Laser Sintering 3D Printing Research Articles

Friction and wear performance of 3D-printed graphite/SiC composites with different graphite layer deflection angles

This study explores the combination of selective laser sintering 3D printing of graphite with the melt infiltration of silicon to produce graphite/SiC self-lubricating composites featuring graphite layers with varying deflection angles. The findings suggest that the deflection angle of graphite layers plays a crucial role in influencing the friction and wear characteristics of the composite materials. Specifically, graphite layers with deflection angles below 45° result in surface crushing and the stacking of lubricating films, leading to a noticeable ploughing effect. Conversely, deflection angles exceeding 60° cause, the graphite layers to break easily within the substrate, making it challenging to consistently provide lubrication over an extended period, consequently resulting in severe abrasive wear. In the range of 45° to 60° deflection angles, the graphite layers exhibit a tendency towards sliding dispersion, facilitating the dynamic filling of surface pits and scratches. This behavior contributes to the demonstration of low friction coefficients (ranging from 0.11 to 0.14) and exceptional wear resistance (measured at 3.23 to 3.79 ×10−6 mm3/Nm).

Small-strain folding of semi-rigid elastomer derives high-performance 3D-printable soft origami actuators

Elastomers with hyperelastic deformation bring prosperity to soft robotics, especially in constituting fluidic actuators, largely due to the merit of large deformation and airtightness. However, the large (typically 0.5–1.5 strain) in-plane stretching of such materials concurrent to motion generation inevitably causes energy loss, hinders force output and accuracy. Particularly, the high nonlinearity of the low-durometer (typically 10A to 30A Shore) hyperelastic elastomers makes the modeling and control of actuators a well-known challenge. In this work, we proposed an alternative approach of using semi-rigid elastomer of significantly larger durometer (70 A–100 A) to create the typical fluidic soft actuator with axial translation, by utilizing small-strain folding to generate motion. Deformation constraints and property programming are combined into a single-piece body, enabling easy fabrication by Selective Laser Sintering 3D-printing and post-treatment for origami patterned structure. Systematic analyses on the principles, modeling and design are presented. The long lifespan (over 1 million cycles), superior output linearity, high energy efficiency (more than 60% increase), and drastically improved force output (more than 98% increase) were validated experimentally, showing high potentials in enabling high-performance soft actuators that are easy to design, fabricate and drive, strong to use, and accurate to control, towards even wider applications.

Friction and wear performance of aluminum-based self-lubricating materials derived from the 3D printed graphite skeletons with different morphologies and orientations

Using selective laser sintering 3D printing, this study shapes graphite in sphere, flake, and fiber morphologies into skeletons with various orientations. These skeletons are then used to create graphite/aluminum alloy composite self-lubricating materials. The results show that graphite morphology and orientation greatly affect the friction and wear properties of these composites. Graphite fiber exhibits the worst friction and wear performance. Perpendicular flake graphite forms a uniform, continuous lubricating film with high thermal conductivity for heat dissipation, preventing severe wear. Spherical graphite modifies the friction surface, achieving the lowest friction coefficient (0.2 ± 0.02) and wear rate (6.64 ×10−4 mm3/Nm) due to protective film, filling, and ball bearing effects.

In Vitro and In Vivo testing of 3D-Printed Amorphous Lopinavir Printlets by SelectiveLaser Sinitering: Improved Bioavailability of a Poorly Soluble Drug.

The aim of this paper was to investigate the effects of formulation parameters on the physicochemical and pharmacokinetic (PK) behavior of amorphous printlets of lopinavir (LPV) manufactured by selective laser sintering 3D printing method (SLS). The formulation variables investigated were disintegrants (magnesium aluminum silicate at 5-10%, microcrystalline cellulose at 10-20%) and the polymer (Kollicoat® IR at 42-57%), while keeping printing parameters constant. Differential scanning calorimetry, X-ray powder diffraction, and Fourier-transform infrared analysis confirmed the transformation of the crystalline drug into an amorphous form. A direct correlation was found between the disintegrant concentration and dissolution. The dissolved drug ranged from 71.1 ± 5.7% to 99.3 ± 2.7% within 120min. A comparative PK study in rabbits showed significant differences in the rate and extent of absorption between printlets and compressed tablets. The values for Tmax, Cmax, and AUC were 4 times faster, and 2.5 and 1.7 times higher in the printlets compared to the compressed tablets, respectively. In conclusion, the SLS printing method can be used to create an amorphous delivery system through a single continuous process.

Investigation on topology-optimized compressor piston by metal additive manufacturing technique: Analytical and numeric computational modeling using finite element analysis in ANSYS

Abstract Air compressors are widely used in factories to power automation systems and store energy. Several studies have been conducted on the performance of reciprocating and screw compressors. Advancements in design and manufacturing techniques, such as generative design and topology optimization, are leading to improved performance and turbomachinery growth. This work presents a methodology to design and manufacture air compressor pistons using topology optimization and metal additive manufacturing. The existing piston is converted to 3D CAD data and topology optimization is conducted to reduce material in stress concentration regions. Thermal and mechanical loads are considered in boundary conditions. The results show reduced material and improved efficiency, which is validated using ANSYS fluent. The optimized 3D model of the piston is too complex for conventional subtractive manufacturing, so laser sintering 3D printing is proposed. Honeycomb pattern infill patterns are used in 3D printing. This investigation is a step toward researching similar methods in other reciprocating compressor components such as cylinder, cylinder head, piston pins, crankshaft, and connecting rods, which will ultimately lead to improved compressor efficiency.

Abrasion‐Resistant and Enhanced Super‐Slippery Flush Toilets Fabricated by a Selective Laser Sintering 3D Printing Technology

Flush toilets waste a significant amount of water every day due to the unavoidable adhesions between human waste and the toilet surfaces. Super‐slippery surfaces can repel complex fluids and various viscoelastic solids, however, are easily broken by mechanical abrasions. Herein, the fabrication of an abrasion‐resistant super‐slippery flush toilet (ARSFT) is reported using a selective laser sintering 3D printing technology. Unlike traditional super‐slippery surfaces with limited thicknesses which can be easily worn away, the powder‐sintered strategy endows the ARSFT not only with a self‐supporting 3D complex shape but also with a porous structure that can accommodate considerable lubricants for an abrasion‐resistant super‐slippery property. As a result, the as‐prepared ARSFT remains clean after contacting with various liquids such as milk, yogurt, highly sticky honey, and starch gel mixed congee, demonstrating excellent repellence to complex fluids. Besides liquids, the ARSFT exhibits a high resistance to sticky synthetic feces. Notably, even after being abraded to 1,000 cycles of abrasion using sandpaper, the ARSFT maintains its record‐breaking super‐slippery capability. The concept of the 3D‐printed object with a superior abrasion‐resistant slippery ability will improve the development of super‐slippery materials and further save water consumption in the human society.

A general method for fabricating polymer-based intrinsic superhydrophobic objects by a selective laser sintering 3D printing strategy

Intrinsic superhydrophobic materials exhibit anti-wetting and abrasion-resistant capabilities simultaneously. However, the existing methods are highly restricted to specific synthetic material species. Here, we report a universal method for diverse polymeric materials to one-step prepare intrinsic superhydrophobic objects via a selective laser sintering (SLS) 3D printing technology. Through layer-by-layer sintering accumulation of polymeric powders and polytetrafluoroethylene (PTFE) grains, the intrinsic superhydrophobic 3D objects can be fabricated according to the programmed digital models. The as-printed samples remained anti-wetting capability even after 600 m sandpaper abrasion under 12.5 kPa, illustrating a record-breaking wear-resistant ability. Furthermore, we printed a chemical reaction platform and an underwater wear-resistant water-air transmedia vehicle, indicating the practical applications in harsh environments. Finally, we demonstrate the universality of this method for other eight kinds of polymers-PTFE composite systems. This work will greatly improve the practical application of superhydrophobic materials and promote the development of 3D printing functional materials.

Moisture‐Thermal Stable, Superhydrophilic Alumina‐Based Ceramics Fabricated by a Selective Laser Sintering 3D Printing Strategy for Solar Steam Generation

AbstractThe solar‐driven interface evaporation is one of the most promising technologies for desalination and wastewater purification. However, in the ebb and flow of the tide, water absorbed in the hydrophilic evaporator bottom would significantly change, leading to the shape deformation of the system and further failure of solar steam generation. Here it is reported that the moisture‐thermal stable and superhydrophilic alumina‐based ceramics can be fabricated by a selective laser sintering (SLS) 3D printing strategy. The printed alumina‐based ceramics possess superhydrophilicity. Along the side surface of the printed sample, a 5 µL water droplet can be fast absorbed in 14 ms. Most importantly, they can maintain stable and high evaporation efficiency even after being dried out for ten times, demonstrating the excellent physical resistance to continuous moisture‐thermal transition. Finally, the “I‐shaped” evaporators are printed with salt‐resistant ability, which can maintain a steady high evaporation efficiency in seawater and 20 wt% brine for long‐term steam generation process. The moisture‐thermal stable alumina‐based ceramics prepared in this work will provide inspiration for stable solar steam generation materials, and expand the development of 3D printing functional materials.

Comparative Analysis of Bone Ingrowth in 3D-Printed Titanium Lattice Structures with Different Patterns.

In this study, metal 3D printing technology was used to create lattice-shaped test specimens of orthopedic implants to determine the effect of different lattice shapes on bone ingrowth. Six different lattice shapes were used: gyroid, cube, cylinder, tetrahedron, double pyramid, and Voronoi. The lattice-structured implants were produced from Ti6Al4V alloy using direct metal laser sintering 3D printing technology with an EOS M290 printer. The implants were implanted into the femoral condyles of sheep, and the animals were euthanized 8 and 12 weeks after surgery. To determine the degree of bone ingrowth for different lattice-shaped implants, mechanical, histological, and image processing tests on ground samples and optical microscopic images were performed. In the mechanical test, the force required to compress the different lattice-shaped implants and the force required for a solid implant were compared, and significant differences were found in several instances. Statistically evaluating the results of our image processing algorithm, it was found that the digitally segmented areas clearly consisted of ingrown bone tissue; this finding is also supported by the results of classical histological processing. Our main goal was realized, so the bone ingrowth efficiencies of the six lattice shapes were ranked. It was found that the gyroid, double pyramid, and cube-shaped lattice implants had the highest degree of bone tissue growth per unit time. This ranking of the three lattice shapes remained the same at both 8 and 12 weeks after euthanasia. In accordance with the study, as a side project, a new image processing algorithm was developed that proved suitable for determining the degree of bone ingrowth in lattice implants from optical microscopic images. Along with the cube lattice shape, whose high bone ingrowth values have been previously reported in many studies, it was found that the gyroid and double pyramid lattice shapes produced similarly good results.

Abrasion-resistant superhydrophilic objects with anisotropic water transport capacities prepared by a selective laser sintering 3D printing strategy

Liquid directional manipulation has been widely used in the fields of microfluidic, microreactor, liquid separation and collection, sewage treatment. Most studies based on the construction of gradient structures on the substrate surface realized liquid directional transportation, but their fragile surfaces are vulnerable to external forces and can only transport thin water film according to the array thickness. Here, we report that abrasion-resistant superhydrophilic objects with anisotropic water transport capacities can be one-step constructed by selective laser sintering (SLS) the composites of hydrophilic glass beads (GBs) and thermoplastic phenol–formaldehyde resin (PF) grains. The long interlayer micro-slits between the adjacent printing layers cooperated with the inserted hydrophilic GBs formed long capillary channels, resulting in anisotropic water transport abilities on different printing surfaces. In addition, the abrasion-resistant ability endowed superhydrophilic mechanical stability. Furthermore, water could climb about ∼26 cm along the horizontal printed sample, showing excellent anti-gravity water transport ability. Finally, we demonstrated that the printed evaporators with diverse salt-resistant structures not only maintain long-term salt resistance, but also possess high evaporation efficiency. The superhydrophilic materials proposed in this study will lead the design and preparation of liquid directional transport materials and provide advanced inspiration for 3D printing functional materials.

Three-Dimensional Printing of Poly-L-Lactic Acid Composite Scaffolds with Enhanced Bioactivity and Controllable Zn Ion Release Capability by Coupling with Carbon-ZnO

Poly-L-lactic acid (PLLA) has gained great popularity with researchers in regenerative medicine owing to its superior biocompatibility and biodegradability, although its inadequate bioactivity inhibits the further use of PLLA in the field of bone regeneration. Zinc oxide (ZnO) has been utilized to improve the biological performance of biopolymers because of its renowned osteogenic activity. However, ZnO nanoparticles tend to agglomerate in the polymer matrix due to high surface energy, which would lead to the burst release of the Zn ion and, thus, cytotoxicity. In this study, to address this problem, carbon-ZnO (C-ZnO) was first synthesized through the carbonization of ZIF-8. Then, C-ZnO was introduced to PLLA powder before it was manufactured as scaffolds (PLLA/C-ZnO) by a selective laser sintering 3D printing technique. The results showed that the PLLA/C-ZnO scaffold was able to continuously release Zn ions in a reasonable range, which can be attributed to the interaction of Zn-N bonding and the shielding action of the PLLA scaffold. The controlled release of Zn ions from the scaffold further facilitated cell adhesion and proliferation and improved the osteogenic differentiation ability at the same time. In addition, C-ZnO endowed the scaffold with favorable photodynamic antibacterial ability, which was manifested by an efficient antibacterial rate of over 95%.

Large-Scale, Abrasion-Resistant, and Solvent-Free Superhydrophobic Objects Fabricated by a Selective Laser Sintering 3D Printing Strategy.

Manufacturing abrasion-resistant superhydrophobic matters is challenging due to the fragile feature of the introduced micro-/nanoscale surface roughness. Besides the long-term durability, large scale at meter level, and 3D complex structures are of great importance for the superhydrophobic objects used across diverse industries. Here it is shown that abrasion-resistant, half-a-meter scaled superhydrophobic objects can be one-step realized by the selective laser sintering (SLS) 3D printing technology using hydrophobic-fumed-silica (HFS)/polymer composite grains. The HFS grains serve as the hydrophobic guests while the sintered polymeric network provides the mechanical strength, leading to low-adhesion, intrinsic superhydrophobic objects with desired 3D structures. It is found that as-printed structures remained anti-wetting capabilities even after undergoing different abrasion tests, including knife cutting test, rude file grinding test, 1000 cycles of sandpaper friction test, tape test and quicksand impacting test, illustrating their abrasion-resistant superhydrophobic stability. This strategy is applied to manufacture a shell of the unmanned aerial vehicle and an abrasion-resistant superhydrophobic shoe, showing the industrial customization of large-scale superhydrophobic objects. The findings thus provide insight for designing intrinsic superhydrophobic objects via the SLS 3D printing strategy that might find use in drag-reduce, anti-fouling, or other industrial fields in harsh operating environments.

Selective laser sintering 3D-Printed conductive thermoplastic polyether-block-amide elastomer/carbon nanotube composites for strain sensing system and electro-induced shape memory

A novel mixed powders made up of laboratory-made thermoplastic polyether-block-amide (TPAE) and multiwalled carbon nanotubes (MWCNTs) for the selective laser sintering (SLS) 3D printing have been prepared through an environment-friendly approach and the carbon nanotube conductive network structure is established in the SLS-processed nanocomposite devices. The electrical properties, strain sensing property and electro-induced shape memory effect of flexible TPAE/MWCNTs nanocomposites are fully investigated. The conductivity of TPAE/MWCNTs nanocomposites increases as the MWCNTs content increases owing to the interconnected MWCNTs conductive network. During compressing test with different deformation strain and speed, the SLS-processed flexible sensor exhibits a regular, fast, sensitive and stable cyclic response which shows its great potential for artificial electronic skin, human-machine interface and health monitoring. The TPAE-5.0C nanocomposite also possessed an excellent shape recovery ability during electro-induced shape memory cycle which was triggered by Joule heat under DC voltage. The MWCNTs-TPAE powder prepared here provides a novel material for SLS 3D-printing and the SLS-processed devices with outstanding performance and multiple functions will be very useful for developing flexible and lightweight wearables in the future.

Using laboratory data to understand how pore aspect ratio influences elastic parameters and amplitude variation with offset

Pore geometry is an important parameter in reservoir characterization that affects the permeability of reservoirs and can also be a controlling factor on the impact of pressure and saturation on reservoirs elastic properties. We have used selective laser sintering 3D printing technology to build physical models to experimentally investigate the impacts of pore aspect ratio on compressional (P-) and shear wave (S-wave) velocities and amplitude variation with offset (AVO). We printed six models to study the effects of the pore aspect ratio of prolate and oblate pore structures on elastic properties and AVO signatures. We found that the P-wave velocity is reduced by decreasing the pore aspect ratio (flatter pore structure), whereas the S-wave velocity is less sensitive to the pore aspect ratio. This effect is reduced when the samples are water saturated. We developed new experimental and processing techniques to extract realistic AVO signatures from our experimental data and found that the pore aspect ratio has similar effects on AVO as fluid compressibility. This indicated that not considering the pore aspect ratio in AVO analysis can lead to misleading interpretations. We also found that these effects are reduced in water-saturated samples.

Recovery of 17β-Estradiol Using 3D Printed Polyamide-12 Scavengers.

Over the past decades, endocrine-disrupting compounds have been under active studies due to their potential environmental impact and increased usage. The actual hormones, especially estrogens, have shown to be one of the major contributors to hormonal waste in wastewater. Wastewater treatment facilities have variable capabilities to handle hormonal compounds and, therefore, different quantities of harmful compounds may end up in the environment. We introduce a simple technique to remove estrogens, such as 17β-estradiol (E2) from wastewater by using 3D printed polyamide-12 (PA12) filters. A selective laser sintering 3D printing was used to manufacture porous PA12 filters with accessible functional groups. Adsorption and desorption properties were studied using gas chromatography with flame ionization detector. The results showed that near quantitative removal of E2 was achieved. The 3D printed filters could also be regenerated and reused without losing their efficiency. During regeneration, E2 could be extracted from the filter without destroying the compound. This opens up possibilities to use the hormone scavenger filters also as concentration tools enabling accurate analyses of sources with trace concentrations of E2.

Antimicrobial ‘inks’ for 3D printing: block copolymer-silver nanoparticle composites synthesised using supercritical CO2

A new synthetic methodology to produce polymer-AgNP composite microparticles using scCO2 is presented. These microparticle possessed long-lived antimicrobial activity and were tested for compatibility in the Laser Sintering 3D printing process.

Impact of Laser Speed and Drug Particle Size on Selective Laser Sintering 3D Printing of Amorphous Solid Dispersions.

This research demonstrates the influence of laser speed and the drug particle size on the manufacturing of amorphous solid dispersions (ASD) and dosage forms thereof using selective laser sintering 3-dimensional (3D) printing. One-step manufacturing of ASD is possible using selective laser sintering 3D printing processes, however, the mechanism of ASD formation by this process is not completely understood and it requires further investigation. We hypothesize that the mechanism of ASD formation is the diffusion and dissolution of the drug in the polymeric carrier during the selective laser sintering (SLS) process and the drug particle size plays a critical role in the formation of said ASDs as there is no mixing involved in the sintering process. Herein, indomethacin was used as a model drug and introduced into the feedstock (Kollidon® VA64 and Candurin® blend) as either unprocessed drug crystals (particle size > 50 µm) or processed hot-melt extruded granules (DosePlus) with reduced drug particle size (<5 µm). These feedstocks were processed at 50, 75, and 100 mm/s scan speed using SLS 3D printing process. Characterization and performance testing were conducted on these tablets which revealed the amorphous conversion of the drug. Both MANOVA and ANOVA analyses depicted that the laser speed and drug particle size significantly impact the drug’s apparent solubility and drug release. This significant difference in performance between formulations is attributed to the difference in the extent of dissolution of the drug in the polymeric matrix, leading to residual crystallinity, which is detrimental to ASD’s performance. These results demonstrate the influence of drug particle size on solid-state and performance of 3D printed solid dispersions, and, hence, provide a better understanding of the mechanism and limitations of SLS 3D printing of ASDs and its dosage forms.

Synergistic application of twin-screw granulation and selective laser sintering 3D printing for the development of pharmaceutical dosage forms with enhanced dissolution rates and physical properties

This study demonstrated the first case of combining a novel continuous granulation technique with powder-bed fusion-based selective laser sintering (SLS) process to enhance the dissolution rate and physical properties of a poorly water-soluble drug. Selective laser sintering and binder jetting 3D printing processes have gained much attention in pharmaceutical dosage form manufacturing in recent times. These powder bed-based 3D printing platforms have been known to face printing and uniformity problems due to the inherent poor flow properties of the pharmaceutical physical mixtures. To address this issue a hot-melt extrusion-based versatile granulation process equipped with a process analytical technology (PAT) tool for the in-line monitoring of critical quality attributes (i.e., solid-state) of indomethacin was developed. The collected granules with enhanced flow properties were mixed with Kollidon® VA64 and a conductive excipient for efficient sintering. These mixtures were further characterized for their bulk properties observing an excellent flow and later subjected to an SLS-3D printing process. The physical mixtures, processed granules, and printed tablets were characterized using conventional as well as advanced solid-state characterizations. These characterizations revealed the amorphous nature of the drug in the processed granules and printed tablets. Further, the in vitro release testing of the tablets with produced granules as a reference standard depicted a notable dissolution advantage (100% drug released in 5 min at >pH 6.8) over the pure drug and the physical mixture. Our developed system known as DosePlus combines innovative continuous granulation and SLS-3D printing process which can potentially improve the physical properties of the bulk drug and formulations in comparison to when used in isolation. This process can further find application in continuous manufacturing of granules and additive manufacturing of pharmaceuticals to produce dosage forms with excellent uniformity and solubility advantage.

Covalent adaptable networks of polydimethylsiloxane elastomer for selective laser sintering 3D printing

Polydimethylsiloxane (PDMS) elastomer is one of most investigated and pioneering 3D printing materials. However, the powder-based 3D printing remains a big challenge due to the thermoset intrinsic character of PDMS. Here we realized the powder-based selective laser sintering (SLS) 3D printing of PDMS elastomer based on one kind of novel self-designed PDMS covalent adaptable networks (CANs) containing hindered pyrazole urea dynamic bonds. The dynamic chemical mechanism of the hindered pyrazole urea bonds is confirmed by small molecule models experiments, density functional theory calculation, and also stress relaxation analysis. The electron-donating large steric hindrance substituent in the pyrazole ring was found to effectively promote the dynamic character of pyrazole urea bond. The PDMS CANs show excellent self-healing and reprocessing properties. Furthermore, kilo-scale PDMS powders were prepared by cryogenic grinding and the powder morphology was optimized for SLS 3D printing. A PDMS insole with complex structure designed based on the personalized foot pressure distribution data was printed, and the foot orthotic and self-healing functions for the insole were demonstrated.

Bone formation at Ti‐6Al‐7Nb scaffolds consisting of 3D honeycomb frame and diamond‐like carbon coating implanted into the femur of beagles

We fabricated Ti-6Al-7Nb bone scaffolds with 5 mm diameter and 20 mm length comprise of a three-dimensional (3D) honeycomb frame structure of truncated octahedra created by selective laser sintering 3D printing. The honeycomb frame was then coated with 0.1μm thick diamond-like carbon (DLC) to increase biocompatibility. A round rod of Ti-6Al-7Nb alloy (ASTM F1295) was as a control material. They were implanted into the femur bones of beagles to evaluate bone morphometrics and to investigate changes in the transcriptome of the new bone tissue using DNA microarray analysis and real-time polymerase chain reaction (PCR). In the present report, the 3D honeycomb material with and without DLC film consisting of a-C:H is referred to as 3D_a-C:H and 3D_non, respectively. At 3 weeks after implantation, the 3D_non had more contact between the new and artificial bones compared with the control, and the 3D_a-C:H had more contact between the new and artificial bones compared with the control and 3D_non. Furthermore, 3D_a-C:H showed even more new bone compared with the control and 3D_non. At 8 weeks after implantation, more appeared lamellar bone with the 3D_a-C:H implant than those with the control and 3D_non. The real-time PCR results at 1week of implantation revealed higher expression levels of VEGF, RANKL, and NOTCH2 expression with 3D_a-C:H than with 3D_non and control. As a result of real-time PCR at 2 weeks of implantation, OPN and CTSK expressions were found to be higher with 3D_a-C:H and 3D_non than that with the control.