Fused Deposition Modeling 3D Printing Research Articles

From Data to Design: Constructing Scapula and Hip Bone Through Online Datasets, Open-Source Software and 3D Printers.

Introduction Human skeletons and bones are essential for medical and allied sciences students. Nowadays, it is becoming challenging to procure bone legally, resulting in medical students' inadequacy of bone. Plaster-of-Paris or resin bone models sold on the market are less detailed than real bones. Aims and objectives This study aims to create a three-dimensional (3D)-printed human bone model with free, open-source software and fused deposition modelling (FDM) 3D printers, compare its accuracy with the original bones and validate it with a textbook description. Methods Scapula and hip bone models were produced using open-source software 3D Slicer from computed tomography (CT) data from the "New Mexico Decedent Image Database". After automated segmentation, bones were edited manually with tools in a 3D Slicer(https://www.slicer.org/) and Meshmixer software(Autodesk Inc., San Rafael, California, United States) and 3D bone models were printed using polylactic (PLA) filament. Results and discussions 3Ddigital models of both bones were successfully created with the maximum possible accuracy with an FDM 3D printer. A 3D digital replica of the scapula obtained after segmentation retained most anatomical features except for the glenoid cavity, as the head of the humerus obscured the glenoid cavity. The 3D digital skeleton of the hip bone retained all anatomical features except articulating surfaces, such as the acetabulum and auricular surface ilium, which were obscured by the head of the femur and sacrum. A few morphological features of both bones differed from the original dry bone, and a few finer details were unclear in the iliac fossa and ischium. After manual editing and post-processing, the final physical model obtained has all the features. Conclusions We conclude that it is possible to produce anatomically accurate models with the greatest possible resemblance and accuracy to the original bones using free and open-source data with an FDM 3D printer.

Thermoplastic polymers as water substitutes

Background. New applications of 3D printing have recently appeared in the fields of radiotherapy and radiology, but the knowledge of many radiological characteristics of the compounds involved is still limited. Therefore, studies are needed to improve our understanding about the transport and interaction of ionizing radiation in these materials. Purpose. The purpose of this study is to perform an analysis of the most important radiation interaction parameters in thermoplastic materials used in Fused Deposition Modeling 3D printing. Additionally, we propose improvements to bring their characteristics closer to those of water and use them as water substitutes in applications such as radiodiagnosis, external radiotherapy, and brachytherapy. Methods. We have calculated different magnitudes as mass linear attenuation, mass energy absorption coefficients, as well as stopping power and electronic density of several thermoplastic materials along with various compounds that have been used as water substitutes and in a new proposed blend. To perform these computations, we have used the XCOM and ESTAR databases from NIST and the EGSnrc code for Montecarlo simulations. Results. From the representation of the calculated interaction parameters, we have been able to establish relationships between their properties and the proportion of certain chemical elements. In addition, studying these same characteristics in different commercial solutions used as substitutes for water phantoms allows us to extrapolate improvements for these polymers. Conclusion. The radiological characteristics of the analyzed thermoplastic materials can be improved by adding some chemical elements with atomic numbers higher than oxygen and by using polyethylene in new blends.

A Preclinical Trial Protocol Using an Ovine Model to Assess Scaffold Implant Biomaterials for Repair of Critical-Sized Mandibular Defects.

The present work describes a preclinical trial (in silico, in vivo and in vitro) protocol to assess the biomechanical performance and osteogenic capability of 3D-printed polymeric scaffolds implants used to repair partial defects in a sheep mandible. The protocol spans multiple steps of the medical device development pipeline, including initial concept design of the scaffold implant, digital twin in silico finite element modeling, manufacturing of the device prototype, in vivo device implantation, and in vitro laboratory mechanical testing. First, a patient-specific one-body scaffold implant used for reconstructing a critical-sized defect along the lower border of the sheep mandible ramus was designed using on computed-tomographic (CT) imagery and computer-aided design software. Next, the biomechanical performance of the implant was predicted numerically by simulating physiological load conditions in a digital twin in silico finite element model of the sheep mandible. This allowed for possible redesigning of the implant prior to commencing in vivo experimentation. Then, two types of polymeric biomaterials were used to manufacture the mandibular scaffold implants: poly ether ether ketone (PEEK) and poly ether ketone (PEK) printed with fused deposition modeling (FDM) and selective laser sintering (SLS), respectively. Then, after being implanted for 13 weeks in vivo, the implant and surrounding bone tissue was harvested and microCT scanned to visualize and quantify neo-tissue formation in the porous space of the scaffold. Finally, the implant and local bone tissue was assessed by in vitro laboratory mechanical testing to quantify the osteointegration. The protocol consists of six component procedures: (i) scaffold design and finite element analysis to predict its biomechanical response, (ii) scaffold fabrication with FDM and SLS 3D printing, (iii) surface treatment of the scaffold with plasma immersion ion implantation (PIII) techniques, (iv) ovine mandibular implantation, (v) postoperative sheep recovery, euthanasia, and harvesting of the scaffold and surrounding host bone, microCT scanning, and (vi) in vitro laboratory mechanical tests of the harvested scaffolds. The results of microCT imagery and 3-point mechanical bend testing demonstrate that PIII-SLS-PEK is a promising biomaterial for the manufacturing of scaffold implants to enhance the bone-scaffold contact and bone ingrowth in porous scaffold implants. MicroCT images of the harvested implant and surrounding bone tissue showed encouraging new bone growth at the scaffold-bone interface and inside the porous network of the lattice structure of the SLS-PEK scaffolds.

Challenges faced with 3D-printed electrochemical sensors in analytical applications.

Prototyping analytical devices with three-dimensional (3D) printing techniques is becoming common in research laboratories. The attractiveness is associated with printers' price reduction and the possibility of creating customized objects that could form complete analytical systems. Even though 3D printing enables the rapid fabrication of electrochemical sensors, its wider adoption by research laboratories is hindered by the lack of reference material and the high "entry barrier" to the field, manifested by the need to learn how to use 3D design software and operate the printers. This review article provides insights into fused deposition modeling 3D printing, discussing key challenges in producing electrochemical sensors using currently available extrusion tools, which include desktop 3D printers and 3D printing pens. Further, we discuss the electrode processing steps, including designing, printing conditions, and post-treatment steps. Finally, this work shed some light on the current applications of such electrochemical devices that can be a reference material for new research involving 3D printing.

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.

Design and analysis of solid ankle foot orthosis by employing mechanical characterization and a low-cost scanning approach for additive manufacturing

PurposeThis study aims to investigate the fabrication of solid ankle foot orthoses (SAFOs) using fused deposition modeling (FDM) printing technology. It emphasizes cost-effective 3D scanning with the Kinect sensor and conducts a comparative analysis of SAFO durability with varying thicknesses and materials, including polylactic acid (PLA) and carbon fiber-reinforced (PLA-C), to address research gaps from prior studies.Design/methodology/approachIn this study, the methodology comprises key components: data capture using a cost-effective Microsoft Kinect® Xbox 360 scanner to obtain precise leg dimensions for SAFOs. SAFOs are designed using CAD tools with varying thicknesses (3, 4, and 5 mm) while maintaining consistent geometry, allowing controlled thickness impact investigation. Fabrication uses PLA and PLA-C materials via FDM 3D printing, providing insights into material suitability. Mechanical analysis uses dual finite element analysis to assess force–displacement curves and fracture behavior, which were validated through experimental testing.FindingsThe results indicate that the precision of the scanned leg dimensions, compared to actual anthropometric data, exhibits a deviation of less than 5%, confirming the accuracy of the cost-effective scanning approach. Additionally, the research identifies optimal thicknesses for SAFOs, recommending a 4 and 5 mm thickness for PLA-C-based SAFOs and an only 5 mm thickness for PLA-based SAFOs. This optimization enhances the overall performance and effectiveness of these orthotic solutions.Originality/valueThis study’s innovation lies in its holistic approach, combining low-cost 3D scanning, 3D printing and computational simulations to optimize SAFO materials and thickness. These findings advance the creation of cost-effective and efficient orthotic solutions.

FDM 3D Printing and Properties of PBAT/PLA Blends.

Biodegradable polylactic acid (PLA) has been widely used in fused deposition modeling (FDM) 3D printing. In order to improve its comprehensive properties in 3D printing, in this study, 0-40% content of polybutylene adipate terephthalate(PBAT) was selected to be blended with PLA in a twin-screw extruder; the resulting pellets were drawn into a homogeneous filament; then, PBAT/PLA samples were prepared by FDM 3D printing, and the effects of the dosage of PBAT on the mechanical properties, thermal behavior, surface wettability and melt flowability of the samples were investigated. The results showed that all the samples could be printed smoothly, and the ductility was slightly improved by the increase in the PBAT dosage; the thermal stability of PLA was enhanced by blending with PBAT, and the crystallinity increased monotonically with the increase in PBAT. After blending with PBAT, the surfaces of the samples were more hydrophilic and flowable. The important conclusion achieved in this work was that the PBAT/PLA blends, especially those containing 30%PBAT, showed great potential to replace petroleum-based plastics and are suitable for use in FDM 3D printing technologies for different applications.

Enhancing Mechanical Characteristics of PETG Carbon Fiber Composite through Various Shell Thickness in FDM Processing

The utilization of PETG (Polyethylene Terephthalate Glycol) carbon fiber composites in Fused Deposition Modelling (FDM) processes has gained significant attention due to their enhanced mechanical properties compared to traditional PETG filaments. This study focuses on investigating the impact of varying shell thickness on the mechanical characteristics of PETG carbon fiber composites fabricated through FDM. The objective is to optimize the shell thickness to achieve superior mechanical performance while maintaining printing efficiency. A series of PETG carbon fiber composites with different shell thicknesses were manufactured using an FDM 3D printer. Mechanical tests, including tensile strength, flexural strength, and impact resistance, were conducted to evaluate the performance of the fabricated specimens. Additionally, micro-structural analysis was performed to understand the influence of shell thickness on the interfacial bonding between PETG matrix and carbon fibers. Preliminary results indicate that increasing shell thickness positively affects the mechanical properties of PETG carbon fiber composites. Tensile and flexural strength show a noticeable improvement with an increase in shell thickness, attributed to enhanced interlayer adhesion and improved load-bearing.

Empirical analysis of sensor type importance for data preparation of real-time operational status monitoring in fused deposition modeling 3D printers

Empirical analysis of sensor type importance for data preparation of real-time operational status monitoring in fused deposition modeling 3D printers

Reducing Temperature of Fused Deposition Modelling 3D Printing for Linalool Fast Dissolving Oral Films by Increasing Printer Nozzle Diameter

Oral thrush and throat infections can occur in a wide range of patients. Treatments are available; however, resistance to drugs is a major problem for treating oral and throat infections. Three-dimensional printing (3DP) of fast dissolving oral films (FDFs) of linalool oil may provide an alternative solution. Linalool oil FDFs were printed by fused deposition modelling across 1–18 % w/w linalool content range with nozzle diameters of 0.4 or 1 mm at the temperature range of 150 °C-185 °C. The FDFs were evaluated for physicochemical and mechanical properties. Increasing the printer nozzle diameter to 1 mm allowed reducing the printing temperature from 185 °C to 150 °C; consequently, more linalool was quantified in the films with improved content uniformity. The higher linalool content in the films increased the film disintegration time and mechanical strength. FDFs containing 10% w/w linalool showed clear antifungal activity against Candida albicans. Raman spectroscopy suggested linalool separation from excipients at higher temperature printing. Viscoelastic measurements indicated that to achieve printing; the elastic modulus of molten filament needed to be higher than the loss modulus at low angular frequencies. In conclusion, increasing the printing nozzle diameter may avoid loss of the active ingredient by reducing the temperature of the 3DP process.

The Effect of the Combination of PLA, PP, and ABS Filaments on Flexural Strength in FDM 3D Printing

3D printing of fused deposition modeling (FDM) technique is one of the most widely used nowadays. One disadvantage of this method is that the printed product has low strength to the fact that the product is developed layer by layer. This research aims to combine PLA, PP, and ABS and determine which results in the highest flexural strength. A Cartesian 3D printer printed specimens according to the ASTM D790 standard. Then, specimens were tested using a universal testing machine. An optic microscope was used to observe the fracture area. The results showed that the combination of PLA-ABS increased flexural strength up to 33.12 MPa. While PLA-PP, PLA-PP-ABS and PP-ABS resulted in a flexural strength of less than half PLA-ABS one, they were 14.90, 14.59 and 12.10 MPa, respectively. All alloy combinations except PLA-ABS were delaminated during the bending test. Delamination causes a decrease in the flexural strength of a specimen.

A floating 3D printed polypill formulation for the coadministration and sustained release of antihypertensive drugs

Polypharmacy is a common issue, especially among elderly patients resulting in administration errors and patient inconvenience. Hypertension is a prevalent health condition that frequently leads to polypharmacy, as its treatment typically requires the co-administration of more than one different Active Pharmaceutical Ingredients (API’s). To address these issues, floating hollow torus-shaped dosage forms were developed, aiming at providing prolonged gastric retention and sustained drug release. The dosage forms (polypills) containing three anti-hypertensive API’s (diltiazem (DIL), propranolol (PRP) and hydrochlorothiazide (HCTZ)) were created via Fused Deposition Modelling 3D printing. A multitude of the dosage forms were loaded into a capsule and the resulting formulation achieved prolonged retention times over a 12-hour period in vitro, by leveraging both the buoyancy of the dosage forms, and the “cheerios effect” that facilitates the aggregation and retention of the dosage forms via a combination of surface tension and shape of the objects. Physicochemical characterization methods and imaging techniques were employed to investigate the properties and the internal and external structure of the dosage forms. Furthermore, an ex vivo porcine stomach model revealed substantial aggregation, adhesion and retention of the 3D printed dosage forms in porcine stomach. In vitro dissolution testing demonstrated almost complete first-order release of PRP and DIL (93.52 % and 99.9 %, respectively) and partial release of HCTZ (65.22 %) in the 12 h timeframe. Finally, a convolution-based single-stage approach was employed in order to predict the pharmacokinetic (PK) parameters of the API’s of the formulation and the resemblance of their PK behavior with previously reported data.

An evaluation of the usability and durability of 3D printed versus standard suture materials.

The capability to produce suture material using three-dimensional (3D) printing technology may have applications in remote health facilities where rapid restocking of supplies is not an option. This is a feasibility study evaluating the usability of 3D-printed sutures in the repair of a laceration wound when compared with standard suture material. The 3D-printed suture material was manufactured using a fused deposition modelling 3D printer and nylon 3D printing filament. Study participants were tasked with performing laceration repairs on the pigs' feet, first with 3-0 WeGo nylon suture material, followed by the 3D-printed nylon suture material. Twenty-six participants were enrolled in the study. Survey data demonstrated statistical significance with how well the 3D suture material performed with knot tying, 8.9 versus 7.5 (p = 0.0018). Statistical significance was observed in the 3D-printed suture's ultimate tensile strength when compared to the 3-0 Novafil suture (274.8 vs. 199.8 MPa, p = 0.0096). The 3D-printed suture also demonstrated statistical significance in ultimate extension when compared to commercial 3-0 WeGo nylon suture (49% vs. 37%, p = 0.0215). This study was successful in using 3D printing technology to manufacture suture material and provided insight into its usability when compared to standard suture material.

Deep Learning-Based Super Resolution Applied to Finite Element Analysis of Fused Deposition Modeling 3D Printing

Deep Learning-Based Super Resolution Applied to Finite Element Analysis of Fused Deposition Modeling 3D Printing

Investigation on Layer Thickness on Mechanical Properties and Dimension Accuracy in Fused Deposition Modelling 3D Printing

In the current era of additive manufacturing, Fused Deposition Modelling (FDM) method of printing is being studied extensively to print a concept model. Therefore, the dimensional accuracy and the mechanical properties of the FDM 3D printed part are very important. In this study, the tensile specimens are prepared according to ASTM D638 Type I. Dimensions of the specimen is measured in the x-direction (length), y-direction (width), and z-direction (height) and is compared against the standard measurement for accuracy. Tensile stress, strain at break and Young’s modulus were also investigated. Overall, the dimension accuracy achieved is more than 98%. The highest accuracy is obtained by using 0.2mm layer thickness and 0.2mm initial layer thickness. The tensile stress, Young’s modulus and strain at break are found to decrease when the layer thickness is increased. This is due having more layer with lesser and smaller voids which increases the strength and stiffness. Increasing initial layer thickness, however, has a low influence on the tensile stress but can greatly affect the Young’s modulus.

Enhancing Fused Deposition Modeling Precision with Serial Communication-Driven Closed-Loop Control and Image Analysis for Fault Diagnosis-Correction.

Additive manufacturing (AM) also commonly known as 3D printing is an advanced technique for manufacturing complex three-dimensional (3D) parts by depositing raw material layer by layer. Various sub-categories of additive manufacturing exist including directed energy deposition (DED), powder bed fusion (PBF), and fused deposition modeling (FDM). FDM has gained widespread adoption as a popular method for manufacturing 3D parts, even for heavy-duty industrial applications. However, challenges remain, particularly regarding part quality. Print parameters such as print speed, nozzle temperature, and flow rate can significantly impact the final product's quality. To address this, implementing a closed-loop quality control system is essential. This system consistently monitors part surface quality during printing and adjusts print parameters upon defect detection. In this study, we propose a simple yet effective image analysis-based closed-loop control system, utilizing serial communication and Python v3.12, a widely accessible software platform. The system's accuracy and robustness are evaluated, demonstrating its effectiveness in ensuring FDM-printed part quality. Notably, this control system offers superior speed in restoring part quality to normal upon defect detection and is easily implementable on commercially available FDM 3D printers, fostering decentralized quality manufacturing.

Fabrication of 3D-Printed Hydrocortisone Triple Pulsatile Tablet Using Fused Deposition Modelling Technology.

Hydrocortisone (HC) is the optimal drug for adolescents diagnosed with congenital adrenal hyperplasia (CAH). Because traditional dosage regimens HC are inconvenient, our study used fused deposition modeling (FDM) three-dimensional (3D) printing technology to solve the problems caused by traditional preparations. First, we designed a core-shell structure tablet with an inner instant release component and an outer delayed release shell. The instant release component was Kollicoat IR: glycerol (GLY): HC = 76.5:13.5:10. Then, we used Affinisol® HPMC 15LV to realize delayed release. Furthermore, we investigated the relationship between the thickness of the delayed release shell and the delayed release time, and an equation was derived through binomial regression analysis. Based on that equation, a novel triple pulsatile tablet with an innovative structure was devised. The tablet was divided into three components, and the drug was released multiple times at different times. The dose and release rate of the tablets can be adjusted by modifying the infill rate of the printing model. The results indicated that the triple pulsatile tablet exhibited desirable release behavior in vitro. Moreover, the physicochemical properties of the drug, excipients, filaments, and tablets were characterized. All these results indicate that the FDM 3D printing method is a convenient technique for producing preparations with intricate structures.

Experimental study on mechanical properties of FDM 3D printed polylactic acid fabricated parts using response surface methodology

The purpose of this study is to examine the mechanical properties of components produced through the Response Surface Methodology for polylactic acid, utilizing the Fused Deposition Modeling 3D printing technique. Polylactic acid is a commonly employed biodegradable polymer, making it a desirable substance for diverse applications. This study involves carrying out experiments to vary process printing parameters like layer height or thickness, part orientation, and infill density. The values of these parameters were obtained using a Response Surface Methodology Box–Behnken experimental design. The mechanical performance of the 3D Printed polylactic acid fabricated was assessed by evaluating their flexural and tensile strength. The test samples for measuring tensile and flexural strength are fabricated according to American Society for Testing and Material standards. The findings suggest that higher strength is achieved when using increased layer height and infill levels. The experimental results indicated that specimens with a filling ratio of 80% exhibited greater tensile strength, while the flexural strength of samples with 50% infill was observed to be higher. Regression analyses and multi-optimization techniques were employed to predict the experimental results. This study provides valuable insights that can significantly impact various industries. Our research on the complex interactions between process variables and mechanical properties has major implications for improving high-strength component manufacturing. As demand for dependable and efficient 3D-printed materials rises, our discoveries improve material design and manufacturing methods, making a significant contribution to the field.

3D Printed Nature Pattern Metastructure for The Sound Absorption Coefficient

This research investigates the influence of the shape of 3D printed metastructures on sound absorption performance, focusing on three distinct configurations inspired by nature: honeycomb, spiderweb, and gyroid. The objectives involve designing and producing sound-absorbing structures using the 3D printing Fused Deposition Modelling (FDM) method. Simultaneously, the study analyzes and compares their sound absorption performance by considering the sound absorption coefficient and the noise reduction coefficient (NRC) for each pore shape. Using computer-aided software, the three different pore shapes were designed and produced using Polylactic Acid (PLA) material through FDM 3D printing. Each design was replicated at three different thicknesses: 10mm, 20mm, and 30mm, all with a diameter of 94mm. The sound absorption coefficient of the samples was evaluated through impedance tube experiments, collecting data for alpha (α) from 250 Hz to 2000 Hz. Subsequently, NRC values were calculated for four different frequencies: 250Hz, 500Hz, 1000Hz, and 2000Hz, ensuring a comprehensive analysis. Results indicate that the gyroid structure exhibited the highest overall sound absorption coefficient across the tested frequency range, followed by the spider-web and honeycomb structures. Additionally, the 30mm thickness demonstrated greater sound-absorbing performance than the 20mm and 10mm thicknesses. These outcomes provide valuable insights into the sound absorption capabilities of 3D printed metastructures, highlighting the superior performance of the gyroid structure. Understanding the impact of pore shape and thickness on sound absorption performance contributes to the development of acoustically optimized materials for various applications

Theoretical and experimental research on the mechanical tests of 3D printed samples from various materials

At this moment, a real industrial, scientific and technological revolution is being discussed worldwide, consisting in the development of Additive Manufacturing AM technologies through the use of 3D printing. The FDM (Fused Deposition Modelling) 3D printing technology consists in the deposition of fusible material layer by layer in the XOY plane, the thickness of the 3D printed layer is g = 0.12 ÷ 0.24 mm, the resolution of 3D printing is r = 0.1mm, while the print head advances vertically on the OZ axis. The purpose of the work is to determine the breaking moment through destructive mechanical bending tests of some samples made by 3D printing from the following materials: ABS+, PETG and PLA. 5 samples were made in 3 printing directions: horizontal, vertical and lateral, resulting in 15 samples for each material. The total number of samples used is 45. Knowing these values, depending on the requirements of the specifications, a certain material and a certain printing position can be used.