3D Printing Technology Research Articles

Inertial microfluidic mixer for biological CubeSat missions

Nanosatellites of CubeSat type due to, i.a., minimized costs of space missions, as well as the potential large application area, have become a significant part of the space economy sector recently. The opportunity to apply miniaturized microsystem (MEMS) tools in satellite space missions further accelerates both the space and the MEMS markets, which in the coming years are considered to become inseparable. As a response to the aforementioned perspectives, this paper presents a microfluidic mixer system for biological research to be conducted onboard CubeSat nanosatellites. As a high complexity of the space systems is not desired due to the need for failure-free and remotely controlled operation, the principal concept of the work was to design an entirely passive micromixer, based on lab-on-chip technologies. For the first time, the microfluidic mixer that uses inertial force generated by rocket engines during launch to the orbit is proposed to provide an appropriate mixing of liquid samples. Such a solution not only saves the space occupied by standard pumping systems, but also reduces the energy requirements, ultimately minimizing the number of battery modules and the whole CubeSat size. The structures of the microfluidic mixers were fabricated entirely out of biocompatible resins using MultiJet 3D printing technology. To verify the functionality of the passive mixing system, optical detection consisting of the array of blue LEDs and phototransistors was applied successfully. The performance of the device was tested utilizing an experimental rocket, as a part of the Spaceport America Cup 2023 competition.Graphical abstract

Hemisection Procedure Facilitated by 3D Printing and a Customized Surgical Guide: A Novel Approach

When there is a lesion in a multi-rooted tooth, but only one root is infected, resective therapies are an effective treatment option for maintaining natural tooth structure. Hemisection may be the best line of action when a single root is decayed or periodontally compromised, but the other is intact. As precision and accuracy are paramount in ensuring the success of this procedure, this case explores the integration of 3D printing technology to create a patient-specific surgical guide that demonstrates excellent adaptability and precision during hemisection procedures. The integration of 3D printing technology in hemisection procedures, through the use of a customized surgical guide, offers a promising avenue for precision dentistry. This case report depicts a situation where the distal root of LR6 had extensive bone loss. Hemisection was planned for the tooth using 3D printing and a customized surgical guide to perform the procedure preserving the mesial root. CPD/Clinical Relevance: The use of patient-specific surgical guides, along with CBCT and 3D printing, can enhance the clinical outcome for hemisection.

An investigation of prototype development using 3D printer: A digital fabrication approach

Abstract Additive manufacturing (AM) is a widely used technique in several industries for rapid prototyping and layer-by-layer fabrication of a new product. The influence of printer settings and print quality is essential for the performance of products in a variety of applications. The popularity of manufacturing using 3D printing is growing rapidly. In view of this, an investigation is carried out on the 3D printing techniques, their applications, and prototype materials for complex mechanical parts such as an impeller. The present study thoroughly considers the fundamental techniques in 3D printing technology, materials, and recent advancements applied to the current application and accepted trends. The 3D printing technology is advantageous as it accepts a wide range of designs, allows customized manufacturing, minimizes waste, builds intricate structures, and creates prototypes rapidly. Layer height of 0.2 mm, speed of 90 mm/s, and infill density of 80% were determined as the optimal print settings considering time, material cost, and properties. Considering the flexural qualities, the optimized values of layer height, print speed, and infill density were 0.15 mm, 70 mm/s, and 50%, respectively. It was observed that the uniform elongation (UEL) and ultimate stress (UTS) of a component increase as the layer thickness increases for the considered layers.

Study on the chloride removal performance of porous anion exchange resin models constructed via 3D printing technology

Industrial production produces a large amount of wastewater containing chloride (Cl-) ions, and elevated concentrations of Cl- pose substantial environmental hazards. This study presents a novel approach using ion exchange resin for the removal of chloride, combined with the advantages of controllable and rapid model design afforded by 3D printing technology, to prepare a porous ion exchange model (PIEM). The optimal conditions for pretreatment, chloride removal, and alkaline regeneration of PIEM were systematically explored. Under these optimal conditions, the chloride removal efficiency of a single PIEM in simulated wastewater with a 1000 mg/L Cl- concentration was 67.4 %. Following five cycles, the chloride removal efficiency stabilized at 40 %. When thirty PIEMs assembled into a quartz tube device were used and subjected to six cycles, the total chloride removal efficiencies reached 85.2 % for 2 L of simulated wastewater with a Cl- concentration of 1000 mg/L and 52.6 % for 1 L of actual wastewater with a Cl- concentration of 2915 mg/L. The mechanism of chloride removal by PIEM involves ion exchange and hydrogen bonding adsorption between the ion exchange resin and Cl- in the surrounding wastewater. This study develops a new method of removing chloride by immobilizing ion exchange resin through 3D printing, which prevents the significant loss of ion exchange resin during the chloride removal process and ensures high efficiency in removing chloride, providing new insights for the development of chloride removal technology.

Application of 3D Printing Technology in Furniture Construction.

In recent years, 3D printing technology has become very important in many fields of science, manufacturing, design, medicine, aviation, sports, etc. Furniture design and manufacturing are also not left out of this trend. In this study, the results of bending moments and stiffness of joints of thin structural elements connected by 3D printing with polylactic acid (PLA) connectors are given. The connectors are newly developed, and information on their strength characteristics is lacking in the literature. Ten joints were investigated, made with 9 and 12 mm plywood and 6 mm MDF. The tested joints constructed by 3D-printed connecting elements show a high strength under arm compression bending load, between 44.16 and 24.02 N·m. The stiffness coefficients of joints with 3D-printed connecting elements are between 348 and 145 N·m/rad and are higher than those of conventional detachable mitre joints but lower than those of glued ones. The type of filling of the hollow section of the connecting elements and the wall thickness influenced the joints' strength and stiffness. Reducing the width of the connecting elements from 40 to 30 mm and the inner radius between the arms from 2 to 1 mm does not significantly affect the joints' strength and stiffness coefficients.

Color Stability of PMMA Resins for Complete Denture Produced by CAD/CAM and 3D Printing Technologies: An In Vitro Study

Color Stability of PMMA Resins for Complete Denture Produced by CAD/CAM and 3D Printing Technologies: An In Vitro Study

Application of a customized 3D-printed osteotomy guide plate for tibial transverse transport

Enhance the efficiency of tibial transverse transport by employing customized 3D-printed osteotomy guide plates and striving to improve precision through CT evaluation for enhanced guide design. 17 diabetic foot patients were treated with the plate for tibial transverse transport. Preoperatively, we collected DICOM data from the affected tibia’s CT and designed the geometric parameters of the tibial cortical bone window. A customized 3D-printed osteotomy guide plate was then fabricated using 3D printing technology. Postoperative X-ray and CT evaluations, conducted at two and five weeks post-surgery, assessed five crucial geometric parameters of the bone window. Measurements included the distance from the upper edge of the tibial cortical bone window to the tibial plateau, the distance from the anterior edge of the tibial cortical bone window to the bone ridge, the height of the tibial cortical bone window, the center-to-center distance between the 4.0 mm diameter Schanz pin and the osteotomy Kirschner pin, and the center-to-center distance of the 4.0 mm diameter Schanz pin. These measured parameters were subsequently compared to the preoperative design parameters. The Clinical trial registration number is ChiCTR2400087174. CT measurements showed no significant differences (P > 0.05) from preoperative design parameters across the five evaluated aspects. The average osteotomy duration was 35 ± 15 min with no bone window fractures. The bone window aligned effectively with the tibial shaft, achieving complete incorporation after distraction. A 4 to 8-month postoperative follow-up confirmed full healing of the tibial surgical wound and diabetic foot wounds. Utilizing customized 3D-printed osteotomy guide plates in tibial transverse bone transport surgery enables accurate translation of preoperative virtual designs into real-time procedures, enhancing surgical efficiency and quality.

Meniscal scaffolds based on self-healable elastomer-hydrogel composites with biomimetic structure and tribological properties for repairing meniscal injuries

Meniscal injuries are increasing dramatically with the aging of the population and the prevalence of sports. Tissue engineering technology is the most promising method for the treatment of meniscal injuries, but the preparation of long-term and durable meniscal scaffolds with mechanical and tribological properties like natural articular cartilage remains a great challenge. Here, inspired by the structure and lubrication mechanism of the meniscus, a durable meniscus scaffold with bionic 3D structure, self-lubrication, and intelligent drug release function is prepared. An elastomer-hydrogel composite consisting of a direct ink writing (DIW) printed elastomer skeleton and a hydrogel matrix is prepared for the meniscus scaffold. The bionic 3D structure of the scaffolds is realized by combining computer-aided structural design and 3D printing technology. The self-healing ability obtained by incorporating dynamic covalent bonds, and the robust interface achieved by co-curing of the elastomer and hydrogel resins, ensure the stability and durability of the composite meniscal scaffolds. Taking advantage of the coexistence of aqueous and oily phases in the emulsion-type hydrogel resin, a hydrophobic phospholipid is loaded into the hydrogel, and achieves excellent boundary lubrication of the composite through its fiction-response release and self-assembly. Moreover, the meniscus scaffolds enable intelligent drug release to adapt to the physiological characteristics during inflammation. In vivo tests in rabbit models validate the protective effect of the scaffold on cartilage. These methods and concepts provide a solid foundation for the preparation of bionic tissue scaffolds.

Bioprinting of Cells, Organoids and Organs-on-a-Chip Together with Hydrogels Improves Structural and Mechanical Cues.

The 3D bioprinting technique has made enormous progress in tissue engineering, regenerative medicine and research into diseases such as cancer. Apart from individual cells, a collection of cells, such as organoids, can be printed in combination with various hydrogels. It can be hypothesized that 3D bioprinting will even become a promising tool for mechanobiological analyses of cells, organoids and their matrix environments in highly defined and precisely structured 3D environments, in which the mechanical properties of the cell environment can be individually adjusted. Mechanical obstacles or bead markers can be integrated into bioprinted samples to analyze mechanical deformations and forces within these bioprinted constructs, such as 3D organoids, and to perform biophysical analysis in complex 3D systems, which are still not standard techniques. The review highlights the advances of 3D and 4D printing technologies in integrating mechanobiological cues so that the next step will be a detailed analysis of key future biophysical research directions in organoid generation for the development of disease model systems, tissue regeneration and drug testing from a biophysical perspective. Finally, the review highlights the combination of bioprinted hydrogels, such as pure natural or synthetic hydrogels and mixtures, with organoids, organoid-cell co-cultures, organ-on-a-chip systems and organoid-organ-on-a chip combinations and introduces the use of assembloids to determine the mutual interactions of different cell types and cell-matrix interferences in specific biological and mechanical environments.

SLM-printed lattice structures with tapered vertical struts: Design, simulation and experimentation

This study, designed new lattice structures using vertical struts that taper off. The degree of tapering was controlled using a parameter called “α”. To fabricate these structures, 3D-printing technology known as SLM (selected laser melting) was used. These lattice structures were also simulated using finite element analysis (FEA) and tested experimentally. The used material was 316L stainless steel. Stress–strain curves provided insights into their deformation behavior, revealing a noteworthy occurrence: the unloading modulus exceeded the loading modulus. The mechanical properties of these absolute and density-normalized lattice structures, demonstrated improvement with higher values of the shape parameter α. Yield stress increased by 31 %, loading modulus by 21 %, and energy absorption by 33 %. Specific yield stress improved by 24 %, and specific energy absorption increased by 27 %. While simulation and experimental results exhibited a correlation, they differed significantly in modulus estimation, with simulations overestimating it by more than 30 %.

Experimental study on the thermal performance of a novel vapor chamber manufactured by 3D-printing technology

Vapor chamber holds great application potential in the field of heat dissipation for high-power electronic devices. This study developed a novel vapor chamber using 3D-printing technology to enhance heat dissipation for compact electronic devices. The vapor chamber was constructed from aluminum alloy with a structural dimension of 60×60×30mm3. In this work, the extended condensation structure of the vapor chamber was combined with an external cooling structure, resulting in a 729 % increase in the external heat dissipation area compared to the evaporation area in a limited space. Extensive experiments were conducted using deionized water as the working fluid under various cooling conditions and heat loads. The results showed that the vapor chamber was capable of maintaining a low thermal resistance at high power and high heat flux conditions, with a minimum thermal resistance of 0.087 °C/W when the heat load was 1000 W. At a cooling water flow rate of 0.1 L/s, the vapor chamber demonstrated the capacity to withstand a critical heat load of up to 1600 W, with the heat flux of 326 W/cm2. Compared to conventional vapor chambers, this novel vapor chamber is better able to achieve stable and efficient heat dissipation under high power and high heat flux conditions, especially in a limited space.

Large depth-of-focus achievement based on an aspheric lens with a ring

Terahertz (THz) imaging technology has been widely studied because of its easy penetration of non-polar materials and low photon energy. To acquire a beam featuring both excellent transverse spatial resolution and a considerable depth-of-focus (DOF) to fulfill the demands of two-dimensional and three-dimensional THz imaging, this paper presents an aspheric lens with ring (ALR). The ALR has a controlled diameter of 50 mm, can be machined by 3D-printed technology, and does not need to use complex imaging optical paths to achieve the large DOF function. In a transmitted point-scan imaging system with a 140 GHz light source, the lens can achieve both a resolution of 6 mm and an effective DOF of 66.4 mm for objects greater than 27 mm from the lens surface.

Polymer microsphere inks for semi-solid extrusion 3D printing at ambient conditions

Extrusion-based 3D printing methods have great potential for manufacturing of personalized polymer-based drug-releasing systems. However, traditional melt-based extrusion techniques are often unsuitable for processing thermally labile molecules. Consequently, methods that utilize the extrusion of semi-solid inks under mild conditions are frequently employed. The rheological properties of the semi-solid inks have a substantial impact on the 3D printability, making it necessary to evaluate and tailor these properties. Here, we report a novel semi-solid extrusion 3D printing method based on utilization of a Carbopol gel matrix containing various concentrations of polymeric microspheres. We also demonstrate the use of a solvent vapor-based post-processing method for enhancing the mechanical strength of the printed objects. As our approach enables room-temperature processing of polymers typically used in the pharmaceutical industry, it may also facilitate the broader application of 3D printing and microsphere technologies in preparation of personalized medicine.

Innovations in 3D printed individualized bone prosthesis materials: revolutionizing orthopedic surgery: a review.

The advent of personalized bone prosthesis materials and their integration into orthopedic surgery has made a profound impact, primarily as a result of the incorporation of three-dimensional (3D) printing technology. By leveraging digital models and additive manufacturing techniques, 3D printing enables the creation of customized, high-precision bone implants tailored to address complex anatomical variabilities and challenging bone defects. In this review, we highlight the significant progress in utilizing 3D printed prostheses across a wide range of orthopedic procedures, including pelvis, hip, knee, foot, ankle, spine surgeries, and bone tumor resections. The integration of 3D printing in preoperative planning, surgical navigation, and postoperative rehabilitation not only enhances treatment outcomes but also reduces surgical risks, accelerates recovery, and optimizes cost-effectiveness. Emphasizing the potential for personalized care and improved patient outcomes, this review underscores the pivotal role of 3D printed bone prosthesis materials in advancing orthopedic practice towards precision, efficiency, and patient-centric solutions. The evolving landscape of 3D printing in orthopedic surgery holds promise for revolutionizing treatment approaches, enhancing surgical outcomes, and ultimately improving the quality of care for orthopedic patients.

The Comparison Between Traditional Versus 3D Printing Combined With Computer Navigation Technique in the Management of Orbital Blowout Fractures.

Three-dimensional printing (3D printing) technology and computer navigation technology have been gradually applied in surgeries for orbital blowout fractures. This study compared the efficacy of traditional techniques (group I) and 3D printing combined with computer navigation technology-assisted techniques (group II) in the management of orbital blowout fractures. All patients treated for orbital blowout fractures in the Affiliated Hospital of Yangzhou University from March 2018 to February 2021 were reviewed. The primary predictive variable was surgical techniques used for orbital fractures (traditional techniques or 3D printing combined with computer navigation technology-assisted techniques). Outcome variables included diplopia, limitation of extraocular muscle movement, and enophthalmos orbital volume. All the surgeries were successfully performed without serious complications. Six months after the operation, the degree of diplopia and limitation of extraocular muscle movement in the traditional techniques group and 3D printing combined with computer navigation technology-assisted techniques group were significantly improved (the former Z= -2.670, P=0.008, the latter Z=-3.584, P<0.001 and the former Z=-4.852, P<0.001, the latter Z=-5.427, P<0.001, respectively). There were no significant differences in the degree of diplopia and limitation of extraocular muscle movement between the 2 groups before the operation (the former Z=-0.842, P=0.400; the latter Z=-0.567, P=0.571), and there were significant differences after the operation (the former Z=-2.773, P=0.006; the latter Z=-2.892, P=0.004), and the 3D printing combined with computer navigation technology-assisted techniques group showed an advantage over the traditional techniques group. The difference in bilateral enophthalmos and orbital volume in traditional techniques groups and 3D printing combined with computer navigation technology-assisted techniques groups was dramatically decreased (the former t=12.558, P<0.001, the latter t=12.659, P<0.001, and the former t=19.194, P<0.001, the latter t=17.770, P<0.001, respectively). There were no significant differences in bilateral enophthalmos and orbital volume between the 2 groups before the operation (the former t=-0.410, P=0.683; the latter t=0.311, P=0.756), and there were significant differences after the operation (the former t=4.081, P<0.001; the latter t=4.078, P<0.001). There were statistically significant differences in surgical time and cost between the traditional technology group and the 3D printing combined with computer navigation technology-assisted technology group (the former t=8.445, P<0.001, and the latter t=3.534, P<0.001); 3D printing combined with computer navigation technology-assisted techniques group spent more surgical time and money than the traditional techniques group. The application of 3D printing combined with computer navigation techniques in the management of orbital blowout fractures can significantly improve the accuracy and safety of the operation. 3D printing combined with computer navigation technology-assisted techniques group spent more surgical time and money.

From Harvest to Healing: The Evolution of Bone Grafts In Oral Implantology

Bone grafts are surgical procedures that involve the transplantation of bone tissue to repair or reconstruct damaged bones. They are commonly used in various medical fields, including dentistry, orthopedics, and particularly within oral and maxillofacial surgery, prosthodontics, and oral radiology, to promote healing and support the integration of implants. This review embarks on a transformative journey through the evolution of bone grafting techniques in oral implantology, beginning with the rudimentary harvesting methods and their inherent limitations. It transitions to modern innovations, spotlighting synthetic and bioengineered materials that enhance biocompatibility and minimize patient morbidity. Key advancements in minimally invasive techniques and guided bone regeneration are meticulously examined, along with the revolutionary impact of 3D imaging and printing technologies on graft customization. The review underscores the synergy between biological principles and cutting-edge technology, illustrating how these breakthroughs not only lead to superior surgical outcomes but also foster improved patient healing and satisfaction. Ultimately, the evolution of bone grafts marks a significant paradigm shift towards more effective, patient-centered strategies in oral implantology. This exploration highlights the pivotal role of advanced bone grafting methods in bolstering osseointegration and ensuring overall implant success, showcasing a commitment to enhancing both clinical efficacy and patient experience for prosthodontists, periodontists, oral and maxillofacial surgeons,oral radiologists, and dentists alike.

Exploring the potential of construction-compatible materials in structural supercapacitors for energy storage in the built environment

As urbanization accelerates, the need for innovative solutions that integrate energy storage within the built environment (BE) becomes increasingly vital for sustainable and multifunctional infrastructure. This review paper delves into the pioneering concept of structural supercapacitors (SSCs), which seamlessly embed energy storage capabilities directly into construction materials such as ordinary portland cement, geopolymers, magnesium phosphate cement, aluminate cement, bricks, wood, and polymers. These materials are readily available and possess inherent structural strength, making them ideal candidates for functionalization as energy storage devices. SSCs rely on the combination of mechanical strength and electrochemical capabilities, allowing structures to serve dual functions—bearing mechanical loads while storing and releasing electrical energy. This review discusses the key components of SSCs, including conductive fillers, electrodes, and electrolytes, and evaluates their electrochemical and mechanical performance. Several critical research gaps have been identified, including the need for alternative conductive fillers to improve ionic conductivity and specific capacitance, advanced additives to enhance multifunctionality and optimization of the interaction between fillers and substrates. Additionally, post-curing treatments and the control of porosity and microstructure require further exploration to balance electrochemical performance with mechanical robustness. Challenges related to integrating SSCs into practical applications, such as environmental durability and mechanical load-bearing capacity, are also highlighted. Furthermore, the potential of 3D printing technology to create customizable SSC structures is identified as a promising area for future research. This review contributes to advancing SSCs and their potential integration into sustainable infrastructure by highlighting the gaps and future directions of the existing literature.

3D printed steel monoliths for CO2 methanation: A feasibility study

Steel honeycomb monoliths have been manufactured by Fused Deposition Modelling-FDM 3D printing technology using 90 % 17–4 PH steel nanoparticles-loaded polymer filament. Pure steel monoliths were obtained after thermal removal of the polymer and steel sintering. NiO-CeO2 active phase nanoparticles were loaded on powder steel and on the steel monoliths, and the supported catalysts were tested in the hydrogenation of CO2 to CH4, paying special attention to the steel pretreatment before active phase loading. The catalytic experiments confirm that totally functional catalysts have been prepared, showing 100 % selective conversion of CO2 to CH4 above 225 ºC and stability in long-term experiments (18 hours at 325 ºC). The catalytic behaviour is improved by H2O2-pretreatment of the steel honeycomb monoliths before the active phase loading. XPS characterization confirms that the surface of the catalysts is oxidised on the fresh catalysts and gets even more oxidised after the catalytic tests. The H2O2-pretreatment of the steel support partially avoids the additional oxidation under reaction conditions, keeping chromium and cerium cations less oxidised than on the catalyst prepared with untreated steel. In addition, evidence about the electronic interaction between the steel support and the NiO-CeO2 (np) active phase are obtained.

Reducing the overpotential of overall water spitting by micro-pump-like electrode engineering

Electrolyzing water for hydrogen generation consumes a significant amount of electricity. Minimizing bubble accumulation on the electrodes can reduce the overpotential, thereby enhancing the efficiency of water electrolysis. In this work, Co1.8Mn1.2S4 as the catalyst for oxygen evolution reaction (OER) was optimized from 54 compounds of oxides and sulfides of Ni, Co, and Mn, then designed a three-dimensional electrode with a pump-like function to expel bubbles from the electrodes. Using laser-assisted curing 3D printing technology, a capillary array with side holes was fabricated and utilized as a support structure for the Co1.8Mn1.2S catalyst. During water electrolysis, the electrolyte enters the interior of the capillary through the side holes, and the bubbles inside the capillary are released from both ends of the capillary. The optimized electrode achieved 10 mA cm−2 at an overpotential of 345 mV during the OER, and reached 100 mA cm−2 at an overpotential of 435 mV. In-situ optical microscopy observations and fluid dynamics simulations demonstrated that bubbles were effectively released through the main outlet of the capillary. In overall water splitting, the current density reached 10 mA cm−2 at 1.646 V, without significant current decay after 60 h continuous operation. The electrode design presented holds promise for broader applications in catalytic reactions, such as CO2 reduction, electrochemical ammonia synthesis, and electrochemical treatment of water pollutants.

3D constructing: Exploring the potential of 3D concrete and clay printing with generative design for architectural innovation

The architectural and construction sectors are experiencing a transformative shift with the advent of 3D constructing. This research delves into the potential of 3D printing technologies when combined with generative design principles to reshape traditional construction methods. Through a comprehensive lens, the study evaluates the generative design workflow, decision-making algorithms, machines capacities and material considerations. Results indicate that, when synergized with generative design, these technologies offer sustainable, efficient, and tailored solutions. The use of accesible materials, such as clay and cement, demonstrates their superiority over conventional alternatives. However, the challenge lies in harmoniously integrating these innovations into architectural practice, ensuring a balance between cutting-edge advancements and practical application. Conclusively, this new approach heralds a future of sustainable and user-centric design, but its full potential can only be tapped with a holistic strategy that encompasses both design and material facets.