3D Printing Technology Research Articles

Using 3D Printing Technology to Replace the Manufacturing Process of Headlight Lens

Using 3D Printing Technology to Replace the Manufacturing Process of Headlight Lens

Upscaling of Copper Slag-Based Geopolymer to 3D Printing Technology

Additive manufacturing using cement has evolved rapidly in recent decades, revolutionizing the construction industry. This technology automates building structures through computer-aided design, offering benefits such as reduced material waste, optimized material distribution, and the ability to use composite materials. This paper aims to examine the potential of using copper-slag-based geopolymers in 3D printing. Geopolymers have gained popularity as an alternative and more energy-efficient material to traditional building materials, while copper slag allows for reducing and managing mining industry waste. Moreover, samples formed in molds based on the same material were produced to evaluate the method of manufacturing on the mechanical properties of geopolymers. This paper presents an evaluation of the mechanical properties including the compressive, flexural, and shear strength of the layered material. It reveals promising results, with strength development mainly observed within the first 14 days. The results show that the compressive strength after 28 days of curing is 46.4 MP and 42.1 MPa for formed and printed samples, respectively. Furthermore, the average bending strength value ranges between 7.4 MPa and 7.8 MPa, regardless of the bending direction and forming method. The obtained results show that printed geopolymers demonstrate adequate layer bonding, confirming the profitability of the 3D printing technology. This research confirms that 3D printing technology enables the use of geopolymer binder materials based on copper slag, which opens the door to sustainable alternatives in construction practices.

Method of Forming Road Surface Replicas Using 3D Printing Technology

Method of Forming Road Surface Replicas Using 3D Printing Technology

A digital duplicating obturator with 3D printing technology

Obturators are vital for restoring function and appearance in patients with maxillofacial defects, though traditional fabrication involves multiple clinical visits and extended production time. This technique report details a digital approach using computer-aided design/manufacturing (CAD/CAM) and 3D printing to duplicate an obturator for a 74-year-old patient with maxillary bone necrosis. By using a chairside intraoral scanner, we obtained a digital model of the existing obturator, avoiding traditional impression-taking and reducing procedural discomfort. A 3D-printed obturator was fabricated, adjusted with a tissue conditioner, and refined to ensure optimal fit. Laboratory processes included using specialized materials and retention techniques. The digital workflow minimized patient visits and improved comfort, underscoring CAD/CAM and 3D printing's potential to enhance clinical efficiency and quality of life for patients requiring complex prosthetic rehabilitation. This approach highlights the practical benefits of integrating digital and analog methods in maxillofacial prosthetics. (Int J Maxillofac Prosthetics 2024;7:16-19)

Design, manufacturing, and multi-modal imaging of stereolithography 3D printed flexible intracranial aneurysm phantoms.

Physical vascular phantoms are instrumental in studying intracranial aneurysms and testing relevant imaging tools and training systems to provide improved clinical care. Current vascular phantom production methods have major limitations in capturing the biophysical and morphological characteristics of intracranial aneurysms with good fidelity and multi-modal imaging capacity. With stereolithography (SLA) 3D printing technology becoming more accessible, newer flexible and transparent printing materials with higher precision controls open the door for improving the efficiency and quality of producing anthropomorphic vascular phantoms but have rarely been explored for the application. This technical note intends to report the feasibility of using SLA 3D printing technology to manufacture flexible intracranial aneurysm phantoms with similar scales to the real anatomy, as well as their capacity for multi-modal flow imaging and analysis, including ultrasound flow imaging, high-speed filming, and particle image velocimetry analysis. We designed and 3D-printed two intracranial aneurysm phantoms with an SLA 3D printer using Formlabs Elastic 50A resin. By using a micropump to introduce cyclical flows in the phantoms, we first employed conventional Doppler and vector flow ultrasonography to observe and measure different fluidic properties. Then, a high-speed camera was used to record particles flowing within the phantom, and we further conducted a particle image velocimetry analysis, including the distribution of mean 2D velocity vectors, average velocity magnitudes, and the mean vorticity fields in the phantom for the high-speed imaging data. We successfully 3D-printed flexible intracranial aneurysm phantoms with similar dimensions to the real anatomy. Additionally, we validated the phantoms' ability to allow visualization, measurement, and analysis of flow dynamics based on both real-time ultrasound and optical imaging. Our proof-of-concept study illustrates that SLA 3D printing using commercial elastic resins can significantly contribute towards facilitating the fabrication of flexible intracranial aneurysms phantoms for training, research, and preoperative planning.

Implementation of additive 3D printing technology in the development of an experimental oxygen-hydrogen low thrust rocket engine

Implementation of additive 3D printing technology in the development of an experimental oxygen-hydrogen low thrust rocket engine

Development and validation of a cost-effective DIY simulation model for McDonald cerclage training.

The prevention of preterm birth is a challenging task for obstetricians. Cervical cerclage, used as both a primary and secondary prevention method for spontaneous preterm birth, is a crucial surgical intervention. It is essential that obstetricians can learn this procedure in a simulated environment before performing the stitches on high-risk patients. This study aimed to develop a simulator based on 3D printing and evaluate its validity for clinical training. The objectives of this study were (1) to design and construct a cost-effective simulator for McDonald cerclage with two different cervix models-a closed cervix and a cervix with bulging membranes-using common material from a DIY store and 3D printing technology and (2) to validate its effectiveness through feedback from learners and experts in cervical cerclage. The self-made simulator was evaluated by obstetricians using a questionnaire with Likert scale. Obstetricians and gynecologists assessed the simulator and found it useful for learning and practicing cervical cerclage. The simulator was deemed valuable for skill training. Cervical cerclage is a complex procedure that should be mastered through simulation rather than initial practice on real patients. Our simulator is a cost-effective model suitable for various clinical settings. It has been validated by obstetricians for both preventive and therapeutic cerclage, demonstrating its efficacy for training in cerclage techniques. Future research should focus on less skilled obstetricians and gynecologists and investigate how repeated use of the simulator can enhance their performance in cerclage stitching.

Application of 3D printing in the treatment of diabetic foot ulcers: current status and new insights

Background and AimsDiabetic foot ulcers (DFUs) are a serious complication of diabetes mellitus (DM), affecting around 25% of individuals with DM. Primary treatment of a DFU involves wound off-loading, surgical debridement, dressings to provide a moist wound environment, vascular assessment, and appropriate antibiotics through a multidisciplinary approach. Three-dimensional (3D) printing technology is considered an innovative tool for the management of DFUs. The utilization of 3D printing technology in the treatment of DFU involves the modernization of traditional methods and the exploration of new techniques. This review discusses recent advancements in 3D printing technology for the application of DFU care, and the development of personalized interventions for the treatment of DFUs.MethodsWe searched the electronic database for the years 2019–2024. Studies related to the use of 3D printing technology in Diabetic foot were included.ResultsA total of 25 identified articles based on database search and citation network analysis. After removing duplicates, 18 articles remained, and three articles that did not meet the inclusion criteria were removed after reading the title/abstract. A total of 97 relevant articles were included during the reading of references. In total, 112 articles were included.Conclusion3D printing technology offers unparalleled advantages, particularly in the realm of personalized treatment. The amalgamation of traditional treatment methods with 3D printing has yielded favorable outcomes in decelerating the progression of DFUs and facilitating wound healing. However, there is a limited body of research regarding the utilization of 3D printing technology in the domain of DFUs.

3D PRINTING OF THIN-WALLED MODELS - STATE-OF-ART

The paper presents an analysis of the state of the art regarding the production of thin-walled models using 3D printing technology. Data based on the Web of Science database was presented in quantitative terms and divided into individual areas of science. 189 publications were found in the years from 2013 to 2024, of which the most, i.e. 82 in the area of Mechanical Engineering. It was observed that some of the publications are grouped around issues related to the study of mainly mechanical properties of both samples and thin-walled cellular structures. Another group of works concerns methods of obtaining thin-walled models using 3D printing technologies. The article characterizes selected exemplary works representing individual areas of science. The need to perform tests of the mechanical properties of thin-walled elements, especially those with a thickness of less than 2 mm, was indicated. Appropriate examples were provided to demonstrate the lower mechanical properties of thin-walled elements compared to solid-type parts manufactured by 3D printing.

Design Rules for 3D Printing‐Assisted Pressure Sensor Manufacturing: Achieving Broad Pressure Range Linearity

AbstractRecent advancements in 3D printing technology have expanded its application to manufacturing pressure sensors. By harnessing the cost‐effectiveness, streamlined processes, and design flexibility of 3D printing, sensor fabrication can be customized to meet specific performance needs. Thus far, 3D printing in pressure sensor development has been primarily limited to creating molds for transferring patterns onto flexible substrates, restricting both material selection and sensor performance. To fully unlock the potential of 3D printing in advanced pressure sensor fabrication, it is crucial to establish effective design rules focused on enhancing the figure of merit performance. This study introduces a universal design strategy aimed at maintaining high sensitivity across a wide pressure range—a challenging feat, as sensitivity significantly decreases at higher pressures. Our approach centers on engineering the deformability of 3D‐printed structures, achieving a linear increase in contact area between sensor patterns and electrodes without reaching saturation. Sensors designed with high elongation and low stiffness exhibit consistent sensitivity of 162.5 kPa⁻¹ across a broad pressure range (0.05–300 kPa). Mechanistic investigations through finite element analysis confirm that engineered deformability is key to achieving this enhanced linear response, offering robust sensing capabilities for demanding applications such as deep‐sea and space exploration.

How 3D Printing Technology Makes Cities Smarter: A Review, Thematic Analysis, and Perspectives

This paper presents a comprehensive review of the transformative impacts of 3D printing technology on smart cities. As cities face rapid urbanization, resource shortages, and environmental degradation, innovative solutions such as additive manufacturing (AM) offer potential pathways for sustainable urban development. By synthesizing 66 publications from 2015 to 2024, the study examines how 3D printing improves urban infrastructure, enhances sustainability, and fosters community engagement in city planning. Key benefits of 3D printing include reducing construction time and material waste, lowering costs, and enabling the creation of scalable, affordable housing solutions. The paper also addresses emerging areas such as the integration of 3D printing with digital twins (DTs), machine learning (ML), and AI to optimize urban infrastructure and predictive maintenance. It highlights the use of smart materials and soft robotics for structural health monitoring (SHM) and repairs. Despite the promising advancements, challenges remain in terms of cost, scalability, and the need for interdisciplinary collaboration among engineers, designers, urban planners, and policymakers. The findings suggest a roadmap for future research and practical applications of 3D printing in smart cities, contributing to the ongoing discourse on sustainable and technologically advanced urban development.

Smartcard: an integrated approach for contaminant monitoring, from field to laboratory.

Effective food safety monitoring requires a multi-step approach from farm to fork, involving different methods, ranging from convenient screening devices to sophisticated laboratory confirmatory testing. However, sample transportation to routine laboratories is time-consuming and expensive. Simplified on-site sampling followed by laboratory analysis offers a potential solution. Dried blood spot (DBS) cards ensure stability and ease of sample transportation and are used in clinical testing. However, the applicability of such an approach could be broader and include the storage of dried extract from more complex (solid) matrices. Therefore, a simplified approach is presented here, using DBS cards for on-site sampling and subsequent laboratory confirmation for food contaminants. To achieve this, an analytical tool (Smartcard) was designed using 3D-printing technology. As a proof of concept, the approach was applied to detect the pesticide fipronil, which is widely used in ornamental flower production to limit pests and on poultry farms. The Smartcard can securely store the sample extracts on a DBS card (dried extract spot (DExS) card), incorporate the lateral flow immunoassay (LFIA) and immediately provide an estimate of contamination levels. After simplified in-syringe extraction of the sample, the LFIA allows direct screening of fipronil (half maximum inhibitory concentration of 6.5µg/l with calibration standards), and the same sample extract can be directly applied to the DExS card for storage and transport to the laboratory, where analyte re-extraction and instrumental analysis is performed using ultra high-pressure liquid chromatography tandem mass spectrometry (UHPLC-MS/MS) detecting fipronil down to 0.8µg/kg.

A neurosurgical nursing training system based on 3D printing models: practice and exploration of precision medicine.

In recent years, the concept of precision medicine has gradually permeated the field of nursing, presenting new challenges for neurosurgical nursing staff. Traditional teaching methods often struggle to adequately convey complex anatomical knowledge and nursing skills, thereby affecting the learning outcomes and clinical decision-making abilities of nurses. As an innovative educational tool, three-dimensional (3D) printing technology has demonstrated significant potential in medical education in recent years. Therefore, this project aims to explore the advantages and feasibility of using 3D printed models as a novel teaching tool in neurosurgical nursing. The study involved 80 nursing personnel who participated in the neurosurgical rotation training at Shaoxing People's Hospital from 2022 to 2023. The control group (40 individuals) used only traditional teaching tools such as textbooks, multimedia courseware, and laboratory equipment for theoretical and practical training based on the curriculum. The experimental group (40 individuals) incorporated a 3D printing model database as an innovative teaching tool on the basis of traditional teaching methods, and used patient-specific 3D printed models for precise nursing training. After the training, both groups were assessed for theoretical and practical abilities, professional values, job satisfaction, and the prognosis of intracranial aneurysm patients they cared for. The experimental group demonstrated superior scores in theoretical and practical abilities, professional values, and job satisfaction compared to the control group. During the training period, patients with intracranial aneurysms receiving precision nursing care from the experimental group showed better quality of life and neurological functional outcomes compared to the control group. The nursing training system based on 3D printing models can enhance the learning efficiency and nursing work satisfaction of nursing personnel. It may have a positive impact on the professional values of nursing personnel, thereby laying a solid foundation for providing high-quality, precise nursing services in the field of neurosurgery in the future.

Design Rational for Total Ankle Arthroplasty: An Update

The design of total ankle arthroplasty (TAA) systems is rapidly evolving as device companies try to keep pace with the expansion of surgical indications and a refinement of techniques for TAA. Even since the publication of the latest “update,” published in 2018, three new designs and three updates on preexisting third-generation implants came onto the market. Improvements in third-generation TAA systems include minimal bone resection, retaining ligamentous support, and anatomic balancing. Fourth-generation systems use 3D printing technology, improved talus and tibia designs based on CT scans of arthritic and normal ankles, and include patient-specific instrumentation. We will then explore the short-term and mid-term outcomes of the previously discussed six TAA systems—INBONE, INFINITY, INVISION (Stryker), Salto-Talaris (Smith and Nephew), Scandinavian Total Ankle Arthroplasty (Enovis), Trabecular Metal Total Ankle (Zimmer Biomet), and VANTAGE (Exactech). As more research pours in regarding mid- to long-term outcomes of these implants, it is important to assess the design rationale and summarize current outcome data for these implants.

Effects of Absorption on the Tribological Properties of Carbon Fiber Reinforced Polyamide-6 Composites Manufactured by Fused Deposition Modeling

Abstract The present work studied the water absorption behavior of polymeric composite materials fabricated using 3D printing technology, as well as its effect on their tribological properties. Polyamide-6 was selected as the base matrix material. Short and continuous carbon fibers are used as the reinforced material. The results showed that the moisture absorption would impair the mechanical properties of polymer matrix and interface bonding between the fiber and the matrix. As a result, the tensile strength of the fiber reinforced polymer composites (FRPCs) decreases with water absorption. Nevertheless, the effects of moisture absorption on the wear properties of FRPCs are more complicated, which are depending on the fiber length and sliding conditions. With the short fiber reinforcements, moisture absorption deteriorated the wear resistance under all the testing conditions. With the increase of moisture level, more severe fiber damage/removal was observed, associated with the higher wear loss. With a relative high volume fracture of continuous carbon fiber (∼35 vol%), however, the wear resistance of the FRPC increased with moisture level, especially under a relatively low load. Based on microscopic observations, it was proposed that water inside FRPC specimens is able to provide the lubricating and cleaning effects, which contribute to a lower friction and smooth worn surfaces. The work provides new insights into designing and selecting printed polymer materials, subjected to different loading conditions.

Traditional and modern methods of construction: Comparative study of the sustainability of single‐family homes

AbstractModern construction methods, such as additive manufacturing, are aimed to enhance the efficiency and quality of construction processes while potentially reducing waste generation and material use, thus contributing to sustainability performance (SP). However, comprehensively understanding the sustainability trade‐offs associated with these methods is crucial for guiding both research and practical applications toward sustainable development. This study aims at quantifying the SP of various construction methods for housing, including traditional, prefabricated, and additive manufacturing approaches. A sustainability index, integrating economic, environmental, social, and technological criteria, is utilized to assess different alternatives. Findings reveal promising aspects of 3D printing technologies, such as potential cost reductions through scale increase and process optimization, minimized material waste generation, creation of skilled employment opportunities, and enhanced construction flexibility and ease. Nevertheless, challenges persist, notably significant greenhouse gas emissions and limited supplier availability. Addressing these challenges is imperative for advancing the sustainable implementation of additive manufacturing in construction.

Regular Dodecahedron-Based Network Structures

The packing and assembly of Platonic solids have fascinated mathematicians for ages. Recently, this fundamental geometrical problem has also attracted the attention of physicists, chemists, and engineers. This growing interest is due to the rapid advancements in various related fields, ranging from the formation of colloidal crystals and the design of metal–organic frameworks to the development of ultra-lightweight metamaterials, which are closely tied to the fast-evolving 3D printing technology. Numerous reports have focused on the assembly of Platonic polyhedra, particularly tetrahedra, for which an optimal packing strategy remains unidentified to this day. However, less attention has been given to the dodecahedron and its networks. This work introduces a new type of framework, designed from regular dodecahedra combined with icosahedron-based binders. The relatively simple design protocol employed here results in a remarkable variety of intriguing networks, which could be potentially useful in fields such as architecture, regenerative medicine, or aeronautics. Additionally, the dodecahedral networks presented in this study led to the discovery of intriguing structures resembling distorted graphene sheets. These structures exhibit features characteristic of both graphene and diamond.

Advances in Global Oyster Reef Restoration: Innovations and Sustainable Ecological Approaches

Oysters have been recognized as ecological engineers for aquatic ecosystems, as oyster reefs provide critical habitats and foraging locations for other marine species. In the past few decades, anthropogenic activities have negatively impacted oyster reef ecosystems across the globe, resulting in a significant decline in their population. This review critically examines the causes and extent of oyster reef degradation, as well as the effectiveness of restoration initiatives employed to reverse this decline. Furthermore, this review evaluates the effectiveness of restoration strategies employed to rehabilitate oyster reefs. Different approaches, such as genetic improvement, suitable site selection, and oyster seeding to enhance oyster reef restorations, are critically reviewed in this paper. Furthermore, some advanced restoration approaches such as 3D printing, shell recycling, and acoustics technologies are also discussed in this paper, which opens the new doors for researchers in the field of restoration ecology. Challenges and barriers hindering successful restoration are also addressed, including financial constraints, regulatory complexities, and public engagement. The findings and insights presented herein contribute to the growing body of knowledge on oyster reef ecology and serve as a valuable resource for policymakers, scientists, and conservation practitioners seeking effective strategies for restoring these vital coastal ecosystems.

Development of Intelligent Construction Robots for In-situ Lunar Resource Utilization

Abstract: With the development of technologies such as 3D printing and artificial intelligence, robotic lunar construction has gradually become a reality. In recent years, many countries have conducted research on lunar construction, among which lunar in-situ resource utilization construction is the most promising option for lunar construction, and intelligent robot construction is the main method of in-situ resource utilization construction. This paper analyzes the trend of intelligent construction and the necessity of lunar construction, and concludes that lunar construction robots have great development prospects and value. Using "ISRU, intelligent construction robot, 3D printing" as keywords, using the method of literature analysis, literature retrieval is conducted on China National Knowledge Infrastructure and Google Scholar databases, and the types of lunar bases, the acquisition of lunar resources, the classification of intelligent construction robots, and the 3D printing technology and Fully adaptable robot assembly and construction technology in lunar in-situ resource utilization are analyzed. The concept, classification, function, auxiliary 3D printing technology and materials required for 3D printing are analyzed in detail. The assembled mortise and tenon structure, fully adaptable assembly robot technology and underground construction technology are described in detail. The intelligent construction technology involved in lunar in-situ resource utilization construction (ISRU) and how to adapt to the lunar environment for construction are systematically analyzed, and the challenges faced in realizing robotic lunar construction are briefly outlined. It provides ideas for scholars studying intelligent construction robots.

Smartphone microscopy: Design and implementation of a dual magnification system

This paper presents a dual magnification smartphone microscope designed for versatile imaging, enabling low magnification for wide-field viewing and high magnification for detailed biological sample analysis and automatic control of the working distance. It offers a cost-effective alternative to traditional lab microscopes, particularly in low-resource settings. Simulated, optimized, and designed using Ansys Zemax OpticStudio, the microscope was fabricated with 3D printing technology. Dual magnification (150x and 1000x) was achieved with two optical paths, improving resolution to 1 µm at higher and 1.5 µm at lower magnifications. The design provides clear and accurate images. The smartphone integration enhances usability, allowing easy magnification switching, image capture, and potential use of diagnostic applications.