Manufacturing Printing Research Articles

Emerging Advances in 3-D & 4-D Printing of Polymeric Nanoarchitectures & Multifacet Applications

3-Dimension printing (3-DPT) or additive manufacturing (AM) technology has been utilized for a while in the construction of customized 3-D objects utilizing computer software such as computer-aided design (CAD). However, the emergence of an innovative and new four-dimensional printing (4-DPT) has enabled the synergy of AM technology with programmable materials in transforming digital processes virtually into physical entities, thereby providing innovation and advanced functionalities. 4-DPT is a procedure facilitating 3-DPT components to undergo programming in order to enable the transformation of their shape with time on exposure to external stimuli such as physical stimuli, including light-responsivity, chemical responsivity, magnetic/electrical responsivity, pH response, thermo-sensitive as well as biological stimulation such as biomolecular responsivity. The inherent difference between 3-DPT and 4-DPT is premised on the shape-changing material (SCM) utilized during manufacturing, depicting the advanced material exhibiting the specified changes in responsivity to external parameters. Therefore, this elucidation presents emerging 4-DPT technology in manufacturing polymeric nanoarchitectures and applications. Furthermore, insight into 4-DPT techniques, including extrusion, direct ink writing (DIW), fused filament fabrication (FFF), and vat photo-polymerization strategies (digital light processing (DLP), stereo-lithography (SLA), and multi-photon polymerization (MPP), are also presented.

A review on recent progress in light metal solid-phase additive manufacturing

Additive manufacturing technology, known for its advantages in rapid layer-by-layer 3D printing, personalized production, and flexible manufacturing, has gained widespread applications in the manufacturing industry. This paper provides an analysis and summary of the recent progress in lightweight metal solid-state additive manufacturing technology and its related process mechanisms. The primary solid-state additive manufacturing technologies currently include ultrasonic additive manufacturing, cold spray additive manufacturing, and friction-based additive manufacturing. The research and application status of solid-state additive manufacturing technology for lightweight metal materials are particularly emphasized, and the characteristics of these three types of solid-state additive manufacturing technologies are compared. In the end, the paper highlights the key directions for future research in solid-state additive manufacturing technology, including additive process mechanisms, simulation study of multi-physics and multi-scale, application of various materials, external field-assisted process modification and optimization through artificial intelligence.

Particle Trajectory Simulation Facilitates the Development of an Efficient Sample Introduction System for Single-Particle ICP-MS Analysis.

Inductively coupled plasma mass spectrometry (ICP-MS) has demonstrated significant capabilities in the analysis of single events, such as single cells and particles. Researchers have been actively pursuing innovations in ICP-MS sample introduction systems to enhance their transport efficiency, as this is critical for ensuring the accuracy of single-event analysis. However, the majority of prior studies have relied heavily on empirical approaches, with limited attention given to the individual characteristics of particles from a theoretical perspective and a lack of efficient manufacturing tools for optimizing related components. Herein, we developed a high-efficiency sample introduction system for single-event ICP-MS analysis by integrating the computational simulation-aided design, precise 3D printing manufacturing, and rapid experimental testing process. For the first time, we simulated the transport trajectories of individual particles passing through the spray chamber, providing theoretical guidance for the design and optimization process. The statistical analysis of particle trajectories revealed that under the absorption boundary condition, particles between 20 and 100 nm achieved transport efficiencies exceeding 18.8%. In comparison, particles larger than 100 nm exhibited 0% transport efficiency due to increased deposition within the spray chamber. The spray chamber was fabricated in-house using a range of 3D printing technologies and materials, streamlining the process and reducing the cost for both manufacturing and validation. Further optimization of the operating parameters, including an increase in temperature, resulted in a notable transport efficiency of 61.1%. The workflow introduced in this study has the potential to transform the research and development of critical mass spectrometry components moving forward.

Fabrication of SS 316L particle-infilled PLA composite filaments from cast-off bi-material extrudates for 3D printing applications.

The identification of recyclable resources are extremely important to balance the growing demand for polymer composite 3D printing and sustainable manufacturing. In the present study, SS 316L powder particle infused PLA filaments are fabricated by deriving PLA from discarded bi-material extrudates, adopting solvent mixing methodology. The matrix reclaimability, composite feedstock fabrication, extrudability and printability are investigated by increasing the solid loading from 10 - 40wt%. Outcomes of the FTIR for 'PLA gel' and 'extrudate dissolved gel' are identical and confirms the matrix reclaimability. Essential characterization studies like XRD, TGA, and DSC are carried out for composite feedstock. The reinforcement dispersion in composites is quantified with the help of microscopy results. The melt rheological studies reveal that all the extruded filaments exhibit shear thinning over a shear rate of 50s-1 and are compatible with 3D printing. The tensile strength is improved by 22.4% after adding 10wt% reinforcement to the recycled PLA. The economical benefits are evaluated by comparing the composite filament fabrication with the pure PLA matrix. The study concludes recommending viscous modifiers to improve filament processability and increase loading capacity beyond 40wt% for indirect metal additive manufacturing.

Molding Quality and Biological Evaluation of a Two-Stage Titanium Alloy Dental Implant Based on Combined 3D Printing and Subtracting Manufacturing.

Metal 3D printing has been used in the manufacturing of dental implants. Its technical advantages include high material utilization and the capacity to form arbitrarily complex structures. However, 3D printing alone is insufficient for manufacturing two-stage titanium implants due to the limited precision in printing titanium alloy parts. In this study, 3D printing was employed to create the implant structure, subsequently complemented by mechanical processing to refine the implant abutment connection and neck. Additionally, the mechanical properties of 3D-printed titanium alloy implants were evaluated through tensile and dynamic fatigue testing. The MTT assay was employed to assess the cytotoxicity of 3D-printed titanium alloy dental implants. The impact of bone union and osteogenesis from 3D-printed titanium alloy dental implants was investigated through in vivo experimentation. The results demonstrated that combining 3D printing with subsequent machining constitutes a viable method for the manufacture of two-stage titanium dental implants. Test results for mechanical properties indicated that heat-treated 3D-printed titanium alloy dental implants possess significant tensile strength and fatigue resistance and are capable of withstanding the robust chewing forces in the oral cavity. In vitro findings revealed that sandblasted and acid-etched 3D-printed titanium alloy exhibited negligible cytotoxicity, with osteoblast differentiation of hMSCs being more pronounced compared with the control group. In vivo studies indicated that no significant differences were observed in bone volume fraction, bone-implant contact rate, and unscrewing torque between 3D-printed titanium alloy dental implants and commercial SLA surface implants at both 1 and 3 months postimplantation.

How Green Innovation and Green Corporate Social Responsibility Transform Green Transformational Leadership Into Sustainable Performance? Evidence From an Emerging Economy

ABSTRACTIn light of the rapidly evolving technology nowadays, a green business model is now required for sustainability and long‐term survival, especially for small and medium‐sized enterprises (SMEs) and general businesses. This study aims to investigate how green transformational leadership and sustainable corporate performance for SMEs interact by examining the coordinating functions of green innovation and green corporate social responsibility in a developing nation. The current study followed the quantitative methodology along with a questionnaire for data collection. The survey's target sample consisted of senior and middle‐level executives from Vietnam's printing and FMCG manufacturing industries. Following the survey, 449 valid responses were gathered, and SmartPLS (version 4.1.0.6) structural equation modeling was used to analyze the collected data. This analysis contributes to the body of knowledge by using the natural resource‐based view Theory and Stakeholder Theory to provide a “three‐green‐model” that includes green transformational leadership, green innovation, and green corporate social responsibility, as well as their combined impact on sustainable corporate performance in a developing nation. The study findings confirm that green transformational leadership has a positive impact on sustainable corporate performance, both directly and indirectly, through green innovation and green corporate social responsibility, leading to better financial and environmental results. This study provides useful insights into how green leadership promotes sustainable growth, giving SMEs a method to balance between social and environmental responsibility and economic success.

3D Printing and Additive Manufacturing: Revolutionizing the Production Process

Additive manufacturing (AM), widely known as 3D printing, is revolutionizing production processes across industries by enabling customization, reducing waste, and enhancing efficiency. This paper explores the fundamentals of AM, its applications in healthcare, aerospace, consumer goods, and construction, and its benefits, including complex geometries and sustainability. It also addresses challenges such as material limitations, regulatory hurdles, and high costs, while highlighting emerging trends like hybrid manufacturing, bioprinting, AI integration, and nanoprinting. Future directions emphasize scaling production, improving education, and fostering global collaboration to unlock the full potential of AM.

Condition-based monitoring techniques and algorithms in 3d printing and additive manufacturing: a state-of-the-art review

Condition-based monitoring techniques and algorithms in 3d printing and additive manufacturing: a state-of-the-art review

3-Dimensional Printing in Healthcare: Manufacturing Techniques and Applications

3D printing and additive manufacturing are interchangeable terms. Additive manufacturing builds models layer by layer using a variety of laser-based or sophisticated printing processes. While this was one of the earliest techniques for 3D printing, the field now widely uses a number of other patented methods. The objective is to analyze the success rate of 3D printing in healthcare. The medical industry has found 3D printing to be highly beneficial in recent years. The application of 3D printing technology allows for greater customization of the therapeutic process, which enhances treatment safety, accuracy, and precision. On the other hand, the disclosure of new materials for 3D printing occurs frequently. For some producers, the right materials might just be a few months or years away. However, printing certain materials may be difficult or impossible. Excellent results are not always possible with 3D printers. We can conclude that 3D printing represents one of the most advanced techniques in healthcare.

THE FUTURE OF 3D PRINTING IN MANUFACTURING (INNOVATIVE TECHNOLOGY REVOLUTIONIZING MANUFACTURING PROCESSES AND PRODUCTS)

"Imagine a world where you can create anything you want just by pressing a button! That's the magic of 3D printing. In the future, this technology will change how we make things in big factories. Instead of traditional methods, like cutting and molding, 3D printers use special materials to build layer by layer. It's like building with Legos, but in real life! This cool technology lets us make custom toys, tools, and even houses. It's like having a superpower to create whatever we can imagine. Scientists are even exploring using 3D printing to make body parts and yummy food! With 3D printing, we can reduce waste and make things more efficiently. It's like a glimpse into the future where creativity knows no bounds. So, get ready to witness the amazing world of 3D printing!" KEYWORDS 3D Printing, Additive Manufacturing, Customization, Sustainability, Bioprinting, Material Innovation, Industry 4.0, Supply Chain, Prototyping, Regulatory Compliance, Automation, Innovative Design, Waste Reduction, Manufacturing Efficiency, Digital Fabrication, Creative Empowerment.

Minimally invasive detection of buprenorphine using a carbon-coated 3D-printed microneedle array.

Amachine learning-assisted 3D-printed conducting microneedle-based electrochemical sensing platformwas developed for wireless, efficient, economical, and selective determination of buprenorphine. The developed microneedle array-based sensing platform used 3D printing and air spray coating technologies for rapid and scalable manufacturing of a conducting microneedle surface. Upon optimization and understanding of the electrode stability, redox behavior, and electrochemical characteristics of as-prepared conducting microneedle array, the developed electrochemical platform was investigated for monitoring different levels of buprenorphine in the artificial intestinal fluid and found to be highly sensitive and selective towards buprenorphine for a wide detection range from 2 to 140μM, with a low limit of detection of 0.129μM. Furthermore, to make the sensing platform user accessible, the experimentally recorded sensing data was used to train a machine learning model and develop a web application for the numerical demonstration of buprenorphine levels at the point of site. Finally, the proof-of-concept study demonstrated that by advancing our prevailing 3D printing and additive manufacturing techniques, a low-cost, user-accessible, and compelling wearable electrochemical sensor could be manufactured for minimally invasive determination of buprenorphine in interstitial fluid.

Bubble-Free Frontal Polymerization of Acrylates via Redox-Initiated Free Radical Polymerization.

Thermal frontal polymerization (FP) of acrylate monomers mixed with conventional peroxide initiators leads to significant bubble formation at the polymerizing front, limiting their practical applications. Redox initiators present a promising alternative to peroxide initiators, as they prevent the formation of gaseous byproducts during initiator decomposition and lower the front temperature, thereby enabling bubble-free FP. In this study, we investigate the FP of acrylate monomers of varying functionalities, including methyl methacrylate (MMA), 1,6-hexanediol diacrylate (HDDA), and trimethylolpropane triacrylate (TMPTA), using N,N-dimethylaniline/benzoyl peroxide (DMA/BPO) redox couple at room temperature and compare their front behavior, pot life, and bubble formation with those of same resin systems mixed with a conventional peroxide initiator, Luperox 231. The use of redox couples in FP of acrylates shows promise for rapid, energy-efficient manufacturing of polyacrylates and can enable new applications such as 3D printing and composite manufacturing.

Bio-mechanical analysis of porous Ti-6Al-4V scaffold: a comprehensive review on unit cell structures in orthopaedic application.

A scaffold is a three-dimensional porous structure that is used as a template to provide structural support for cell adhesion and the formation of new cells. Metallic cellular scaffolds are a good choice as a replacement for human bones in orthopaedic implants, which enhances the quality and longevity of human life. In contrast to conventional methods that produce irregular pore distributions, 3D printing, or additive manufacturing, is characterized by high precision and controlled manufacturing processes. AM processes can precisely control the scaffold's porosity, which makes it possible to produce patient specific implants and achieve regular pore distribution. This review paper explores the potential of Ti-6Al-4V scaffolds produced via the SLM method as a bone substitute. A state-of-the-art review on the effect of design parameters, material, and surface modification on biological and mechanical properties is presented. The desired features of the human tibia and femur bones are compared to bulk and porous Ti6Al4V scaffold. Furthermore, the properties of various porous scaffolds with varying unit cell structures and design parameters are compared to find out the designs that can mimic human bone properties. Porosity up to 65% and pore size of 600 μm was found to give optimum trade-off between mechanical and biological properties. Current manufacturing constraints, biocompatibility of Ti-6Al-4V material, influence of various factors on bio-mechanical properties, and complex interrelation between design parameters are discussed herein. Finally, the most appropriate combination of design parameters that offers a good trade-off between mechanical strength and cell ingrowth are summarized.

Material selection and design of intake blades for aircraft engines based on additive manufacturing

Abstract The intake blades of aircraft engines are mainly used to capture and guide external air into the engine and are the foundation of engine operation. Their materials and design are related to the performance level and reliability of the entire engine. The “additive” 3D printing manufacturing method has the advantages of high precision, low cost, less material waste, strong design, and a short research and development cycle. This article proposes the use of GH4169 high-temperature alloy as the 3D printing material for the service requirements of aircraft engine intake blades, constructs a 3D printing model, and designs and realizes the 3D printing of engine intake blades.

Rapid Prototyping Technology: A Driving Force in Product Design Innovation

Abstract: This paper explores the transformative impact of rapid prototyping on product design processes across various industries. Rapid prototyping, characterized by its ability to quickly create physical models from digital designs, significantly enhances the iterative design phase, facilitating early testing and validation of concepts. RP includes the integration of technologies such as 3D printing, computer-aided design (CAD), and additive manufacturing in accelerating product iterations, reducing time-to-market, and fostering innovation. Rapid prototyping (RP) has emerged as a transformative approach in product development, significantly enhancing design processes across various industries. Sectors including automotive, consumer electronics and healthcare show how rapid prototyping streamlines communication among stakeholders, enhances user feedback incorporation, and reduces production costs

Mechanical characterization of FDM components made of polyaryletherketone (PAEK) for aerospace applications: a comparison of direct printing and box-cut sample manufacturing strategies

This study delves into the manufacturing strategies employed for fabricating tensile samples utilized in the mechanical characterization of material extrusion (MEX) components constructed with polyaryletherketone (PAEK) for aerospace applications. Two distinct methods were investigated for obtaining tensile test samples: direct cutting and extraction from a box. These methods were examined under both as-printed and annealing conditions. Quasistatic tensile tests were conducted along the building direction to evaluate the impact of processing conditions on the adhesion of overlying layers. The results unveiled significant disparities in mechanical behavior and crystallinity between directly printed samples and those derived from the box. The Young’s modulus exhibited marginal influence; however, the tensile strength of directly printed samples measured at 30 MPa (prior to annealing), corresponding to 50% of the strength observed in samples cut from the box (60 MPa). Moreover, the elongation at rupture of directly printed samples was found to be less than 2%, while that of cut samples exceeded 8%. Notably, directly printed samples exhibited a significant degree of incipient crystallization (12.18%), contrasting with the lower level of crystallinity observed in samples cut from the box (3.27%). These findings underscore the importance of recognizing the limitations associated with direct sample printing, emphasizing its crucial role in accurately characterizing components destined for the aerospace industry. Furthermore, this understanding is pivotal for optimizing the performance and reliability of MEX-printed PAEK components in aerospace engineering applications.

Perspective on Water-Soluble Two-Photon Initiator for Two-Photon Polymerization.

Two-photon polymerization (TPP) as an unparalleled technology empowers the rapid prototyping of customized three-dimensional (3D) micro/nanostructures, garnering noticeable interest in tissue engineering, drug delivery, and regenerative medicine. These applications have a high requirement on the biocompatibility and integrity of 3D structures. Therefore, it is important to develop two-photon initiator with good water-solubility, initiation efficiency, and biocompatibility. Here, we share our insights into the development of a water-soluble two-photon initiator (WTPI) and applications from the material and manufacturing perspective. We highlight the nonlinear optical properties and the synthesis of WTPI through three pathways. Then we further demonstrate the applications of the TPP technique in the aqueous phase in the fields of tissue engineering, 4D printing, and ceramic manufacturing. Finally, a general conclusion and outlook are provided for the future development and application of WTPI.

An Additive Manufacturing MicroFactory: Overcoming Brittle Material Failure and Improving Product Performance through Tablet Micro-Structure Control for an Immediate Release Dose Form.

Additive manufacturing of pharmaceutical formulations offers advanced micro-structure control of oral solid dose (OSD) forms targeting not only customised dosing of an active pharmaceutical ingredient (API) but also custom-made drug release profiles. Traditionally, material extrusion 3D printing manufacturing was performed in a two-step manufacturing process via an intermediate feedstock filament. This process was often limited in the material space due to unsuitable (brittle) material properties, which required additional time to develop complex formulations to overcome. The objective of this study was to develop an additive manufacturing MicroFactory process to produce an immediate release (IR) OSD form containing 250 mg of mefenamic acid (MFA) with consistent drug release. In this study, we present a single-step additive manufacturing process employing a novel, filament-free melt extrusion 3D printer, the MicroFactory, to successfully print a previously 'non-printable' brittle Soluplus®-based formulation of MFA, resulting in targeted IR dissolution profiles. The physico-chemical properties of 3D printed MFA-Soluplus®-D-sorbitol formulation was characterised by thermal analysis, Fourier Transform Infrared spectroscopy (FTIR), and X-ray Diffraction Powder (XRPD) analysis, confirming the crystalline state of mefenamic acid as polymorphic form I. Oscillatory temperature and frequency rheology sweeps were related to the processability of the formulation in the MicroFactory. 3D printed, micro-structure controlled, OSDs showed good uniformity of mass and content and exhibited an IR profile with good consistency. Fitting a mathematical model to the dissolution data correlated rate parameters and release exponents with tablet porosity. This study illustrates how additive manufacturing via melt extrusion using this MicroFactory not only streamlines the manufacturing process (one-step vs. two-step) but also enables the processing of (brittle) pharmaceutical immediate-release polymers/polymer formulations, improving and facilitating targeted in vitro drug dissolution profiles.

Sustainable Support Material for Overhang Printing in 3D Concrete Printing Technology

The advantage of 3DCP technologies is the ability to fabricate free-form structures. However, printing openings in concrete structures are limited by the presence of overhanging sections. While various 3D printing and additive manufacturing technologies have established methods for handling overhangs with temporary supports, many existing techniques for 3D concrete printing still rely on wooden planks and corbelling, which restrict the design flexibility and slope angles. The objective of this study is to develop a removable and sustainable support material with high printability performance. This support material serves as temporary support for overhang sections in 3D-printed structures and can be removed once the primary concrete has hardened sufficiently. This study observed that increasing the recycled glass content in the mixture raises both the dynamic and static yield stresses, with only mixtures containing up to 60% recycled glass remaining pumpable. Optimization of the mixture design aimed to balance high flowability and buildability, and the results indicated that a mixture with 60% recycled glass content is optimal. The effectiveness of the optimized support material was validated through the successful printing of a structure featuring a free-form opening and overhang section.

Advances in textile-based microfluidics for biomolecule sensing.

Textile-based microfluidic biosensors represent an innovative fusion of various multidisciplinary fields, including bioelectronics, material sciences, and microfluidics. Their potential in biomedicine is significant as they leverage textiles to achieve high demands of biocompatibility with the human body and conform to the irregular surfaces of the body. In the field of microfluidics, fabric coated with hydrophobic materials serves as channels through which liquids are transferred in precise amounts to the sensing element, which in this case is a biosensor. This paper presents a condensed overview of the current developments in textile-based microfluidics and biosensors in biomedical applications over the past 20 years (2005-2024). A literature search was performed using the Scopus database. The fabrication techniques and materials used are discussed in this paper, as these will be key in various modifications and advancements in textile-based microfluidics. Furthermore, we also address the gaps in the application of textile-based microfluidic analytical devices in biomedicine and discuss the potential solutions. Advances in textile-based microfluidics are enabled by various printing and fabric manufacturing techniques, such as screen printing, embroidery, and weaving. Integration of these devices into everyday clothing holds promise for future vital sign monitoring, such as glucose, albumin, lactate, and ion levels, as well as early detection of hereditary diseases through gene detection. Although most testing currently takes place in a laboratory or controlled environment, this field is rapidly evolving and pushing the boundaries of biomedicine, improving the quality of human life.