Direct Light Processing Research Articles

Comparison of elastic properties of periodic and aperiodic porous structures produced by additive methods

The aim of this work was to design, print, and examine elastic properties of porous structures with various parameters and beam distributions. These structures, generated using an algorithm, featured three types of lattices: octet, cubic, and Voronoi diagram-based, with different porosities (40 %, 60 %, 80 %) and beam sizes (0.45 mm, 0.66 mm). They were printed using Direct Light Processing and examined using X-ray computed microtomography. Compression tests were conducted to determine the Young’s modulus. The results were compared with computer simulations performed using Abaqus. The tools used, such as 3D printing and X-ray computed microtomography, were described, and the results and conclusions of the tests were presented. As a result, comparable outcomes were obtained for structures with higher beam diameter, while significantly different results were observed for structures with lower beam diameter.

Evaluation on Surface Characteristics, Accuracy, and Dimensional Stability of Tooth Preparation Dies Fabricated by Conventional Gypsum and 3D-Printed Workflows.

To evaluate the surface characteristics, accuracy (trueness and precision), and dimensional stability of tooth preparation dies fabricated using conventional gypsum and direct light processing (DLP), stereolithography (SLA), and polymer jetting printing (PJP) techniques. Gypsum preparation dies were replicated according to the reference data and imported into DLP, SLA, and PJP printers, and the test data were obtained by scanning after 0, 1, 3, 7, 14, 28, and 42 days. After analyzing the surface characteristics, a best-fit algorithm between the test and the reference data was used to evaluate the accuracy and dimensional stability of the preparation dies. The data were analyzed by one-way analysis of variance and Tukey test or Kruskal-Wallis H test (α = .05). Compared with the gypsum group (3.61 ± 0.59 μm), the root mean square error (RMSE) values of the SLA group (5.33 ± 0.48 μm) was rougher (P < .05), the PJP group (2.43 ± 0.37 μm) was smoother (P < .05), and the DLP group (2.92 ± 0.91 μm) had no significant difference (P > .05). For trueness, the RMSE was greater in the PJP (34.90 ± 4.91 μm) and SLA (19.01 ± 0.95 μm) groups than in the gypsum (16.47 ± 0.47 μm) group (P < .05), and no significant difference was found between the DLP (17.10 Å} 1.77 μm) and gypsum groups. Regarding precision, the RMSE ranking was gypsum = DLP = SLA < PJP group. The RMSE ranges in the gypsum, DLP, PJP, and SLA groups at different times were 6.79 to 8.86 μm, 5.44 to 10.17 μm, 10.16 to 11.28 μm, and 10.94 to 32.74 μm, respectively. Although gypsum and printed preparation dies showed statistically significant differences in surface characteristics, accuracy, and dimensional stability, all tooth preparation dies were clinically tolerated and used to produce fixed restorations.

3D Printed Bioinspired Hierarchical Surface Structure with Tunable Wettability

Abstract Nature has examples of impressive surfaces and interfaces with diverse wettability stemming from superhydrophilicity to superhydrophobicity. The multiscale surface structures found in biological systems generally have high geometric complexity, which makes it challenging to replicate their characteristics, especially using traditional fabrication techniques. It is even more challenging to fabricate such complex microstructures with tunable wettability. In this paper, we propose a method to tune the wettability of a micro-scale surface by changing the geometrical parameters of embedded micro-structures in the surface. By taking inspiration from an insect (springtails), we designed micropillar arrays with different roughness by adjusting geometric parameters such as reentrant angle, pitch distance, and the number of spikes and pillars. This study shows that, by changing geometrical parameters in microscale, the apparent contact angle, and hence the surface wettability can be calibrated. The microscale pillars were fabricated using a precise micro direct light processing (uDLP) three-dimensional (3D) printer. Different printing parameters were studied to optimize the geometric parameters to fabricate 3D hierarchical structures with high accuracy and resolution. By controlling the size of different features of the pillar, pillar number, and layout of the mushroom-shaped micropillars, the wettability of the surface is possible to be tuned from a highly nonwetting liquid/material combination to highly wetting material. Such wettability tuning capability expands the design space for many biomedical and thermofluidic applications.

Marginal and internal discrepancies associated with carbon digital light synthesis additively manufactured interim crowns

Statement of problemThe carbon digital light synthesis (DLS) or continuous liquid interface production (CLIP) technology is an innovative additive manufacturing technology using oxygen-inhibited photopolymerization to create a continuous liquid interface of unpolymerized resin between the growing component and the exposure window. This interface eliminates the need for an incremental layer-by-layer approach, allowing for continuous creation and increased printing speed. However, the internal and marginal discrepancies associated with this new technology remain unclear. PurposeThe purpose of this in vitro study was to evaluate the marginal and internal discrepancies by using the silicone replica technique of interim crowns fabricated by 3 different manufacturing technologies: direct light processing (DLP), DLS, and milling. Material and methodsA mandibular first molar was prepared, and a crown was designed with a computer-aided design (CAD) software program. The standard tessellation language (STL) file was used to create 30 crowns from the DLP, DLS, milling technologies (n=10). The gap discrepancy was determined using the silicone replica approach, with 50 measurements made with a ×70 microscope for each specimen for the marginal and internal gaps. The data were analyzed using 1-way ANOVA, followed by the Tukey HSD post hoc test (α=.05). ResultsThe DLS group had the least marginal discrepancy compared with the DLP and milling groups (P<.001). The DLP group showed the highest internal discrepancy followed by the DLS and milling groups (P=.038). No significant difference was found between DLS and milling in terms of internal discrepancy (P>.05). ConclusionsThe manufacturing technique had a significant effect on both internal and marginal discrepancies. The DLS technology showed the smallest marginal discrepancies.

Comparison in Terms of Accuracy between DLP and LCD Printing Technology for Dental Model Printing.

Background: The aim of this study is to evaluate the accuracy of a Liquid Crystal Display (LCD) 3D printer compared to a Direct Light Processing (DLP) 3D printer for dental model printing. Methods: Two different printers in terms of 3D printing technology were used in this study. One was a DLP 3D printer and one an LCD 3D printer. The accuracy of the printers was evaluated in terms of trueness and precision. Ten STL reference files were used for this study. For trueness, each STL file was printed once with each 3D printer. For precision, one randomly chosen STL file was printed 10 times with each 3D printer. Afterward, the models were scanned with a model scanner, and reverse engineering software was used for the STL comparisons. Results: In terms of trueness, the comparison between the LCD 3D printer and DLP 3D printer was statistically significant, with a p-value = 0.004. For precision, the comparison between the LCD 3D printer and the DLP 3D printer was statistically significant, with a p-value = 0.011. Conclusions: The DLP 3D printer is more accurate in terms of dental model printing than the LCD 3D printer. However, both DLP and LCD printers can accurately be used to print dental models for the fabrication of orthodontic appliances.

A Comparative Analysis of Dental Measurements in Physical and Digital Orthodontic Case Study Models.

Background and Objectives: Study models are essential tools used in the dental teaching process. The aim of the present study was to compare the values obtained by manual and digital orthodontic measurements on physical and digital case study models. Materials and Methods: The physical experimental models were obtained by traditional pouring (improved stone-type IV gypsum products) and by additive manufacturing (resins). The digital experimental models were created by scanning the physical ones, using a white light-emitting diode (LED) source and an L-shaped dental scanner—Swing DOF (DOF, Seoul, Korea). The physical study models were first measured using a digital caliper, and then, they were scanned and evaluated using the DentalCad 3.0 Galway software (exocad GmbH, Darmstadt, Germany). The Pont, Linder–Harth, and Bolton indices, which are used in orthodontics for training students, were derived using the available data. Results: When comparing the linear measurement mean ranks taken on physical study models to those of digital models, no statistically significant differences (p > 0.05) were found. A similar result was also shown when the dentoalveolar growth indicators were analyzed. Conclusions: It can be concluded that dental study models made by direct light processing (DLP) and pouring type IV class gypsum are both acceptable for orthodontic teaching purposes.

Rinsing postprocessing procedure of a 3D-printed orthodontic appliance material: Impact of alternative post-rinsing solutions on the roughness, flexural strength and cytotoxicity

ObjectiveThe present study evaluated the effect of different rinsing postprocessing solutions on surface characteristics, flexural strength, and cytotoxicity of an additive manufactured polymer for orthodontic appliances. These solutions have been deemed an alternative to the standard isopropanol which is a flammable liquid, known to have toxic effects. MethodsTested specimens were manufactured using direct light processing of an orthodontic appliance polymer (FREEPRINT® splint 2.0, Detax) and post-processed with different post-rinsing solutions, including isopropanol (IPA), ethanol (EtOH), EASY 3D Cleaner (EYC), Yellow Magic7 (YM7), and RESINAWAY (RAY), respectively. All groups were post-cured following the manufacturer’s instructions. Surface topography and roughness (Ra and Rv) were evaluated. In addition, flexural strength was measured by a three-point bending test. An extract test was performed to evaluate cytotoxicity. The data were analyzed by the Kruskal-Wallis test with Dunn's multiple comparisons test (p < 0.05). ResultsVarious post-rinsing solutions did not significantly affect the roughness values (Ra and Rv). Specimens post-processed with EtOH (98.1 ± 12.4 MPa) and EYC (101.1 ± 6.3 MPa) exhibited significantly lower flexural strength compared to the groups of IPA (110.7 ± 5.3 MPa), RAY (112.1 ± 5.6 MPa) and YM7 (117.3 ± 5.9 MPa), respectively. Finally, there were no cytotoxic effects of parts cleaned with different post-rinsing solutions. SignificanceConsidering the use of 3D-printed orthodontic appliance materials, different rinsing postprocessing procedures did not affect surface characteristics. However, the flexural strength was significantly influenced, which could be attributed to the chemical ingredients of the post-rinsing solutions. Various post-rinsing treatments had no alternation concerning cytocompatibility.

Trueness and precision of skin surface reproduction in digital workflows for facial prosthesis fabrication

Statement of problemHow much skin surface details of facial prostheses can be transferred throughout the digital production chain has not been quantified. PurposeThe purpose of this in vitro study was to quantify the amount of skin surface details transferred from the prosthesis virtual design through the prototype printing with various additive manufacturing (AM) methods to the definitive silicone prosthesis with an indirect mold-making approach. Material and methodsTwelve test blocks with embossed wrinkles of 0.05 to 0.8 mm and 12 test blocks with applied earlobe skin structures were printed with stereolithography (SLA), direct light processing (DLP), and PolyJet methods (n=4). DLP and SLA prototype specimens were duplicated in wax. All specimens were then transferred into medical-grade silicone. Rz values of the wrinkle test blocks and the root mean square error (RMSE) of the earlobe test blocks were evaluated by laser topography to determine the trueness and precision of each stage. ResultsFor the earlobe test blocks, the PolyJet method had superior trueness and precision of the final skin surface reproduction. The SLA method showed the poorest trueness, and the DLP method, the lowest precision. For the wrinkle test blocks, the PolyJet method had the best wrinkle profile reproduction level, followed by DLP and SLA. ConclusionsThe indirect mold-making approach of facial prostheses manufacturing may be associated with 7% of skin surface profile loss with SLA, up to 20% with DLP, and no detail loss with PolyJet.

Cytotoxicity, Colour Stability and Dimensional Accuracy of 3D Printing Resin with Three Different Photoinitiators.

Biocompatibility is important for the 3D printing of resins used in medical devices and can be affected by photoinitiators, one of the key additives used in the 3D printing process. The choice of ingredients must be considered, as the toxicity varies depending on the photoinitiator, and unreacted photoinitiator may leach out of the polymerized resin. In this study, the use of ethyl (2,4,6-trimethylbenzoyl) phenylphosphinate (TPO-L) as a photoinitiator for the 3D printing of resin was considered for application in medical device production, where the cytotoxicity, colour stability, dimensional accuracy, degree of conversion, and mechanical/physical properties were evaluated. Along with TPO-L, two conventional photoinitiators, phenylbis (2,4,6-trimethylbenzoyl) phosphine oxide (BAPO) and diphenyl (2,4,6-trimethylbenzoyl) phosphine oxide (TPO), were considered. A total of 0.1 mol% of each photoinitiator was mixed with the resin matrix to prepare a resin mixture for 3D printing. The specimens were printed using a direct light processing (DLP) type 3D printer. The 3D-printed specimens were postprocessed and evaluated for cytotoxicity, colour stability, dimensional accuracy, degree of conversion, and mechanical properties in accordance with international standards and the methods described in previous studies. The TPO-L photoinitiator showed excellent biocompatibility and colour stability and possessed with an acceptable dimensional accuracy for use in the 3D printing of resins. Therefore, the TPO-L photoinitiator can be sufficiently used as a photoinitiator for dental 3D-printed resin.

3D printing for aneurysms clipping elective surgery

This paper deals with the realisation of 3D printed cerebral aneurysms by using the direct light processing (DLP) technique. The aim was to improve the anatomy knowledge, training and surgical planning on individualised patient-specific basis. Computed tomography angiography and digital subtraction angiography of three patients were used to create 3D virtual models by using a commercial image-processing software. The DLP technique was aimed at realising the corresponding 3D physical models. These were firstly evaluated by the surgeons and then, if acceptable, used for the patient-specific treatment planning. All three models provided a comprehensive 3D representation of the related anatomical structure of the aneurysms improving the understanding of the surrounding vessels and their relationships. Moreover, the use of the DLP technology allowed fabricating the 3D models of the cerebral aneurysms in a low-time and low-cost consuming way.

Investigation of two-phase flow regimes in square minichannels with different mixers created using additive technologies

In this paper, the effect of the junction angle on the Taylor flow regime characteristics was investigated. Using the Direct Light Processing method, minichannel mixers with different liquid and gas junction angles (from 30° to 150°) relative to the minichannel axis were manufactured. An experimental study of the two-phase flow formation was carried out, where Milli-Q® water was used as a working liquid, and high purity nitrogen was used as a working gas. A method of two-phase flow characteristic analysis using a high-speed shadow technique and automatic postprocessing was developed. Two-phase flow regimes were investigated in a wide range of gas and liquid flow rates. Size distribution of gas bubbles and liquid slugs and the distribution of bubble velocities were analyzed. The mechanisms of Taylor bubble formation and their characteristics, depending on the junction angle, were investigated.

Additive Manufacturing for Neurosurgery: Digital Light Processing of Individualized Patient-Specific Cerebral Aneurysms.

This study aims at demonstrating the feasibility of reproducing individualized patient-specific three-dimensional models of cerebral aneurysms by using the direct light processing (DLP) 3D printing technique in a low-time and inexpensive way. Such models were used to help neurosurgeons understand the anatomy of the aneurysms together with the surrounding vessels and their relationships, providing, therefore, a tangible supporting tool with which to train and plan surgical operations. The starting 3D models were obtained by processing the computed tomography angiographies and the digital subtraction angiographies of three patients. Then, a 3D DLP printer was used to print the models, and, if acceptable, on the basis of the neurosurgeon’s opinion, they were used for the planning of the neurosurgery operation and patient information. All the models were printed within three hours, providing a comprehensive representation of the cerebral aneurysms and the surrounding structures and improving the understanding of their anatomy and simplifying the planning of the surgical operation.

Accuracy Evaluation of Additively and Subtractively Fabricated Palatal Plate Orthodontic Appliances for Newborns and Infants-An In Vitro Study.

Different approaches for digital workflows have already been presented for their use in palatal plates for newborns and infants. However, there is no evidence on the accuracy of CAD/CAM manufactured orthodontic appliances for this kind of application. This study evaluates trueness and precision provided by different CAM technologies and materials for these appliances. Samples of a standard palatal stimulation plate were manufactured using stereolithography (SLA), direct light processing (DLP) and subtractive manufacturing (SM). The effect of material (for SM) and layer thickness (for DLP) were also investigated. Specimens were digitized with a laboratory scanner (D2000, 3Shape) and analyzed with a 3D inspection software (Geomagic Control X, 3D systems). For quantitative analysis, differences between 3D datasets were measured using root mean square (RMS) error values for trueness and precision. For qualitative analysis, color maps were generated to detect locations of deviations within each sample. SM showed higher trueness and precision than AM technologies. Reducing layer thickness in DLP did not significantly increase accuracy, but prolonged manufacturing time. All materials and technologies met the clinically acceptable range and are appropriate for their use. DLP with 100 µm layer thickness showed the highest efficiency, obtaining high trueness and precision within the lowest manufacturing time.

Stereolithography vs. Direct Light Processing for Rapid Manufacturing of Complete Denture Bases: An In Vitro Accuracy Analysis

The topical literature lacks any comparison between stereolithography (SLA) and direct light processing (DLP) printing methods with regard to the accuracy of complete denture base fabrication, thereby utilizing materials certified for this purpose. In order to investigate this aspect, 15 denture bases were printed with SLA and DLP methods using three build angles: 0°, 45° and 90°. The dentures were digitalized using a laboratory scanner (D2000, 3Shape) and analyzed in analyzing software (Geomagic Control X, 3D systems). Differences between 3D datasets were measured using the root mean square (RMS) value for trueness and precision and mean and maximum deviations were obtained for each denture base. The data were statistically analyzed using two-way ANOVA and Tukey’s multiple comparison test. A heat map was generated to display the locations of the deviations within the intaglio surface. The overall tendency indicated that SLA denture bases had significantly higher trueness for most build angles compared to DLP (p < 0.001). The 90° build angle may provide the best trueness for both SLA and DLP. With regard to precision, statistically significant differences were found in the build angles only. Higher precision was revealed in the DLP angle of 0° in comparison to the 45° and 90° angles.

Fracture resistance of additive manufactured and milled implant-supported interim crowns

Statement of problemInterim dental prostheses can be fabricated by using subtractive or additive manufacturing technologies. However, the fracture resistance of implant-supported interim crowns fabricated by using vat-polymerization additive manufacturing methods remains unclear. PurposeThe purpose of this in vitro study was to evaluate the fracture resistance of anterior and posterior screw-retained implant-supported interim crowns fabricated by using subtractive and vat-polymerization direct light processing (DLP) additive manufacturing procedures. Material and methodsAn implant (Zinic Implant RP ∅4.0×10 mm) was placed in a 15×15-mm polymethylmethacrylate block. An implant abutment (ZiaCam, nonrotatory RP) was positioned on each implant. The virtual implant abutment standard tessellation language (STL) file provided by the manufacturer was imported into a software program (exocad v2.2 Valletta) to design 2 anatomic contour crowns, a maxillary right central incisor (anterior group) and a maxillary right premolar (posterior group). Each group was subdivided into 2 subgroups depending on the manufacturing method: milled (milled subgroup) and additive manufacturing (additive manufacturing subgroup). For the milled subgroup, an interim material (Vivodent CAD Multi) and a milling machine were used to fabricate all the specimens (N=40, n=10). For the additive manufacturing subgroup, a polymer interim material (SHERAprint-cb) and a DLP printer (SHERAprint 30) were used to manufacture all the specimens at a 50-μm layer thickness and 45-degree build orientation as per the manufacturer’s instructions. Then, each specimen was cemented to an implant abutment by using composite resin cement (Multilink Hybrid Abutment HO) as per the manufacturer’s instructions. A universal testing machine was used for fracture resistance analysis, and the failure mode was recorded. The Shapiro-Wilk test revealed that data were normally distributed. One-way ANOVA and Tukey multiple comparison were selected (α=.05). ResultsOne-way ANOVA revealed significant differences among the groups (P<.05). The anterior milled subgroup obtained a significantly higher fracture resistance mean ±standard deviation value of 988.4 ±54.8 N compared with the anterior additive manufacturing subgroup of 636.5 ±277.1 N (P<.001), and the posterior milled subgroup obtained significantly higher mean ±standard deviation of 423.8 ±68 N than the additive manufacturing subgroup of 321.3 ±128.6 N (P=.048). All groups presented crown fracture without abutment fracture. ConclusionsManufacturing procedures and tooth type influenced the fracture resistance of screw-retained implant-supported interim crowns. Milled specimens obtained higher fracture resistance compared with the DLP additive manufacturing groups. The anterior group was higher than the posterior group.

Structural Factors and Electrochemical Behaviors of 3D Architected Carbon Electrodes

Cycling of lithium-ion batteries composed of intercalation materials and electrolyte involves interfacial reactions and transports, governed by differences in ion concentrations, currents, and potentials. Those electrochemical behaviors have been investigated by characterizing simplified electrode structure such as thin film and single particle, and bridging the knowledge toward commercial batteries with modeling and simulations. However, the stochastic structure of slurry electrodes commonly used in commercial batteries makes it hard to investigate local environments in the battery system and understand relations between electrochemical factors and resulting phenomena such as solid electrolyte interface formation and lithium dendrite formations at local sites. Here, we address this challenge by developing deterministic 3D architected carbon electrode with micron-to-centimeter form factors and mechanical integrity, which enables us to prescribe the electrode architecture with the consideration of distribution of ion concentrations, currents and potentials and investigate electrochemical responses in battery operation and then conduct post-characterization of the electrode.The 3D architected carbon electrodes were fabricated by the combination of direct light processing (DLP) 3D printing and pyrolysis process. The uniform shrinkage of 3D printed UV-cured polymer during pyrolysis led to the fabrication of 3D architected carbon with the prescribed structure. The electrode is fully controllable in micron-to-centimeter length scales to prescribe porous structure, electrode thickness and relative position to the counter electrode.To demonstrate the 3D architected carbon as an electrode of lithium ion batteries, we constructed a half-cell with beam-based 3D architected carbon (Figure 1) using a 2032 coin cell. To compare effects of structural factors, we chose to vary two structural factors independently, either sample thickness or beam diameter, which directly relate to diffusion length in electrolyte or electrode and locked all other parameters. Those structural factors (i.e. beam diameter and thickness) were varied in the estimated electrode diffusion-limit regime. The galvanostatic cycling at different current densities showed improved rate performance as decreasing electrode diffusion length, which agreed with the estimation that electrode diffusion was the rate-limiting process. In the regime, furthermore, slurry electrodes made by pulverizing 3D carbon electrode into particles showed similar rate performance to the 3D architected carbon electrode for the same mass loadings. These results also indicate that non-tortuous porous structure of the 3D architected carbon did not take advantage of effective lithium ion transport trajectories in electrolyte because of the electrode diffusion-limiting regime.In addition, we used the 3D architected carbon electrode to investigate solid electrolyte interface (SEI) variation in a cell scale. The deterministic 3D architecture can prescribe local ion concentrations in the porous structure and its mechanical integrity enables us to investigate SEI on the 3D architected carbon electrode at different locations as post-characterization in nanoscale. This multi-scale tunable 3D architected electrode with mechanical integrity enables to elucidate relations between structural factors of battery electrodes and electrochemical behaviors, which may lead to designing rational battery electrode in multi-scales.

Accuracy evaluation of complete-arch models manufactured by three different 3D printing technologies: a three-dimensional analysis.

Purpose This study aimed to evaluate the trueness and precision of complete-arch models printed with three-dimensional printers via three different printing technologies.Methods An arch-shaped master model was designed using software (RapidForm XOR2, 3D Systems Inc., USA), and the digital master model was printed 10 times with three-dimensional printers using stereolithography (SLA), direct light processing (DLP), and Polyjet technology (n = 30). The printed models were then scanned with an industrial scanner to create the respective digital models. All digital models were compared with the master model, and an evaluation of the trueness was performed by model superimposition with Geomagic Control software (3D Systems, Rock Hill, SC, USA). Precision was determined for each case by superimposing some combination of the 10 datasets in each group.Results The trueness of the printed models was 46.2 µm for the DLP printer, 51.6 µm for the SLA printer, and 58.6 µm for the Polyjet printer. The DLP models were significantly better than the Polyjet models (p = .005). However, the Polyjet models (30.4 µm) were more precise than the SLA (37.6 µm) and DLP (43.6 µm) models (p < .001, p = .016). Furthermore, the SLA (11.8 µm) was the most accurate printer in the Z-direction (p = .016, p = .002).Conclusions The 3D printing technologies showed significant differences in the precision and trueness of complete-arch measurements. Although DLP was more accurate other tested 3D printers, the accuracy of all 3D printed models was within clinical tolerance, and they were clinically acceptable and could be used for the production of fixed restorations.

Evaluation of direct light processing for the fabrication of bioactive ceramic scaffolds: Effect of pore/strut size on manufacturability and mechanical performance

Bioactive ceramic scaffolds for bone regeneration consisting of a three-dimensional mesh of interpenetrating struts with square section were fabricated via Digital Light Processing (DLP). The ability of the technique to manufacture 3D porous structures from β-tricalcium phosphate (β-TCP) powders with different dimensions of struts and pores was evaluated, identifying the possibilities and limitations of the manufacturing process. Small pore sizes were found to seriously complicate the elimination of excess slurry from the scaffold’s innermost pores. The effect of the strut/pore size on the mechanical performance of the scaffolds under compressive stresses was also evaluated, but no significant influence was found. Under compressive stresses, the structures resulted weaker when tested perpendicularly to the printing plane due to interlayer shear failure. Interlayer superficial grooves are proposed as potential failure-controlling defects, which could also explain the lack of a Weibull size effect on the mechanical strength of the fabricated DLP scaffolds.

In vitro accuracies of 3D printed models manufactured by two different printing technologies.

This study aims to compare the accuracies of full-arch models printed by two different 3D printing technologies. A mandibular horseshoe-shaped master model was designed with RapidForm XOR2 software The master model was printed 10 times with 3D printers using direct light processing (DLP) and PolyJet technology (n=20). The printed models were then scanned with an industrial scanner and saved in STL file. All digital models superimposed with the master model STL file and comparison of the trueness was performed using Geomagic Control 3D analysis software. The precision was calculated by superimposing combinations of the 10 data sets in each group. The trueness of printed models was 46 µm for the DLP printer and 51 µm for PolyJet printer; however, this difference was not statistically significant (p=0.155). The precision of printed models was 43 µm for the DLP printer and 54 µm for PolyJet printer. DLP printed models were more precise than the PolyJet printed models (p<0.001). The 3D printing technologies showed significant differences in the trueness of full-arch measurements. Although DLP printed models had better trueness than PolyJet printed models, all of the 3D printed models were clinically acceptable and might be used for the production of fixed restorations.

Additive Manufacturing (AM) Capacitive Acoustic and Ultrasonic Transducers Using a Commercial Direct Light Processing (DLP) Printer

In recent years, there has been increasing interest in using additive manufacturing (3D printing) technology to fabricate sensors and actuators due to rapid prototyping, low-cost manufacturing processes, customized features and the ability to create complex geometries at micrometre scale. State of the art additive manufactured acoustic and ultrasonic transducers show limitations in miniaturization, repeatability (defects) and sensitivity. This new work encompasses the development of a capacitive acoustic and ultrasonic transducer, including its fabrication process using a commercial digital light processing printer and output signal characterization with a custom-made amplification circuit. A set of capacitive-acoustic and ultrasonic transducers was fabricated and tested using different diaphragm diameters from 1.8 - 2.2 mm, for comparison, with central operating frequency between 19 - 54 kHz, respectively. This capacitive transducer design has a receiving sensitivity of up to 0.4 mV/Pa at its resonant frequency, and a comparison with a commercial reference microphone is provided.