Three-dimensional Fabrication Research Articles

Yarn-level numerical simulation based on micro-CT reconstruction for the stentering process of warp-knitted three-dimensional mesh fabric

Yarn-level numerical simulation based on micro-CT reconstruction for the stentering process of warp-knitted three-dimensional mesh fabric

Three-dimensional moisture transport fabric for enhanced moisture management in protective clothing

Three-dimensional moisture transport fabric for enhanced moisture management in protective clothing

Unravelling the mechanics of knitted fabrics through hierarchical geometric representation

Knitting interloops one-dimensional yarns into three-dimensional fabrics that exhibit behaviour beyond their constitutive materials. How extensibility and anisotropy emerge from the hierarchical organization of yarns into knitted fabrics has long been unresolved. We seek to unravel the mechanical roles of tensile mechanics, assembly and dynamics arising from the yarn level on fabric nonlinearity by developing a yarn-based dynamical model. This physically validated model captures the mechanical response of knitted fabrics, analogous to flexible metamaterials and biological fibre networks due to geometric nonlinearity within such hierarchical systems. Fabric anisotropy originates from observed yarn–yarn rearrangements during alignment dynamics and is topology-dependent. This yarn-based model also provides a design space of knitted fabrics to embed functionalities by varying geometric configuration and material property in instructed procedures compatible to machine manufacturing. Our hierarchical approach to build up a knitted fabric computationally modernizes an ancient craft and represents a first step towards mechanical programmability of knitted fabrics in wide engineering applications.

A novel quasi-static MEMS piezoelectric micromirror array with a high fill factor and three degrees of freedom

This paper presents the design of a novel 3×3 piezoelectric micromirror array (PMMA) with an 84.6 % fill factor and describes a three-dimensional hidden fabrication platform. The fabricated device operates with quasi-static mode in 3-degree-of-freedom, namely tip, tilt, and piston. In order to achieve a high fill factor, a three-dimensional hidden micromirror array structure is introduced, and is realized through multi-layer bonding. In addition, a double-stop-layer’s glass cover for optical device was employed to realize transparent wafer-level packaging. The device testing result achieves a mechanical tilting angle of 4.4 mrad at 82.5 VDC with over 99.5 % linearity. This design has the potential to achieve a larger size of micromirror arrays.

Seed-guided high-repetition-rate femtosecond laser oxidation for functional three-dimensional silicon structure fabrication

Laser oxidation provides a flexible maskless functional three-dimensional silicon structure fabrication strategy. Here, oxide layers are fabricated on silicon substrates by high-repetition-rate femtosecond laser irradiation. Formation mechanisms of the femtosecond laser oxidation are analyzed to tune the oxide layer morphology. When the laser fluence is high, the oxidation process is accompanied by laser ablation, so the oxide layer is always on top of laser ablated groove. To obtain the flat oxide layer, defect is firstly generated on silicon substrate by the laser irradiation at a high laser fluence of 126 mJ/cm2, function as a high optical absorption. It is called seed as it can assist to achieve lower fluence laser oxidation at 38 mJ/cm2 and result in a flat oxide layer. Full width at half-maximum of the oxide layer is also reduced. The laser fabricated oxide layers are used as etching masks. Three-dimensional silicon gratings are fabricated by deep reactive ion etching, which demonstrate desirable beam diffraction properties.

Enhanced broadband sound absorption of multi-layer composite material based on three-dimensional warp-knitted spacer fabric

Compared with other sound-absorbing materials, spacer fabric with a “sandwich” structure has many advantages, such as light weight, an environmentally friendly production process, recyclability, versatility, low production cost and high efficiency, and strong designability of the organizational structure. However, as a porous sound-absorbing material, the effective sound-absorbing frequency band of the spacer fabric is concentrated at high frequencies, so the sound-absorbing performance needs to be improved. This paper establishes a Johnson–Champoux–Allard theoretical model by using a genetic algorithm to characterize the sound absorption performance of the three-dimensional (3D) warp-knitted spacer fabric. The theoretical model is validated through finite element analysis and experimental methods. Based on this model, two composite materials are designed to improve the sound absorption performance: (1) multi-layer spacer fabric composite material and (2) multi-layer spacer fabric-aluminum foil composite material. Numerical simulation and experimental results show that the sound absorption performance is significantly improved by widening the effective frequency band and increasing the sound absorption coefficient. The contribution of this paper is twofold. Firstly, the theoretical acoustic model of 3D warp-knitted spacer fabric is established. Secondly, the superior sound absorption performance is achieved by proposing multi-layer and multi-material composite material. The spacer fabric-based composite material has broad application prospects in the field of noise reduction and sound insulation. The paper provides a theoretical basis and more strategies for the acoustic and multifunctional design of spacer fabric in the future.

A numerical study on the effects of fabric structure on the impact resistance of 3D interlock woven fabrics

Three-dimensional (3D) woven fabrics have emerged as an effective structure for ballistic protection due to their flexibility, multi-impact resistance, and ability to form complex shapes. However, the influence of different 3D fabric architectures on ballistic performance is not fully understood. This study investigates the ballistic response of three types of 3D angle-interlock woven fabrics (3DTAWF, 3DSSWF, 3DSBWF) using numerical simulations with experimentally validated material models. Full-scale fabric models enable examining the dynamic behavior at the yarn level. Results show 3DSBWF exhibits the best ballistic performance with higher ballistic limit and energy absorption compared to 3DTAWF and 3DSSWF. Damage evolution indicates 3DSBWF and 3DSSWF have better structural integrity during penetration. The higher warp density and straighter warp path contribute to balanced warp-weft energy absorption and improved impact resistance in 3DSBWF. This study elucidates the role of 3D fabric structure on energy absorption patterns and failure morphology. The findings provide valuable insights into 3D woven fabric designs for optimizing ballistic protection performance.

The mechanical properties of Kevlar three-dimensional angle-interlock fabrics and composites

In this article, in order to investigate the difference of mechanical properties between three-dimensional angle-interlock (3DAI) structure and two-dimensional (2D) structure. Kevlar filaments were used as raw material to prepare 3DAI fabrics. The tensile properties of Kevlar 3DAI fabrics were investigated and the influence of warp damage and crimp wave height on the tensile properties was analyzed too. The bending properties and low-velocity impact properties of the 3DAI Kevlar/EP composites and the 2D composites were compared. The results revealed that the warp degradation and crimp percentage in 3DAI fabrics increase with the increase of weft density. The maximum warp degradation rate is 15% and the maximum crimp percentage is 5.4%, which has a negative effect on the mechanical properties of the 3DAI fabrics and the developed Kevlar/EP composites. Compared with the 2D plain composites, the 3DAI composites have superior impact resistance and anti-stratification performance. Moreover, which also has a superior ability to withstand multiple impacts.

Sweat permeable and ultrahigh strength 3D PVDF piezoelectric nanoyarn fabric strain sensor

Commercial wearable piezoelectric sensors possess excellent anti-interference stability due to their electronic packaging. However, this packaging renders them barely breathable and compromises human comfort. To address this issue, we develop a PVDF piezoelectric nanoyarns with an ultrahigh strength of 313.3 MPa, weaving them with different yarns to form three-dimensional piezoelectric fabric (3DPF) sensor using the advanced 3D textile technology. The tensile strength (46.0 MPa) of 3DPF exhibits the highest among the reported flexible piezoelectric sensors. The 3DPF features anti-gravity unidirectional liquid transport that allows sweat to move from the inner layer near to the skin to the outer layer in 4 s, resulting in a comfortable and dry environment for the user. It should be noted that sweating does not weaken the piezoelectric properties of 3DPF, but rather enhances. Additionally, the durability and comfortability of 3DPF are similar to those of the commercial cotton T-shirts. This work provides a strategy for developing comfortable flexible wearable electronic devices.

Constructing lightweight ternary interpenetrating network of carbon fabric/siloxane/phenolic aerogels for long-time high-temperature thermal protection

Lightweight ablative material has served the critical role of protecting space vehicles upon hypersonic entry. However, low oxidation resistance hinders its long-time high-efficiency service in a high-temperature oxidizing atmosphere. Herein, we prepared a lightweight ternary interpenetrating network of three-dimensional carbon fabric, siloxane aerogel, and phenolic aerogel, which are structurally interpenetrating in macro-, micron-to nanoscale and chemically crosslinking at the molecular scale, resulting in a unique combination of low-density (∼0.3 g/cm3), good thermal stability and oxidation resistance, outstanding mechanical properties, and ultralow thermal conductivity. More intriguingly, long-time thermal protection performance (zero surface recession and temperature below 60 °C at 38 mm in-depth after being exposed to 1300 °C for 20 min). The findings of this work provide not only a great potential candidate material for long-time thermal protection in aviation and aerospace applications but also a simple but efficient approach to fabricating multifunctional binary, ternary, and even multiple interpenetrating networks.

Bioengineered cell-constructs using decellularized fish skin-based composite bioink for regenerating muscle tissue

A biocomposite for enhancing muscle tissue regeneration was introduced using decellularized fish skins. Decellularized tilapia and cod skin were explored as constituents of the composite and compared with the conventionally used decellularized extracellular matrix (dECM) derived from porcine skin tissue. As a cell-laden bioink for 3D bioprinting, the choice of tilapia skin dECM, which possesses remarkable printability, allows for precise three-dimensional (3D) structure fabrication. Meanwhile, cod skin dECM was selected as the dispersed phase for enhancing biological activities because of its omega-3 unsaturated fatty acid, which is known to promote angiogenesis and is crucial for nutrient supply during tissue regeneration and lower inflammation. Through meticulous compositional optimization of the fish skin dECMs, efficient printability and high myogenic activity of the fish skin dECM composite were attained. In vitro evaluations using adipose stem cells clearly demonstrated the support of the cell-laden composite bioink for myogenesis, as determined by various cellular activities, including myogenic genes, compared to those of the porcine-based dECM bioink. The regenerative potential of the composites was validated using an in vivo mouse model of volumetric muscle loss. Based on these results, this study provides valuable insights into the use of decellularized fish skin as composite biomaterials and demonstrates their distinct advantages in muscle tissue engineering, in terms of both printability and bioactivity induction.

A novel process study of biomass-based graphene-enriched body based on selective laser sintering technology

Laser-induced graphene (LIG) on natural wood is a novel method for producing porous graphene composite materials with low cost and high efficiency. However, the three-dimensional (3D) fabrication of biomass-derived LIG remains challenging, restricting its applications in various domains. This paper introduces a “SCG” (sintering, carbonization and grapheneization) preparation strategy, which integrates selective laser sintering and multiple laser processes to achieve rapid fabrication of graphene-enriched structures from natural biomass materials with complex shapes. The experiment demonstrates that the sintering necks are preserved during the carbonization and graphitization process, maintaining the original interlocking state of the upper and lower layers. The laser power and irradiation times for producing porous graphene have an optimal range, beyond which the quality of the synthesized graphene deteriorates. This study validates the effectiveness of this method and investigates the optimal process parameters and application directions. This method not only offers a 3D fabrication technique for biomass-derived LIG for the first time, but also enables 3D printing of biomass carbon electrodes, which have the benefits of wide applicability, no need for activators, low cost, and high efficiency.

Influence of clamping methods on the ballistic performance of 3D shallow straight-joint woven fabrics

The interlaminar strength and designability of three-dimensional shallow straight-joint woven fabrics make them a promising material for personal protective armor. This study investigated the influence of clamping methods on the ballistic mechanism of three-dimensional shallow straight-joint woven fabrics. The study used a mesoscopic yarn-level full-size model developed based on the finite element method to analyze the energy absorption patterns, back face deformation, and damage morphology of the three-dimensional shallow straight-joint woven fabrics under different clamping methods. The results show that the clamping method has a significant influence on the ballistic performance of the fabric. With the weft-sides clamped, its ballistic limit velocity and failure morphology are similar to four-sides clamping, with more negligible energy absorption and failure area. Warp-sides clamped is second, while the corner held undergoes the maximum out-of-plane displacement and energy absorption, exhibiting an utterly different failure mechanism. This study shows that the clamping method of a fabric affects its ballistic performance through interaction with the fabric’s internal structure.

Preparation and Performance of Wearable Pressure Sensor Based on Three-Dimensional Flexible Fabric and Its Wireless Transmission System

Preparation and Performance of Wearable Pressure Sensor Based on Three-Dimensional Flexible Fabric and Its Wireless Transmission System

Bionic design of knitted fabrics for ice and snow sports

The extreme environment of winter sports significantly impacts the performance of athletes, leading to a need for clothing that meets composite functional requirements such as warmth, comfort, and protection to improve competition performance. Knitted fabrics for ice and snow sports with excellent heat and moisture performance were inspired by the water collection and transmission system used by the Moloch horridus. A bionic design model of multi-state fabric morphology was developed by using a topological derivation method and three-dimensional parametric surface modeling technology. The experimental results showed that the four single-sided three-dimensional fabrics have better moisture management characteristics and it is possible to achieve an excellent thermal insulation performance. The textile design application models based on this new design method can provide a feasible solution for developing high-performance textiles for winter sports.

Study of Electrical and Mechanical Properties of Polypyrrole-Coated Three-Dimensional Spacer Fabric

In this study, the liquid phase oxidative polymerization method was utilized to prepare polypyrrole conductive three-dimensional spacer fabrics. By controlling pyrrole solution, oxidant FeCl3 solution, dopant p-toluene sulfonic acid concentration and reaction time, the optimal process for the preparation of conductive spacer fabrics was obtained. This led to the best preparation process of polypyrrole-coated three-dimensional spacer conductive fabric (polypyrrole/three-dimensional spacer fabrics) being obtained. The results showed that the conductive properties of polypyrrole/three-dimensional spacer fabrics were the best when 0.10 mol/L pyrrole, 0.40 mol/L oxidant FeCl3 solution, and 0.40 mol/L dopant p-toluene sulfonic acid were prepared within a 2-h reaction time. The properties of polypyrrole/three-dimensional spacer fabrics were analyzed using the results from surface resistance, Fourier transform-infrared spectroscopy, mechanical properties, and stability tests. The results showed that polypyrrole was well attached to the three-dimensional spacer fabric surface, and the concentration of polypyrrole in the fabric exhibited an inverse correlation with changes in surface resistance. The mechanical properties of polypyrrole/three-dimensional spacer fabrics after treatment exhibit superior performance, with consistent changes in the meridional and zonal electrical properties during tensile testing and can maintain excellent long-term electrical stability in atmospheric environments.

Low-Velocity Impact and Post-Impact Residual Flexural Properties of Kevlar/EP Three-Dimensional Angle-Interlock Composites.

In this study, five three-dimensional angle-interlock fabrics with different warp and weft densities were fabricated using 1000D Kevlar filaments. The Kevlar/EP composites were prepared by vacuum-assisted molding techniques. The low-velocity impact property of the composite was tested, focusing on the effects of the warp and weft densities, impact energy, impactor shape, and impactor diameter. The damage area, dent depth, and crack lengths in the warp and weft direction were used to evaluate the impact performance, and the specimens were compared with plain-weave composites with similar areal densities. The dominant failure mode of the conical impactor was fiber fracture, while the dominant failure mode of the hemispherical impactor was fiber-resin debonding. The cylindrical impactor showed only minor resin fragmentation. The residual flexural strength of the composite after impact was tested to provide insights into its mechanical properties. The study findings will provide a theoretical basis for the optimization of the design of impact-resistant structures using such materials and facilitate their engineering applications.

Transforming Object Design and Creation: Biomaterials and Contemporary Manufacturing Leading the Way.

In the field of three-dimensional object design and fabrication, this paper explores the transformative potential at the intersection of biomaterials, biopolymers, and additive manufacturing. Drawing inspiration from the intricate designs found in the natural world, this study contributes to the evolving landscape of manufacturing and design paradigms. Biomimicry, rooted in emulating nature's sophisticated solutions, serves as the foundational framework for developing materials endowed with remarkable characteristics, including adaptability, responsiveness, and self-transformation. These advanced engineered biomimetic materials, featuring attributes such as shape memory and self-healing properties, undergo rigorous synthesis and characterization procedures, with the overarching goal of seamless integration into the field of additive manufacturing. The resulting synergy between advanced manufacturing techniques and nature-inspired materials promises to revolutionize the production of objects capable of dynamic responses to environmental stimuli. Extending beyond the confines of laboratory experimentation, these self-transforming objects hold significant potential across diverse industries, showcasing innovative applications with profound implications for object design and fabrication. Through the reduction of waste generation, minimization of energy consumption, and the reduction of environmental footprint, the integration of biomaterials, biopolymers, and additive manufacturing signifies a pivotal step towards fostering ecologically conscious design and manufacturing practices. Within this context, inanimate three-dimensional objects will possess the ability to transcend their static nature and emerge as dynamic entities capable of evolution, self-repair, and adaptive responses in harmony with their surroundings. The confluence of biomimicry and additive manufacturing techniques establishes a seminal precedent for a profound reconfiguration of contemporary approaches to design, manufacturing, and ecological stewardship, thereby decisively shaping a more resilient and innovative global milieu.

Photocrosslinkable silk-based bioinks embedded with growth factor loaded microspheres towards cell-free 3D printing approach for biomimetic regeneration of meniscal tissue

Fibrocartilaginous meniscal tear regeneration is a major challenge due to the large avascular regions which suffer several injuries among all age-groups. Mostly, meniscus implants are focused on the development of multi-layered meniscus constructs and scaffolds that mimic the macro-architecture, functionality and mechanical strength. The native human menisci consist of vascular and avascular regions that contain different cellular phenotypes and are hence composed of a gradient of extracellular matrix (ECM) components. The biochemical composition of the inner, middle and outer regions of the knee menisci plays a significant role in the mechanical behavior and its overall functionality. We have developed a photo-polymerizing mulberry and non-mulberry silk-based biomaterial ink which is laden with growth factor loaded gelMA microspheres for the zone-specific regeneration of full thickness meniscus tears using three-dimensional (3D) fabrication. We have fabricated growth factor loaded gelMA microspheres and encapsulated them within the biomaterial ink for controlled release of Connective Tissue Growth Factor (CTGF) and Transforming Growth Factor-beta3 (TGF-β3) from the different zones of the meniscus constructs. The growth factor releasing constructs demonstrate the requisite mechanical resilience, degradability and release behaviour for regeneration of meniscal tissue. The developed growth factor loaded constructs demonstrate zone specific phenotypic differentiation of adipose derived stem cells and extracellular matrix deposition by the differentiated stem cells in vitro. The microsphere loaded constructs were found to be immuno-compatible as well. Therefore, these bioactive microsphere-laden 3D printed meniscus constructs would potentially promote regeneration and integration of meniscal tissue in vivo.

A Systematic Integration Study of Traditional Hand-Weaving Techniques in Lingnan Region in the Context of Deep Learning

Abstract In this paper, firstly, on the basis of the traditional hand weaving technique in Lingnan area, modern digital technology is used to integrate it systematically, so as to construct the three-dimensional weaving technique. Secondly, the structural properties of the three-dimensional woven fabrics are investigated through the two-step and four-step weaving methods in terms of the movement trajectories of the three-dimensional woven fabrics within the cross-section. Finally, the basic properties of bamboo weaving materials were analyzed in order to facilitate the force simulation analysis of the obtained morphological model samples of parametric Lingnan region bamboo weaving craft products using the structural simulation analysis software SIM-SOLID. The results show that in the structural force study of bamboo weaving craft products, the equivalent viscous damping coefficient is calculated by taking the first hysteresis loop of each stage of the loading cycle, and its maximum deformation is 0.428 mm, which is 0.003 mm smaller than that of the model with unfixed joints, which indicates that the performance of the Lingnan region weaving technique is optimized obviously by adopting the three-dimensional weaving technique. This paper provides theoretical references for the digital integration of traditional hand-woven techniques and the enhancement of structural properties of woven materials in the Lingnan region.