Printing Method Research Articles

A novel printing strategy to fabricate polyetheretherketone (PEEK)-based composites via hollow filaments filled with multiple reinforcements

ABSTRACT Polyetheretherketone (PEEK)-based composites fabricated by material extrusion (ME) have attracted broad research attention; however, the complex pre-made composite filament process makes them inflexible. In this work, a novel composite printing strategy was proposed by filling composite powder into hollow filaments to construct composite filaments for printing. This strategy eliminated the screw extrusion composite filament process and fabricated composite parts directly using composite powders. Hydroxyapatite-reinforced polyetheretherketone (HA-PEEK) and carbon fibre-reinforced polyetheretherketone (CF-PEEK) composite specimens were fabricated based on the proposed printing method, and their chemical, physical, and mechanical properties were investigated. To improve the mechanical performance of the specimens, annealing was conducted. It was found that the printed composite specimens had excellent mechanical properties. The highest flexural strengths of the 10% HA-PEEK-R and 5% CF-PEEK-R specimens were detected as 352.9 and 399.4 MPa, respectively. The compression strengths of the 10% HA-PEEK-R and 20% CF-PEEK-R specimens peaked, representing 123.0 and 137.2 MPa, respectively. Furthermore, adding different functional reinforcement fillers or various filler contents to different segments of hollow filaments, sandwich structures and gradient structures were successfully fabricated.

Analysis of emission of volatile organic compounds and thermal degradation in investment casting using fused deposition modeling (FDM) and three-dimensional printing (3DP) made of various thermoplastic polymers.

The study examined the degradation process of various types of polymers used to form models using the fused deposition modeling (FDM) and three-dimensional printing (3DP) methods and used in the investment casting method. Commercial filaments made of polylactide (PLA), acrylonitrile butadiene styrene terpolymer (ABS), high-impact polystyrene (HIPS), polyamide 12 (PA12), poly(methyl methacrylate) (PMMA), and polypropylene (PP) were used to produce gypsum molds. The assessment included organic volatile compounds (VOCs) released during mold heating and model degradation, which is characteristic of this technological process. The screening qualitative chromatographic analysis of decomposition products sampled from various points of the production hall made it possible to define potential threats related to the processing of selected polymers and the necessary preventive measures. Furthermore, passive diffusion-type samplers were used at the sampling stage of VOCs emitted to the gaseous phase to reduce nuisance and user interference. Studies have been completed to characterize the thermoplastic polymer degradation process. The coupled thermogravimetry (TGA) with analysis of gaseous products by infrared spectroscopy with Fourier transformation (FT-IR) has been used. The presented results are the first to compare and rate the use of this still-developing novel aspect of castings by the method of fused models.

Scaling Heat Transfer and Pressure Losses of Novel Additively Manufactured Rib Designs

Abstract Rib turbulators are a key cooling feature that enables increased heat transfer on the interior of gas turbine components. As metal additive manufacturing becomes available for developing turbine parts, it is becoming increasingly important to understand how the surface roughness intrinsic to this manufacturing method impacts the performance of rib turbulators. To explore what impact roughness has on rib turbulator performance, several relevant scale test coupons were manufactured on two different additive machines out of IN718. Additionally, several coupons were built at large scales to effectively reduce the relative roughness size impacts and determine scale effects. A range of different wavy broken rib designs, varying both rib wavelength and orientation within a channel were evaluated. Coupon geometry and surface roughness were characterized using both computed tomography scans and optical profilometry. Variations between the print methods were found to have limited impact on the surface roughness, but significant impact on the accuracy to meet the design intent with rib heights varying by 30%. Following characterization, coupons were flow tested and it was found that the ribs that more regularly disturbed the flow as a function of their geometry most significantly enhanced heat transfer and pressure drop. The performance index of the broken wavy ribs was similar to other advanced rib designs, such as broken or V shaped ribs, but augmentations to heat transfer and pressure drop were generally lower. The rib performance was compared as a function of relative roughness, and it was found that increases in relative roughness resulted in increased friction factor and heat transfer, especially at higher Reynolds numbers.

Methods to Enhance Mechanical Strength of 3D Printed Chitosan Scaffolds for Jawbone Regeneration

Current jaw reconstruction methods using autografts and allografts have limitations such as donor site morbidity, limited bone volume, and immunological rejection. As opposed to surgical methods synthetic biomaterials are used however they often fall short in providing the optimal combination of biocompatibility, mechanical strength, and customizable design required for effective jawbone reconstruction. 3D-printed chitosan scaffolds offer a promising alternative due to their biocompatibility, ease of customization, and potential for improved mechanical strength. This review explores strategies to optimize 3D-printed chitosan scaffolds for jaw reconstruction. We examine ways to increase their mechanical strength without compromising biocompatibility, with a particular emphasis on chemical modifications such as hydroxyapatite (HA) and beta-tricalcium phosphate (β-TCP) cross-linking and chitosan polyelectrolyte complex formation. We also discuss the critical roles that 3D printing processes (FDM and SLA) and intrinsic chitosan qualities (degree of deacetylation) play in making an ink printable. Optimizing 3D printing methods for chitosan-ceramic composites and exploring biocompatible additives to enhance printability are identified as key areas for further research. By addressing these challenges, 3D-printed chitosan scaffolds have the potential to become next-generation biomaterials for jaw reconstruction, revolutionizing the field through precise anatomical adaptation, enhanced osteoconductivity, controlled biodegradation, and the capacity for incorporating bioactive molecules, ultimately leading to accelerated bone regeneration and improved functional and aesthetic outcomes.

Regularity through randomness: Bioinspired quasi-amorphous photonic structures for multilevel information encryption

The biological world has produced a wealth of complex photonic materials offering abundant design inspirations. However, creating these intricate photonic structures intertwining order, disorder, and hierarchical arrangements remains challenging. Achieving this necessitates nano-fabrication technologies capable of integrating intended macroscopic properties while accommodating microscopic variability or randomness, akin to the operational principles observed in biological organisms. Here, we present quasi-amorphous photonic structure (QAPS) patterns with regulated sophisticated visual effects through hierarchically distributions of photonic elements with engineered randomness. Enabled by an infiltration-assisted (IFAST) inkjet printing method, the visual appearances of QAPS patterns are precisely controlled by collective harnessing of nanoscale resonant scattering of colloids, mesoscale interferences, and macroscale light transporting. The QAPS patterns exhibit isotropic diffuse colors, unprecedented iridescence and enable multichannel encrypted information that can be selectively identified using specific filters at particular specular illumination angles. Additionally, the intricate infiltration fields confer high adjustability in colloidal assembly, offering sophisticated packing geometries and color distributions at the microscale, which can serve as physical unclonable security features. The exceptional structural complexity and optical versatility of QAPSs enable the integration of multilevel security features within a single system, providing a promising roadmap to achieve larger information capacity, multichannel cryptography, and enhanced encryption levels.

Low cost modelling tools for the design of additively manufactured acoustic materials

Additive manufacturing (AM) methods have unlocked new capabilities in the design of acoustic materials and their topologies. This has enabled the design of devices with breakthrough performance in sound absorption and insulation while achieving subwavelength characteristics. However, material fabrication through AM presents its own challenges. These challenges include inherent defects which can be specific to the printing method employed. Examples of defects in low-cost AM include void formation, surface roughness and poor bonding between layers. Each of these features of AM have different acoustic impacts which may degrade the performance of a design. To optimize the production of additively manufactured acoustic materials it is imperative that designers can exploit features, such as surface roughness, to enhance rather than degrade the overall material performance. The aim of this paper is to investigate the effects of surface roughness in extrusion-based AM on acoustic material performance. A novel, low-cost numerical methodology is used to capture the influence of surface roughness in a subwavelength acoustic absorber. With this approach the impact of roughness can be captured in the design process. The intention is to develop efficient low-cost design methodologies that can be exploited for industrial development of novel additively manufactured acoustic materials.

Non-animal derived recombinant collagen-based biomaterials as a promising strategy towards adipose tissue engineering

Adipose tissue engineering (ATE) has been gaining increasing interest over the past decades, offering promise for new and innovative breast reconstructive strategies. Animal-derived gelatin-methacryloyl (Gel-MA) has already been applied in a plethora of TE strategies. However, due to clinical concerns, related to the potential occurrence of immunoglobulin E-mediated immune responses and pathogen transmission, a shift towards defined, reproducible recombinant proteins has occurred. In the present study, a recombinant protein based on human collagen type I, enriched with arginine-glycine-aspartic acid was functionalized with photo-crosslinkable methacryloyl moieties (RCPhC1-MA), processed into 3D scaffolds and compared with frequently applied Gel-MA from animal origin using an indirect printing method applying poly-lactic acid as sacrificial mould. For both materials, similar gel fractions (>65%) and biodegradation times were obtained. In addition, a significantly lower mass swelling ratio (17.6 ± 1.5 versus 24.3 ± 1.4) and mechanical strength (Young's modulus: 1.1 ± 0.2 kPa versus 1.9 ± 0.3 kPa) were observed for RCPhC1-MA compared to Gel-MA scaffolds.In vitroseeding assays showed similar cell viabilities (>80%) and a higher initial cell attachment for the RCPhC1-MA scaffolds. Moreover, the seeded adipose-derived stem cells could be differentiated into the adipogenic lineage for both Gel-MA and RCPhC1-MA scaffolds, showing a trend towards superior differentiation for the RCPhC1-MA scaffolds based on the triglyceride and Bodipy assay. RCPhC1-MA scaffolds could result in a transition towards the exploitation of non-animal-derived biomaterials for ATE, omitting any regulatory concerns related to the use of animal derived products.

Effect of impregnation temperature and concentration of alumina sol on the properties of 3D printed silica ceramics

Due to the glass transition of molten quartz and the layer-by-layer 3D printing method, the strength of the finished ceramics is low. Therefore, it is necessary to find a suitable method to improve the mechanical properties of 3D printed silica ceramics used as casting molds for turbine blades. Vacuum impregnation is a very attractive method to introduce new phases into ceramic pores through liquid impregnation, thereby improving the mechanical properties of ceramic parts. In this study, 3D printed silica ceramics were impregnated with alumina sol, and the effect of impregnation temperature and concentration of alumina sol on the properties of the samples were investigated. The cristobalite content and mechanical properties of silica ceramics impregnated by alumina sol with different concentration and temperature were compared. The impregnation of alumina sol can promote the formation of cristobalite phase in the ceramics, and the appropriate amount of cristobalite can improve the mechanical properties of the ceramics. When the concentration of alumina is 15 wt% and the impregnation temperature is 60℃, the overall performance of alumina sol impregnated samples is the best, with a flexural strength of 22.70 ± 0.46 MPa, a bulk density of 1.70 ± 0.02 g /cm3, and a porosity of 25.89 ± 1.32 %.

Engineered Shape-Morphing Transitions in Hydrogels Through Suspension Bath Printing of Temperature-Responsive Granular Hydrogel Inks.

4D printing of hydrogels is an emerging technology used to fabricate shape-morphing soft materials that are responsive to external stimuli for use in soft robotics and biomedical applications. Soft materials are technically challenging to process with current 4D printing methods, which limits the design and actuation potential of printed structures. Here, a simple multi-material 4D printing technique is developed that combines dynamic temperature-responsive granular hydrogel inks based on hyaluronic acid, whose actuation is modulated via poly(N-isopropylacrylamide) crosslinker design, with granular suspension bath printing that provides structural support during and after the printing process. Granular hydrogels are easily extruded upon jamming due to their shear-thinning properties and their porous structure enables rapid actuation kinetics (i.e., seconds). Granular suspension baths support responsive ink deposition into complex patterns due to shear-yielding to fabricate multi-material objects that can be post-crosslinked to obtain anisotropic shape transformations. Dynamic actuation is explored by varying printing patterns and bath shapes, achieving complex shape transformations such as 'S'-shaped and hemisphere structures. Furthermore, stepwise actuation is programmed into multi-material structures by using microgels with varied transition temperatures. Overall, this approach offers a simple method to fabricate programmable soft actuators with rapid kinetics and precise control over shape morphing.

Polymer microsphere inks for semi-solid extrusion 3D printing at ambient conditions

Extrusion-based 3D printing methods have great potential for manufacturing of personalized polymer-based drug-releasing systems. However, traditional melt-based extrusion techniques are often unsuitable for processing thermally labile molecules. Consequently, methods that utilize the extrusion of semi-solid inks under mild conditions are frequently employed. The rheological properties of the semi-solid inks have a substantial impact on the 3D printability, making it necessary to evaluate and tailor these properties. Here, we report a novel semi-solid extrusion 3D printing method based on utilization of a Carbopol gel matrix containing various concentrations of polymeric microspheres. We also demonstrate the use of a solvent vapor-based post-processing method for enhancing the mechanical strength of the printed objects. As our approach enables room-temperature processing of polymers typically used in the pharmaceutical industry, it may also facilitate the broader application of 3D printing and microsphere technologies in preparation of personalized medicine.

4D printing of liquid crystal elastomer composites with continuous fiber reinforcement

Multifunctional composites have been continuously developed for a myriad of applications with remarkable adaptability to external stimuli and dynamic responsiveness. This study introduces a 4D printing method for liquid crystal elastomer (LCE) composites with continuous fibers and unveils their multifunctional actuation and exciting mechanical responses. During the printing process, the relative motion between the continuous fiber and LCE resin generates shear force to align mesogens and enable the monodomain state of the matrix materials. The printed composite lamina exhibits reversible folding deformations that are programmable by controlling printing parameters. With the incorporation of fiber reinforcement, the LCE composites not only demonstrate high actuation forces but also improved energy absorption and protection capabilities. Diverse shape-changing configurations of 4D composite structures can be achieved by tuning the printing pathway. Moreover, the incorporation of conductive fibers into the LCE matrix enables electrically induced shape morphing in the printed composites. Overall, this cost-effective 4D printing method is poised to serve as an accessible and influential approach when designing diverse applications of LCE composites, particularly in the realms of soft robotics, wearable electronics, artificial muscles, and beyond.

Topology optimization of coronary artery stent considering structural and hemodynamic parameters

In the present study, the impact of geometric variables and structural features of stents on hemodynamic parameters is investigated. Intravascular stent implantation is a treatment method whose success largely depends on the geometric structure of the stent and its effect on hemodynamic parameters. Medical devices called stents are inserted into arteries to restore blood flow when an artery is blocked. In this research, an optimal stent was designed and its effect compared to the common commercial stent used for coronary arteries was investigated and compared. It has been found that the geometry of the stent has an effective impact on the wall shear stress in the stented artery. Therefore, in this article, the importance of stent structures in the treatment of the coronary artery disease is discussed. For this purpose, first, an optimal stent is created with the topology optimization technique to find the best structure in the stent design. Finally, the optimized stent is numerically verified with ANSYS software and compared with existing commercial stents, and then the prototype is fabricated using additive manufacturing techniques. Commercial software ABAQUS, SolidWorks, and ANSYS are used in this research. The results showed that in optimizing a square plate, a sample with a minimum residual volume limit equal to 10 and 7 % can be selected as the optimal state. The results indicate that the new design can improve the distribution of wall shear stresses to reduce the adverse hemodynamic changes. Therefore, the proposed stent geometric structure can help improve the treatment. Finally, the optimized stent along with a commercial stent was made with the 3D printing method.

Contactless Printing of Food Micro-Particles Controlled by Ultrasound

Traditional food 3D printing technology, which primarily relies on mechanical control, often faces challenges such as low resolution, stringent material requirements, limited flexibility, and cumbersome equipment. To overcome these limitations, we developed an innovative food 3D printing method utilizing ultrasonic phased arrays and subsequently designed a contactless printing device employing this advanced technology. The device effectively manipulates the phase and amplitude of the ultrasonic phased array to focus the sound field on a specific location. We have successfully demonstrated preliminary control over the suspension of small food particles, including popcorn, chocolate, honey, and marshmallows, using this apparatus. Following this, popcorn particles were selected for detailed practical printing and further analysis.Additionally, we established a software platform, Ultr_printing, based on Ultraino, for intelligent simulation and control of the printing process. Leveraging FPGA and Arduino controllers, this setup facilitates rapid signal transmission from personal computers to sensors, ensuring quick and adaptable movement of suspended particles. Experimental results confirm that the device consistently controls the food particles, irrespective of their motion state. Notably, it achieves a printing precision of 0.16 mm when handling popcorn particles measuring 1.5 mm in diameter. The process, entirely contactless and free from contamination, preserves the original flavor of the food particles. This technology is particularly effective for high-precision printing of micro-scale shapes and offers considerable benefits in assembly and precision manufacturing.

Enhancing properties in material extrusion process by developing alternating layer printing method using RepRap code

Enhancing properties in material extrusion process by developing alternating layer printing method using RepRap code

Effects of Ultrasonic Vibration on 3D Printing of Polylactic Acid/Akermanite Nanocomposite Scaffolds

The mechanical properties of 3D-printed scaffolds for load-bearing implantation are crucial. Although the addition of nanoparticles to polymeric matrix scaffolds can improve their mechanical and biological properties, due to certain limitations in printability, high amounts of reinforcement cannot be used. Therefore, in this study, an attempt was made to use ultrasonic (UT) vibration to inhibit nozzle clogging during fused filament fabrication (FFF) of polylactic acid (PLA) scaffolds including 0, 20, and 40 wt.% Akermanite (Ak). Nozzle clogging happened during the conventional 3D printing of PLA-40wt.%Ak, while that did not occur during UT-assisted 3D printing of PLA-40wt.%Ak. Results of X-ray Diffraction (XRD) analysis and Scanning Electron Microscopy (SEM) indicated that applying ultrasonic (UT) vibration had no negative effect on the phases and morphology of the scaffolds. The results obtained by the compression test indicated that applying UT during 3D-printing resulted in almost 27% increment of elastic modulus and almost 25% increase of the compressive strength of the scaffolds. As the conclusion, this study highlights the effectiveness of ultrasonic-assisted 3D printing in producing nanocomposite scaffolds with significantly higher nanoparticle loadings, as compared to conventional printing methods. By utilizing ultrasonic vibration during the printing process, the study showcases the possibility of overcoming viscosity limitations and optimizing the mechanical performance of scaffolds for various biomedical applications, including bone tissue engineering.

Estimation of antiparasitic activity of fungal extracts towards Leishmania donovani in murine model

Background. Fungi produce many compounds have pharmaceutical usage. The current study was aimed to extract therapeutic compounds from fungi that grow in critical conditions and fungi that can be produced commercially which may have potential therapeutic activities against Leishmania donovani. The current study was aimed to extract therapeutic compounds from fungi that grow in critical conditions and fungi that can be produced commercially which may have potential therapeutic activities against Leishmania donovani. Methods. Two fungal isolates were used to evaluate antileishmanial activities of their extracts, the first due to Aspergillus terreus was isolated from salty sediments, while another represented local edible mushroom of Agaricus bisporus. The experiment was conducted in vivo after four weeks infection of Leishmania donovani. Infected mice were treated intraperitonially with 2 and 4 mg/kg daily for 10 days. Result. All compound has a significant effect on the viability and decrease the number of parasites in animal in comparison with pentostam, as well as, the M19 was appeared with highest effect in both concentrations. The method of examining infected tissues had a role in determining the number of parasites without affecting the percentage of presence in different treatments, as the numbers of parasites calculated in the tissue sections are more realistic than the number of parasites calculated in the printing method, as counting the parasite with tissue sections gives an impression of the spatial distribution of the parasite, whether within tissues or body fluids, unlike the printing method, which shows the presence of the parasite in body fluids and immune cells thus be suitable for the diagnosis of parasite amastigote in vivo. Conclusion. The compound extracted during study and diagnoses by GC-Mass technique are promising applicants for research on new drugs with anti-Leishmania activity derived from natural products.

THE IMPULSES OF MODERNJADIDISM AND THE ROLEOF PRINTING

Jadidism, a reform movement among Muslims of the Russian Empire in the late 19th and early 20th centuries, played a key role in cultural and educational evolution. One of the main factors that contributed to its development began to be distributed in the form of newspapers, magazines, fiction books, scientific manuals, etc. The purpose of this study is to analyze the role of the press in the development and spread of Jadidism.The scientific originality of the work lies in deepening the understanding of the processes of the cultural revolution among the Turkic-Muslim peoples living on the territory of the Russia n Empire, and the role of the press in these processes. Practical originality lies in the possibility of using the data obtained to develop modern traditions of cultural and educational development of the Turkic peoples.The article uses historical analysis as well as descriptive and sociocultural methods to determine the relationships between technological advances in printing and ideological changes in Jadidism, using print methods such as a literacy measurement tool, the promotion of secular education, and the formation of modern Turkic identity.The study showed that print media are a central mechanism in disseminating Jadidist idea s and establishing the positions of reformers. The analysis found that the use of printed materials significantly accelerated economic development and led to profound changes in socia l development.The results of the study can be used to develop strategies for supporting and developing cultural and educational initiatives , as well as to study contemporary media in the field of socia l movement and progressive trends in other cultural contexts.

Comparative Evaluation of Fracture Strength of Implant Supported Crown Fabricated from CAD/CAM and 3D Printed Resin Matrix Ceramic

Objective: To compare fracture strength of screw-retained implant-supported crown of resin matrix ceramic when fabricated using CAD/CAM and 3D printing Material and method: vericom Mazic® Duro (CAD/CAM Nano Hybrid Ceramic) was used as particle-filled composite CAD/CAM material, saremco Print Crowntec (3D printable resins-based) as 3D printed composite material, and the control group was composed of IPS e.max. ZirCAD ivoclar vivadent (zirconia) was used to fabricate mandibular first molar screw-retained, implant-supported crowns. After the fabrication, the crowns were cemented with the Rely X U200 self-adhesive resin cement (3M ESPE, Germany) on stock abutments tightened to analogs embedded in acrylic resin. Finally, all crowns were subjected to a fracture resistance test. fracture strength was evaluated by using one–way ANOVA with Chi-square used for the association between the modes of fracture. Result: The results showed that there were significant differences between all the groups used, the control group (Group zirconia) was significantly higher, as the mean was equal to 6391 N. Followed by Group vericom (cad/cam) with a mean of 2558 N, then Group seramco (3D printing) with a mean of 817.92 N. Dunnett T3 test showed statistically significant differences in fracture resistance between the three groups. There was no significant difference between the modes of fracture and the methods. Conclusion: Screw-retained implant-supported crowns manufactured by CAD/CAM technique had better fracture resistance value than those of the 3D printed technique. Clinical Relevance: resin matrix ceramic is a possible substitute for zirconia in an implant-supported crown

On the suitability of photocuring-assisted DIW for manufacturing complex prosthesis from commercial dental composites

A 3-D printing method to produce dental prostheses of complex shapes from a commercial, photocurable resin-ceramic slurry is developed and optimized. The microstructure, mechanical properties and wear behavior of the resulting material are evaluated and compared with a conventional/control sample and other ceramic-polymer dental composites. Commercial resin-ceramic dental slurries can be successfully extruded and appropriately photocured in a low cost 3-D printing system to produce cost-efficient complex dental parts that could be used in indirect restorations. The printing process does not appreciably introduce defects in the material and the 3-D printed composites exhibit mechanical properties (hardness, elastic modulus) and wear resistance comparable to the control material and analogous, conventional dental composites. The main wear mechanisms under sliding contact against a hard antagonist are plastic deformation at the asperity level and ceramic particle pull-out due to filler/matrix interfacial weakness.Graphical 3-D printing commercial resin-filler slurries creates cost-efficient tooth prostheses with properties akin to conventional dental composites

3D-printed broadband electromagnetic wave-absorbing basalt/CF/PLA composites with a high current path for lightning strike protection

In this study, we used the three-dimensional (3D) printing method to design and fabricate a radar-absorbing structure (RAS) to protect against damage caused by lightning strikes. A carbon black-dispersed 3D filament was used as reinforcement in the composite, and metalized fibers served as the feedstock for 3D-printing. The return losses measured in the X-band and Ku-band (8.2–18 GHz) indicated a maximum return loss of −28.98 dB at 10.68 GHz, with a broad bandwidth of 6.56 GHz in the frequency range of 8.2-18 GHz. A coupled electrical–thermal analysis confirmed that the proposed carbon black-dispersed filament provided conductive paths, which contributed to direct current, energy dissipation, and lightning strike protection. The 3D-printing method ensured a sufficient level of electrical conductivity, limiting the area and depth of damage caused by lightning strikes. Therefore, 3D-printed-RASs, reinforced by electrically conductive materials, can effectively protect against lightning strikes.