X-ray Computed Tomography Research Articles

Influence of geometric imperfections on the mechanical behavior for Invar 36 alloy lattice structures fabricated by selective laser melting

The studies on the mechanical behavior of Invar 36 alloy lattice structures prepared by additive manufacturing process are limited. In this paper, the influence of geometric imperfections generated during the additive manufacturing process on the mechanical behavior of Invar 36 alloy lattice structures was investigated. To realize lightweight and high load-bearing capacity, lattice structures with different fillet radii were designed and subsequently fabricated by selective laser melting (SLM) process. Compression tests based on in-situ X-ray computed tomography (X-CT) were conducted to evaluate the manufacturing quality and corresponding mechanical behavior. Differences between design models and fabricated lattices were quantitatively compared. Various geometric imperfections, including strut waviness, varying cross-sections, visible surface defects, visible defects at strut intersections, and roughness on struts, were observed. Additionally, deformation patterns at different loading stages were also obtained, primarily manifesting as the yielding of the nodes and the buckling of the struts. Importantly, struts with varying cross-sections possess the most significant influence on the deformation behavior.

High-temperature stability of ambient-cured one-part alkali-activated materials incorporating graphene nanoplatelets for thermal energy storage

This study aims to develop an ambient-cured nano-engineered one-part alkali-activated materials with excellent thermal characteristics using graphene nanoplatelets (GNPs) and ternary precursors. Their compressive strength, thermal properties, microstructure, pore structure were characterised through visual observation, isothermal calorimetry, TGA, XRD, SEM/EDS and X-ray μCT after high temperature exposure to 200–800 °C. The research findings indicated high strength characteristics of the developed AAM (∼80 MPa) at ambient condition, which could further reach to approx. 100 MPa after being heated up to 400 °C. GNPs provided nucleation effects for promoting geopolymerisation and crystallisation. As observed from X-ray CT, a high extent of severe cracks initiated from the core and propagated towards the surface. From SEM/EDS analysis, high Na/Al and Na/Si ratios or low Si/Al and Ca/Si ratios highly correlated to thermal stability. Overall, the research outcomes implied the promising use of the nano-engineered AAMs for thermal energy storage (TES) at 400 °C.

Investigation on the influence of gradation design on the road performance of cold mixed epoxy asphalt mixture based on microstructure evaluation

Cold mixed epoxy asphalt mixture (CMEAM) has excellent anti-deformation and fatigue performance which shows remarkable superiority on bridge pavements. Previous studies have done comprehensive researches on its properties through macroscopic experiments. However, few studies revealed the impact of gradation design on the road property of CMEAM through microscopic method. Thus, in this paper, X-Ray computed tomography (X-ray CT), nanoindentation (NI), field emission scanning electron microscopy (FESEM) and mercury intrusion porosimetry (MIP) are introduced to investigate the coarse aggregates contact degree, the thickness and elastic modulus of interfacial transition zone (ITZ) and the pore diameter distribution of CMEAM. Results showed that the contact points of coarse aggregates in EA-05 mixture are around 40 while those in EA-10 mixture are around 20. (40°, 50°) is the key inclination angle interval for EA-10 mixture type while (70°, 80°) and (10°, 20°) are of significance for EA-05 mixture type. The contact points and inclination angles are positively and inversely proportional to Marshall stability, respectively. In addition, the ITZ thickness of EA-05 and EA-10 mixture is below 10 μm and above 40 μm, respectively. The ITZ elastic modulus of EA-10 mixture is approximately 1.5 times than that of EA-05. The thickness and elastic modulus of ITZ are inversely proportional to low-temperature indirect tensile strain (εT). Meanwhile, EA-05 mixture has higher proportion in gel micropores and middle capillary pores while EA-10 mixture has higher proportion in mesopores and large capillary pores. Mesopores has the highest correlation coefficients with tensile strength ratio (TSR), followed by large capillary pores. The suggested proportion for above two type pores is around 21.5% and 51.0%, respectively.

The current practice in the diagnostic work-up of patients with hemoptysis of unknown etiology: an international survey.

Hemoptysis is a challenging and potentially life-threatening medical condition. The most appropriate diagnostic work-up is debated and several diagnostic approaches are implemented worldwide. An international, online survey was carried out to investigate the current practice of the diagnostic work-up of patients with hemoptysis of unknown etiology. Overall, 604 physicians responded to the survey. At baseline, chest X-ray was suggested as the first diagnostic investigation by 342 (56.6%) participants. Computed tomography (CT) was suggested in each patient with non- and life-threatening hemoptysis by 310 (51.3%) and 526 (87.1%) respondents, respectively. Contrast-enhanced CT is the currently preferred technique (333, 55.1%). In case of patchy ground glass opacities and negative CT, 287 (47.5%) and 222 (36.8%) participants, respectively, would always offer bronchoscopy. Otorhinolaryngological evaluation was mostly suggested in case of suspected upper airways bleeding before other investigations (212, 35.1%). A follow-up was recommended for idiopathic hemoptysis by the majority of the participants (316, 52.3%). A multidisciplinary assessment is deemed crucial for each patient with life-threatening hemoptysis (437, 72.4%). Chest X-ray and contrast-enhanced CT are currently preferred as the first diagnostic investigations, regardless of hemoptysis severity. Bronchoscopy is suggested in case of negative radiological examination and when CT shows only ground glass opacities. Otorhinolaryngological evaluation is advised before any other investigations when upper airways bleeding is suspected. Patients with idiopathic hemoptysis are suggested to undergo a clinical follow-up and in case of life-threatening bleeding a multidisciplinary assessment is deemed crucial. Due to the heterogeneous approaches a consensus statement would be needed.

491 Clinical and Radiographic Features of Mesenteric Ischemia after Intra-Aortic Balloon Pump Placement

OBJECTIVES/GOALS: Intra-aortic balloon pumps are commonly used as circulatory support in patients with critically reduced cardiac function. The goal of this study is to estimate the incidence of mesenteric ischemia as an understudied vascular complication and to describe the clinical and radiographic characteristics of patients experiencing this complication. METHODS/STUDY POPULATION: We will be conducting a retrospective analysis of the electronic medical records of all patients who underwent intra-aortic balloon pump (IABP) placement between October 2020 and April 2023 at our academic medical center to identify the incidence of mesenteric ischemia. We will describe the clinical course of these patients and characterize them based on demographic features and risk factors for vascular complications including medical comorbidities. Finally, we will assess available chest x-ray and thoracoabdominal CT imaging for adequacy of balloon tip positioning, concordance between balloon size and aortic dimensions, and compromise of any visceral arteries in patients who experienced mesenteric ischemia vs. those who did not. RESULTS/ANTICIPATED RESULTS: We anticipate approximately 150 patients to have recieved IABPs over this period with at least 4 known cases of mesenteric ischemia. We will describe the clinical presentation of these cases and their often fatal outcomes. We expect several known risk factors will be present in these patients, including history of peripheral vascular disease, diabetes, or smoking history. On chest x-ray, we predict balloon tip positioning to be suboptimal (defined as >5cm below the aortic arch) in many patients, both those with mesenteric ischemia and those without, but a greater discordance on CT imaging between balloon size and aortic dimensions with greater evidence of visceral compromise in patients with mesenteric ischemia compared to those without. DISCUSSION/SIGNIFICANCE: Mesenteric ischemia is a serious and poorly studied complication of intra-aortic balloon pumps. Understanding the hospital course, clinical characteristics, and radiographic features present in these patients may guide clinicians in the early recognition and management of this potentially fatal complication.

Application of ultrasonography in diagnosis and treatment of children with congenital muscular torticollis.

Congenital muscular torticollis (CMT) is a more common childcare disease, which belongs to muscle-skeletal system diseases, and is more common in newborns. The disease is mainly due to congenital contracture due to chest locks, which leads to asymmetric head and neck. For such diseases, clear diagnosis and treatment in the early days is an important way to improve the prognosis of children. Compared with X-ray film, CT, and MRI, ultrasound examination has the advantages of low examination cost, short time, and no exposure to radiation during the examination. Moreover, ultrasound examination can provide an objective basis for the clinical diagnosis and prognosis evaluation of CMT children. This article reviews the latest research progress of conventional ultrasound, color Doppler ultrasound, and ultrasound elastography in the clinical diagnosis of CMT children and assisting in the formulation of treatment plans.

Modeling of 3D-printed composite filaments using X-ray computer tomography images segmented by neural networks

This study introduces a novel semi-analytical two-scale approach to model 3D-printed composite filament where both fibers and voids are present. The proposed approach utilizes micro computer tomography (micro-CT) images to visualize fibers and voids. Then, a novel segmentation process based on neural network algorithms (specifically the YOLO v7 algorithm) is employed to segment the distinct fiber and void phases. The volume fractions and the geometries of the phases are then used in the first scale (the micro-scale) of the approach and the effective elastic properties of internal regions of the filament are obtained using the Mori–Tanaka effective field method. These regions are then joined together to form the second scale (the macro-scale), for which the elastic properties are evaluated using the finite element method. The two-scale approach is applied for 3D-printed nylon reinforced with continuous carbon fibers and the predictions of the elastic properties are compared to tensile tests conducted on the single filament. A great agreement is observed for Young’s modulus along the fiber direction of the single printed filament.

Correction to: The Origin and Differentiation of CO2-Rich Primary Melts in Ocean Island Volcanoes: Integrating 3D X-Ray Tomography with Chemical Microanalysis of Olivine-Hosted Melt Inclusions from Pico (Azores)

Correction to: The Origin and Differentiation of CO2-Rich Primary Melts in Ocean Island Volcanoes: Integrating 3D X-Ray Tomography with Chemical Microanalysis of Olivine-Hosted Melt Inclusions from Pico (Azores)

Terahertz recognition of composite material interfaces based on ResNet-BiLSTM

This manuscript presents a framework that integrates a residual network (ResNet) with a bidirectional long short-term memory network (BiLSTM) for effective feature extraction and interface positioning in terahertz signal analysis. This innovative approach employs spatial and temporal feature extraction modules to process terahertz signals, enabling the automatic detection of interfaces and defects in both coating and bonded structure samples. The experimental results indicate that the interface positioning accuracy of the method aligns with the manual analysis outcomes for coating samples exceeding 80 µm in thickness. Furthermore, it exhibits a high degree of consistency with X-ray CT detection results when detecting defects in the adhesive layer, with an error margin ranging from 1.07 % to 5.39 %. Significantly, we have also conducted preliminary analyses on actual samples, further underscoring the robustness and generalizability of our model. This method offers an efficient automated tool for terahertz signal analysis and holds promise for industrial detection applications. Future research will aim to broaden the range of samples and application scenarios, thereby increasing the technology’s practicality in quality control and production line detection.

Lithium-Ion Batteries under the X-ray Lens: Resolving Challenges and Propelling Advancements

The quest for high-performance lithium-ion batteries (LIBs) is at the forefront of energy storage research, necessitating a profound understanding of intricate processes like phase transformations and thermal runaway events. This review paper explores the pivotal role of X-ray spectroscopies in unraveling the mysteries embedded within LIBs, focusing on the utilization of advanced techniques for comprehensive insights. This explores recent advancements in in situ characterization tools, prominently featuring X-ray diffraction (XRD), X-ray tomography (XRT), and transmission X-ray microscopy (TXM). Each technique contributes to a comprehensive understanding of structure, morphology, chemistry, and kinetics in LIBs, offering a selective analysis that optimizes battery electrodes and enhances overall performance. The investigation commences by highlighting the indispensability of tracking phase transformations. Existing challenges in traditional methods, like X-ray absorption spectroscopy (XAS), become evident when faced with nanoscale inhomogeneities during the delithiation process. Recognizing this limitation, the review emphasizes the significance of advanced techniques featuring nanoscale resolution. These tools offer unprecedented insights into material structures and surface chemistry during LIB operation, empowering researchers to address the challenges posed by thermal runaway. Such insights prove critical in unraveling interfacial transport mechanisms and phase transformations, providing a roadmap for the development of safe and high-performance energy storage systems. The integration of X-ray spectroscopies not only enhances our understanding of fundamental processes within LIBs but also propels the development of safer, more efficient, and reliable energy storage solutions. In spite of those benefits, X-ray spectroscopies have some limitations in regard to studying LIBs, as referred to in this review.

Photothermal effect in X-ray images for computed tomography of metallic parts: Stainless steel spheres.

The environmental impact on industrial X-ray tomography systems has gained its attention in terms of image precision and metrology over recent years, yet is still complex due to the variety of applications. The current study explores the photothermal repercussions of the overall radiation exposure time. It shows the emerging dimensional uncertainty when measuring a stainless steel sphere by means of circular tomography scans. The authors develop a novel frame difference method for X-ray radiographies to evaluate the spatial changes induced in the projected absorption maps on the X-ray panel. The object of interest has a simple geometry for the purpose of proof of concept. The dominant source of the observed radial uncertainty is the photothermal effect due to high-energy X-ray scattering at the metal workpiece. Thermal variations are monitored by an infrared camera within the industrial tomography system, which confines that heat in the industrial grade X-ray system. The authors demonstrate that dense industrial computed tomography programs with major X-ray power notably affect the uncertainty of digital dimensional measurements. The registered temperature variations are consistent with dimensional changes in radiographies and hence form a source of error that might result in visible artifacts within the 3D image reconstruction. This contribution is of fundamental value to reach the balance between the number of projections and radial uncertainty tolerance when performing analysis with X-ray dimensional exploration in precision measurements with industrial tomography.

Time-lapse 3D Micro-tomography of Calcite Column Experiments to Study pH-Dependent Dynamic Dissolution Processes

We investigated the spatiotemporal evolution of calcite dissolution processes using time-lapse high-resolution X-ray CT imaging of live column experiments and real-time data logging of effluent pH and TDS. We evaluated the sensitivity of three pH solutions (7, 5, and 4) to dissolution processes. The results showed spatial variations in dissolution associated with spatial variation in porosity and pore sizes, manifesting as spatial heterogeneity in the dissolution pattern. Dissolution was dominant in larger pores compared to smaller ones. The magnitude of this uneven spatial dissolution exceeded the overall dissolution. However, the total porosity increased linearly over the time of dissolution experiments, with the slope dependent on the pH of the injected solution. Surface area decreased linearly during dissolution, and the decrease in surface area was also found to depend linearly on the increase in total porosity. The temporal evolution of pH-dependent reaction rates demonstrated a decreasing trend that followed a power-law behavior. The time to reach the steady reaction rate, which was evaluated from changes in calcite volume, appeared to be significantly later than the time at which the tracer reached its asymptote. The reaction rate at these two distinct times could differ by an order of magnitude. We emphasize the use of the steady state in mineral volume changes method to determine representative reaction rates in porous media, the significance of which emerges due to the coupling of hydrodynamic and reactive transport processes originating at the pore scale.

TinyMSI: A cost-effective handheld device for non-contact diabetic wound monitoring

Devices characterizing diabetic foot ulcers and other wounds currently fall into two categories. Expensive clinically-oriented devices that use mature technologies such as X-ray CT and hyperspectral imaging or low-cost solutions that leverage deep learning to infer wound characterization from conventional smartphone camera images or simple surrogate markers. Mature medical-grade devices are too expensive for primary care and assisted living facilities. Low-cost solutions rely too much on indirect statistical inference to be clinically suitable. Therefore, we propose a device that leverages mature, clinically suitable optical technologies to provide a solution for these facilities. Recognizing that individual combinations of 1–2 bands of active illumination are used individually to capture pulsation, vascular, and oxygenation images. We combine all these bands into a single multispectral lighting source to create a multi-functional, reliable device for wound assessment. We selected these bands to leverage CMOS cameras near orthogonality between the RGB channels and leverage that CMOS cameras can also sense near IR light if a filter is not present, reducing overall system complexity and needed bands. For each function, the necessary lights are turned on, and the captured raw video is then fed to the corresponding sequence of image processing steps. No deep learning models are used, so large training datasets are not required. Our device is also small, lightweight, and handheld.

Enhancing the sensitivity of 3D printed sensors via ironing and void reduction

ABSTRACT Material Extrusion (MEX) Additive Manufacturing (AM) has risen as a promising technology to monolithically manufacture smart structures with embedded sensors. Despite all the benefits of MEX AM, 3D printed piezoresistive sensors still suffer from low sensitivity, making them unsuitable for the detection of low values of force, displacement and bending angle. In the present paper, a simple, effective, and inexpensive method to increase the sensitivity in 3D printed sensors is proposed, based on the leveraging of the ironing strategy, which resulted in an improvement in the sensitivity of 83% compared to traditional process parameter selection. The ironing strategy reduced intralayer porosity by 59%, as verified by X-Ray CT. Additionally, the ironing strategy involves an increased healing time, which promotes the polymer chain diffusion between layers, which translated into a greater stability of the sensor when cyclically stressed. Smart structures capable of detecting small forces (0.19 N of resolution against 1.96 N for traditional MEX scenario) and smart auxetic devices have been manufactured, demonstrating the potential of the proposed approach. The present research demonstrates the ability to reduce interlayer voids by using an intrinsic feature of the MEX process and consequently improve electrical performance of 3D printed sensors.

Quantitative analysis and comprehensive evaluation of coarse aggregate morphology for asphalt pavement

The morphological characteristics of coarse aggregate play a crucial role in the mechanical properties, durability, and construction performance of asphalt mixtures and pavements in highway engineering. This study aims to quantitatively analyze the morphological characteristics of coarse aggregate and establish comprehensive evaluation indicators for its quality and performance. Two-dimensional cross-sectional images of coarse aggregates are obtained using the self-developed laser scanning equipment, and edge features are extracted using the Canny operator and edge tracing algorithm. Six morphological characteristic indicators are selected, and factor analysis is employed to propose comprehensive shape and edge feature for coarse aggregates. The results show that the proposed evaluation indicators effectively capture the shape and edge feature of coarse aggregates, with the exception of roughness, which is deemed unsuitable for evaluation. Factor analysis of six indicator values in 2,700 two-dimensional images led to the proposal of Shape Factor (SF) and Edge Feature Factor (EFF) as significant factors affecting aggregate shape and edge characteristics, respectively. Following optimization, SF ranged from 0.041 to 1.793, while EFF ranged from 0.368 to 1.745. The spearman’s rank correlation coefficient revealed strong correlations between the evaluation of coarse aggregate shape and edge features using the line laser-based comprehensive evaluation index. Specifically, correlation coefficients of 0.864 and 0.805 exceeded those of commonly used methods such as AIMS and X-ray CT, indicating the rationality and accuracy of the self-developed laser scanning device in evaluating aggregate morphology. This research provides strong support for the construction of highway engineering and optimization of coarse aggregate production and supply.

SLAP Trial: Shock Wave Lithotripsy and Mechanical Percussion Therapy Post ESWL for Renal Calculi.

We conducted a prospective randomised control trial. Included patients were males and females greater than 18 years of age with single or multiple ipsilateral renal calculi of total ≤10 mm on plain X-ray and noncontrast CT KUB. ESWL was performed at a single centre, at supine position under general anaesthesia with maximum 3000 shocks at a rate of 100 shocks per minute. Patients were discharged and randomised to either the control arm or MPI therapy. MPI therapy was self-directed in a home setting for 10 minutes a day, three times per week. Both arms had standard follow-up at 12 weeks with a plain X-ray KUB. Patients in the control group were offered cross over to the MPI arm after 12 weeks if residual stone fragments were detected. Statistical analysis was performed using SPSS software via Chi squared and Fisher's exact tests. Ethical approval was obtained via the Prince Charles Hospital HREC Committee, HREC/2022/QPCH/84961. 70 patients met inclusion criteria and underwent ESWL, and 5 were withdrawn. 33 patients were randomised to the MPI group and 32 to the control group. MPI significantly increased the stone clearance rate anywhere in the kidney (87.9% in the MPI group versus 59.4% in the control group, p=0.089), as well as the clearance rate in the lower pole (91.7% in the MPI group versus 63.2% in the control group, p=0.022). Delayed percussion did not improve the clearance rate over primary percussion (p=0.835). This study has shown that MPI can be effectively performed in a home setting without the need for medical supervision and results in improved stone clearance rates post ESWL. The main limitations to the study were the use of X-ray over CT during the follow-up and variability in MPI compliance and administration. Further research is warranted into standardising home MPI protocols. This trial is registered with ANZCTR387061.

Potential of Cytokines in the Management of Intervertebral Disc Degeneration

The illness known as intervertebral disc degeneration (IDD) is characterized by discomfort in the intervertebral discs. The IDD is made up of the annulus fibrosus (AF) and nucleus pulposus (NP), which function as a joint and cushion for the spine. IDD can develop with ageing, which can cause the NP to herniate and cause pain. IDD patients experience detrimental effects on their quality of life and mental health in addition to their physical health. It also poses a critical economic burden on society as a whole. Imaging techniques used for the diagnosis are disc herniation, X-ray plain film, CT, and MRI are discussed as imaging modalities, with MRI being particularly useful for diagnosing disc herniation. Treatment approaches range from conservative methods to surgical intervention, related to the type of IDD. Nonsteroidal anti-inflammatory medications, rest, traction therapy, and physical therapy are examples of non-surgical therapies. Options for surgery include conventional open surgery, microsurgical lumbar discectomy, minimally invasive IVD removal surgery, and artificial IVD replacement surgery. Many studies are focused on the role of cytokines to explain the cause of IDD. And these cytokines can be classified as cell cycle inhibitor, proinflammatory factor and growth factor. The article highlights cell cycle inhibitors (p16INK4a and p53), proinflammatory factors (IL-1β and TNF-α), and growth factor (TGF-β) involvement in IDD. However, currently, there are no cytokine-based treatments available for IDD in clinical practice. Future research could focus on developing new treatment or prevention targets for IL-1β or TNF-α.

Frictional heat-assisted performance enhancement in dynamic Schottky contact of Al/Ag2Se-based tribovoltaic nanogenerator

The tribovoltaic nanogenerator (TVNG) has evolved in recent years as a novel type of nanogenerator designed to address the limitations of the standard triboelectric nanogenerator in terms of output signal and charge generation. Besides the outstanding characteristics, the tribovoltaic effect can also well be coupled with another effect to further boost the output performance. In this work, we proposed firstly a frictional heat-assisted performance enhancement in dynamic Schottky contact from the rubbing between n-type silver selenide (Ag2Se) and aluminum. The chemical composition and physical characteristics of the Ag2Se ceramic were analyzed using X-ray diffraction, scanning electron microscopy, and Synchrotron X-ray tomography techniques. UV–Vis spectroscopy and UPS were also utilized in order to validate the semiconducting property of the n-type Ag2Se ceramic. Moreover, the presence of the Schottky junction was demonstrated through the analysis of the current-bias voltage characteristic curve of the Ag2Se/aluminum (Al) contact under varying stress and temperature conditions. The built-in electric field plays a crucial part in the tribovoltaic effect by efficiently transferring the excited carriers to an external load through sliding contact between Ag2Se and Al. Demonstrating the synergy between tribovoltaic and thermoelectric effects becomes achievable through the excellent thermoelectric property of Ag2Se. Herein, the proposed TVNG generated a peak output voltage and current of around 0.7 V and 24.8 nA, respectively, achieving a maximum output power of 12.6 nW at a load resistance of 10 kΩ. The influence of frictional heat on the output performance of the proposed TVNG was well demonstrated by the thermal-induced voltage and enhanced electrical output from continuous sliding. The concepts given in this study establish the basis for the progress of effective energy collection employing semiconducting materials and the advancement of flexible harvesting and sensing device development in the future.

Pore structure characterization and effective thermal conductivity modeling of fibrous building thermal insulation materials based on X-ray tomography

The existing structural characterization methods of building materials as well as thermal conductivity calculation models can not be directly applied when considering fibrous building thermal insulation materials with intricate skeletons. In this study, rock wool is considered the research object, and the X-ray tomography method is used to characterize the pore structure and extract structural parameters. Based on the actual pore morphology of the material, the pores in the representative elementary volume (REV) are reasonably assumed to be cubic. Additionally, considering the contact thermal resistance of fibers and the randomness of pore distribution, the curved pattern of heat conduction pathway with the ever-changing diameter is reasonably simplified into a series-parallel form of the curved heat chain with the same diameter. On this basis, the fractal models of effective thermal conductivity are established in horizontal and vertical directions. Finally, a modified formula for the effective thermal conductivity calculation of fiber thermal insulation materials is proposed, taking into account the influence of fiber orientation on the material thermal conductivity. It was shown that the relative deviation between the calculated correction value and the experimental value of the effective thermal conductivity is all less than 16.13%.

General Semi-Solid Freeze Casting for Uniform Large-Scale Isotropic Porous Scaffolds: An Application for Extensive Oral Mucosal Reconstruction.

Ice-templated porous biomaterials possess transformative potential in regenerative medicine; yet, scaling up ice-templating processes for broader applications-owing to inconsistent pore formation-remains challenging. This study reports an innovative semi-solid freeze-casting technique that draws inspiration from semi-solid metal processing (SSMP) combined with ice cream-production routines. This versatile approach allows for the large-scale assembly of various materials, from polymers to inorganic particles, into isotropic 3D scaffolds featuring uniformly equiaxed pores throughout the centimeter scale. Through (cryo-)electron microscopy, X-ray tomography, and finite element modeling, the structural evolution of ice grains/pores is elucidated, demonstrating how the method increases the initial ice nucleus density by pre-fabricating a semi-frozen slurry, which facilitates a transition from columnar to equiaxed grain structures. For a practical demonstration, as-prepared scaffolds are integrated into a bilayer tissue patch using biodegradable waterborne polyurethane (WPU) for large-scale oral mucosal reconstruction in minipigs. Systematic analyses, including histology and RNA sequencing, prove that the patch modulates the healing process toward near-scarless mucosal remodeling via innate and adaptive immunomodulation and activation of pro-healing genes converging on matrix synthesis and epithelialization. This study not only advances the field of ice-templating fabrication but sets a promising precedent for scaffold-based large-scaletissue regeneration.