4V, leading to reduced corrosion currents during dynamic potential polarization. Furthermore, laser remelting treatment has the capability to transform and refine the α phase into a finer lamellar and needle-like structure, thereby increasing the density of passivation nucleation sites during the corrosion process, resulting in the formation of a high-density passivation layer, and ultimately improving the corrosion resistance. By gaining a better understanding of the underlying mechanisms involved in high-energy pulsed treatment, this work provides valuable insights that can be used to optimize the treatment process and improve the overall surface properties of Ti-6Al-4V alloys.

Effects of Slit Edge Notches on Mechanical Properties of 3D-Printed PA12 Nylon Kirigami Specimens.

Kirigami structures, a Japanese paper-cutting art form, has been widely adopted in engineering design, including robotics, biomedicine, energy harvesting, and sensing. This study investigated the effects of slit edge notches on the mechanical properties, particularly the tensile stiffness, of 3D-printed PA12 nylon kirigami specimens. Thirty-five samples were designed with various notch sizes and shapes and printed using a commercial 3D printer with multi-jet fusion (MJF) technique. Finite element analysis (FEA) was employed to determine the mechanical properties of the samples computationally. The results showed that the stiffness of the kirigami samples is positively correlated with the number of edges in the notch shape and quadratically negatively correlated with the notch area of the samples. The mathematical relationship between the stretching tensile stiffness of the samples and their notch area was established and explained from an energy perspective. The relationship established in this study can help fine-tune the stiffness of kirigami-inspired structures without altering the primary parameters of kirigami samples. With the rapid fabrication method (e.g., 3D printing technique), the kirigami samples with suitable mechanical properties can be potentially applied to planar springs for hinge structures or energy-absorbing/harvesting structures. These findings will provide valuable insights into the development and optimization of kirigami-inspired structures for various applications in the future.

Microleakage of Restorative Materials Used for Temporization of Endodontic Access Cavities.

A tight temporary seal applied to an access cavity is thought to improve endodontic outcomes. This study aims to assess the bacterial and glucose microleakage of different types and combinations of temporary restorations. Human-extracted incisors were instrumented, dressed with a calcium hydroxide paste, and sealed with Cavit W (CW), CW/Ketac Molar (CW/KM), CW/Smart Dentin Replacement (CW/SDR), Intermediate restorative material/KM (IRM/KM), or Clip F (CF). Standardized 3D-printed hollow test specimens were manufactured and temporized in the same manner. The specimens were examined for bacterial and glucose leakage for 28 days. Data were analyzed using a Kaplan-Meier survival analysis. CW/SDR and CF showed the least bacterial and glucose leakage over time. CW, CW/KM, and IRM/KM had similarly high levels of glucose leakage, but CW/KM and IRM/KM provided a tighter seal against bacterial penetration than CW. CW/SDR and CF should be considered for the sealing of access cavities of teeth previously restored with methacrylate-based materials.

Effect of Different Standard Geometry Shapes on the Tensile Properties of 3D-Printed Polymer.

This study presents a comparative analysis of the tensile properties of 3D-printed polymer specimens with different standard geometry shapes. The objective is to assess the influence of printing orientation and geometry on the mechanical performance. Rectangular-shaped ASTM D3039 specimens with angles of 0°, 15°, and 90° are compared to various tensile test specimens based on ASTM and ISO standards. All specimens are fabricated using polyethylene terephthalate glycol (PETG) material through fused deposition modeling (FDM). Two printing orientations, flat and on-edge, are investigated, and tensile strength, elastic modulus, strain, and elongation at break are measured. The study examines the weak spot commonly found at the neck of the specimens and evaluates the broken areas. Additionally, a numerical analysis using the finite element method (FEM) is performed to identify stress risers' locations in each specimen type. Experimental results show that the ASTM D3039-0° specimen printed in the on-edge orientation exhibits the highest tensile properties, while the flat orientation yields the best results in terms of the broken area. The ISO 527-2 specimens consistently display lower tensile properties, irrespective of the printing orientation. The study highlights the enhanced tensile properties achieved with the rectangular shape. Specifically, the tensile strength of ASTM D3039-0° was 17.87% and 21% higher than that of the ISO 527 geometry shape for the flat and on-edge orientations, respectively. The numerical analysis indicated that the ISO 527-2 specimen had either no or minimal stress raisers, and the higher stresses observed in the narrow section were isolated from the gripping location. The findings contribute to understanding the relationship between standard geometry shapes, printing orientation, and the resulting tensile properties of 3D-printed polymer specimens.

Second-grade elasticity of three-dimensional pantographic lattices: theory and numerical experiments

A continuum theory of pantographic lattices, based on second-grade elasticity, is presented. The proposed model is able to describe the mechanical behavior of a type of material structure made up of multiple layers of pantographic sheets connected with a third family of fibers. Thus, these materials are characterized by an orthogonal pattern of fibers that can bend, stretch and twist. Numerical experiments illustrate the predictive potential of the model when the material is subjected to different types of mechanical loads, including compression, torsion and two kinds of bending. Analyzing the material responses for these various tests makes it possible to reveal unusual deformation patterns characteristic of such “pantographic blocks.” Numerical simulations using the finite element method are intended to assist in designing an experimental program using 3D-printed specimens made of different materials.

Numerical and experimental investigation on creep response of 3D printed Polylactic acid (PLA) samples. Part I: The effect of building direction and unidirectional raster orientation

The main aim of this research work is to investigate the effects of building directions and raster orientations on the creep behavior of 3D-printed plastic material and to develop rheological constitutive models to estimate the creep behavior of components. These components have been manufactured through the Fused Deposition Modeling (FDM) technique in which materials are heated and extruded through a nozzle to create 3D Polylactic acid (PLA) specimens. Since 3D-printed specimens exhibit anisotropic behavior, studying their building condition is necessary. Both building direction and raster orientation are among the fabrication conditions that play a major role in the mechanical behavior of the specimens. The tensile behavior of 3D-produced PLA specimens and their creep behavior were evaluated. To model the creep behavior of 3D printed PLA, three different types of rheological constitutive models, Zener, Burgers, and modified Burgers were used analytically and numerically. The finite element (FE) model of the 3D printed unnotched samples was developed to predict the creep behavior of notched samples. The results show that 3D FE models can predict the creep behavior of AM-notched specimens with high accuracy.