Fused Filament Fabrication Printing Research Articles

Effect of infill ratio on fracture toughness of Fused Filament Fabrication (FFF) polymeric adhesive joints

ABSTRACT In order to optimize the stiffness/weight ratio and to reduce the manufacturing time, Additive Manufacturing (AM) components are built up by a solid skin and a partially filled core. The filled/total volume ratio is called infill ratio and it is one of the printing parameters to be selected. Since the infill ratio affects the global as well as the local adherend stiffness, i.e. the stiffness close to the joint interface, this paper aims at exploring the effect of this parameter on the Mode I fracture toughness of adhesive joints of AM materials, for a given infill pattern. Therefore, PLA (PolyLactic Acid) AM adherends have been manufactured with an FFF (Fused Filament Fabrication) printer at infill ratios ranging between 20% and 100% and bonded with a structural epoxy adhesive to form a DCB (Double Cantilever Beam) joint for Mode I fracture toughness testing. Finite Element (FE) simulation of a stationary crack in the adhesive layer has been done to evaluate the strain energy release rate along the crack front at different infill ratios in order to highlight local changes in its distribution that can correlate the variation of fracture toughness with infill ratio recorded in the experiments.

Material and process engineering aspects to improve the quality of the bonding layer in a laser-assisted fused filament fabrication process

The mechanical properties of components manufactured ("printed") by the Fused Filament Fabrication (FFF) process are usually limited by the cohesion achieved between melt-processed thermoplastic filament strands perpendicular to the filament deposition direction. This significantly limits the usefulness of the FFF process and commercial FFF printers for the production of a wide range of functional components and consumer goods, so that the FFF process is currently used for the production of prototypes for visualization purposes only. In order to open up potential markets for structural components in the future, the realization of an optimized bonding layer quality via a significantly improved cohesion between the filament strands is essential. Since the mechanical properties of polymeric materials generally depend on the density of molecular entanglements and tie molecules in the material structure, it is of the utmost importance to realize the highest possible density of such entanglements and tie molecules between the individual filament layers also in FFF components. The present work deals with different methods of heat input to improve the entanglement and tie molecule density in the bonding layer of FFF components through enhanced polymer diffusion at temperatures far above the glass transition temperature for amorphous plastics or the melting temperature for semi-crystalline plastics, respectively. Heat can be either globally or locally introduced by conduction, convection, and radiation, the latter being the most effective for the FFF process when applied locally via properly controlled laser radiation. Ideally, a compact, cost effective and easy to use radiation source is used for this purpose. Hence, a setup based on a diode laser is presented in this work. Furthermore, an idealized calculation of the amount of heat required to promote the formation of interfilament bonds and thus to achieve an increased mechanical property profile was carried out. Two types of materials commonly used for the FFF process, polylactic acid (PLA) and acrylic-butadiene-styrene copolymer (ABS), were used for the experimental procedure. After producing a special monofilament with improved laser absorption characteristics, test specimens were produced. As a reference, test specimens made of the same materials were printed with the conventional FFF process. The differently manufactured test specimens were characterized optically and visually, using a stereomicroscope, and mechanically, using tensile tests. In addition, specimens were produced with a specially designed device for local heat input onto the substrate layer region just ahead of the new filament deposition. The effectiveness of this laser-assisted method could be proven in tests by adjusting the process parameters of the FFF process. After finding the optimum printing speed (equivalent to the laser power applied) for the materials PLA and ABS, an optical examination of the fracture surfaces of test specimens with filaments laid down perpendicular to an applied tensile load showed a significant increase in plastic deformation capacity, indicative of an improved interfilament bonding. This was confirmed by the mechanical property values determined in tensile tests. Thus, for optimized printing speeds, an increase in tensile strength values of ~20% for PLA and ~7% for ABS was achieved. For elongation at break, the improvements were ~21% for PLA and ~34% for ABS, respectively. The methodology of laser-assisted FFF printing thus offers great potential for mechanically and structurally optimized functional components with specifically introduced anisotropy. • Interfilament entanglements control strength of printed polymer parts. • Novel diode laser-assisted fused filament fabrication process (FFF) is presented. • Enhanced local laser absorption and heat introduction via specific additives. • improved bonding layer strength of FFF components was achieved.

Automated In Situ Placing of Metal Components Into 3-D Printed FFF Objects

Screws are often used to connect 3-D printed parts to other objects. When screwing directly into printed plastic, the reliability is limited, and the connection can wear out over time. For more reliable connections, standard metal nuts are often inserted into slots designed into the object. This article presents an approach where nuts and other ferromagnetic components are integrated directly into the part while printing it. Our prototype machine is a modified Prusa-I3 fused filament fabrication printer with an electromagnetic pick and place tool. We introduce augmented slicing software, where the user can insert generic component models from a library and place them at arbitrary positions in the object. Cavities for the components and additional G-code commands for robotic placing are automatically generated and sent to the printer. A printed component tray is attached to the printbed, allowing different part configurations for each print. The pick and place unit is controlled by our OctoPrint plugin OctoPNP.

Effects of cooling during 3D Printing for PLA filaments on printed models quality

Desktop 3D filament printers have spread among different categories of users, whether amateurs or professionals. And the most common filament is PLA Polylactic Acid for its ease of use and its environmentally friendly print, in the 3D printing process for extrusion filament / thermoplastics, the hot end Extruder raises the temperature of it to obtain the appropriate viscosity for its flow through the Nozzel, the nozzle is then moved from place to place within the print space by the 3D printer movement system to gradually extrude an entire object layer by layer as the filament moves inside The printer is through the hot end and the nozzle, it is under the control of the printer through the commands of the G-CODE file, so its behavior is controlled by its temperature and flow velocity controlling, but once it leaves the nozzle, and the deposition process begins, it becomes out of control, leaving its properties easily affected by environmental factors. Because of its soft state, it helps ease the control of the forces of gravity and pulls its strings down, causing deformation Its layers. It is therefore of utmost importance to ensure that it does not move or deform after leaving the nozzle. This is done by returning it to its solid state as soon as possible, and here it appears the importance of cooling. Keywords: Statement of the problem: The quality of 3D PLA prints produced by fused filament fabrication printers was affected by the cooling process during printing. Importance: The importance of the research lies in showing the effect of cooling on the quality of 3D PLA printed parts and showing methods of controlling it to improve the quality of 3D printed models. Objectives: The research aims toidentify problems in PLA printed models related to cooling and improve its quality by adjusting part cooling. Research Methodology: The research depends on the descriptive approach and the experimental method in applying solutions and observing the results. Main results:The most important results of the research are that cooling is one of the important factors affecting the quality of models printed with poly-lactic acid filament. Cooling is closely related to the problems of wrinkling of protruding parts, deformation of bridges and accurate ends of models, as well as problems of dimensional accuracy. And the design of the air distribution duct attached to the part cooling fan affects the print quality.

Investment casting with FFF (fused filament fabrication)-printed appliances: the intermediate step.

Some modifications of orthodontic appliances such as the rapid maxillary expansion (RME) device with a Hyrax screw or Herbst are fabricated using traditional investment casting (lost-wax casting). This is precise but very labor-intensive. New technologies enable us today to use direct selective laser sintering (SLS) to produce freeform metallic structures. These machines are very expensive and only available in specialized laboratories. The aim of this investigation was to combine fused filament fabrication (FFF) 3D printing with wax-based filaments to produce orthodontic appliances via investment casting. For demonstration purposes, a lingual arch, a palatal arch, and an RME appliance were digitally designed based on an intraoral scan. The *.stl files were sliced and printed with a dual-nozzle FFF printer. The object was printed with a wax-based filament especially suited for investment casting, and support structures were printed with water-soluble polyvinyl-alcohol (PVA) filament. The printed objects were cast in metal and finished. All appliances were successfully cast and polished. They were provisionally placed intraorally. The fit was clinically very good and comparable to traditionally crafted appliances. The printing and handling of the parts made of these special filaments is challenging. With this experiment, the successful production of investment casting using FFF printing was shown for the first time.

Investigations on Roller-Based Filament Drives

The filament drive is a key part of the extrusion assembly of a Fused Filament Fabrication printer. This investigation examines the maximum feed force and the slip of different driving rollers using a filament made of polylactic-acid (PLA) on a test stand. The test stand systematically varies the main feed process parameters: feed velocity, pinch force between the rollers, and feed force. The maximum feed force has a characteristic dependency on the pinch force combined with a feed-velocity-dependency, which is influenced by the outer diameter of the driving roller. The slip was found to increase linearly with the feed force. The slip decreases with increasing pinch force and is nearly constant for pinch forces above 77 N—172 N, depending on the driving roller tooth geometry and outer diameter. A model derived from contact mechanics was used for phenomenological modeling of the slip in relation to pinch force and feed velocity. An exponential ansatz provided good modeling of the slip at a constant pinch force. The model of the slip combined with the extrusion forces in the liquefier can be used to estimate the material flow in the future, thus leading to increased precision of the parts in a magnitude of systems.

Strength and elastic properties of 3D printed PVDF-based parts for lightweight biomedical applications

Research results on 3D printed fluoropolymers are scarce since the filaments were introduced commercially only in the last several years to enable fused filament fabrication (FFF) of structural components for more demanding service conditions, where chemical, UV or fire resistance, high purity, sterilizability or biocompatibility are critical such as in biomedical industry. This experimental study reports on additive manufacturing and quasi-static mechanical testing of polyvinylidene fluoride (PVDF) and in-vitro cytocompatible polyvinylidene fluoride-co-hexafluoropropylene (PVDF-HFP) specimens that were 3D printed with different infill patterns at 75% density (linear, cubic, cross, concentric, octet, zigzag, triangular). Recommendations are provided for addressing issues related to weak adhesion and obtrusive warping, which occur in open-chamber FFF printer due to semi-crystalline and hydrophobic nature of PVDF-based thermoplastics. The measured tensile and flexural stress-strain curves are analyzed to determine the influence of strut-based infills on the strength and elastic performance by including comparisons in ratios between strength, modulus of elasticity and weight of the specimens. The concentric pattern demonstrates the highest tensile strength, while the cross and triangular lattices – the lowest one. In three-point bending, the linear pattern delivers the lowest strength, while the rest exhibit comparable mechanical properties. The results are conducive to the design of 3D printable PVDF homopolymer and copolymer load-bearing structures serving as lightweight high-performance components in biomedical applications.

Fused Filament Fabrication Based on Polyhydroxy Ether (Phenoxy) Polymers and Related Properties.

This paper describes the first-time application of polyhydroxy ether polymers, so-called phenoxy, to fused filament fabrication (FFF). Phenoxy is an amorphous thermoplastic polymer that is based on the same building blocks as epoxide resins. This similarity creates some unique properties such as dissolution to epoxide systems, which is why phenoxy is used as an additive for toughening. In this study, the processing parameters were characterized, a filament was extruded and applied to FFF printing, and the final mechanical characteristics were determined. The study concludes with a comparison with other standard FFF materials.

Effect of low vacuum environment on the fused filament fabrication process

The purpose of this research was to investigate the suitability of the Fused Filament Fabrication (FFF) process for low pressure/vacuum environment. This included investigating the ability of an FFF printer to function in a vacuum and evaluation of the dimensional accuracy and mechanical properties of the manufactured components. For this purpose, a commercially available FFF printer using polycarbonate as raw material was placed in a vacuum environment of 10 mbar. Test components were then fabricated in vacuum with a control group fabricated in a normal atmosphere (1 bar). Test components were evaluated for dimensional and mass accuracy, quality and presence of defects. Flexural, tensile and compressive testing was carried out according to ASTM D790, D638 and D695 respectively. Dimensional analysis of components showed equivalent small deviation for both environments. Components fabricated in the vacuum environment had 5.4% higher tensile yield strength and 59% higher extension at break compared to components printed in a normal atmosphere indicating an increased strength and ductility. Components tested in compression had approximately 11.2% higher compressive strength when printed in a vacuum environment. No differences were observed during the flexural test. In space, due to the vacuum environment, polymers and organic material are susceptible to release molecules via an outgassing process. Assessment of the molecular organic contamination generate during the printing process in vacuum is low and seems to mostly originated from the components of the printer. The results provided demonstrated the possibility to use the FFF process in a vacuum environment to fabricate dimensionally accurate, high-quality polycarbonate components with a variety of geometries without loss of mechanical performance. This work provides a proof of concept that FFF can be used to develop out-of-earth manufacturing technologies (in orbit/in space/on planet) allowing part production for new maintenance and repair strategy or to potentially manufacture entire structure more efficiently overpassing launch constrain by using only raw material brought from earth.

3D printing in surgical simulation: emphasized importance in the COVID-19 pandemic era

3D printing in surgical simulation: emphasized importance in the COVID-19 pandemic era

Structure-function assessment of 3D-printed porous scaffolds by a low-cost/open source fused filament fabrication printer

Additive manufacturing encompasses a plethora of techniques to manufacture structures from a computational model. Among them, fused filament fabrication (FFF) relies on heating thermoplastics to their fusion point and extruding the material through a nozzle in a controlled pattern. FFF is a suitable technique for tissue engineering, given that allows the fabrication of 3D-scaffolds, which are utilized for tissue regeneration purposes. The objective of this study is to assess a low-cost/open-source 3D printer (In-House), by manufacturing both solid and porous samples with relevant microarchitecture in the physiological range (100–500 μm pore size), using an equivalent commercial counterpart for comparison. For this, compressive tests in solid and porous scaffolds manufactured in both printers were performed, comparing the results with finite element analysis (FEA) models. Additionally, a microarchitectural analysis was done in samples from both printers, comparing the measurements of both pore size and porosity to their corresponding computer-aided design (CAD) models. Moreover, a preliminary biological assessment was performed using scaffolds from our In-House printer, measuring cell adhesion efficiency. Finally, Fourier transform infrared spectroscopy – attenuated total reflectance (FTIR–ATR) was performed to evaluate chemical changes in the material (polylactic acid) after fabrication in each printer. The results show that the In-House printer achieved generally better mechanical behavior and resolution capacity than its commercial counterpart, by comparing with their FEA and CAD models, respectively. Moreover, a preliminary biological assessment indicates the feasibility of the In-House printer to be used in tissue engineering applications. The results also show the influence of pore geometry on mechanical properties of 3D-scaffolds and demonstrate that properties such as the apparent elastic modulus (Eapp) can be controlled in 3D-printed scaffolds.

Effects of Two Melt Extrusion Based Additive Manufacturing Technologies and Common Sterilization Methods on the Properties of a Medical Grade PLGA Copolymer.

Although bioabsorbable polymers have garnered increasing attention because of their potential in tissue engineering applications, to our knowledge there are only a few bioabsorbable 3D printed medical devices on the market thus far. In this study, we assessed the processability of medical grade Poly(lactic-co-glycolic) Acid (PLGA)85:15 via two additive manufacturing technologies: Fused Filament Fabrication (FFF) and Direct Pellet Printing (DPP) to highlight the least destructive technology towards PLGA. To quantify PLGA degradation, its molecular weight (gel permeation chromatography (GPC)) as well as its thermal properties (differential scanning calorimetry (DSC)) were evaluated at each processing step, including sterilization with conventional methods (ethylene oxide, gamma, and beta irradiation). Results show that 3D printing of PLGA on a DPP printer significantly decreased the number-average molecular weight (Mn) to the greatest extent (26% Mn loss, p < 0.0001) as it applies a longer residence time and higher shear stress compared to classic FFF (19% Mn loss, p < 0.0001). Among all sterilization methods tested, ethylene oxide seems to be the most appropriate, as it leads to no significant changes in PLGA properties. After sterilization, all samples were considered to be non-toxic, as cell viability was above 70% compared to the control, indicating that this manufacturing route could be used for the development of bioabsorbable medical devices. Based on our observations, we recommend using FFF printing and ethylene oxide sterilization to produce PLGA medical devices.

Modeling Fused Filament Fabrication using Artificial Neural Networks

With industries pushing towards digitalized production, adaption to expectations and increasing requirements for modern applications, has brought additive manufacturing (AM) to the forefront of Industry 4.0. In fact, AM is a main accelerator for digital production with its possibilities in structural design, such as topology optimization, production flexibility, customization, product development, to name a few. Fused Filament Fabrication (FFF) is a widespread and practical tool for rapid prototyping that also demonstrates the importance of AM technologies through its accessibility to the general public by creating cost effective desktop solutions. An increasing integration of systems in an intelligent production environment also enables the generation of large-scale data to be used for process monitoring and process control. Deep learning as a form of artificial intelligence (AI) and more specifically, a method of machine learning (ML) is ideal for handling big data. This study uses a trained artificial neural network (ANN) model as a digital shadow to predict the force within the nozzle of an FFF printer using filament speed and nozzle temperatures as input data. After the ANN model was tested using data from a theoretical model it was implemented to predict the behavior using real-time printer data. For this purpose, an FFF printer was equipped with sensors that collect real time printer data during the printing process. The ANN model reflected the kinematics of melting and flow predicted by models currently available for various speeds of printing. The model allows for a deeper understanding of the influencing process parameters which ultimately results in the determination of the optimum combination of process speed and print quality.

Syringe pump extruder and curing system for 3D printing of photopolymers

Development of new additive manufacturing materials often requires the production of several batches of relatively large volumes in order to print and test objects. This can be difficult for many materials that are expensive or difficult to produce in large volumes on the laboratory scale. Bioprinter systems are advantageous in this regard, however, commercial systems are expensive or do not have the ability to use photopolymers. Herein, we outline a Syringe Pump Extruder and Curing System (SPECS) modification for inexpensive filament-based 3D printers which enables the use of standard bioplotter materials and photopolymers. The system is capable of using multiple syringe volumes and needle sizes that can be quickly and easily exchanged. The SPECS modification is demonstrated using a Prusa i3 mk3 fused filament fabrication printer to print several 3D objects and films using stereolithography (SLA) photopolymer resin. Geometric accuracy in the X, Y, and Z directions was ±0.1 mm using a 5 ml syringe, 22-gauge needle, and commercial SLA resin. The SPECS system could be of great benefit for laboratories pursing material development in the area of additive manufacturing.

Mechanical property variance amongst vertical fused filament fabricated specimens via four different printing methods

AbstractAmongst additive manufacturing processes, fused filament fabrication (FFF) is one of the most affordable and cost‐efficient technologies that can produce complex shaped components with an increasing number of printable polymers such as the polyaryletherketone family, polyetherimide and polyphenylene sulfide. Despite the gain in popularity, there is a lack of standardisation in specimen preparation and mechanical testing of FFF samples. This study investigates the effect of different methods of printing vertical tensile specimens on the mechanical properties when the material and the printing parameters are fixed. A slow crystallising polyetherketoneketone grade was selected as the printing material to exclude the effect of crystallisation on the interlayer bonding strength, leaving the temperature‐dependent amorphous molecular diffusion across the layers as the governing mechanism. Vertical tensile specimens made by four printing methods – individually printed, machined and connected (based on ISO 527‐2‐1A and ISO 527‐2‐1BA) – were assessed. Individually printed vertical specimens were found to have the highest mean tensile strength, owing to the high level of diffusion induced by the very short layer time. The strengths of specimens printed via the other three methods are less sensitive to the effect of layer time, due to the lower rate of change during cooling and its relationship with the local temperature at the interlayer surface. This study highlights the importance of the disclosure of FFF printing methods along with any reported mechanical data. © 2021 The Authors. Polymer International published by John Wiley &amp; Sons Ltd on behalf of Society of Chemical Industry.

Additive manufacturing of continuous carbon fiber tubes and experimental investigation of the energy absorption capability under quasi-static loading

Additive manufacturing (AM) is becoming increasingly important in the field of mechanical engineering. Therefore, the mechanical performance of this new technology can have a huge impact on the component’s life. Hence, a fourth axis is added to an existing Fused Filament Fabrication printer and a customized slicing strategy is used. To meet the high demands of mechanical strength, a symmetrical layer stack-up with an alternating variation of the inclination angle is printed onto the fourth axis. Each tube consists of eight layers in total. Starting from α = 15° fiber angle [+15,-15,0,0]S up to α = 75° fiber angle with a 15° angle increase. Each layer has a height of t1 = 0.125 mm thickness adding up to a tube wall thickness of tw = 1 mm. These tubes are tested under quasi-static axial loading conditions in a universal testing machine.

Expansion of the Fused Filament Fabrication (FFF) Process Through Wire Embedding, Automated Cutting, and Electrical Contacting

Additive manufacturing is establishing new forms of manufacturing processes to produce functional parts. It is thus seen as a hope for a shift towards decentralised production and the associated positive effects on the environment. The most widespread process, Fused Filament Fabrication, already impresses with a large variety of materials and the possibility of including non-polymeric additives as fibre materials. To support this development, this paper describes a form of wire implementation as an add-on for existing FFF systems, that can be realised without major changes to hardware or software. The aim is to integrate electrical functions directly into the component - in one manufacturing process. The process is based on a hybrid material made of PLA with a copper core, which was developed in advance. Within this work, two retrofittable units for FFF printers are described, which cut a continuous wire with a diameter of 0.2 mm embedded in a polymer in a fully automatic manner. Furthermore, two thermal contacting processes are presented, which make it possible to contact the embedded wire via the heated extruder nozzle and metallic inserts. Thereby, a best contact resistance of 0.009 ± 0.0023 Ω (50% confidence interval) could be achieved for a screw contact. For a plug-in or solder contacts, a contact resistance of 0.059 ± 0.028Ω (50% confidence interval) was realised. In terms of process technology, the wire deposition within the plastic structure could be reliably realised at printing speeds of 10 mm/s on straight sections and 1 mm/s in curves with a radius of 5 mm. The developed process was successfully validated using a functional demonstrator. The functional sample can be selectively heated to the glass transition temperature and reversibly formed. In summary, the developed methods are suitable for cost-effectively expanding existing FFF systems to integrate electrical functions during the 3D printing process.

Selected Applications of Stimuli-Responsive Polymers: 4D Printing by the Fused Filament Fabrication Technology

In the past few years four-dimensional (4D) printing technologies have attained worldwide interest and they are now considered the "next big thing". The aim of this research is to provide three selected examples of stimuli-responsive polymer (SRP) applications additively manufactured (AM) by the fused filament fabrication (FFF) technique. To that end, a CCT BLUE filament of thermo-responsive polymer was chosen to produce a water temperature indicator, which changes colour from blue to white when temperature increases; a CCU RED filament of photo-responsive polymer was used to produce a sunlight / UV indicator bracelet; a transparent PLA CLEAR polymer, a CCU RED photo-responsive polymer, and an electrical conductive PLA polymer were selected to produce a smart business card stand. The temperature indicator capability was analysed based on examining colour changes as a function of temperature changes. The sunlight/UV indicator capability was analysed based on the inspection of colour change as a function of absorbed sun/ultraviolet light. The electrical conductivity of the conductive PLA polymer was examined by performing resistance measurements. All three objects were successfully produced and their functionality was demonstrated. We hope that these examples will catalyse the expansion of FFF 4D printed SRP applications, as much work remains to be done in designing the parts and developing FFF printing parameters that take advantage of the stimuli-responsive materials currently being developed for FFF technology.

Evaluation of the Circularity of Recycled PLA Filaments for 3D Printers

The circular economy model offers great opportunities to companies, as it not only allows them to capture additional value from their products and materials, but also reduce the fluctuations of price-related risks and material supply. These risks are present in all kind of businesses not based on the circular economy. The circular economy also enables economic growth without the need for more resources. This is because each unit has a higher value as a result of recycling and reuse of products and materials after use. Following this circular economics framework, the Polytechnic University of Madrid (Universidad Politécnica de Madrid, UPM) has adopted strategies aimed at improving the circularity of products. In particular, this article provides the result of obtaining recycled PLA filament from waste originating from university 3D FFF (fused filament fabrication) printers and waste generated by “Coronamakers” in the production of visors and parts for PPEs (Personal Protective Equipment) during the lockdown period of COVID-19 in Spain. This filament is used in the production of 3D printed parts that university students use in their classes, so the circular loop is closed. The obtained score of Material Circularity Indicator (MCI) of this material has been calculated, indicating its high level of circularity.

Pandemic-Driven Development of a Medical-Grade, Economic and Decentralized Applicable Polyolefin Filament for Additive Fused Filament Fabrication.

A polyolefin with certified biocompatibility according to USP class VI was used by our group as feedstock for filament-based 3D printing to meet the highest medical standards in order to print personal protective equipment for our university hospital during the ongoing pandemic. Besides the chemical resistance and durability, as well as the ability to withstand steam sterilization, this polypropylene (PP) copolymer is characterized by its high purity, as achieved by highly efficient and selective catalytic polymerization. As the PP copolymer is suited to be printed with all common printers in fused filament fabrication (FFF), it offers an eco-friendly cost–benefit ratio, even for large-scale production. In addition, a digital workflow was established focusing on common desktop FFF printers in the medical sector. It comprises the simulation-based optimization of personalized print objects, considering the inherent material properties such as warping tendency, through to validation of the process chain by 3D scanning, sterilization, and biocompatibility analysis of the printed part. This combination of digital data processing and 3D printing with a sustainable and medically certified material showed great promise in establishing decentralized additive manufacturing in everyday hospital life to meet peaks in demand, supply bottlenecks, and enhanced personalized patient treatment.