3D-printed Objects Research Articles

Optimizing Color-Difference Formulas for 3D-Printed Objects.

Based on previous visual assessments of 440 color pairs of 3D-printed samples, we tested the performance of eight color-difference formulas (CIELAB, CIEDE2000, CAM02-LCD, CAM02-SCD, CAM02-UCS, CAM16-LCD, CAM16-SCD, and CAM16-UCS) using the standardized residual sum of squares (STRESS) index. For the whole set of 440 color pairs, the introduction of kL (lightness parametric factor), b (exponent in total color difference), and kL + b produced an average STRESS decrease of 2.6%, 26.9%, and 29.6%, respectively. In most cases, the CIELAB formula was significantly worse statistically than the remaining seven formulas, for which no statistically significant differences were found. Therefore, based on visual results using 3D-object colors with the specific shape, size, gloss, and magnitude of color differences considered here, we concluded that the CIEDE2000, CAM02-, and CAM16-based formulas were equivalent and thus cannot recommend only one of them. Disregarding CIELAB, the average STRESS decreases in the kL + b-optimized formulas from changes in each one of the four analyzed parametric factors were not statistically significant and had the following values: 6.2 units changing from color pairs with less to more than 5.0 CIELAB units; 2.9 units changing the shape of the samples (lowest STRESS values for cylinders); 0.7 units changing from nearly-matte to high-gloss samples; and 0.5 units changing from 4 cm to 2 cm samples.

DigiTac: A DIGIT-TacTip Hybrid Tactile Sensor for Comparing Low-Cost High-Resolution Robot Touch

Deep learning combined with high-resolution tactile sensing could lead to highly capable dexterous robots. However, progress is slow because of the specialist equipment and expertise. The DIGIT tactile sensor offers low-cost entry to high-resolution touch using GelSight-type sensors. Here we customize the DIGIT to have a 3D-printed sensing surface based on the TacTip family of soft biomimetic optical tactile sensors. The DIGIT-TacTip (DigiTac) enables direct comparison between these distinct tactile sensor types. For this comparison, we introduce a tactile robot system comprising a desktop arm, mounts and 3D-printed test objects. We use tactile servo control with a PoseNet deep learning model to compare the DIGIT, DigiTac and TacTip for edge- and surface-following over 3D-shapes. All three sensors performed similarly at pose prediction, but their constructions led to differing performances at servo control, offering guidance for researchers selecting or innovating tactile sensors. All hardware and software for reproducing this study will be openly released. Project website: www.lepora.com/digitac. Project repository: www.github.com/nlepora/digitac-design.

Compact retarding potential analyzers enabled by glass-ceramic vat polymerization for CubeSat and laboratory plasma diagnostics

We report the design, fabrication, and characterization of novel, digitally manufactured, compact retarding potential analyzers (RPAs), i.e., multi-electrode instruments that can be used as in-orbit mass spectrometers and as on-ground/in-orbit ion energy analyzers. Unlike most RPAs reported in the literature, our devices enforce active aperture alignment across the grid stack, maximizing ion transmission. The RPA electrode housing (the most critical component of the RPA, as it precisely positions the electrodes to maximize grid stack transmission while avoiding space charge effects and providing electrical insulation) is additively manufactured in Vitrolite® (a printable glass-ceramic) via vat polymerization, resulting in non-porous, high-temperature compatible, and high-vacuum compatible hardware. Metrology of as-printed (green) Vitrolite Ⓡ parts shows an in-plane, per axis manufacturing accuracy of 60 µm (i.e., the in-plane length of the voxels) and an out-of-plane manufacturing accuracy of 100 µm (i.e., the height of the slices). Vitrolite Ⓡ 3D-printed objects annealed at 900 °C show a ~5 % shrinkage, a slightly larger maximum tensile stress, a similar Young’s modulus, and a larger compression yield stress compared to green samples. Also, the assembly misalignment between the grids and a 3D-printed housing annealed at 900 °C is a twofold larger compared to using a green housing. Annealing 3D-printed Vitrolite Ⓡ at temperatures above 900 °C causes significant distortion of the printed part due to material reflow, which is incompatible with a precision engineering application. Four different RPA designs were synthesized to probe the ionosphere (design with floating grid alignment at the aperture level) and laboratory plasmas (designs with floating grid aperture alignment at the cluster level). Simulations conducted in this study show that the RPA design that enforces floating grid aperture alignment at the aperture level attains the best performance, although RPA designs that implement floating grid aperture alignment at the cluster level are more resilient to grid misalignment. Experimental characterization of the RPAs using an ion source and a helicon plasma source is consistent with expected performance and the literature. Plasmas with a Debye length as small as 50 µm were successfully characterized using the reported sensors, matching the performance of state-of-the-art RPAs manufactured via semiconductor microfabrication. • Study reports the first plasma sensors enabled by glass-ceramic 3D printing. • Four sensor designs for probing ionospheric and laboratory plasmas were developed. • Sensors successfully characterized plasmas with a Debye length as small as 50 µm. • Device performance on par with that of state-of-the-art, Si microfabricated sensors.

Wavelength Selective Multi-Material 3D Printing of Soft Active Devices Using Orthogonal Photoreactions.

Orthogonal photoreactions provide a unique way to locally and independently control (thermo)mechanical properties and functionality of polymer networks simply by choice of the wavelength. Herein, a library of acrylate functional coumarin monomers is synthesized, which are cured by sequence-dependent wavelength orthogonality. In the presence of a long wavelength absorbing photoinitiator, the monomers undergo rapid curing by visible light induced radical chain growth polymerization. Subsequent irradiation with light in the UV-A region selectively initiates the [2+2] photocycloaddition of the coumarin chromophores, which is confirmed by FTIR and UV-vis experiments. Through a well-targeted design, acrylate-based and thiol-acrylate resin formulations are prepared, whose fast curing rate, low viscosity, and prolonged storage stability enable the one-step fabrication of multi-material structures by digital light processing (DLP) 3D printing. By using a dual-wavelength printer, which operates at two different wavelengths (405 and 365nm), objects comprising soft (ε =22%, σ =7.5MPa) and stiff (ε=2%, σ =8.3MPa) domains are printed with a single resin vat. Along with tensile properties, the wavelength selective change in the network structure features a local control of the glass transition temperature (ΔTg =17°C) in the 3D-printed objects. Soft active devices are fabricated by dual-wavelength DLP 3D printing, with distinct domains having a higher Tg and the local programming of multi shapes is demonstrated.

Influencing the Shape Recovery and Thermomechanical Properties of 3DP PLA Using Smart Textile and Boehmite Alumina and Thermochromic Dye Modifiers

The technology of 4DP utilizes shape memory materials (SMMs). Among the SMMs, SMP is the material that has potential and is ideal for this technology. However, due to their restrictions, fillers are incorporated to produce a novel shape memory polymer composite (SMPC). The objective of the present work was to investigate how the modification of PLA via the incorporation of boehmite alumina and thermochromic dye, and the use of 3DP on polyester fabric to make smart material textiles (SMT), influenced the shape-memory properties of printed objects. SMPCs with 3 wt% BA particles were prepared by means of the fused deposition modelling (FDM) process, with heat used as an actuation. It was demonstrated that sample thickness and the method of PLA modification affected the shape recovery of 3D-printed objects. All neat PLA samples recovered their angle fully for all thicknesses, while modified PLA incorporated with BA particles and dye recovered its initial angle fully at 1 mm thickness and showed less recovery for 1.5- and 2 mm-thicknesses. The 1 mm-thick sample was then chosen for printing onto the textile material for all samples. When printed onto the fabric, the neat PLA and SMPCs recovered their initial shapes fully, while samples with the dye added into the PLA and SMPC did not recover their initial shape fully due to the presence of the dye, which hindered the movement of the polymer chains. SEM revealed good layer bonding for the SMPCs compared to the neat PLA, which led to improved mechanical properties. The thermal stability of PLA was improved by the BA particles; furthermore, the dye and BA particles nucleated the crystallization of PLA, resulting in an enhanced storage modulus. Overall, a biodegradable 3D-printed object of 1 mm in thickness with improved thermal and mechanical properties was produced, with and without the use of the textile.

RoamFab: A Design Tool for Reconfiguring Parameterized Mechanisms to 3D Models With Structural Optimization

Creating personalized 3D printing objects has become increasingly popular with the advance in end-user modeling tools and fabrication techniques. However, it remains challenging for novice makers to design and fabricate functional objects with mechanical motion such as linear or rotational. To empower users to add mechanical movements to their models for particular needs, we first investigate the commonly used 3D printable mechanisms and parameterize four mechanical primitives. We then provide a computational approach to reconfigure the mechanical primitives to user-provided 3D models, with an underlying structural optimization procedure according to a specified bending force. We further showcase a set of design examples and conduct a user study to demonstrate the potential of our approach in creating personalized functional artifacts.

Surface Fault Detection in 3D Printed Objects Using Deep Learning

Abstract: Robots and machines in Industry 4.0 must be able to operate efficiently and autonomously. They should work in a way that makes the work efficient and substantially error-free. A key component of Industry 4.0, additive manufacturing, or 3D printing, is bringing forth a wave of innovation in daily life by creating everything from toys to furniture to screws. The enthusiast typically uses 3D printing. To create 3D objects for private or commercial usage, various printing techniques have been developed. These techniques include fused deposition modelling (FDM), stereolithography (SLA), digital light processing (DLP), and selective laser sintering (SLS). Despite the enormous potential for AM techniques to produce unique parts on demand and with little material waste, 3D printing is not typically used in mass production. This is due to two reasons. The cost of printing is too high, and since 3D printing is typically a labour-intensive process, it would not be practical to implement it in a mass production setting. Secondly, there is no quality assurance process other than manual inspection. By applying Deep Learning to automate the QC control component of 3D printing, we hope to solve the second issue. Our research demonstrates an in-situ monitoring strategy without causing damage that can find surface flaws in 3D-printed products. We suggest a deep learning-based method in this work to assess the quality of a 3D-printed object. Deep Convolution Neural Network and Deep Convolution Neural Network with Random Forest algorithm are the first two approaches used to do this.

Three-Dimensional Printing of an Apigenin-Loaded Mucoadhesive Film for Tailored Therapy to Oral Leukoplakia and the Chemopreventive Effect on a Rat Model of Oral Carcinogenesis.

Oral leukoplakia, which presents as white lesions in the oral cavity, including on the tongue, is precancerous in nature. Conservative treatment is preferable, since surgical removal can markedly reduce the patient’s quality of life. In the present study, we focused on the flavonoid apigenin as a potential compound for preventing carcinogenesis, and an apigenin-loaded mucoadhesive oral film was prepared using a three-dimensional (3D) bioprinter (semi-solid extrusion-type 3D printer). Apigenin-loaded printer inks are composed of pharmaceutical excipients (HPMC, CARBOPOL, and Poloxamer), water, and ethanol to dissolve apigenin, and the appropriate viscosity of printer ink after adjusting the ratios allowed for the successful 3D printing of the film. After drying the 3D-printed object, the resulting film was characterized. The chemopreventive effect of the apigenin-loaded film was evaluated using an experimental rat model that had been exposed to 4-nitroquinoline 1-oxide (4NQO) to induce oral carcinogenesis. Treatment with the apigenin-loaded film showed a remarkable chemopreventive effect based on an analysis of the specimen by immunohistostaining. These results suggest that the apigenin-loaded mucoadhesive film may help prevent carcinogenesis. This successful preparation of apigenin-loaded films by a 3D printer provides useful information for automatically fabricating other tailored films (with individual doses and shapes) for patients with oral leukoplakia in a future clinical setting.

Investigation of Tensile Properties of Different Infill Pattern Structures of 3D-Printed PLA Polymers: Analysis and Validation Using Finite Element Analysis in ANSYS.

The advancement of 3D-printing technology has ushered in a new era in the production of machine components, building materials, prototypes, and so on. In 3D-printing techniques, the infill reduces the amount of material used, thereby reducing the printing time and sustaining the aesthetics of the products. Infill patterns play a significant role in the property of the material. In this research, the mechanical properties of specimens are investigated for gyroid, rhombile, circular, truncated octahedron, and honeycomb infill structures (hexagonal). Additionally, the tensile properties of PLA 3D-printed objects concerning their infill pattern are demonstrated. The specimens were prepared with various infill patterns to determine the tensile properties. The fracture of the specimen was simulated and the maximum yield strengths for different infill structures and infill densities were determined. The results show the hexagonal pattern of infill holds remarkable mechanical properties compared with the other infill structures. Through the variation of infill density, the desired tensile strength of PLA can be obtained based on the applications and the optimal weight of the printed parts.

From Three-Dimensional (3D)- to 6D-Printing Technology in Orthopedics: Science Fiction or Scientific Reality?

Over the past three decades, additive manufacturing has changed from an innovative technology to an increasingly accessible tool in all aspects of different medical practices, including orthopedics. Although 3D-printing technology offers a relatively inexpensive, rapid and less risky route of manufacturing, it is still quite limited for the fabrication of more complex objects. Over the last few years, stable 3D-printed objects have been converted to smart objects or implants using novel 4D-printing systems. Four-dimensional printing is an advanced process that creates the final object by adding smart materials. Human bones are curved along their axes, a morphological characteristic that augments the mechanical strain caused by external forces. Instead of the three axes used in 4D printing, 5D-printing technology uses five axes, creating curved and more complex objects. Nowadays, 6D-printing technology marries the concepts of 4D- and 5D-printing technology to produce objects that change shape over time in response to external stimuli. In future research, it is obvious that printing technology will include a combination of multi-dimensional printing technology and smart materials. Multi-dimensional additive manufacturing technology will drive the printing dimension to higher levels of structural freedom and printing efficacy, offering promising properties for various orthopedic applications.

Print fidelity metrics for additive manufacturing of cement-based materials

Additively manufactured cement-based structures for infrastructure applications suffer from in-construction shape deformations, which are a strong function of process conditions and the rheology of the printing material (cement paste, mortar, or concrete). Thus, characterization of the shape of such manufactured objects is critical to establish and ensure fidelity to the original CAD model. In this study, a number of quantitative metrics were used to compare the dimensional and shape accuracy of laboratory-scale printed cement-based objects. A new method is described that uses the axes of minimum moment of inertia and the centroid as the basis for aligning and comparing objects. X-ray computed tomography (XCT) data was used to characterize both internal and external features. Details of the logic and image processing requirements are given and typical sample irregularities that lead to quantification of uncertainty are illustrated. The effect of sampling statistics on metric confidence was studied and guidelines are provided for good sampling protocols. The results show the extent to which different penalty logics provide sensitivity for the detection of specific types of flaws. Furthermore, when the minimum moment of inertia is used as the basis for alignment and comparison, a high correlation is found between boundary-based and volume-based fidelity metrics. Such quantitative printability metrics are necessary to establish a basis for evaluating the repeatable shape fidelity of 3D-printed objects and for quantitatively studying how rheology affects both the manufacturing process and the final built part. The method is illustrated for benchmark printed objects fabricated using three hydrogel forming polymers as printing aids.

Optimizing Parametric Factors in CIELAB and CIEDE2000 Color-Difference Formulas for 3D-Printed Spherical Objects.

The current color-difference formulas were developed based on 2D samples and there is no standard guidance for the color-difference evaluation of 3D objects. The aim of this study was to test and optimize the CIELAB and CIEDE2000 color-difference formulas by using 42 pairs of 3D-printed spherical samples in Experiment I and 40 sample pairs in Experiment II. Fifteen human observers with normal color vision were invited to attend the visual experiments under simulated D65 illumination and assess the color differences of the 82 pairs of 3D spherical samples using the gray-scale method. The performances of the CIELAB and CIEDE2000 formulas were quantified by the STRESS index and F-test with respect to the collected visual results and three different optimization methods were performed on the original color-difference formulas by using the data from the 42 sample pairs in Experiment I. It was found that the optimum parametric factors for CIELAB were = 1.4 and = 1.9, whereas for CIEDE2000, = 1.5. The visual data of the 40 sample pairs in Experiment II were used to test the performance of the optimized formulas and the STRESS values obtained for CIELAB/CIEDE2000 were 32.8/32.9 for the original formulas and 25.3/25.4 for the optimized formulas. The F-test results indicated that a significant improvement was achieved using the proposed optimization of the parametric factors applied to both color-difference formulas for 3D-printed spherical samples.

Electrospinning for the Modification of 3D Objects for the Potential Use in Tissue Engineering

Electrospinning is often investigated for biotechnological applications, such as tissue engineering and cell growth in general. In many cases, three-dimensional scaffolds would be advantageous to prepare tissues in a desired shape. Some studies thus investigated 3D-printed scaffolds decorated with electrospun nanofibers. Here, we report on the influence of 3D-printed substrates on fiber orientation and diameter of a nanofiber mat, directly electrospun on conductive and isolating 3D-printed objects, and show the effect of shadowing, taking 3D-printed ears with electrospun nanofiber mats as an example for potential and direct application in tissue engineering in general.

Effect of Temperature Field on Deformation of 3D-Printed Polylactic Acid Objects under Forced Convection

Effect of Temperature Field on Deformation of 3D-Printed Polylactic Acid Objects under Forced Convection

Recovery of Waste Material from Biobags: 3D Printing Process and Thermo-Mechanical Characteristics in Comparison to Virgin and Composite Matrices.

The purpose of this study is to limit the environmental impact of packaging applications by promoting the recycling of waste products and the use of sustainable materials in additive manufacturing technology. To this end, a commercial polylactide acid (PLA)-based filament derived from waste production of bio-bags is herein considered. For reference, a filament using virgin PLA and one using a wood-based biocomposite were characterized as well. Preliminary testing involved infrared spectroscopy, differential scanning calorimetry (DSC), and thermogravimetric analysis (TGA). The effect of printing parameters (namely bed temperature, layer thickness, top surface layers, retraction speed, and distance) on the final aesthetics of 3D printed parts was verified. The results allow us to attest that the thermal properties of recycled polymer are comparable to those of virgin PLA and biocomposite. In the case of recycled polymer, after the extrusion temperature, bed temperature, and printing speed are estabilished the lowest allowable layer thickness and an appropriate choice of retraction movements are required in order to realize 3D-printed objects without morphological defects visible to the naked eyes. In the case of wood biocomposite, the printing process was complicated by frequent obstructions, and in none of the operating conditions was it possible to obtain an aesthetically satisfying piece of the chosen geometry (Lego-type bricks) Finally, mechanical testing on the 3D printed parts of each system showed that the recycled PLA behaves similarly to virgin and wood/PLA filaments.

Applicability of Selected 3D Printing Materials in Electrochemistry.

This manuscript investigates the chemical and structural stability of 3D printing materials (3DPMs) frequently used in electrochemistry. Four 3D printing materials were studied: Clear photopolymer, Elastic photopolymer, PET filament, and PLA filament. Their stability, solubility, structural changes, flexibility, hardness, and color changes were investigated after exposure to selected organic solvents and supporting electrolytes. Furthermore, the available potential windows and behavior of redox probes in selected supporting electrolytes were investigated before and after the exposure of the 3D-printed objects to the electrolytes at various working electrodes. Possible electrochemically active interferences with an origin from the 3DPMs were also monitored to provide a comprehensive outline for the use of 3DPMs in electrochemical platform manufacturing.

Review and Future/Potential Application of Mixed Reality Technology in Orthopaedic Oncology.

In orthopaedic oncology, surgical planning and intraoperative execution errors may result in positive tumor resection margins that increase the risk of local recurrence and adversely affect patients’ survival. Computer navigation and 3D-printed resection guides have been reported to address surgical inaccuracy by replicating the surgical plans in complex cases. However, limitations include surgeons’ attention shift from the operative field to view the navigation monitor and expensive navigation facilities in computer navigation surgery. Practical concerns are lacking real-time visual feedback of preoperative images and the lead-time in manufacturing 3D-printed objects. Mixed Reality (MR) is a technology of merging real and virtual worlds to produce new environments with enhanced visualizations, where physical and digital objects coexist and allow users to interact with both in real-time. The unique MR features of enhanced medical images visualization and interaction with holograms allow surgeons real-time and on-demand medical information and remote assistance in their immediate working environment. Early application of MR technology has been reported in surgical procedures. Its role is unclear in orthopaedic oncology. This review aims to provide orthopaedic tumor surgeons with up-to-date knowledge of the emerging MR technology. The paper presents its essential features and clinical workflow, reviews the current literature and potential clinical applications, and discusses the limitations and future development in orthopaedic oncology. The emerging MR technology adds a new dimension to digital assistive tools with a more accessible and less costly alternative in orthopaedic oncology. The MR head-mounted display and hand-free control may achieve clinical point-of-care inside or outside the operating room and improve service efficiency and patient safety. However, lacking an accurate hologram-to-patient matching, an MR platform dedicated to orthopaedic oncology, and clinical results may hinder its wide adoption. Industry-academic partnerships are essential to advance the technology with its clinical role determined through future clinical studies.

Development of a quasi-collimated UV LED backlight for producing uniform and smooth 3D printing objects.

3D printing techniques have great potential in the direct fabrication of microfluidic and many kinds of molds, such as dental and jewelry models. However, the resolution, surface roughness, and critical dimension uniformity of 3D printing objects are still a challenge for improvement. In this article, we proposed a 405nm light emitting diode (LED) backlight module based on stacks of structured films, and the full width half maximum (FWHM) of the angular distribution of this module is reduced to less than ± 15°. Compared with the commercial lens array optical module, the ten points intensity uniformity of an 8.9" build area is improved from 56% to 80%. Moreover, we found that the surface roughness and the sharpness of the edge of the printing objects are also obviously improved by our novel quasi-collimated LED backlight module. These features give us a promising way for the application of microfluidics and micro-optics components in the future.

Itaconic-Acid-Based Sustainable Poly(ester amide) Resin for Stereolithography.

Material science is recognized as a frontrunner in achieving a sustainable future, owing to its primary reliance upon petroleum-based chemical raw materials. Several efforts are made to implement common renewable feedstocks as an alternative to common fossil resources. For this purpose, additive manufacturing (AM) represents promising and effective know-how for the replacement of high energy- and resource-demanding processes with more environmentally friendly practices. This work presents a novel biobased ink for stereolithography, which has been formulated by mixing a photocurable poly(ester amide) (PEA) obtained from renewable resources with citrate and itaconate cross-linkers and appropriate photopolymerization initiators, terminators, and dyes. The mechanical features and the relative biocompatibility of 3D-printed objects have been carefully studied to evaluate the possible resin implementation in the field of the textile fashion industry.

Investigation on simultaneous change of deformation, color and aroma of 4D printed starch-based pastes from fruit and vegetable as induced by microwave

Conventional 3D printing exhibits serious limitation for it requires a support layer upon which more layers can be formed. A designed structure that lacks such a layer is therefore very difficult, if not impossible, to be printed. A novel means to allow 4D deformation of simple 3D-printed object into complex suspended structure is therefore proposed; microwave irradiation was used to induce the desired directed deformation. In this study, yellow flesh peach-buckwheat paste was used to study the effects of model structure and microwave power on directed 4D deformation behavior. Then, finite-element based simulation was conducted to investigate interactions between the printed object and microwave irradiation. Experiments and simulations showed that local high temperature generated by microwave (200 W) caused directional micro puffing at resulting hot spots, forming a driving force to allow 3D-printed objects to rapidly undergo 4D deformation (within 90 s). The verification test also proved that puffing was the main factor driving 4D deformation. This strategy could combine with color and flavor changing microcapsules to realize the synchronous 4D printing process of deformation, color changing, and aroma changing within 15 s, induced by a household microwave oven (700 W). The purpose of this study is to provide a new 4D printing method interacting with consumers in a short time, which could be applied to children's food.