Direct 3D Printing Research Articles

In-vitro perforation of the round window membrane via direct 3-D printed microneedles.

The cochlea, or inner ear, is a space fully enclosed within the temporal bone of the skull, except for two membrane-covered portals connecting it to the middle ear space. One of these portals is the round window, which is covered by the Round Window Membrane (RWM). A longstanding clinical goal is to reliably and precisely deliver therapeutics into the cochlea to treat a plethora of auditory and vestibular disorders. Standard of care for several difficult-to-treat diseases calls for injection of a therapeutic substance through the tympanic membrane into the middle ear space, after which a portion of the substance diffuses across the RWM into the cochlea. The efficacy of this technique is limited by an inconsistent rate of molecular transport across the RWM. A solution to this problem involves the introduction of one or more microscopic perforations through the RWM to enhance the rate and reliability of diffusive transport. This paper reports the use of direct 3D printing via Two-Photon Polymerization (2PP) lithography to fabricate ultra-sharp polymer microneedles specifically designed to perforate the RWM. The microneedle has tip radius of 500 nm and shank radius of 50 μ m, and perforates the guinea pig RWM with a mean force of 1.19 mN. The resulting perforations performed in vitro are lens-shaped with major axis equal to the microneedle shank diameter and minor axis about 25% of the major axis, with mean area 1670 μ m2. The major axis is aligned with the direction of the connective fibers within the RWM. The fibers were separated along their axes without ripping or tearing of the RWM suggesting the main failure mechanism to be fiber-to-fiber decohesion. The small perforation area along with fiber-to-fiber decohesion are promising indicators that the perforations would heal readily following in vivo experiments. These results establish a foundation for the use of Two-Photon Polymerization lithography as a means to fabricate microneedles to perforate the RWM and other similar membranes.

A Metallographic Review of 3D Printing/Additive Manufacturing of Metal and Alloy Products and Components

Applications and examples of light and electron micrographs illustrating microstructures, which describe metallurgical phenomena in 3D printing/additive manufacturing of metal and alloy products and components, are presented along with extensive process and processing parameter descriptions and review. Examples include microstructures that have defined turbine blade fabrication and optimization over the past half century, including contemporary electron beam melting fabrication of turbine blade alloys and other novel microstructures and architectures, which result from layer by layer, non-equilibrium melt solidification and epitaxial growth involving powder bed laser and electron beam fabrication. Phase transformations and second-phase formation by rapid cooling in metal and alloy components fabricated by laser and electron beam melting technologies are illustrated for a range of high-temperature materials. Using a range of examples, the advantages of fabricating complex (especially porous) biomedical and related commercial products are described. Prospects for future developments of direct 3D metal and alloy droplet printing, as a key component of the digital factory of the future, are described. This technology is compared with more conventional solidification and powder bed layer building thermo-kinetics, especially in the context of large structure and component fabrication.

Direct 3D printing of silicone facial prostheses: A preliminary experience in digital workflow

Direct silicone printing may be applied to the fabrication of maxillofacial prostheses, although its clinical feasibility is unknown. The present clinical report shows an early application of a directly printed silicone prosthesis for the rehabilitation of a nasal defect. Two extraoral scanning systems were used to capture the face and the defect. The virtual construction of the nasal prosthesis was performed with free-form software. Two prostheses were printed in silicone and post-processed by manual sealing and coloring. The clinical outcome was acceptable for an interim prosthesis; however, the marginal adaptation and color match were not satisfactory without further individualization.

Direct 3D Printing of Ultralight Graphene Oxide Aerogel Microlattices

AbstractGraphene aerogel microlattices (GAMs) hold great prospects for many multifunctional applications due to their low density, high porosity, designed lattice structures, good elasticity, and tunable electrical conductivity. Previous 3D printing approaches to fabricate GAMs require either high content of additives or complex processes, limiting their wide applications. Here, a facile ion‐induced gelation method is demonstrated to directly print GAMs from graphene oxide (GO) based ink. With trace addition of Ca2+ ions as gelators, aqueous GO sol converts to printable gel ink. Self‐standing 3D structures with programmable microlattices are directly printed just in air at room temperature. The rich hierarchical pores and high electrical conductivity of GAMs bring admirable capacitive performance for supercapacitors. The gravimetric capacitance (Cs) of GAMs is 213 F g−1 at 0.5 A g−1 and 183 F g−1 at 100 A g−1, and retains over 90% after 50 000 cycles. The facile, direct 3D printing of neat graphene oxide can promote wide applications of GAMs from energy storage to tissue engineering scaffolds.

Direct 3D Printing of Reactive Agitating Impellers for the Convenient Treatment of Various Pollutants in Water

AbstractMass transfer plays a key role in the diffusion‐controlled heterogeneous reactions. Varied efforts have been made to design the structure of catalysts and reactors to optimize the diffusion process. Herein, a facile strategy is reported to construct highly reactive agitating impeller (denoted as AI) by employing 3D printing and a facile surface activation treatment. On the one hand, experimental results and numerical simulation analysis reveal that the 3D printing AI with appropriate structure can not only effectively eliminate external diffusion but also conveniently be separated from heterogeneous reaction systems. On the other hand, surface activation helps to significantly promote the chemical reactivity of AI for Fenton and galvanic replacement reaction, which are used to treat organic and inorganic pollutants in water, respectively. Benefiting from these cooperative merits, the integrated catalytic AI delivers a catalytic performance toward Fenton reactions as high as a homogeneous catalyst, and the removal rate for heavy metal ions is nearly 100% through galvanic replacement. This 3D printing with surface engineering strategy should also be extended to other applications, and provide new field for preparing efficient and durable heterogeneous catalysts in a more economical way.

Fabrication of 3D Microfluidic Channels and In‐Channel Features Using 3D Printed, Water‐Soluble Sacrificial Mold

AbstractRecent advent of additive manufacturing potentiates the fabrication of microchannels, albeit with limitations in resolution of printed structures, freedom of geometry, and choice of printable materials. Herein, a method is developed by sacrificial molding to fabricate microchannels in various polymer matrices and geometries. This method allows for rapid fabrication of 3D microchannels and channels harboring intricate in‐channel features. The method uses commercially available fused deposition modeling 3D printer and filament made of polyvinyl alcohol (PVA). Mechanically stable molds are fabricated for 3D microchannels that can be completely removed in water. Importantly, the PVA mold is stable and resilient in hydrogels despite being hygroscopic. Perfusion channels are fabricated in biocompatible substrates such as gelatin and poly(ethylene glycol) diacrylate. Fabrication of the network of 3D multilayer microchannels is demonstrated by preassembling sacrificial molds from modular pieces of molds. Intricate staggered‐herringbones grooves (SHGs) are also fabricated within microchannels to produce micromixers. The versatility and resilience of the method developed here is advantageous for biological and chemical applications that require 3D configurations of microchannels in various matrices, which would not be compatible with fabrication by direct 3D printing and softlithography.

Direct 3D Printing of High Strength Biohybrid Gradient Hydrogel Scaffolds for Efficient Repair of Osteochondral Defect

AbstractThe emerging 3D printing technique allows for tailoring hydrogel‐based soft structure tissue scaffolds for individualized therapy of osteochondral defects. However, the weak mechanical strength and uncontrollable swelling intrinsic to conventional hydrogels restrain their use as bioinks. Here, a high‐strength thermoresponsive supramolecular copolymer hydrogel is synthesized by one‐step copolymerization of dual hydrogen bonding monomers, N‐acryloyl glycinamide, and N‐[tris(hydroxymethyl)methyl] acrylamide. The obtained copolymer hydrogels demonstrate excellent mechanical properties—robust tensile strength (up to 0.41 MPa), large stretchability (up to 860%), and high compressive strength (up to 8.4 MPa). The rapid thermoreversible gel ⇔ sol transition behavior makes this copolymer hydrogel suitable for direct 3D printing. Successful preparation of 3D‐printed biohybrid gradient hydrogel scaffolds is demonstrated with controllable 3D architecture, owing to shear thinning property which allows continuous extrusion through a needle and also immediate gelation of fluid upon deposition on the cooled substrate. Furthermore, this biohybrid gradient hydrogel scaffold printed with transforming growth factor beta 1 and β‐tricalciumphosphate on distinct layers facilitates the attachment, spreading, and chondrogenic and osteogenic differentiation of human bone marrow stem cells (hBMSCs) in vitro. The in vivo experiments reveal that the 3D‐printed biohybrid gradient hydrogel scaffolds significantly accelerate simultaneous regeneration of cartilage and subchondral bone in a rat model.

Hydrolytically Stable MOF in 3D‐Printed Structures

AbstractMetal–organic frameworks (MOFs) are a well‐developed field of materials, having a high potential for various applications such as gas storage, water purification, and catalysis. Despite the continuous discoveries of new MOFs, so far there are only a limited number of industrial applications, partially due to their low chemical stability and limited mechanical properties, as well as difficulties in integration within functional devices, Herein, a new approach is presented toward the fabrication of MOF‐based devices, utilizing direct 3D printing. By this method, 3D, flexible, and hydrolytically stable MOF‐embedded polymeric structures are fabricated. It is found that the adsorption capacity of the 3D‐printed MOF is retained, with significantly improved hydrolytic stability of the printed MOFs (copper benzene‐1,3,5‐tricarboxylate) compared to the MOF only. It is expected that applying 3D printing technologies, for the fabrication of functional MOF objects such as filters and matrices for columns and flow reactors, will open the way for utilization of this important class of materials.

Microscale 3D Printing of Nanotwinned Copper.

Nanotwinned (nt)-metals exhibit superior mechanical and electrical properties compared to their coarse-grained and nanograined counterparts. nt-metals in film and bulk forms are obtained using physical and chemical processes including pulsed electrodeposition (PED), plastic deformation, recrystallization, phase transformation, and sputter deposition. However, currently, there is no process for 3D printing (additive manufacturing) of nt-metals. Microscale 3D printing of nt-Cu is demonstrated with high density of coherent twin boundaries using a new room temperature process based on localized PED (L-PED). The 3D printed nt-Cu is fully dense, with low to none impurities, and low microstructural defects, and without obvious interface between printed layers, which overall result in good mechanical and electrical properties, without any postprocessing steps. The L-PED process enables direct 3D printing of layer-by-layer and complex 3D microscale nt-Cu structures, which may find applications for fabrication of metamaterials, sensors, plasmonics, and micro/nanoelectromechanical systems.

Ceramic-Based 4D Components: Additive Manufacturing (AM) of Ceramic-Based Functionally Graded Materials (FGM) by Thermoplastic 3D Printing (T3DP).

In our study, we investigated the additive manufacturing (AM) of ceramic-based functionally graded materials (FGM) by the direct AM technology thermoplastic 3D printing (T3DP). Zirconia components with varying microstructures were additively manufactured by using thermoplastic suspensions with different contents of pore-forming agents (PFA), which were co-sintered defect-free. Different materials were investigated concerning their suitability as PFA for the T3DP process. Diverse zirconia-based suspensions were prepared and used for the AM of single- and multi-material test components. All of the samples were sintered defect-free, and in the end, we could realize a brick wall-like component consisting of dense (<1% porosity) and porous (approx. 5% porosity) zirconia areas to combine different properties in one component. T3DP opens the door to the AM of further ceramic-based 4D components, such as multi-color, multi-material, or especially, multi-functional components.

Direct 3D Printing of Catalytically Active Structures

3D printing of materials with active functional groups can provide custom-designed structures that promote chemical conversions. Herein, catalytically active architectures were produced by photopolymerizing bifunctional molecules using a commercial stereolithographic 3D printer. Functionalities in the monomers included a polymerizable vinyl group to assemble the 3D structures and a secondary group to provide them with active sites. The 3D-printed architectures containing accessible carboxylic acid, amine, and copper carboxylate functionalities were catalytically active for the Mannich, aldol, and Huisgen cycloaddition reactions, respectively. The functional groups in the 3D-printed structures were also amenable to postprinting chemical modification. As proof of principle, chemically active cuvette adaptors were 3D printed and used to measure in situ the kinetics of a heterogeneously catalyzed Mannich reaction in a conventional solution spectrophotometer. In addition, 3D-printed millifluidic devices with c...

Biomimetic heterogenous elastic tissue development

There is an unmet need for artificial tissue to address current limitations with donor organs and problems with donor site morbidity. Despite the success with sophisticated tissue engineering endeavours, which employ cells as building blocks, they are limited to dedicated labs suitable for cell culture, with associated high costs and long tissue maturation times before available for clinical use. Direct 3D printing presents rapid, bespoke, acellular solutions for skull and bone repair or replacement, and can potentially address the need for elastic tissue, which is a major constituent of smooth muscle, cartilage, ligaments and connective tissue that support organs. Thermoplastic polyurethanes are one of the most versatile elastomeric polymers. Their segmented block copolymeric nature, comprising of hard and soft segments allows for an almost limitless potential to control physical properties and mechanical behaviour. Here we show direct 3D printing of biocompatible thermoplastic polyurethanes with Fused Deposition Modelling, with a view to presenting cell independent in-situ tissue substitutes. This method can expeditiously and economically produce heterogenous, biomimetic elastic tissue substitutes with controlled porosity to potentially facilitate vascularisation. The flexibility of this application is shown here with tubular constructs as exemplars. We demonstrate how these 3D printed constructs can be post-processed to incorporate bioactive molecules. This efficacious strategy, when combined with the privileges of digital healthcare, can be used to produce bespoke elastic tissue substitutes in-situ, independent of extensive cell culture and may be developed as a point-of-care therapy approach.

Design of tunable acoustic metamaterials using 3D computer graphics

The goal of this work is to investigate how the combination of 3D computer graphics and finite element software can be used to rapidly design materials with tunable properties for noise and vibration mitigation applications. Algorithms and software that create three-dimensional objects, known collectively as 3D computer graphics, are widely used artistically for rendering, animation, and game creation. These approaches allow for the design of complex topological structures such as cellular solids. This presentation describes the use of 3D computer graphics to design cellular structures, which can be imported into finite element software in order to determine effective vibrational properties. This approach is advantageous for several reasons. It allows for quick variation of parameters of cellular solids such as porosity and void fraction. It also is time efficient compared to alternative methods such as performing computed tomography scans on physical samples and analyzing the imaged files. Furthermore, resulting designs can be easily fabricated by direct 3D printing. This presentation will include analysis and discussion of designs generated by the proposed approach.

Functional micro-concrete 3D hybrid structures fabricated by two-photon polymerization

Arbitrary micro-scale three-dimensional (3D) structures fabrication is a dream to achieve many exciting goals that have been pursued for a long time. Among all these applications, the direct 3D printing to fabricate human organs and integrated photonic circuits are extraordinary attractive as they can promote the current technology to a new level. Among all the 3D printing methods available, two-photon polymerization (2PP) is very competitive as it is the unique method to achieve sub-micron resolution to make any desired tiny structures. For the conventional 2PP, the building block is the photoresist. However, the requirement for the building block is different for different purposes. It is very necessary to investigate and improve the photoresist properties according to different requirements. In this paper, we presented one hybrid method to modify the mechanical strength and light trapping efficiency of the photoresist, which transfers the photoresist into the micro-concretes. The micro-concrete structure can achieve ±22% strength modification via a silica nano-particles doping. The structures doped with gold nano-particles show tunable plasmonic absorption. Dye doped hybrid structure shows great potential to fabricate 3D micro-chip laser.

3D-Printed Multidrug-Eluting Stent from Graphene-Nanoplatelet-Doped Biodegradable Polymer Composite.

Patients with percutaneous coronary intervention generally receive either bare metal stents or drug-eluting stents to restore the normal blood flow. However, due to the lack of stent production with an individual patient in mind, the same level of effectiveness may not be possible in treating two different clinical scenarios. This study introduces for the first time the feasibility of a patient-specific stenting process constructed from direct 3D segmentation of medical images using direct 3D printing of biodegradable polymer-graphene composite with dual drug incorporation. A biodegradable polymer-carbon composite is prepared doped with graphene nanoplatelets to achieve controlled release of combinatorics as anticoagulation and antirestenosis agents. This study develops a technology prototyped for personalized stenting. An in silico analysis is performed to optimize the stent design for printing and its prediction of sustainability under force exerted by coronary artery or blood flow. A holistic approach covering in silico to in situ-in vivo establishes the structural integrity of the polymer composite, its mechanical properties, drug loading and release control, prototyping, functional activity, safety, and feasibility of placement in coronary artery of swine.

Patient-specific pediatric silicone heart valve models based on 3D ultrasound.

Patient-specific heart and valve models have shown promise as training and planning tools for heart surgery, but physically realistic valve models remain elusive. Available proprietary, simulation-focused heart valve models are generic adult mitral valves and do not allow for patient-specific modeling as may be needed for rare diseases such as congenitally abnormal valves. We propose creating silicone valve models from a 3D-printed plastic mold as a solution that can be adapted to any individual patient and heart valve at a fraction of the cost of direct 3D-printing using soft materials. Leaflets of a pediatric mitral valve, a tricuspid valve in a patient with hypoplastic left heart syndrome, and a complete atrioventricular canal valve were segmented from ultrasound images. A custom software was developed to automatically generate molds for each valve based on the segmentation. These molds were 3D-printed and used to make silicone valve models. The models were designed with cylindrical rims of different sizes surrounding the leaflets, to show the outline of the valve and add rigidity. Pediatric cardiac surgeons practiced suturing on the models and evaluated them for use as surgical planning and training tools. Five out of six surgeons reported that the valve models would be very useful as training tools for cardiac surgery. In this first iteration of valve models, leaflets were felt to be unrealistically thick or stiff compared to real pediatric leaflets. A thin tube rim was preferred for valve flexibility. The valve models were well received and considered to be valuable and accessible tools for heart valve surgery training. Further improvements will be made based on surgeons' feedback.

Investigation of the adhesion properties of direct 3D printing of polymers and nanocomposites on textiles: Effect of FDM printing process parameters

In this paper, 3D printing as a novel printing process was considered for deposition of polymers on synthetic fabrics to introduce more flexible, resource-efficient and cost effective textile functionalization processes than conventional printing process like screen and inkjet printing. The aim is to develop an integrated or tailored production process for smart and functional textiles which avoid unnecessary use of water, energy, chemicals and minimize the waste to improve ecological footprint and productivity. Adhesion of polymer and nanocomposite layers which were 3D printed directly onto the textile fabrics using fused deposition modeling (FDM) technique was investigated. Different variables which may affect the adhesion properties including 3D printing process parameters, fabric type and filler type incorporated in polymer were considered. A rectangular shape according to the peeling standard was designed as 3D computer-aided design (CAD) to find out the effect of the different variables. The polymers were printed in different series of experimental design: nylon on polyamide 66 (PA66) fabrics, polylactic acid (PLA) on PA66 fabric, PLA on PLA fabric, and finally nanosize carbon black/PLA (CB/PLA) and multi-wall carbon nanotubes/PLA (CNT/PLA) nanocomposites on PLA fabrics. The adhesion forces were quantified using the innovative sample preparing method combining with the peeling standard method. Results showed that different variables of 3D printing process like extruder temperature, platform temperature and printing speed can have significant effect on adhesion force of polymers to fabrics while direct 3D printing. A model was proposed specifically for deposition of a commercial 3D printer Nylon filament on PA66 fabrics. In the following, among the printed polymers, PLA and its composites had high adhesion force to PLA fabrics.

The Use of 3D Metal Printing (Direct Metal Laser Sintering) in Removable Prosthodontics.

The use of 3D printing is expanding and it is envisaged that it will have an increasing presence within dentistry. Having an appreciation and understanding of such technology is therefore paramount. It is currently used to produce a variety of dental objects/prostheses. This paper briefly looks at 3D printing in dentistry and specifically describes the use of the direct metal laser sintering 3D printing technique in the production of cobalt chromium removable prosthesis frameworks. Clinical relevance: Understanding the different technologies that can and are being used within the dental field is important, particularly as it is a rapidly changing field. Having an understanding of such technologies will allow practitioners to utilize such technologies appropriately in the management of their patients.

Pediatric laryngeal simulator using 3D printed models: A novel technique.

Simulation to acquire and test technical skills is an essential component of medical education and residency training in both surgical and nonsurgical specialties. High-quality simulation education relies on the availability, accessibility, and reliability of models. The objective of this work was to describe a practical pediatric laryngeal model for use in otolaryngology residency training. Ideally, this model would be low-cost, have tactile properties resembling human tissue, and be reliably reproducible. Pediatric laryngeal models were developed using two manufacturing methods: direct three-dimensional (3D) printing of anatomical models and casted anatomical models using 3D-printed molds. Polylactic acid, acrylonitrile butadiene styrene, and high-impact polystyrene (HIPS) were used for the directly printed models, whereas a silicone elastomer (SE) was used for the casted models. The models were evaluated for anatomic quality, ease of manipulation, hardness, and cost of production. A tissue likeness scale was created to validate the simulation model. Fleiss' Kappa rating was performed to evaluate interrater agreement, and analysis of variance was performed to evaluate differences among the materials. The SE provided the most anatomically accurate models, with the tactile properties allowing for surgical manipulation of the larynx. Direct 3D printing was more cost-effective than the SE casting method but did not possess the material properties and tissue likeness necessary for surgical simulation. The SE models of the pediatric larynx created from a casting method demonstrated high quality anatomy, tactile properties comparable to human tissue, and easy manipulation with standard surgical instruments. Their use in a reliable, low-cost, accessible, modular simulation system provides a valuable training resource for otolaryngology residents. N/A. Laryngoscope, 127:E132-E137, 2017.

Versatile Graphene Oxide Putty-Like Material.

Versatile graphene oxide putty-like material (GOP) with excellent processability is developed by mediating a graphene oxide suspension with aniline. Arbitrarily predesigned architectures on both microscopic and macroscopic scales can be molded easily. GOP cannot only be used as starting material for direct 3D printing of particular configurations, but also can be tailored into the patterned structures on various substrates for large-scale production of device arrays.