Additive Manufacturing Approach Research Articles

Temperature and solvent facilitated extrusion based 3D printing for pharmaceuticals

On demand manufacturing of patient-specific oral doses provides significant advantages to patients and healthcare staff. Several 3D printing (3DP) technologies have been proposed as a potential digital alternative to conventional manufacturing of oral tablets. For an additive manufacturing approach to be successful for on-demand preparation, a facile process with minimal preparation steps and training requirements is needed. A novel hybrid approach to the 3D printing process is demonstrated here based on combining both a solvent and heating to facilitate extrusion. The system employed a moderate elevated temperature range (65-100 °C), a brief drying period, and a simple set-up. In this approach, a compact material cylinder is used as a pharmaceutical ink to be extruded in a temperature-controlled metal syringe. The process proved compatible with hygroscopic polymers [Poly(vinyl alcohol (PVA) and polyvinylpyrrolidone (PVP)] and a number of pharmaceutical fillers (lactose, sorbitol and D-mannitol). The fabricated tablets demonstrated acceptable compendial weight and content uniformity as well as mechanical resistance. In vitro drug release of theophylline from 3D printed tablets was dependent on the nature of the polymer and its molecular weight. This reported approach offers significant advantages compared to other 3DP technologies: simplification of pre-product, the use of a moderate temperature range, a minimal drying period, and avoiding the use of mechanically complicated machinery. In the future, we envisage the use of this low-cost and facile approach to fabricate small batches of bespoke tablets.

3D-Printed Soft Lithography for Complex Compartmentalized Microfluidic Neural Devices.

Compartmentalized microfluidic platforms are an invaluable tool in neuroscience research. However, harnessing the full potential of this technology remains hindered by the lack of a simple fabrication approach for the creation of intricate device architectures with high‐aspect ratio features. Here, a hybrid additive manufacturing approach is presented for the fabrication of open‐well compartmentalized neural devices that provides larger freedom of device design, removes the need for manual postprocessing, and allows an increase in the biocompatibility of the system. Suitability of the method for multimaterial integration allows to tailor the device architecture for the long‐term maintenance of healthy human stem‐cell derived neurons and astrocytes, spanning at least 40 days. Leveraging fast‐prototyping capabilities at both micro and macroscale, a proof‐of‐principle human in vitro model of the nigrostriatal pathway is created. By presenting a route for novel materials and unique architectures in microfluidic systems, the method provides new possibilities in biological research beyond neuroscience applications.

Temperature effect on all-inkjet-printed nanocomposite piezoresistive sensors for ultrasonics-based health monitoring

The sensing performance of nanocomposite piezoresistive sensors in acquiring broadband acousto-ultrasonic wave signals is scrutinized in an extensive regime of temperature variation from −60 to 150 °C, which spans the thermal extremes undergone by most aircraft and spacecraft. Ultralight and flexible, the sensors are all-inkjet-printed using a drop-on-demand additive manufacturing approach, and then optimized sensitive to the ultraweak disturbance induced by acousto-ultrasonic waves in virtue of quantum tunneling effect. Under high-intensity thermal cycles from −60 to 150 °C, the sensors have proven stability and accuracy in responding to signals in a broad band from static to half a megahertz. Compared with conventional broadband sensors such as piezoelectric wafers, this genre of inkjet-printed nanocomposite sensors avoids the influence of increased dielectric permittivity during the measurement of high-frequency signals at elevated temperatures. Use of the sensors for characterizing undersized cracks in a typical aerospace structural component under acute temperature variation has spotlighted the alluring application potentials of the all-inkjet-printed nanocomposite sensors in implementing in-situ structural health monitoring for key aircraft and spacecraft components.

Assembly of Materials Building Blocks into Integrated Complex Functional Systems

Assembly of Materials Building Blocks into Integrated Complex Functional Systems

Direct Ink Writing of Mineral Materials: A review

Due to the intrinsically limited mechanical properties, functionalities and structures of mineral material composites (MMCs) made through traditional fabrication approaches, there is a critical need to develop novel three dimensional (3D) forming techniques that can construct mineral material composites (MMCs) and structures with high performance and functionalities. The direct ink writing (DIW), as a slurry deposition based additive manufacturing approach for MMCs, offers many advantages in terms of high precision, complex geometry, multi-material capability, cost effectiveness and environmental friendliness. This review gives a comprehensive overview on the state-of-art of DIW fabricated MMCs, including material classification, formulation and processing. It presents the key aspects of material processing and their effects on the properties and performance of DIW formed mineral materials. In addition, it illustrates the applications of DIW in the fields of architecture, tissue engineering, functional micro parts and geological engineering modelling.

3D Extrusion Printability of Rice Starch and Optimization of Process Variables

Three-dimensional extrusion printing is an additive manufacturing approach with numerous emerging applications in the food industry. In this research, the effect of nozzle size (1.2 to 1.7 mm), print speed (800 to 2200 mm/min), and motor speed (120 to 240 rpm) on the printability of rice starch were studied. Uniformity and ease of extrusion were considered, and the printed constructs were carefully observed for thread quality, binding property, finishing, texture, layer definition, shape, dimensional stability, and appearance. The rheological behavior of the material supply was studied, and the scientific rationale behind the printability of starch is discussed in detail. Printing rice starch at higher motor speeds (180–240 rpm) with lower printing speeds (800–1500 mm/min) resulted in better printability. The results of this study would be a foundation for future 3D food printing studies using rice starch.

Additive Manufacturing for Soft Robotics: Design and Fabrication of Airtight, Monolithic Bending PneuNets with Embedded Air Connectors.

Air tightness is a challenging task for 3D-printed components, especially for fused filament fabrication (FFF), due to inherent issues, related to the layer-by-layer fabrication method. On the other hand, the capability of 3D print airtight cavities with complex shapes is very attractive for several emerging research fields, such as soft robotics. The present paper proposes a repeatable methodology to 3D print airtight soft actuators with embedded air connectors. The FFF process has been optimized to manufacture monolithic bending PneuNets (MBPs), an emerging class of soft robots. FFF has several advantages in soft robot fabrication: (i) it is a fully automated process which does not require manual tasks as for molding, (ii) it is one of the most ubiquitous and inexpensive (FFF 3D printers costs < $200) 3D-printing technologies, and (iii) more materials can be used in the same printing cycle which allows embedding of several elements in the soft robot body. Using commercial soft filaments and a dual-extruder 3D printer, at first, a novel air connector which can be easily embedded in each soft robot, made via FFF technology with a single printing cycle, has been fabricated and tested. This new embedded air connector (EAC) prevents air leaks at the interface between pneumatic pipe and soft robot and replaces the commercial air connections, often origin of leakages in soft robots. A subsequent experimental study using four different shapes of MBPs, each equipped with EAC, showed the way in which different design configurations can affect bending performance. By focusing on the best performing shape, among the tested ones, the authors studied the relationship between bending performance and air tightness, proving how the Design for Additive Manufacturing approach is essential for advanced applications involving FFF. In particular, the relationship between chamber wall thickness and printing parameters has been analyzed, the thickness of the walls has been studied from 1.6 to 1 mm while maintaining air tightness and improving the bending angle by 76.7% under a pressure of 4 bar. It emerged that the main printing parameter affecting chamber wall air tightness is the line width that, in conjunction with the wall thickness, can ensure air tightness of the soft actuator body.

Dynamic Capillary-Driven Additive Manufacturing of Continuous Carbon Fiber Composite

Summary Additive manufacturing (AM) of lightweight and energy-efficient composites using continuous carbon fibers and thermosetting polymers offers great opportunities for advancing composite manufacturing with design flexibility, reliability, and repeatability. However, to date there have been few AM techniques reported to process continuous fiber-reinforced thermosetting composites. Here, we report a dynamic capillary-driven AM approach with a controllable viscosity and degree of curing of polymer to enable its fast and near-simultaneous infusion and curing to implement in situ solidification of composites into arbitrary shapes. Using the technique, we developed a robotic system consisting of a uniquely designed printing head and an automated robot arm, yielding a 3D printer that enables us to print a composite on 2D and 3D substrates or in free space. The printed composite had high fiber volume fraction (58.6%) and degree of curing (95%) with high mechanical strength (810 MPa) and modulus (108 GPa).

Naturally architected microstructures in structural materials via additive manufacturing

Despite recent advances in our understanding of the unique mechanical behavior of natural structural materials such as nacre and human bone, traditional manufacturing strategies limit our ability to mimic such nature-inspired structures using existing structural materials and manufacturing processes. To this end, we introduce a customizable single-step approach for additively fabricating geometrically-free metallic-based structural composites showing directionally-tailored, location-specific properties. To exemplify this capability, we present a layered metal-ceramic composite not previously reported exhibiting significant directional and site-specific dependence of properties along with crack arrest ability difficult to achieve using traditional manufacturing approaches. Our results indicate that nature-inspired microstructural designs towards directional properties can be realized in structural components using a novel additive manufacturing approach.

Laser-arc hybrid additive manufacturing of stainless steel with beam oscillation

A novel additive manufacturing approach integrating an oscillating laser beam and a cold metal transfer arc was developed to balance the surface accuracy, deposition efficiency, and mechanical properties of the deposited parts. The new method was termed as oscillating laser-arc hybrid additive manufacturing (O-LHAM). The sample properties of the wire-arc additive manufacturing (WAAM), laser-arc hybrid additive manufacturing (LHAM), and O-LHAM processes were compared. It was found that some new phenomena were induced by beam oscillation. First, both the surface roughness and minimum processing margin of the O-LHAM sample were reduced to 20 % of the WAAM sample, because the droplet transfer was stabilized by the laser-arc synergic effects. Second, the grains were refined, and the {001} <100>-cube texture content was decreased to 1.6 %, as the oscillation induced a strong stirring effect on the molten pool. The nondestructive X-ray test suggested that the visible porosity within the O-LHAM sample was suppressed by beam oscillation when the periodically oscillated laser keyhole could “capture” the bubbles, while the porosity within the LHAM sample reached 24 %. Due to the microstructure changes and the porosity suppression, the O-LHAM almost eliminated the anisotropy of tensile strength and improved the elongation by up to 34 %.

Multi-physics continuum modelling approaches for metal powder additive manufacturing: a review

PurposeThis paper aims to present a systematic approach in the literature survey related to metal additive manufacturing (AM) processes and its multi-physics continuum modelling approach for its better understanding.Design/methodology/approachA systematic review of the literature available in the area of continuum modelling practices adopted for the powder bed fusion (PBF) AM processes for the deposition of powder layer over the substrate along with quantification of residual stress and distortion. Discrete element method (DEM) and finite element method (FEM) approaches have been reviewed for the deposition of powder layer and thermo-mechanical modelling, respectively. Further, thermo-mechanical modelling adopted for the PBF AM process have been discussed in detail with its constituents. Finally, on the basis of prediction through thermo-mechanical models and experimental validation, distortion mitigation/minimisation techniques applied in PBF AM processes have been reviewed to provide a future direction in the field.FindingsThe findings of this paper are the future directions for the implementation and modification of the continuum modelling approaches applied to PBF AM processes. On the basis of the extensive review in the domain, gaps are recommended for future work for the betterment of modelling approach.Research limitations/implicationsThis paper is limited to review only the modelling approach adopted by the PBF AM processes, i.e. modelling techniques (DEM approach) used for the deposition of powder layer and macro-models at process scale for the prediction of residual stress and distortion in the component. Modelling of microstructure and grain growth has not been included in this paper.Originality/valueThis paper presents an extensive review of the FEM approach adopted for the prediction of residual stress and distortion in the PBF AM processes which sets the platform for the development of distortion mitigation techniques. An extensive review of distortion mitigation techniques has been presented in the last section of the paper, which has not been reviewed yet.

Bioprinting 101: Design, Fabrication, and Evaluation of Cell-Laden 3D Bioprinted Scaffolds.

3D bioprinting is an additive manufacturing technique that recapitulates the native architecture of tissues. This is accomplished through the precise deposition of cell-containing bioinks. The spatiotemporal control over bioink deposition permits for improved communication between cells and the extracellular matrix, facilitates fabrication of anatomically and physiologically relevant structures. The physiochemical properties of bioinks, before and after crosslinking, are crucial for bioprinting complex tissue structures. Specifically, the rheological properties of bioinks determines printability, structural fidelity, and cell viability during the printing process, whereas postcrosslinking of bioinks are critical for their mechanical integrity, physiological stability, cell survival, and cell functions. In this review, we critically evaluate bioink design criteria, specifically for extrusion-based 3D bioprinting techniques, to fabricate complex constructs. The effects of various processing parameters on the biophysical and biochemical characteristics of bioinks are discussed. Furthermore, emerging trends and future directions in the area of bioinks and bioprinting are also highlighted. Graphical abstract [Figure: see text] Impact statement Extrusion-based 3D bioprinting is an emerging additive manufacturing approach for fabricating cell-laden tissue engineered constructs. This review critically evaluates bioink design criteria to fabricate complex tissue constructs. Specifically, pre- and post-printing evaluation approaches are described, as well as new research directions in the field of bioink development and functional bioprinting are highlighted.

Nanoengineered Osteoinductive Bioink for 3D Bioprinting Bone Tissue.

Bioprinting is an emerging additive manufacturing approach to the fabrication of patient-specific, implantable three-dimensional (3D) constructs for regenerative medicine. However, developing cell-compatible bioinks with high printability, structural stability, biodegradability, and bioactive characteristics is still a primary challenge for translating 3D bioprinting technology to preclinical and clinal models. To overcome this challenge, we developed a nanoengineered ionic covalent entanglement (NICE) bioink formulation for 3D bone bioprinting. The NICE bioinks allow precise control over printability, mechanical properties, and degradation characteristics, enabling custom 3D fabrication of mechanically resilient, cellularized structures. We demonstrate cell-induced remodeling of 3D bioprinted scaffolds over 60 days, demonstrating deposition of nascent extracellular matrix proteins. Interestingly, the bioprinted constructs induce endochondral differentiation of encapsulated human mesenchymal stem cells (hMSCs) in the absence of osteoinducing agent. Using next-generation transcriptome sequencing (RNA-seq) technology, we establish the role of nanosilicates, a bioactive component of NICE bioink, to stimulate endochondral differentiation at the transcriptome level. Overall, the osteoinductive bioink has the ability to induce formation of osteo-related mineralized extracellular matrix by encapsulated hMSCs in growth factor-free conditions. Furthermore, we demonstrate the ability of NICE bioink to fabricate patient-specific, implantable 3D scaffolds for repair of craniomaxillofacial bone defects. We envision development of this NICE bioink technology toward a realistic clinical process for 3D bioprinting patient-specific bone tissue for regenerative medicine.

The structural origins of brittle star arm kinematics: An integrated tomographic, additive manufacturing, and parametric modeling-based approach

Brittle stars are known for the high flexibility of their arms, a characteristic required for locomotion, food grasping, and for holding onto a great diversity of substrates. Their high agility is facilitated by the numerous discrete skeletal elements (ossicles) running through the center of each arm and embedded in the skin. While much has been learned regarding the structural diversity of these ossicles, which are important characters for taxonomic purposes, their impact on the arms’ range of motion, by contrast, is poorly understood. In the present study, we set out to investigate how ossicle morphology and skeletal organization affect the flexibility of brittle star arms.Here, we present the results of an in-depth analysis of three brittle star species (Ophioplocus esmarki, Ophiopteris papillosa, and Ophiothrix spiculata), chosen for their different ranges of motion, as well as spine size and orientation. Using an integrated approach that combines behavioral studies with parametric modeling, additive manufacturing, micro-computed tomography, scanning electron microscopy, and finite element simulations, we present a high-throughput workflow that provides a fundamental understanding of 3D structure-kinematic relationships in brittle star skeletal systems.

Porous zinc scaffolds for bone tissue engineering applications: A novel additive manufacturing and casting approach.

As a degradable metal, zinc (Zn) has attracted an immense amount of interest as the next generation of bioresorbable implants thanks to its modest corrosion rate and its vital role in bone remodeling, yet very few studies have thoroughly investigated its functionality as a porous implant for bone tissue engineering purposes. Zn bone scaffolds with two different pore sizes of 900μm and 2mm were fabricated using additive manufacturing-produced templates combined with casting. The compressive properties, corrosion rates, biocompatibility, and antibacterial performance of the bioscaffolds were examined and compared to a non-porous control. The resulting textured and porous Zn scaffolds exhibit a fully interconnected pore structure with precise control over topology. As pore size and porosity increased, mechanical strength decreased, and corrosion rate accelerated. Cell adhesion and growth on scaffolds were enhanced after an ex vivo pretreatment method. In vitro cellular tests confirmed good biocompatibility of the scaffolds. As porosity increased, potent antibacterial rates were also observed. Taken together, these results demonstrate that Zn porous bone scaffolds are promising for orthopedic applications.

An additive manufacturing approach to bioreactor design for mesenchymal stem cell culture

Bioreactor design is a challenging endeavour that aims to provide the most ideal environment in which cells can grow and biological reactions can occur. The emergence of regenerative medicine and stem cell therapies has led to the need for more diverse environmental requirements in the bioreactor design space.The study presented uses an additive manufacturing approach for the initial design phase of a packed/fluidized bed bioreactor for mesenchymal stem cell expansion. Combining 3D-printing with CFD for precision control over the bioreactor flow dynamics. Novel flow distributors were developed to engender swirling particle fluidization. The design was simulated and optimised using CFD, demonstrating an increase from 0.01 m/s to 0.02 m/s in the radial velocity of 3.0 mm macrocarriers (1080 kg/m3) at the minimum fluidization velocity. An autoclavable prototype was constructed to illustrate proof-of-concept in the use of swirling flow distribution to enhance cell attachment efficiency (compared to static culture system). Commercial Cytodex 1 carriers were tested: an improvement in attachment efficiency after 24 h from 50 % to 95 % was induced by the swirling flow distributor, with subsequent expansion of 2.4-fold after 6 days of culture.The computational design, modelling and 3D-printing of complex geometric architecture that control the flow dynamics within a bioreactor, provides a novel approach to bioprocess unit operation development for manufacturing novel ATMPs.

Optimization of energy and directional response of a small 4π silicon dosemeter for quality control of CT/CBCT-units – A 3D CAD, Monte-Carlo, AM approach

A 4π radiation dosemeter for use in medical radiology was designed. It is based on a solid state silicon detector, a sensor wafer, a flex card, a 3D plastic holder and a spherical stainless steel filter with a distribution of holes around the detector. The detector is attached to the wafer using only low Z material. To achieve an energy and directional response which is as uniform as possible for various radiation qualities and beam directions, the filter was designed using a series of Monte Carlo calculations. The energy filter and its hole pattern were created using Additive Manufacturing (AM) in the form of metal 3D printing. The functionality of the dosemeter was designed to fulfill the quality criteria of a combined energy and angular dependence of less than 5% for the IEC beam qualities RQR and RQT in the range of 65–145 kV. This is a major improvement to the existing solutions that may need software corrections to be used for the same beam quality range.

Rapid Assembly of Small Materials Building Blocks (Voxels) into Large Functional 3D Metamaterials

AbstractHerein, various 3D additive manufacturing approaches are reviewed in terms of two important figures of merit: maximum voxel printing rate and minimum voxel size. Voxel sizes from several 100 µm down to the 100 nm scale are covered. Original results on multifocus two‐photon printing at around voxel printing rates of 107 voxels s−1 are presented in this context, which significantly surpass previous best values. These advances are illustrated by and applied to the making of microstructured 3D (chiral) mechanical metamaterials that are composed of more than one‐hundred‐thousand unit cells in three dimensions. Previous best values for unit cells of similar complexity are smaller by two orders of magnitude.

Areal Surface Roughness Optimization of Maraging Steel Parts Produced by Hybrid Additive Manufacturing.

We report on an experimental study and statistical optimization of the surface roughness using design of experiments and the Taguchi method for parts made of 1.2709 maraging steel. We employ a hybrid additive manufacturing approach that combines additive manufacturing by selective laser melting with subtractive manufacturing using milling in an automated process within a single machine. Input parameters such as laser power, scan speed, and hatching distance have been varied in order to improve surface quality of unmachined surfaces. Cutting speed, feed per tooth, and radial depth of cut have been varied to optimize surface roughness of the milled surfaces. The surfaces of the samples were characterized using 3D profilometry. Scan speed was determined as the most important parameter for non-machined surfaces; radial depth of cut was found to be the most significant parameter for milled surfaces. Areal surface roughness could be reduced by up to 40% for unmachined samples and by 23% for milled samples as compared to the prior state of the art.

Layered 3D Printing by Tethered Pyro-Electrospinning

Nowadays it is easy to imagine that the exploitation of different additive manufacturing approaches could find use in regenerative medicine and frontiers nanotechnology with a strong interest in the development of in vivo bio-incubators that better replicate the tissue environment. Various electrospinning technologies have been exploited for the fabrication of composite polymeric architectures, where fibers have been used for the construction layer by layer of micro-architectures. Unfortunately, in case of processing biomaterials, the intrinsic factors of the materials could become obstacles when considering such advanced engineering methods. Here, for the first time, we use the pyro-EHD process for the fabrication of layered three-dimensional architectures made using a biodegradable and biocompatible polymer. The proposed approach for layered 3D printing works at mild temperature allowing deposition at high resolution and great flexibility in manufacturing, avoiding high voltage generators, and nozzles. The layered 3D printing, activated by the pyro-electric effect, is discussed and characterized in terms of geometrical features and processing parameters. Different geometries and micro-architecture (wall, square, triangle, and hybrid structures) have been demonstrated and over printing of composite polymer, obtained by mixing multiwall carbon nanotubes and fluorochrome, has been discussed, focusing on the use of a biodegradable and biocompatible polymer.