Printing Platform Research Articles

Multi‐Material Gradient Printing Using Meniscus‐enabled Projection Stereolithography (MAPS)

AbstractLight‐based additive manufacturing methods are widely used to print high‐resolution 3D structures for applications in tissue engineering, soft robotics, photonics, and microfluidics, among others. Despite this progress, multi‐material printing with these methods remains challenging due to constraints associated with hardware modifications, control systems, cross‐contamination, waste, and resin properties. Here, a new printing platform coined Meniscus‐enabled Projection Stereolithography (MAPS) is reported, a vat‐free method that relies on generating and maintaining a resin meniscus between a crosslinked structure and bottom window to print lateral, vertical, discrete, or gradient multi‐material 3D structures with no waste and user‐defined mixing between layers. MAPS is compatible with a wide range of resins shown and can print complex multi‐material 3D structures without requiring specialized hardware, software, or complex washing protocols. MAPS's ability to print structures with microscale variations in mechanical stiffness, opacity, surface energy, cell densities, and magnetic properties provides a generic method to make advanced materials for a broad range of applications.

Comprehensive Study of Stereolithography and Digital Light Processing Printing of Zirconia Photosensitive Suspensions

Zirconia ceramics are used in a wide range of applications, including dental restorations, bioimplants, and fuel cells, due to their accessibility, biocompatibility, chemical resistance, and favorable mechanical properties. Following the development of 3D printing technologies, it is possible to rapidly print zirconia-based objects with high precision using stereolithography (SLA) and digital light processing (DLP) techniques. The advantages of these techniques include the ability to print multiple objects simultaneously on the printing platform. To align with the quality standards, it is necessary to focus on optimizing processing factors such as the viscosity of the suspension and particle size, as well as the prevention of particle agglomeration and sedimentation during printing, comprising the choice of a suitable debinding and sintering mode. The presented review provides a detailed overview of the recent trends in preparing routes for zirconium oxide bodies; from preparing the suspension through printing and sintering to characterizing mechanical properties. Additionally, the review offers insight into applications of zirconium-based ceramics.

Development of modular extrusion bioprinter prototype

Introduction: The aim of this work was to develop a prototype of a modular extrusion bioprinter capable of performing 2D and 3D printing with hydrogels based on sodium alginate and gelatin. Materials and methods: The bioprinter uses Cartesian coordinate system, the print head is movable in Y and Z axes, the printing platform is in X axis and equipped with cooling system. Constructs were printed with 3 types of gels: based on gelatin with the addition various concentrations of xanthan gum; based on combination of gelatin and sodium alginate; based on gelatin and xanthan gum with the addition of carbon nanotubes. Results: The constructs from various gels corresponded to the structure determined by their digital models. Conclusions: The developed system allows performing 2D and 3D printing with gels based on gelatin, sodium alginate, including those containing carbon nanotubes and/or xanthan gum for a wide range of experimental tasks.

Fracture Analysis of 316L Specimens Fabricated via Material Extrusion Additive Manufacturing: Influence of Building Orientation and Notch Acuity

ABSTRACTThree‐point bending tests were performed on notched specimens extracted from cuboids of 316L stainless steel produced via material extrusion additive manufacturing. The cuboids were printed vertically and horizontally on the printing platform to account for the building orientation effect on the mechanical performance. For each orientation, three notch sizes were considered. Overall, the specimens printed with building direction parallel to the loading direction outperformed the others. A significant notch size effect was observed in these specimens since the sharpest notch provoked a decrease in the peak load reached by the specimens in comparison with larger notches. On the contrary, this effect was less relevant among the other specimens, which presented a conspicuous amount of residual porosity that contributed to the premature failure. Further investigations were carried out to correlate the building orientation to the density of the parts and, ultimately, to the investigated mechanical properties. The ASED and TCD criteria were also applied to assess their accuracy in the failure prediction of the tested specimens.

High speed vibration compensation using magnetic fiducials via NIMBLE

Additive manufacturing (AM) technology, specifically 3D printing, holds great promise for in-orbit manufacturing. In-space printing can significantly reduce the mass, cost, and risk of long-term space exploration by enabling replacement parts to be made as needed and reducing dependence on Earth. However, printing in a zero-gravity environment poses challenges due to the absence of a rigid ground for the print platform, which can result in vibrational and rotational forces that may impact printing integrity. To address this issue, this paper proposes a novel linear magnetic position tracking algorithm, named Navigation Integrating Magnets By Linear Estimation (NIMBLE), for dynamic vibration compensation during 3D printing of truss structures in space. Compared to the most commonly used nonlinear optimization method, the NIMBLE algorithm is more than two orders of magnitude faster. With only a single 3-axis magnet sensor and a small NdFeB magnet, the NIMBLE algorithm provides a simple and easily implemented tracking solution for in-orbit 3D printing.

A 3D Printing Platform for Design and Manufacturing of Multi-Functional Cementitious Construction Components and Its Validation for a Post-Tensioned Beam.

Three-dimensional printing of cementitious materials for construction has been extensively investigated in recent years, with several demonstration projects successfully carried out. These efforts aim to leverage the printing process to achieve more efficient production of components compared to conventional concrete technologies. This includes both the process itself (eliminating the formwork stage) and the flexibility in producing complexly shaped elements. To maximize the potential of 3D printing in the construction industry, additional steps must be taken, grounded in a holistic view of the entire process. This involves integration of the production chain, including design, materials, and manufacturing of components, to create elements with optimal performance, encompassing structural, environmental, and architectural aspects. Such multi-functionality requires the viewing of 3D printing not just as a production technology but as a platform enabling the integration of all these components. To advance this approach, quantitative tools are developed to optimize the following three key components: material composition; manufacturing parameters to ensure buildability; and design tools to optimize multiple performance criteria, particularly structural and architectural shape. A demonstration component, namely a post-tensioned beam, featuring two multi-functional characteristics-structural and architectural-is designed, produced, and evaluated. The scientific concepts and research tools used to develop these quantitative design tools are multidisciplinary, including rheological characterization, control of the internal structure and composition of granular materials, simulation of the mechanical behavior of green material during printing, and the hardened properties of the components, all utilizing structural optimization to enhance performance.

3D Printed Microneedles for the Transdermal Delivery of NAD+ Precursor: Toward Personalization of Skin Delivery.

3D printing of microneedles (μNDs) for transdermal therapy has the potential to enable patient personalization based on the target disease, site of application, and dosage requirements. To convert this concept to reality, it is necessary that the 3D printing technology can deliver high resolution, an affordable cost, and large print volumes. With the introduction of benchtop 4K and 8K 3D printers, it is now possible to manufacture medical devices like μNDs at sufficient resolution and low cost. In this research, we systematically optimized the 3D printing design parameters such as resin viscosity, print angle, layer height, and curing time to generate customizable μNDs. We have also developed an innovative 3D coating microtank device to optimize the coating method. We have applied this to the development of novel μNDs to deliver an established NAD+ precursor molecule, nicotinamide mononucleotide (NMN). A methacrylate-based polymer photoresin (eSun resin) was diluted with methanol to adjust the resin viscosity. The 3D print layer height of 25 μm yielded a smooth surface, thus reducing edge-ridge mismatches. Printing μNDs at 90° to the print platform yielded 84.28 ± 2.158% (n = 5) of the input height thus increasing the tip sharpness (48.52 ± 10.43 μm, n = 5). The formulation containing fluorescein (model molecule), sucrose (viscosity modifier), and Tween-20 (surface tension modifier) was coated on the μNDs using the custom designed microtank setup, and the amount deposited was determined fluorescently. The dye-coated μND arrays inserted into human skin (in vitro) showed a fluorescence signal at a depth of 150 μm (n = 3) into the skin. After optimization of the 3D printing parameters and coating protocol using fluorescein, NMN was coated onto the μNDs, and its diffusion was assessed in full-thickness human skin in vitro using a Franz diffusion setup. Approximately 189 ± 34.5 μg (5× dipped coated μNDs) of NMN permeated through the skin and 41.2 ± 7.53 μg was left in the skin after 24 h. Multiphoton microscopy imaging of NMN-coated μND treated mouse ear skin ex vivo demonstrated significantly (p < 0.05) increased free-unbound NADPH and reduced fluorescence lifetime of NADPH, both of which are indicative of cellular metabolic rates. Our study demonstrates that low-cost benchtop 3D printers can be used to print high-fidelity μNDs with the ability to rapidly coat and release NMN which consequently caused changes in intracellular NAD+ levels.

Holographic direct sound printing

Direct sound printing (DSP), an alternative additive manufacturing process driven by sonochemical polymerization, has traditionally been confined to a single acoustic focal region, resulting in a voxel-by-voxel printing approach. To overcome this limitation, we introduce holographic direct sound printing (HDSP), where acoustic holograms, storing cross-sectional images of the desired parts, pattern acoustic waves to induce regional cavitation bubbles and on-demand regional polymerization. HDSP outperforms DSP in terms of printing speed by one order of magnitude and yields layerless printed structures. In our HDSP implementation, the hologram remains stationary while the printing platform moves along a three-dimensional path using a robotic arm. We present sono-chemiluminescence and high-speed imaging experiments to thoroughly investigate HDSP and demonstrate its versatility in applications such as remote ex-vivo in-body printing and complex robot trajectory planning. We showcase multi-object and multi-material printing and provide a comprehensive process characterization, including the effects of hologram design and manufacturing on the HDSP process, polymerization progression tracking, porosity tuning, and robotic trajectory computation. Our HDSP method establishes the integration of acoustic holography in DSP and related applications.

Feasibility of continuous switching 3D printing on surimi

Continuous switching 3D printing that allows multiple materials printed in a single nozzle was introduced to verify its applicability to the food system, which aims to improve the switching ability and manufacturing precision of multi-material 3D printed food. By integrating a self-developed 3D printing platform with logical adjustments of extrusion pressure and 3D motion, the feasible continuous switching of surimi was achieved. Moreover, employing a dual-channel continuous switching extrusion nozzle, the study elucidated the influence of surimi rheological properties on the interface behavior between pastes during extrusion. Through the analysis of fluid dynamics behavior of channel flow and utilization of simulation technology, a channel extension solution was formulated. Extending the length of the non-extrusion channel to 15 mm effectively prevented intrusion over 4 mm at an extrusion speed of 40 mm/s. This study managed to repetitively switch between two kinds of surimi pastes within a 2 mm unit length. Meanwhile, three types of 3D printing modes were established based on the control of Gcode, and the corresponding model offset correction enabled precise deposition of 2 mm × 1 mm units. The research also succeeded in 3D printing complex structures, such as meat-fat structure of beef based on surimi.

Automated structural repair based on continuous carbon fiber reinforced plastic 3D printing and online model reconstruction

AbstractAdditive manufacturing of continuous carbon fiber reinforced plastic (CCFRP) has gained increasing prominence in structural repair through material accumulation. However, the repairing process entails laborious preliminary tasks, such as positioning, model reconstruction, and data input. In this article, computer vision is integrated into a CCFRP 3D printing device and a printing path‐selecting strategy is proposed to automate the repair process with accuracy and efficiency. An irregularly damaged structure is placed arbitrarily on the printing platform. Subsequently, the damaged area is extracted by semantic segmentation to construct a 3D model. The printing paths including zig‐zag and contour offset infilling for an irregular damage area are selected, according to the prediction of flexural modulus based on the finite element method. Finally, an in‐situ composite printing is conducted based on coaxial extrusion principle. The results show that the intersection over union (IOU) of regular damaged areas by the applied pyramid scene parsing network (PSPNet) segmentation model is 0.81. Semantic segmentation is more robust than conventional feature extraction based on filtering methods. The appearance of the repaired structure is consistent with that of the surrounding structure. The combination of CV and additive manufacturing technology presents a new way to simplify the repair process and improve repair effects.Highlights An automated repairing system for irregular damaged areas is established. Deep learning for semantic segmentation is integrated into 3D printing. Finite element submodule is introduced to select optimal printing paths. The CCFRP 3D printing is introduced to surface defect repairing.

Minimal-Invasive 3D Laser Printing of Microimplants in Organismo.

Multi-photon 3D laser printing has gathered much attention in recent years as a means of manufacturing biocompatible scaffolds that can modify and guide cellular behavior in vitro. However, in vivo tissue engineering efforts have been limited so far to the implantation of beforehand 3D printed biocompatible scaffolds and in vivo bioprinting of tissue constructs from bioinks containing cells, biomolecules, and printable hydrogel formulations. Thus, a comprehensive 3D laser printing platform for in vivo and in situ manufacturing of microimplants raised from synthetic polymer-based inks is currently missing. Here, a platform for minimal-invasive manufacturing of microimplants directly in the organism is presented by one-photon photopolymerization and multi-photon 3D laser printing. Employing a commercially available elastomeric ink giving rise to biocompatible synthetic polymer-based microimplants, first applicational examples of biological responses to in situ printed microimplants are demonstrated in the teleost fish Oryzias latipes and in embryos of the fruit fly Drosophila melanogaster. This provides a framework for future studies addressing the suitability of inks for in vivo 3D manufacturing. The platform bears great potential for the direct engineering of the intricate microarchitectures in a variety of tissues in model organisms and beyond.

Developing an innovative 3D printing platform for production of personalised medicines in a hospital for the OPERA clinical trial

Breast cancer is the most frequently diagnosed cancer in women worldwide, and non-adherence to adjuvant hormonotherapy can negatively impact cancer recurrence and relapse. Non-adherence is associated with side effects of hormonotherapy. Pharmacological strategies to mitigate the side effects include coadministration of antidepressants, however patients remain non-adherent. The aim of this work was to develop medicines containing both hormonotherapy, tamoxifen (20 mg), along with anti-depressants, either venlafaxine (37.5 or 75 mg) or duloxetine (30 or 60 mg), to assess the acceptability and efficacy of this personalised approach for mitigating tamoxifen side effects in a clinical trial. A major criterion for the developed medicines was the production rate, specified at minimum 200 dosage units per hour to produce more than 40,000 units required for the clinical trial. A novel capsule filling approach enabled by the pharmaceutical 3D printer M3DIMAKER 2 was developed for this purpose. Firstly, semi-solid extrusion 3D printing enabled the filling of tamoxifen pharma-ink prepared according to French compounding regulation, followed by filling of commercial venlafaxine or duloxetine pellets enabled by the development of an innovative pellet dispensing printhead. The medicines were successfully developed and produced in the clinical pharmacy department of the cancer hospital Gustave Roussy, located in Paris, France. The developed medicines satisfied quality and production rate requirements and were stable for storage up to one year to cover the duration of the trial. This work demonstrates the feasibility of developing and producing combined tamoxifen medicines in a hospital setting through a pharmaceutical 3D printer to enable a clinical trial with a high medicines production rate requirement.

A Novel Compliant Connection Mechanism with Thermal Distortion Self-Elimination Function.

As a novel technology for fabricating large-screen OLED devices, OLED inkjet printing places extreme demands on the positioning accuracy of inkjet printing platforms. However, thermal deformation of the connection mechanism often reduces the printing precision of OLED printing equipment, significantly impacting overall print quality. This study introduces a compliant connection mechanism that achieves precise positioning of the inkjet printing platform and can self-eliminate thermal distortion. The design of the mechanism's core component is based on the Freedom and Constraint Topology (FACT) principle. This component is constructed from three distinct compliant sections arranged in series, collectively providing three degrees of freedom. Furthermore, the resistance to deformation caused by gravity and other external forces was evaluated by analyzing both vertical and horizontal stiffness. To validate the mechanism's thermal distortion elimination and gravity resistance capabilities, finite element analysis (FEA) was carried out. The results demonstrate that the mechanism effectively reduces the maximum deformation of the platform by approximately 46% and the average deformation across the entire platform by approximately 59%. These findings confirm that the mechanism has potential in high-precision positioning tasks that need to mitigate thermal distortion.

A study of mechanical properties of photosensitive resins used in vat photopolymerization process

In recent years, the rapid advancement of Additive Manufacturing (AM) technology has led to resource-efficient processes and reduced gaps between design and product/prototypes. Particularly, sectors like medicine and dentistry stand to gain from these advancements if materials with suitable mechanical characteristics for clinical use are available. One such evolving AM process is VAT photopolymerization through LCD 3D Printer technology, characterized by the curing of photosensitive polymeric resins. This study aims to assess the impact of the angle of layer photopolymerization of UV resin in three positions (horizontal, vertical, and inclined at 45°) using a cost-effective LCD 3D Printer. Additionally, specimens, distributed across five positions on the printing platform, underwent testing with three types of UV light-curing resin. Mechanical properties, including tensile stress, elasticity modulus, and hardness, were evaluated and analyzed statistically. Results indicate that both the chosen manufacturing platform position and the inclined layer angle significantly influence the final characteristics of the workpiece.

Optimal Process Parameters for FDM‐Based 3D Printing of Metal‐Polymer Mixtures with Low‐Temperature Powder Feeding

In this study, a proprietary powder‐fed 3D printer is employed to fabricate impellers from metal‐polymer mixtures via low‐temperature extrusion, simplifying the traditional complex metal molding process. By adjusting the extrusion speed and temperature, various quality impeller blanks are produced, identifying optimal printing conditions. The best results are achieved with a feed temperature of 170 °C, extrusion speed of 6 r min−1, printing platform temperature of 50 °C, and nozzle temperature of 175 °C, achieving a surface roughness of Ra = 9.973 μm. Post‐processing densification of the stainless steel wheels reach 97.23%, with a tensile strength of 255 MPa, elongation at break of 49%, and hardness of 60 HRB. These parameters meet the physical and mechanical standards required for general metal parts, demonstrating potential for precision metal processing in sectors such as aircraft engines, gas turbines, and high‐performance pumps.

Luminescent Supramolecular Metallogels: Drug Loading and Eu(III) as Structural Probe.

Supramolecular metallogels combine the rheological properties of gels with the color, magnetism, and other properties of metal ions. Lanthanide ions such as Eu(III) can be valuable components of metallogels due to their fascinating luminescence. In this work, we combine Eu(III) and iminodiacetic acid (IDA) into luminescent hydrogels. We investigate the tailoring of the rheological properties of these gels by changes in their metal:ligand ratio. Further, we use the highly sensitive Eu(III) luminescence to obtain information about the chemical structure of the materials. In special, we take advantage of computational calculations to employ an indirect method for structural elucidation, in which the simulated luminescent properties of candidate structures are matched to the experimental data. With this strategy, we can propose molecular structures for different EuIDA gels. We also explore the usage of these gels for the loading of bioactive molecules such as OXA, observing that its aldose reductase activity remains present in the gel. We envision that the findings from this work could inspire the development of luminescent hydrogels with tunable rheology for applications such as 3D printing and imaging-guided drug delivery platforms. Finally, Eu(III) emission-based structural elucidation could be a powerful tool in the characterization of advanced materials.

News coverage in Australian media: A comprehensive analysis

News media in Australia plays a crucial role in shaping public opinion, influencing political discourse, and reflecting societal values. This paper provides a comprehensive analysis of news coverage in Australian media, exploring various dimensions including content, bias, framing, and audience engagement. Drawing on a diverse range of sources, including print, broadcast, and digital platforms, the study examines prominent themes such as political discourse and government policies, social and cultural affairs, economic matters and financial markets, environmental concerns and climate change, international relations and global affairs, and technology and innovation. Through thematic analysis, the paper illuminates the dynamic interplay between media content and societal dynamics, shedding light on the challenges and opportunities facing the Australian media landscape in the digital age.

Visual control for robotic 3D printing on a moving platform

In recent years, there has been significant progress in developing specialized 3D printing techniques that cater to various demanding applications. However, the current state of this technology is challenged when it comes to complex in situ printing scenarios, which require a controlled printing platform. The lack of a stable printing platform is a fundamental limitation of its use in in situ applications. To address this issue, we present a novel platform-independent 3D fabrication process that enables printing on platforms with non-cooperative movement. The process overcomes the challenge of high-speed tracking, motion compensation, and real-time printing by developing a closed-loop visual feedback-controlled robotic printing process. The proposed process incorporates a marker-based visual detection and tracking controller setup, which is discussed in detail. The algorithm consists of two loops running asynchronously: a high-speed inner control loop and an outer measurement loop. This setup enables precise and accurate tracking of the printing platform, compensating for any disturbances during the printing process. Our experimental results demonstrate the successful printing of simple linear geometries, even with low-disturbing platform velocities. Moreover, the tracking controllers' ability to handle measurement occlusion is validated, showing the proposed process's robustness and effectiveness. Our work provides a significant step towards enabling 3D printing in complex in situ printing scenarios.

Polar-coordinate line-projection light-curing continuous 3D printing for tubular structures

3D printing techniques offer an effective method in fabricating complex radially multi-material structures. However, it is challenging for complex and delicate radially multi-material model geometries without supporting structures, such as tissue vessels and tubular graft, among others. In this work, we tackle these challenges by developing a polar digital light processing technique which uses a rod as the printing platform. The 3D model fabrication is accomplished through line projection. The rotation and translation of the rod are synchronized to project and illuminate the photosensitive material volume. By controlling the distance between the rod and the printing window, we achieved the printing of tubular structures with a minimum wall thickness as thin as 50 micrometers. By controlling the width of fine slits at the printing window, we achieved the printing of structures with a minimum feature size of 10 micrometers. Our process accomplished the fabrication of thin-walled tubular graft structure with a thickness of only 100 micrometers and lengths of several centimeters within a timeframe of just 100 s. Additionally, it enables the printing of axial multi-material structures, thereby achieving adjustable mechanical strength. This method is conducive to rapid customization of tubular grafts and the manufacturing of tubular components in fields such as dentistry, aerospace, and more.

Revolutionizing Three-Dimensional Printing: Enhancing Quality Assurance and Point-of-Care Integration through Instrumentation.

Three-dimensional printing in the field of additive manufacturing shows potential for customized medicines and solving gaps in paediatric formulations. Despite successful clinical trials, 3D printing use in pharmaceutical point-of-care is limited by regulatory loopholes and a lack of Pharmacopoeia guidelines to ensure quality. Semi-solid extrusion is a 3D printing technology that stands out for its versatility, but understanding the fluid dynamics of the semi-solid mass is critical. The aim of this research is to look into the advantages of instrumenting a 3D printer with a semi-solid extrusion motor-driven printhead, which is able to record the printing pressure over time, for in situ characterization of the semi-solid mass and quality evaluation of dosage forms. Four formulations using hydrochlorothiazide as the active pharmaceutical ingredient and several excipients were used. Their flow properties were studied at different printing speeds and temperatures using traditional techniques (rheometer and Texture Analyzer) and the proposed semi-solid extrusion motor-driven printhead incorporated into a printing platform. In addition, the influence of printing speed in the printing process was also evaluated by the study of printing pressure and printlet quality. The results demonstrated the similarities between the use of a Texture Analyzer and the semi-solid extrusion motor-driven. However, the latter enables temperature selection and printing speed in accordance with the printing process which are critical printing parameters. In addition, due to the incorporation of a sensor, it was possible to conclude, for the first time, that there is a link between changes in essential printing parameters like printing speed or formulations and variations in printing pressure and printlet quality attributes such as the energy require to obtain a single dosage unit, weight or diameter. This breakthrough holds a lot of potential for assuring the quality of 3D printing dosage forms and paving the way for their future incorporation into point-of-care settings.