Affordable 3D Research Articles

Approaches to manufacturing affordable 3D printed modules to improve the durability of white canes for visually impaired people

In this study, 3D printing-based solutions are sought to improve the durability of guide canes of visually impaired individuals. The financial inaccessibility of technological white canes is a challenge that this study addresses by integrating additive manufacturing. The proposed solutions are designing a ball caster tip with a suspension mechanism, manufacturing a barrier detection and vibration alert system, and a 3D-printed flexible cover for the guide cane. Each solution is specially prototyped for this study using Computer-Aid Design (CAD). It aims to produce accessories that can upgrade any regular cane to a more durable and comfortable state by easily clipping them onto any cane. The solutions were assessed under three criteria, for which the visually impaired consultee of the research was assigned weights for further evaluation. The assessment has been conducted based on each solution’s effectiveness, cost, and comfort. According to the evaluation of the visually impaired consultee, the ball caster with suspension mechanism yielded the highest score for the assessment criteria. Further recommendations have been made for each solution to decrease the volume occupancy and increase lifespan, durability, and comfort.

From medical imaging to 3D printed anatomical models: a low-cost, affordable 3D printing approach

From medical imaging to 3D printed anatomical models: a low-cost, affordable 3D printing approach

Affordable 3D Orientation Visualization Solution for Working Class Remotely Operated Vehicles (ROV).

ROV operators often encounter challenges with orientation awareness while operating underwater, primarily due to relying solely on 2D camera feeds to manually control the ROV robot arm. This limitation in underwater visibility and orientation awareness, as observed among Malaysian ROV operators, can compromise the accuracy of arm placement, and pose a risk of tool damage if not handle with care. To address this, a 3D orientation monitoring system for ROVs has been developed, leveraging measurement sensors with nine degrees of freedom (DOF). These sensors capture crucial parameters such as roll, pitch, yaw, and heading, providing real-time data on the ROV's position along the X, Y, and Z axes to ensure precise orientation. These data are then utilized to generate and process 3D imaging and develop a corresponding 3D model of the operational ROV underwater, accurately reflecting its orientation in a visual representation by using an open-source platform. Due to constraints set by an agreement with the working class ROV operators, only short-term tests (up to 1 min) could be performed at the dockyard. A video demonstration of a working class ROV replica moving and reflecting in a 3D simulation in real-time was also presented. Despite these limitations, our findings demonstrate the feasibility and potential of a cost-effective 3D orientation visualization system for working class ROVs. With mean absolute error (MAE) error less than 2%, the results align with the performance expectations of the actual working ROV.

Design, calibration and performance evaluation of a small-scale 3D printer for accelerating research in additive manufacturing in construction

3D printing in construction presents numerous advantages, such as geometric flexibility, potential cost and time savings, the incorporation of recycled and sustainable materials, and reduced waste, thereby reducing the construction sector's environmental impact. Despite these advantages, the widespread adoption of AM in construction faces hurdles, primarily due to the prohibitive costs of large-scale concrete printers — typically ranging from $180,000 to over $1 million — and technological constraints that impede research and development efforts within the construction sector. To address these challenges, our study focuses on designing, developing, calibrating and evaluating an affordable lab-scale 3D printer specifically tailored for cement-based materials, aiming to lower the entry barrier for AM research in construction. This paper presents a proof-of-concept for a simple, yet functional printing technology that meet the requirements for research studies. The study details the development process, from the conceptual design to the calibration of printing parameters. The development process included the assessment of preliminary extrusion system designs integrated with the motion systems of a fused deposition modeling 3D printer. Subsequently, material studies were carried out to determine optimal material mix compositions and ratios. A comprehensive calibration of printing parameters using statistical analysis was proposed to ensure consistent and quality printing. The printability and applicability of the proposed small-scale 3D printer were assessed by printing samples and testing their thermal properties. Cost analysis showed that the proposed 3D printer, costing $273, offers benefits compared to existing market alternatives. The study illustrates the potential of small-scale 3D printers to facilitate construction research and practices, thereby promoting the development of sustainable construction methods.

RetroSphere: Enabling Low-power and Affordable 3D Input for Lightweight Augmented Reality Devices

RetroSphere introduces a self-contained 6-degree-of-freedom (6DoF) controller tracker, designed for seamless integration with resourceconstrained Augmented Reality (AR) devices such as AR glasses and smartphones. This system employs a tracking mechanism using one to three retro-reflective spheres on a passive controller, thus eliminating the need for any onboard electronics or batteries. Detection is enabled by a stereo pair of mass-produced infrared blob trackers, each outfitted with infrared LED emitters. The system utilizes a lightweight stereo depth-estimation algorithm on an Arduino-compatible ESP32 microcontroller to achieve 6DoF tracking. RetroSphere achieves a tracking accuracy of approximately 96.5%, with positional errors as low as 3.5 cm across a tracking range of 100 cm, while maintaining a power consumption of just about 400 mW. The complete hardware and firmware details for RetroSphere are available as open source on GitHub: https://github.com/AnantaBalaji/RetroSphere

From medical imaging to 3D printed anatomical models: a low-cost, affordable 3D printing approach.

To share our experience in creating precise anatomical models using available open-source software. An affordable method is presented, where from a DICOM format of a computed tomography, a segmentation of the region of interest is achieved. The image is then processed for surface improvement and the DICOM format is converted to STL. Error correction is achieved and the model is optimized to be printed by stereolithography with a desktop 3D printer. Precise measurements of the dimensions of the DICOM file (CT), the STL file, and the printed model (3D) were carried out. For the C6 vertebra, the dimensions of the horizontal axis were 55.3 mm (CT), 55.337 mm (STL), and 55.3183 mm (3D). The dimensions of the vertebral body were 14.2 mm (CT), 14.551 mm (STL), and 14.8159 mm (3D). The length of the spinous process was 18.2 mm (CT), 18.283 mm (STL), and 18.2266 mm (3D), while its width was 8.5 mm (CT), 8.3644 mm (STL), and 8.3226 mm (3D). For the C7 vertebra, the dimensions of the horizontal axis were 58.6 mm (CT), 58.739 mm (STL), and 58.7144 mm (3D). The dimensions of the vertebral body were 14 mm (CT), 14.0255 mm (STL), and 14.2312 mm (3D). The length of the spinous process was 18.7 mm (CT), 18.79 mm (STL), and 18.6458 mm (3D), and its width was 8.9 mm (CT), 8.988 mm (STL), and 8.9760 mm (3D). The printing of a 3D model of bone tissue using this algorithm is a viable, useful option with high precision.

Investigating Digital Forensic Artifacts Generated from 3D Printing Slicing Software: Windows and Linux Analysis

Although Three-dimensional (3D) printers have legitimate applications in various fields, they also present opportunities for misuse by criminals who can infringe upon intellectual property rights, manufacture counterfeit medical products, or create unregulated and untraceable firearms. The rise of affordable 3D printers for general consumers has exacerbated these concerns, making it increasingly vital for digital forensics investigators to identify and analyze vital artifacts associated with 3D printing. In our study, we focus on the identification and analysis of digital forensic artifacts related to 3D printing stored in both Linux and Windows operating systems. We create five distinct scenarios and gather data, including random-access memory (RAM), configuration data, generated files, residual data, and network data, to identify when 3D printing occurs on a device. Furthermore, we utilize the 3D printing slicing software Ultimaker Cura version 5.7 and RepetierHost version 2.3.2 to complete our experiments. Additionally, we anticipate that criminals commonly engage in anti-forensics and recover valuable evidence after uninstalling the software and deleting all other evidence. Our analysis reveals that each data type we collect provides vital evidence relating to 3D printing forensics.

Prototyping of portable medicine containers with embossed braille using an affordable desktop 3D printer

PurposePrototyping with affordable 3D printers empowers small businesses to create prototypes within a day and carry out multiple iterations of design, size, shape or assembly based on analytical results, bringing better products to market faster. This paper aims to turn the ideas into proofs of concept, advance these concepts to realistic prototypes and investigate the quality of printed prototypes prior to large-scale production.Design/methodology/approachThe experimental approach focuses on the prototyping of portable medicine containers by Fused Deposition Modeling (FDM), modifying the prototypes by adding auxiliary braille flags that indicate patient initials and dosing information, and performing the moisture permeation study as well as the stability study for model drug products (i.e. ibuprofen tablets, guaifenesin tablets, dextromethorphan HBr soft gel capsules).FindingsThe study shows that an affordable 3D printer helps to create functional and visual prototypes that give a realistic depiction of the design and offer physical objects that could be investigated for product quality and feasibility.Originality/valueTo the best of the authors’ knowledge, this study was the first attempt to use a desktop FDM-based 3D printer to prototype portable medicine containers in a blister packet appearance with auxiliary braille flags that help validate early concepts and facilitate the conversation on refining product features in a rapid and affordable manner.

Development of the Extrusion Based Food 3D Printer Machine by Modifying Fused Deposition Modelling (FDM) 3D Printer

The additive manufacturing (AM) technique is the method to objectify a design by adding the material layer-by-layer. AM for food 3D printing application is used to modify the process of food production in aspects of shape, color, flavor, texture, and nutrition. However, the price of food 3D printers available in the market is too high compared to the benefits they can provide. Addressing this issue, modifying the traditional fused deposition modelling (FDM) 3D printer can be a cheaper alternative that offers more advantages for food production process. This study provides the modification of the FDM 3D printer, such as the designing, fabricating, and setting the new extrusion mechanism to develop the food 3D printer. The modifications are mainly in the extrusion mechanism where the printing material changes from filament into semi-fluid food material. The proposed food 3D printer then tested by printing two different using semi-fluid food materials, i.e., strawberry, and peanut jam. In addition, two different shapes, three different dimensions, and two travel speeds are being selected for the printing test, i.e., 40 and 60 mm/s. As a result, the FDM 3D printer was modified and converted successfully into a food 3D printer. Based on the printing outcomes, it was showed that the strawberry jam has a better surface finish than peanut jam due to its texture consistency. Moreover, the strawberry material also has a lower percentage of error particularly when printed at slower speed. This research is expected to contribute to the development of affordable food 3D printers in Indonesia.

A Versatile 3D-Printable Soft Pneumatic Actuator Design for Multi-Functional Applications in Soft Robotics.

Soft pneumatic actuators (SPAs) play a crucial role in generating movements and forces in soft robotic systems. However, existing SPA designs require significant structural modifications to be used in applications other than their original design. The present article proposes an omni-purpose fully 3D-printable SPA design inspired by membrane type mold and cast SPAs. The design features a spring-like zig-zag structure 3D-printed using an affordable 3D printer with thermoplastic polyurethane and a minimum wall thickness between 0.4 and 0.6 mm. The new SPA can perform unidirectional extension (30% extension) and bidirectional (rotation around same axis) bending (100°), with the ability to exert 10 N blocking force for 350 kPa pressure input. In addition, the design exhibits the capability to be scaled down for the purpose of accommodating limited spaces, while simultaneously enabling the reconfigurable interconnection of multiple SPAs to adapt to larger areas and navigate intricate trajectories that were not originally intended. The SPA's ability to be used in multiple applications without structural modification was validated through testing as a robot end-effector (gripper), artificial muscles in a soft tendon-driven prosthetic hand, a tube/tunnel navigator, and a robot crawler.

A 3D-printed hollow microneedle-based electrochemical sensing device for in situ plant health monitoring

Plant health monitoring is devised as a new concept to elucidate in situ physiological processes. The need for increased food production to nourish the growing global population is inconsistent with the dramatic impact of climate change, which hinders crop health and exacerbates plant stress. In this context, wearable sensors play a crucial role in assessing plant stress. Herein, we present a low-cost 3D-printed hollow microneedle array (HMA) patch as a sampling device coupled with biosensors based on screen-printing technology, leading to affordable analysis of biomarkers in the plant fluid of a leaf. First, a refinement of the 3D-printing method showed a tip diameter of 25.9 ± 3.7 μm with a side hole diameter on the microneedle of 228.2 ± 18.6 μm using an affordable 3D printer (<500 EUR). Notably, the HMA patch withstanded the forces exerted by thumb pressing (i.e. 20-40 N). Subsequently, the holes of the HMA enabled the fluid extraction tested in vitro and in vivo in plant leaves (i.e. 13.5 ± 1.1 μL). A paper-based sampling strategy adapted to the HMA allowed the collection of plant fluid. Finally, integrating the sampling device onto biosensors facilitated the in situ electrochemical analysis of plant health biomarkers (i.e. H2O2, glucose, and pH) and the electrochemical profiling of plants in five plant species. Overall, this electrochemical platform advances precise and versatile sensors for plant health monitoring. The wearable device can potentially improve precision farming practices, addressing the critical need for sustainable and resilient agriculture in changing environmental conditions.

A high-resolution handheld millimeter-wave imaging system with phase error estimation and compensation

Despite the enormous potential of millimeter-wave (mmWave) imaging, the high cost of large-scale antenna arrays or stringent prerequisites of the synthetic aperture radar (SAR) principle impedes its widespread application. Here, we report a portable, affordable, and high-resolution 3D mmWave imaging system by overcoming the destructive motion error of handheld SAR imaging. This is achieved by revealing two important phenomenons: spatial asymmetry of motion errors in different directions, and local similarity of phase errors exhibited by different targets, based on which we formulate the challenging phase error estimation problem as a tractable point spread function optimization problem. Experiments demonstrate that our approach can recover high-fidelity 3D mmWave images from severely distorted signals and augment the aperture size by over 50 times. Since our system does not rely on costly massive antennas or bulky motion controllers, it can be applied for diverse applications including security inspection, autonomous driving, and medical monitoring.

A Review of 3D Printing and Surgical Planning

Three-Dimensional Printing (3DP), also known as rapid prototyping or additive manufacturing, has revolutionized the field of medicine, particularly in preoperative planning. By transforming intricate Two-Dimensional (2D) medical imaging data into tangible, patient-specific Three-Dimensional (3D) models, 3DP enhances surgical precision and patient care. This technology facilitates detailed preoperative visualization, enabling surgeons to interact with accurate anatomical models, plan complex procedures, and anticipate potential challenges. The evolution of 3DP, driven by advances in Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA), has democratized access to affordable and sophisticated 3D printers, spurring innovation in medical applications. In this study, a comprehensive review of the literature on the integration of 3DP technology into preoperative planning is conducted. Applications across various surgical disciplines, including cardiovascular, orthopedic, craniofacial, neurosurgical, oncological, transplant, and pediatric surgeries are examined. Benefits of 3DP in providing tactile feedback, creating patient-specific surgical guides and implants, and enhancing surgical simulation and training are evaluated. Additionally, challenges associated with the high costs, time-intensive processes, and material limitations of 3DP are assessed. Findings demonstrate that 3DP significantly reduces operative times, improves surgical outcomes, and lowers complication rates. The study highlights the transformative impact of 3DP on surgical practice and underscores its potential for future advancements. With ongoing research and innovation in materials science, bioprinting, artificial intelligence, and augmented reality, 3DP is poised to further revolutionize preoperative planning, offering more personalized, precise, and patient-centered healthcare solutions.

3D printed porous membrane integrated devices to study the chemoattractant induced behavioural response of aquatic organisms.

Biological models with genetic similarities to humans are used for exploratory research to develop behavioral screening tools and understand sensory-motor interactions. Their small, often mm-sized appearance raises challenges in the straightforward quantification of their subtle behavioral responses and calls for new, customisable research tools. 3D printing provides an attractive approach for the manufacture of custom designs at low cost; however, challenges remain in the integration of functional materials like porous membranes. Nanoporous membranes have been integrated with resin exchange using purpose-designed resins by digital light projection 3D printing to yield functionally integrated devices using a simple, economical and semi-automated process. Here, the impact of the layer thickness and layer number on the porous properties - parameters unique for 3D printing - are investigated, showing decreases in mean pore diameter and porosity with increasing layer height and layer number. From the same resin formulation, materials with average pore size between 200 and 600 nm and porosity between 45% and 61% were printed. Membrane-integrated devices were used to study the chemoattractant induced behavioural response of zebrafish embryos and planarians, both demonstrating a predominant behavioral response towards the chemoattractant, spending >85% of experiment time in the attractant side of the observation chamber. The presented 3D printing method can be used for printing custom designed membrane-integrated devices using affordable 3D printers and enable fine-tuning of porous properties through adjustment of layer height and number. This accessible approach is expected to be adopted for applications including behavioural studies, early-stage pre-clinical drug discovery and (environmental) toxicology.

Enantioselective C-H bond functionalization under Co(III)-catalysis.

While progress in enantioselective C-H functionalization has been accomplished by employing 4d and 5d transition metal-based catalysts, the rapid depletion of these metals in the earth's crust poses a serious threat to making these protocols sustainable. On the other hand, because of their unique reactivity, low toxicity, and high earth abundance, newer strategies utilizing affordable 3d transition metals have come to the forefront. Among the first-row transition metals, high-valent cobalt has recently attracted a lot of attention for catalytic C-H functionalization with mono and bidentate directing groups. This approach was extended for asymmetric catalysis due to a fairly thorough knowledge of its catalytic cycles. Four major themes have been investigated as a result of this insight: (1) rational design of a chiral Cp#Co(III)-catalyst, (2) chiral carboxylic acid with achiral Cp*Co(III)-catalysts using monodentate directing groups, (3) cobalt/salox-based systems, and (4) cobalt/chiral phosphoric acid-based hybrid systems with bidentate directing groups. Herein, we highlight the recent developments in high-valent cobalt-catalyzed enantioselective C-H functionalization up to October 2023, with the strong belief that the current state-of-the-art can attract considerable interest in the synthetic community, encouraging discoveries in the evolving landscape of asymmetric catalysis.

Utilization of accessible resources in the fabrication of an affordable, portable, high-resolution, 3D printed, digital microscope for Philippine diagnostic applications.

Philippine clinical laboratory licensing requirements mandate that diagnostic microscopy for Tuberculosis (TB) sputum microscopy, urinalysis, pap smears, wet smears, an option for complete blood count, stool exams, and malaria thick and thin smears should be accessible and available in health facilities including primary care centers. However, access to these essential diagnostics is hampered by the lack of trained personnel, relatively high costs for supplies and equipment especially in rural and underserved areas. This served as motivation for our team to utilize accessible resources in the form of affordable 3D printers, available CAD software, and components to build our low-cost Openflexure microscope (OFM) prototype. We successfully fabricated our prototype for a total of 310$ with a weight of 525g. We used pathology teaching slides from the Ateneo School of Medicine and Public Health and examined the OFM prototype imaging capabilities. The calculated image resolution was 13% higher compared to an LED light microscope sample captured by a mobile phone at 40x and 15% for 100x. The sampled slide images had adequate clarity with some identifiable cellular features for Rheumatic Heart Disease (RHD), Tuberculosis in soft tissue, and Ascariasis. We were able to correct the color aberrations of the OFM we built and was able to scan images up to 1000x magnification without using oil. Given the features and cost, the OFM prototype can be an attractive and affordable option as an alternative or augmentation to diagnostic microscopy in Philippine primary care. Moreover, it may enable telepathology to support diagnostic microscopy in frontline care.

OpenASAP: An affordable 3D printed atmospheric solids analysis probe (ASAP) mass spectrometry system for direct analysis of solid and liquid samples

Atmospheric Solids Analysis Probe (ASAP) mass spectrometry is a versatile technique allowing direct sampling of solid and liquid samples, but its adoption is limited due to the high cost of commercial ASAP systems. To address this, we present OpenASAP, an open-source ASAP system for mass spectrometers that can be fabricated for $20 or less using 3D-printing. Our design is readily adaptable to instruments from different manufacturers and can be produced with a variety of additive manufacturing techniques on consumer-grade 3D-printers. The probe allows for rapid sampling of solid and liquid samples without sample preparation, making it useful for high throughput screening, investigating spatial localization and function of analytes in biological samples, and incorporating mass spectrometry in instructional settings. We demonstrate its effectiveness by obtaining mass spectra of three natural product standards at levels as low as 10 ng/ml in liquid samples, and detecting these metabolites in microbial cultures that are difficult to analyze due to complex sample matrices or analyte properties. Furthermore, we demonstrate direct sampling of thin layer chromatography (TLC) spots of these cultures.

Enhancing Dimensional Accuracy in Budget-Friendly 3D Printing through Solid Model Geometry Tuning and Its Use in Rapid Casting

Achieving precise dimensional accuracy and improving surface quality are the primary research and development objectives in the engineering and industrial applications of 3D printing (3DP) technologies. This experimental study investigates the pivotal role of solid model geometry tuning in enhancing the dimensional accuracy of affordable 3D printing technologies, with a specific focus on economical engineering applications. This experiment utilises low-cost Material Extrusion/Fused Filament Fabrication (FFF) and Stereolithography (SLA)/Digital Light Processing (DLP) 3D-printed patterns for the meticulous measurement of errors in the X, Y, and Z directions. These errors are then used to refine subsequent solid models, resulting in a marked improvement in dimensional accuracy (i.e., 0.15%, 0.33%, and 2.16% in the X, Y, and Z directions, respectively) in the final DLP 3D-printed parts. The study also derives and experimentally validates a novel and simple mathematical model for tuning the solid model based on the calculated linear directional errors (ei, ej, and ek). The developed mathematical model offers a versatile approach for achieving superior dimensional accuracy in other 3D printing processes. Medium-sized (4 to 10 cm) wax-made DLP- and PLA-made patterns are used to test the ceramic mould-building capacity for rapid casting (RC), where the FFF-based 3D-printed (hollow inside) pattern favours successful RC. This work comprehensively addresses the critical challenges encountered in low-cost DLP and FFF processes and their scopes in engineering applications. It provides novel suggestions and answers to improve the effectiveness, quality, and accuracy of the FFF 3D printing process for future applications in RC.

Affordable and reliable three-dimensional printing: a prospective study of seven distal radius fractures

Purpose: Three-dimensional (3D) printing is now widely available, and its potential applications to surgery are limitless. However, 3D printing is presently performed at only a few large institutions. We developed a 3D printing workflow using an affordable 3D printer and open-source 3D printing software. We tested whether this combination could produce a model that reliably reflects real bone. Methods: We performed a prospective study with a target sample size of seven. Patients with distal radius fractures were enrolled from October 2021 to February 2022. The 3D-printed models of the fractures were produced using open-source software (3D Slicer [Surgical Planning Laboratory, Harvard Medical School] and Cura [Ultimaker]) and a $600 printer. The anterior-to-posterior (AP) and radial-to-ulnar (RU) widths of the fracture sites were measured on computed tomography (CT) images, in 3D printed models, and in real bones (during surgery). Surgery was simulated using the 3D models; the locations and profiles of implants were compared to those placed during real surgery, which was performed without simulation data.Results: The fracture AP and RU widths did not differ significantly among the CT, 3D model, and real bone measurements. Interclass correlation coefficients indicated that the measurements were reliable (0.943 [p&lt;0.001] and 0.917 [p&lt;0.001], respectively). When the implant profiles of the simulations and surgical procedures were compared, only the most distal (radial) screws were significantly longer in the simulations (p=0.016). The plate location also differed significantly (p=0.043). Conclusions: Our 3D printing workflow is affordable yet produces reliable bone models.

Simple and Easily Connectable Transition from Empty Substrate-Integrated Waveguide to a 3D Printed Rectangular Waveguide

3D printing is one of the most promising manufacturing methods in the most developed technological fields, including microwave hardware fabrication. On the other hand, the well-known manufacturing methods of planar substrate integrated circuits allow high-quality prototypes to be made at low cost and with mass production capabilities. The combination of both manufacturing methods, 2D or 2.5D (substrate integrated circuits) and 3D (3D printed structures), will allow us to take advantage of the main strengths of each technology and minimise disadvantages. In this article, for the first time, a transition structure between the Empty Substrate-Integrated Waveguide (ESIW) technology—a planar waveguide integrated on a printed circuit board—and a standard rectangular waveguide manufactured by 3D printing is proposed. This transition will make it possible to combine planar circuits with 3D structures, thus taking advantage of the benefits of both types of technologies. The fabricated prototype presents low losses (0.6 dB for the transmission coefficient and 15 dB for reflection coefficient), good electrical response (very flat), and simultaneously good mechanical stability and robustness to manufacturing and assembly errors. The proposed design for this transition piece is easily realisable for a wide range of affordable 3D printers. Repeatability is guaranteed and the proposed transition allows us to combine different SIC structures to 3D printed circuits. Hence, this transition will enable advancements in the fabrication of microwave devices, particularly with regard to satellite communications.