3D Printing Process Research Articles

Personalized 3D Printing of Artificial Vertebrae: A Predictive Bone Density Modeling Approach for Robotic Cutting Applications

Robotic vertebral plate cutting poses significant challenges due to the complex bone structures of the lumbar spine, which consist of varying densities in cortical and cancellous regions. This study addresses these challenges by developing a predictive model for robotic vertebral plate cutting force and bone quality recognition through the fabrication of artificial vertebrae with controlled, consistent bone density. To address the variability in bone density between cortical and cancellous regions, CT data are utilized to predict target bone density, serving as a foundation for determining the optimal 3D printing process parameters. The proposed methodology integrates a Response Surface Methodology (RSM), Back Propagation (BP) neural network, and genetic algorithm (GA) to systematically evaluate the effects of key process parameters, such as the filling density, material flow rate, and layer thickness, on the printed vertebrae’s density. A one-factor experimental approach and RSM-based central composite design are applied to build an initial bone density prediction model, followed by Sobol’s sensitivity analysis to quantify the influence of each parameter. The GA-BP neural network model is then employed to rapidly and accurately identify optimal printing parameters for different bone layer densities. The resulting optimized models are used to fabricate personalized artificial lumbar vertebrae, which are subsequently validated through robotic cutting experiments. This research not only contributes to the advancement in personalized 3D printing technology but also provides a reliable framework for developing patient-specific surgical planning models in robot-assisted orthopedic surgery.

4D Printing of PLA/PBS Biopolymers: Impact of Polymer Grade Variations on Thermomechanical Performance

4D Printing of PLA/PBS Biopolymers: Impact of Polymer Grade Variations on Thermomechanical Performance

Effect of silver morphology on rheology and photopolymerization characteristics of Silver-Hydroxyapatite slurry for Vat Photopolymerization-based 3D printing process

The present work deals with the processing of HA-silver photocurable slurry to make composites using the Vat-photopolymerization process. Slurries with increasing amount of silver addition in the HA-Ag (0, 5, 10, 15%) slurry have been prepared using monomers with photo-initiators and printed successfully. Silver powder used in this study is in the form of flakes and spheres. A shear thinning behaviour of all the compositions of the slurries has been observed which is essential to fabricate defect-free parts. With increase in silver addition to 15 wt%, the viscosity decreased by around 60 % however curing depth was compromised. From SEM micrographs it was observed that HA with silver flakes showed better sintering with sintering density of 95% compared to only HA and HA with spherical silver samples.

3D printed feathers with embedded aerodynamic sensing.

Bird flight is often characterized by outstanding aerodynamic efficiency, agility and adaptivity in dynamic conditions. Feathers play an integral role in facilitating these aspects of performance, and the benefits feathers provide largely derive from their intricate and hierarchical structures. Although research has been attempted on developing membrane-type artificial feathers for bio-inspired aircraft and micro air vehicles (MAVs), fabricating anatomically accurate artificial feathers to fully exploit the advantages of feathers has not been achieved. Here, we present our 3D printed artificial feathers consisting of hierarchical vane structures with feature dimensions spanning from 10-2 to 102 mm, which have remarkable structural, mechanical and aerodynamic resemblance to natural feathers. The multi-step, multi-scale 3D printing process used in this work can provide scalability for the fabrication of artificial feathers tailored to the specific size requirements of aircraft wings. Moreover, we provide the printed feathers with embedded aerodynamic sensing ability through the integration of customized piezoresistive and piezoelectric transducers for strain and vibration measurements, respectively. Hence, the 3D printed feather transducers combine the aerodynamic advantages from the hierarchical feather structure design with additional aerodynamic sensing capabilities, which can be utilized in future biomechanical studies on birds and can contribute to advancements in high-performance adaptive MAVs.&#xD.

Four-Dimensional Printing of Multi-Material Origami and Kirigami-Inspired Hydrogel Self-Folding Structures.

Four-dimensional printing refers to a process through which a 3D printed object transforms from one structure into another through the influence of an external energy input. Self-folding structures have been extensively studied to advance 3D printing technology into 4D using stimuli-responsive polymers. Designing and applying self-folding structures requires an understanding of the material properties so that the structural designs can be tailored to the targeted applications. Poly(N-iso-propylacrylamide) (PNIPAM) was used as the thermo-responsive material in this study to 3D print hydrogel samples that can bend or fold with temperature changes. A double-layer printed structure, with PNIPAM as the self-folding layer and polyethylene glycol (PEG) as the supporting layer, provided the mechanical robustness and overall flexibility to accommodate geometric changes. The mechanical properties of the multi-material 3D printing were tested to confirm the contribution of the PEG support to the double-layer system. The desired folding of the structures, as a response to temperature changes, was obtained by adding kirigami-inspired cuts to the design. An excellent shape-shifting capability was obtained by tuning the design. The experimental observations were supported by COMSOL Multiphysics® software simulations, predicting the control over the folding of the double-layer systems.

State of art on evaluation of three- to six-dimensional novel additive manufacturing technology for biomedical applications

Additive manufacturing has evolved over the last few decades. Three-dimensional printing is a digital manufacturing technology that provides nearly endless options for the creation of an accessible instrument for all parts of various medical practices, including tissue engineering, through meticulous optimization of material, processing, and geometry for every point in an object. Three-dimensional printing has opened up a new, faster, and safer manufacturing process, despite its incapability to fabricate complex structures and objects. Recently, novel four-dimensional printing techniques have been developed for the transformation of typical stable three-dimensional printed parts into smart objects. The limitations of three-dimensional printing could be remedied with four-dimensional printing, by applying time as the fourth dimension. Self-repairing and speedy printing are two additional benefits of this technology's by using smart materials. By adapting this technology, numerous medical domains could be profited. Four-dimensional printing does not have the ability to produce curved complicated forms. However, five-dimensional printing overcomes the flaws seems in four-dimensional printing. Five-dimensional additive manufacturing relies on the rotation of both the print bed and the extruder head. Five-dimensional printing outlasts in terms of durability than three- and four-dimensional printing. Currently, a combination of the principles of four- and five-dimensional printing into a single process is called six-dimensional printing. In six-dimensional printing, the form changes over time due to the reaction of environmental factors, which is primarily used in biomedical applications. This paper summarizes extensive research on biomaterials in the field of biomedical science and discusses the present implications of three-, four-, five-, and six-dimensional printing techniques.

4D Printing of Multifunctional and Biodegradable PLA-PBAT-Fe3O4 Nanocomposites with Supreme Mechanical and Shape Memory Properties.

4D printing magneto-responsive shape memory polymers (SMPs) using biodegradable nanocomposites can overcome their low toughness and thermal resistance, and produce smart materials that can be controlled remotely without contact. This study presented the development of 3D/4D printable nanocomposites based on poly (lactic acid) (PLA)-poly (butylene adipate-co-terephthalate) (PBAT) blends and magnetite (Fe3O4) nanoparticles. The nanocomposites are prepared by melt mixing PLA-PBAT blends with different Fe3O4 contents (10, 15, and 20 wt%) and extruded into granules for material extrusion 3D printing. The morphology, dynamic mechanical thermal analysis (DMTA), mechanical properties, and shape memory behavior of the nanocomposites are investigated. The results indicated that the Fe3O4 nanoparticles are preferentially distributed in the PBAT phases, enhancing the storage modulus, thermal stability, strength, elongation, toughness, shape fixity, and recovery of the nanocomposites. The optimal Fe3O4 loading is found to be 10 wt%, as higher loadings led to nanoparticle agglomeration and reduced performance. The nanocomposites also exhibited fast shape memory response under thermal and magnetic activation due to the presence of Fe3O4 nanoparticles. The 3D/4D printable nanocomposites demonstrated multifunctional multi-trigger shape-memory capabilities and potential applications in contactless and safe actuation.

Ageing effects on the mechanical properties stability of 3D printed material under compression

The paper deals with the examination of the ageing effects on the mechanical properties stability of 3D printed material via stereolithography under compression when subjected to various conditions, including UV radiation, X-rays, and the effects of time, from the opening of the bottle with the material to the 3D-printing process. The sets of samples under investigation were subjected to quasi-static and dynamic compression loading using an Split Hopkinson Pressure Bar. The aim of this paper is to investigate the long-term stability of the samples in terms of their mechanical properties and material behaviour and their degradation pattern. Despite the manufacturer’s information, it was found that the mechanical behaviour of the printed samples was significantly affected by the ageing process.

Light‐ and Heat‐Responsive Superhydrophobic Surfaces with Shape Memory Capacity Prepared by 4D Printing

Light‐ and Heat‐Responsive Superhydrophobic Surfaces with Shape Memory Capacity Prepared by 4D Printing

Characterization of PLA/LW-PLA Composite Materials Manufactured by Dual-Nozzle FDM 3D-Printing Processes.

This study investigates the properties of 3D-printed composite structures made from polylactic acid (PLA) and lightweight-polylactic acid (LW-PLA) filaments using dual-nozzle fused-deposition modeling (FDM) 3D printing. Composite structures were modeled by creating three types of cubes: (i) ST4-built with a total of four alternating layers of the two filaments in the z-axis, (ii) ST8-eight alternating layers of the two filaments, and (iii) CH4-a checkered pattern with four alternating divisions along the x, y, and z axes. Each composite structure was analyzed for printing time and weight, morphology, and compressive properties under varying nozzle temperatures and infill densities. Results indicated that higher nozzle temperatures (230 °C and 240 °C) activate foaming, particularly in ST4 and ST8 at 100% infill density. These structures were 103.5% larger on one side than the modeled dimensions and up to 9.25% lighter. The 100% infill density of ST4-Com-PLA/LW-PLA-240 improved toughness by 246.5% due to better pore compression. The ST4 and ST8 cubes exhibited decreased stiffness with increasing temperatures, while CH4 maintained consistent compressive properties across different conditions. This study confirmed that the characteristics of LW-PLA become more pronounced as the material is printed continuously, with ST4 showing the strongest effect, followed by ST8 and CH4. It highlights the importance of adjusting nozzle temperature and infill density to control foaming, density, and mechanical properties. Overall optimal conditions are 230 °C and 50% infill density, which provide a balance of strength and toughness for applications.

Study on hybrid 3D printing and milling process for customized polyether-ether-ketone components.

Polyether-ether-ketone (PEEK) has been widely applied in various fields due to its excellent mechanical properties and biocompatibility. The efficient and high-quality customized manufacturing of PEEK components are investigated in this study by the hybrid 3D printing and milling process. At first, the alternating hybrid process is selected and verified by comparing two typical hybrid process categories and conducting experiments, respectively. Second, a set of procedures are designed to automate the engineering application of the hybrid process trying to avoid the disadvantages of manual programing. Then, considering the tool length and possible interferences during the hybrid process, a model segmentation algorithm, namely, the exchange principle of avoiding interference (EPAI) is proposed. Based on the introduced EPAI and the programing language Python, the additive and subtractive hybrid manufacturing (ASHM) data processing procedure is proposed and realized by post-processing of the conventional 3D printing codes. Finally, the feasibility experiments have been conducted. The experimental results verify the hybrid manufacturing process in the fabrication of parts with complex internal features. The surface roughness Ra and dimensional error L of the parts have been reduced by 75.5% and 85.2%, respectively, while the shear strength τ has been increased by 14.1%. Compared with conventional milling process, the material consumption is reduced by 48.7%.

Decentralized approach for incorporating waste wind turbine blades into 3D printing filaments using mechanical recycling

AbstractThe increasing awareness in environmental safety has led to rapid development in production of electricity using wind energy with wind turbines. The widespread deployment of wind turbines has outpaced the effective recycling of End‐of‐Life wind turbines. This study explores the potential of mechanically recycling decommissioned wind turbine blades (WTB) as reinforcement material in 3D printing processes. Utilizing mechanical grinding, materials were extracted from the waste blades and subsequently analyzed using Fourier transform infrared spectroscopy, Differential scanning calorimetry, and thermogravimetric analysis to determine optimal processing conditions. The reclaimed materials were then blended with recycled polypropylene through single‐screw extrusion to fabricate tensile test samples via Fused Deposition Modeling. The impact of print orientation on mechanical strength was examined at 0°, 45°, and 90° angles. Morphological analysis was conducted on the fractured specimens to assess the failure characteristics. The findings indicate that samples printed at a 90° orientation exhibited superior mechanical properties, suggesting a viable pathway for incorporating wind turbine waste into sustainable manufacturing cycles.Highlights A decentralized‐mechanical recycling technique to the waste WTB. The necessary material parameters for the operations employed in this study. Reinforced 3D printable filaments from waste WTB. Stronger reinforced filaments obtained from proper fiber alignment.

Synergetic effect of bioglass and nano montmorillonite on 3D printed nanocomposite of polycaprolactone/gelatin in the fabrication of bone scaffolds

Nowadays, bone injuries and disorders have increased all over the world and can reduce the quality of human life. Bone tissue engineering repair approaches require new biomaterials and methods to construct scaffolds with the required structural properties as well as improved performance. As potential therapeutic strategies in bone tissue engineering, 3D printed scaffolds have been developed. Polycaprolactone/Ceramic composites have attracted considerable attention due to their cytocompatibility, biodegradability, and physical properties. In this study, a 3D printing process was used to create polycaprolactone (PCL)-Gelatin (GEL) scaffolds containing varying concentrations of Bioglass (BG) and Nano Montmorillonite (MMT). This mixture was then loaded into a 3D printer, and the scaffolds were printed layer by layer. After constructing the scaffolds, they were then examined for their physical, chemical, and biological characteristics. Surface appearance was analyzed with a scanning electron microscope (SEM), which revealed that NC increased the diameter of pores from 465 to 480 μm. The elements in the scaffolds were evaluated by EDX analysis, and a uniform dispersion of nano montmorillonite particles was observed. The compressive strength reached 76.43 MPa for PCL/G/35 %MMT/15 %BG scaffold. Also, the rate of water absorption, biodegradability and bioactivity of PCL-GEL scaffolds increased significantly in the presence of NC. According to the MTT cell test results, adding BG and NC increased cell proliferation, adhesion and cell viability to 127.7 %. These findings indicated that the 3D printed PCL/G/35 %MMT/15 %BG scaffold has promising strategies for bone repair applications. Also, polynomial curve fitting shows that scaffold degradability after soaking in PBS can be predicted using the initial weight and soaking time. Adding more variables and data could improve prediction accuracy, reducing the need for experiments and conserving resources.

3D Printing of Hierarchical Structures Made of Inorganic Silicon-Rich Glass Featuring Self-Forming Nanogratings.

Hierarchical structures are abundant in nature, such as in the superhydrophobic surfaces of lotus leaves and the structural coloration of butterfly wings. They consist of ordered features across multiple size scales, and their advantageous properties have attracted enormous interest in wide-ranging fields including energy storage, nanofluidics, and nanophotonics. Femtosecond lasers, which are capable of inducing various material modifications, have shown promise for manufacturing tailored hierarchical structures. However, existing methods, such as multiphoton lithography and three-dimensional (3D) printing using nanoparticle-filled inks, typically involve polymers and suffer from high process complexity. Here, we demonstrate the 3D printing of hierarchical structures in inorganic silicon-rich glass featuring self-forming nanogratings. This approach takes advantage of our finding that femtosecond laser pulses can induce simultaneous multiphoton cross-linking and self-formation of nanogratings in hydrogen silsesquioxane. The 3D printing process combines the 3D patterning capability of multiphoton lithography and the efficient generation of periodic structures by the self-formation of nanogratings. We 3D-printed micro-supercapacitors with large surface areas and a high areal capacitance of 1 mF/cm2 at an ultrahigh scan rate of 50 V/s, thereby demonstrating the utility of our 3D printing approach for device applications in emerging fields such as energy storage.

Effect of food hydrocolloids on 3D meat-analog printing and deep-fat-frying

Three-dimensional (3D) printing of food product is an emerging technology. This study investigated the effects of hydrocolloid addition on 3D printing of plant-protein based meat-analogs. Meat-analog inks were formulated with soy protein isolate, gluten, canola oil, and water. Hydrocolloids (xanthan gum, pectin, hydroxypropyl methylcellulose, guar gum, locust bean gum) were added to meat-analogs formulation. The influence of hydrocolloid addition and deep-fat-frying on 3D printing process parameters, thermal, structural, and physicochemical properties of meat-analogs, were investigated. Formulated inks were used to create a specific 3D cylindrical model geometry and the printed structure were subjected to deep-fat-frying (at 180 °C, 90sec) in canola oil. Results showed that the meat-analog ink's viscosity (3871–5482 Pa s), 3D printing rate (0.34–0.39 g s−1), printing error (2.51–10.37%), printing precision (81.97–97.27%), dimensional stability (91.22–98.61%), and cooking loss (5.69–14.23%) were significantly (p < 0.05) impacted by the incorporation of hydrocolloid. Moisture-fat profile of uncooked 3D printed meat-analogs were identical, however, differences in color attributes (L∗, a∗, b∗) among the hydrocolloids added samples were observed. Moisture, fat, and color traits of 3D printed meat-analogs were substantially impacted by deep-fat-frying. During deep-fat-frying, the loss of moisture, absorption of fat, and changes in color attributes were associated with the types of hydrocolloids incorporated in formulating the meat-analog's ink. Overall, surface's structure, chemical profile, and glass-transition-temperature of 3D printed deep-fat-fried meat-analogs were extremely impacted by the addition of hydrocolloids as well as by the types of used hydrocolloids in meat-analog ink.

Optimizing the grasping behavior of a soft robot's gripper

AbstractIn this study, smart composite materials based on 4D printing technology were used to determine the grasping ability of four‐claw gripper of soft robot. First, fused deposition modeling (FDM) is used to prepare polylactic acid (PLA) strips on the surface of a rectangular bamboo substrate to create a single‐claw gripper for a smart composite soft robot, while using stimulus (heat) to deform and recover its original shape. Here, the authors first evaluate the deformation and recovery angle of the single‐claw gripper of the smart composite soft robot, as well as various processing parameters such as heating temperature and time. This study then used FDM to print PLA ribbons on cross‐shaped bamboo sheets to design the four‐claw gripper of soft robot and its gripper technology was actuation type. Then, the four‐claw gripper of soft robot was used to grab the table tennis ball to test its grasping ability. Finally, four processing parameters (width of claw, pitch of PLA ribbon, heating temperature, and heating time) were applied to determine the grasping ability of the four‐claw gripper of soft robot. The optimal processing parameters for the grasping ability of the four‐claw gripper of soft robot were width of claw of 20.2 mm, pitch of PLA ribbon of 1 mm, heating temperature of 200°C, and the heating time of 15 s. The authors also applied the operation window of two processing parameters to discuss the success of the grasping ability of the four‐claw gripper of soft robot. The innovation of this study is the use of PLA/bamboo composite materials as the four‐claw gripper of soft robot and these materials are cheap, easy to obtain, and can be recycled naturally. This study uses a simple thermal stimulus to enable the four‐claw gripper of soft robot to easily grasp irregular objects.Highlights The innovative composite material of polylactic acid and bamboo fabricated by 3D printing. Width of claw and heating temperature are the key factors on grasping ability. Operating window of grasping ability appears on four‐claw gripper of soft robot.

Enhancing precision in 3D printing for highly functional printing with high-speed vision

3D printing has revolutionized product design and manufacturing across various industries by enabling the creation of complex geometries with minimal waste. Despite its advancements, 3D printing still faces significant challenges, including spatial constraints and process control limitations. This paper introduces novel approaches to improve the functionality and precision of material extrusion 3D printers for the fused deposition modeling method, particularly for additional printing tasks such as printing on existing objects or continuing a print on a relocated object without prior knowledge of its position or even the environment is changed. We introduce a compensation system integrating a high-speed vision system for robot arms to address these challenges. Our system employs a three-step pose estimation process—fast point feature histograms (FPFH)-based, corner-based, and sub-pixel edge-based methods—to ensure high accuracy in restoring the position of printed pieces for additional printing tasks on a given object. Experimental results demonstrate substantial improvements in printing precision, with the system achieving sub-millimeter and sub-pixel accuracy. These advancements not only eliminate work area constraints but also enhance the adaptability and reliability of 3D printing processes.

3D-Printed high performance PEEK/CF-PEEK polymer composites—An investigation on microstructural characteristics and mechanical performance

This study investigates the microstructural characteristics and mechanical properties of 3D-printed polyether ether ketone (PEEK) and carbon fiber-reinforced PEEK (PEEK CF20) composites. Using a specifically optimized 3D printing process parametric condition, samples of pure PEEK and PEEK CF20 (containing 20% carbon fiber) were fabricated. Mechanical properties were estimated by tensile, flexural, and interlaminar shear strength (ILSS) tests, performed as per ISO and DIN standards. Results indicated that PEEK CF20 exhibits significantly enhanced mechanical properties compared to pure PEEK. The tensile strength of PEEK CF20 was 81.069 MPa, compared to 76.070 MPa for pure PEEK. Maximum load values were 1456.608 N for PEEK CF20 and 1286.137 N for pure PEEK, while ILSS values were 15.76 MPa for PEEK CF20 and 11.82 MPa for pure PEEK. Microstructural analysis through field emission scanning electron microscopy (FESEM) revealed that PEEK CF20 had better fiber-matrix bonding and fewer defects compared to pure PEEK.

4D Printing of Thermally Activated Self-Healing Shape Memory Polyurethanes

4D Printing of Thermally Activated Self-Healing Shape Memory Polyurethanes

3D Printing of Wood Composites: State of the Art and Opportunities

With the production of wood waste constantly on the increase, questions relating to its recycling and reuse are becoming unavoidable. The reuse of wood and its derivatives can be achieved through the production of composite materials, using wood as a reinforcement or even as the main matrix of the material. Additive manufacturing (also known as 3D printing) is an emerging and very promising process, particularly with the use of bio-based and renewable materials such as wood or its industrial derivatives. The aim of this paper is to present an overview of additive manufacturing processes using wood as a raw material and including industrial solutions. After presenting wood and its waste products, all the additive manufacturing processes using wood or its industrial derivatives will be presented. Finally, for each 3D printing process, this review will consider the current state of research, the industrial solutions that may exist, as well as the main challenges and issues that still need to be overcome.