Search

This study investigates the design of additive manufacturing for controlled crack propagation using process parameters and lattice structures. We examine two lattice types-octet-truss (OT) and diamond (DM)-fabricated via powder bed fusion with Ti-6Al-4V. Lattice structures are designed with varying densities (10%, 30%, and 50%) and process using two different laser energies. Using additive-manufactured specimens, Charpy impact tests are conducted to evaluate the fracture behavior and impact energy levels of the specimens. Results show that the type of the lattice structures, the density of the lattice structures, and laser energy significantly influence crack propagation patterns and impact energy. OT exhibits straighter crack paths, while DM demonstrates more random fracture patterns. Higher-density lattices and increased laser energy generally improve the impact energy. DM consistently outperformed OT in the impact energy for angle specimens, while OT showed superior performance in stair specimens. Finally, a case study demonstrates the potential for combining OT and DM structures to guide crack propagation along predetermined paths, offering a novel approach to protect critical components during product failure.

In this study, we present the energy absorption capabilities achieved through the application of hybrid lattice structures, emphasizing their potential across various industrial sectors. Utilizing Ti-6Al-4V and powder bed fusion (PBF) techniques, we fabricated distinct octet truss, diamond, and diagonal lattice structures, tailoring each to specific densities such as 10, 30, and 50%. Furthermore, through the innovative layering of diverse lattice types, we introduced hybrid lattice structures that effectively overcome the inherent energy absorption limitations of single-lattice structures. As a result, we conducted a comprehensive comparison between single-lattice structures and hybrid lattice structures of equal density, unequivocally showcasing the latter's superior energy absorption performance in terms of compression. The single-lattice structure, OT, showed an energy absorption of 42.6 J/m 3 , while the reinforced hybrid lattice structure, OT-DM, represented an energy absorption of 77.8 J/m 3 . These findings demonstrate the significant potential of hybrid lattice structures, particularly in energy-intensive domains such as shock absorption structures. By adeptly integrating various lattice architectures and leveraging their collective energy dissipation properties, hybrid lattice structures offer a promising avenue for addressing energy absorption challenges across diverse industrial applications.

The development of advanced biomaterials and manufacturing processes to fabricate biologically and mechanically appropriate scaffolds for bone tissue is a significant challenge. Polycaprolactone (PCL) is a biocompatible and degradable polymer used in bone tissue engineering, but it lacks biofunctionalization. Bioceramics, such as hydroxyapatite (HA) and β tricalcium phosphate (β-TCP), which are similar chemically to native bone, can facilitate both osteointegration and osteoinduction whilst improving the biomechanics of a scaffold. Carbon nanotubes (CNTs) display exceptional electrical conductivity and mechanical properties. A major limitation is the understanding of how PCL-based scaffolds containing HA, TCP, and CNTs behave in vivo in a bone regeneration model. The objective of this study was to evaluate the use of three-dimensional (3D) printed PCL-based composite scaffolds containing CNTs, HA, and β-TCP during the initial osteogenic and inflammatory response phase in a critical bone defect rat model. Gene expression related to early osteogenesis, the inflammatory phase, and tissue formation was evaluated using quantitative real-time PCR (RT-qPCR). Tissue formation and mineralization were assessed by histomorphometry. The CNT+HA/TCP group presented higher expression of osteogenic genes after seven days. The CNT+HA and CNT+TCP groups stimulated higher gene expression for tissue formation and mineralization, and pro- and anti-inflammatory genes after 14 and 30 days. Moreover, the CNT+TCP and CNT+HA/TCP groups showed higher gene expressions related to M1 macrophages. The association of CNTs with ceramics at 10wt% (CNT+HA/TCP) showed lower expressions of inflammatory genes and higher osteogenic, presenting a positive impact and balanced cell signaling for early bone formation. The association of CNTs with both ceramics promoted a minor inflammatory response and faster bone tissue formation.

Decarburization is an unwanted carbon-loss phenomenon on the surfaces of a material when they are exposed to oxidizing environments at elevated temperatures. Decarburization of steels after heat treatment has been widely studied and reported. However, up to now, there has not been any systematic study on the decarburization of additively manufactured parts. Wire-arc additive manufacturing (WAAM) is an efficient additive manufacturing process for producing large engineering parts. As the parts produced by WAAM are usually large in size, the use of a vacuum environment to prevent decarburization is not always feasible. Therefore, there is a need to study the decarburization of WAAM-produced parts, especially after the heat treatment processes. This study investigated the decarburization of a WAAM-produced ER70S-6 steel using both the as-printed material and samples heat-treated at different temperatures (800 °C, 850 °C, 900 °C, and 950 °C) for different durations (30 min, 60 min, and 90 min). Furthermore, numerical simulation was carried out using Thermo-Calc computational software to predict the carbon concentration profiles of the steel during the heat treatment processes. Decarburization was found to occur not only in the heat-treated samples but also on the surfaces of the as-printed parts (despite the use of Ar for shielding). The decarburization depth was found to increase with an increase in heat treatment temperature or duration. The part heat-treated at the lowest temperature of 800 °C for merely 30 min was observed to have a large decarburization depth of about 200 μm. For the same heating duration of 30 min, an increase in temperature of 150 °C to 950 °C increased the decarburization depth drastically by 150% to 500 μm. This study serves well to demonstrate the need for further study to control or minimize decarburization for the purpose of ensuring the quality and reliability of additively manufactured engineering components.

Concrete 3D printing is a sustainable solution for manufacturing efficient designs and creating less waste, and selecting the optimal materials to use can amplify the advantages of this technology. In this study, we explore printing lightweight concrete by replacing normal weight aggregate with lightweight aggregates such as cenospheres, perlite, and foam beads. We adopt a systematic approach to investigate mixtures using different formulation methods such as the specific gravity and packing factor methods to improve the printing and mechanical performances of the mixtures. The rheological results showed significant improvement in the flow characteristics of the different mixtures using both the specific gravity method and the packing factor method to formulate the mixtures. Furthermore, a statistical tool was used to achieve optimal performance of the mixtures in terms of high specific compressive strength, high flow characteristics, and good shape retention capability by maximizing the specific compressive strength ratio, slump flow, and the static yield stress, while minimizing the slump, dynamic yield stress, and plastic viscosity. With the above design objectives, the optimal percentages of the aggregate replacements (cenosphere, perlite, and EPS foam beads) were 42%, 68%, and 44%, respectively. Finally, the optimized results also showed that the mixture with cenosphere aggregate replacement had the highest specific strength.

The first years of an infant's life represent a sensitive period for neurodevelopment where one can see the emergence of nascent forms of executive function (EF), which are required to support complex cognition. Few tests exist for measuring EF during infancy, and the available tests require painstaking manual coding of infant behaviour. In modern clinical and research practice, human coders collect data on EF performance by manually labelling video recordings of infant behaviour during toy or social interaction. Besides being extremely time-consuming, video annotation is known to be rater-dependent and subjective. To address these issues, starting from existing cognitive flexibility research protocols, we developed a set of instrumented toys to serve as a new type of task instrumentation and data collection tool suitable for infant use. A commercially available device comprising a barometer and an inertial measurement unit (IMU) embedded in a 3D-printed lattice structure was used to detect when and how the infant interacts with the toy. The data collected using the instrumented toys provided a rich dataset that described the sequence of toy interaction and individual toy interaction patterns, from which EF-relevant aspects of infant cognition can be inferred. Such a tool could provide an objective, reliable, and scalable method of collecting early developmental data in socially interactive contexts.

Additive manufacturing is one the most promising fabrication strategies for the fabrication of bone tissue scaffolds using biodegradable semi-crystalline polymers. During the fabrication process, polymeric material in a molten state is deposited in a platform and starts to solidify while cooling down. The build-up of consecutive layers reheats the previously deposited material, introducing a complex thermal cycle with impacts on the overall properties of printed scaffolds. Therefore, the accurate prediction of these thermal cycles is significantly important to properly design the additively manufactured polymer scaffolds and the bonding between the layers. This paper presents a novel multi-stage numerical model, integrating a 2D representation of the dynamic deposition process and a 3D thermal evolution model to simulate the fabrication process. Numerical simulations show how the deposition velocity controls the spatial dimensions of the individual deposition layers and the cooling process when consecutive layers are deposited during polymer printing. Moreover, numerical results show a good agreement with experimental results.

This research investigates the accelerated hydrolytic degradation process of both anatomically designed bone scaffolds with a pore size gradient and a rectangular shape (biomimetically designed scaffolds or bone bricks). The effect of material composition is investigated considering poly-ε-caprolactone (PCL) as the main scaffold material, reinforced with ceramics such as hydroxyapatite (HA), β-tricalcium phosphate (TCP) and bioglass at a concentration of 20 wt%. In the case of rectangular scaffolds, the effect of pore size (200 μm, 300 μm and 500 μm) is also investigated. The degradation process (accelerated degradation) was investigated during a period of 5 days in a sodium hydroxide (NaOH) medium. Degraded bone bricks and rectangular scaffolds were measured each day to evaluate the weight loss of the samples, which were also morphologically, thermally, chemically and mechanically assessed. The results show that the PCL/bioglass bone brick scaffolds exhibited faster degradation kinetics in comparison with the PCL, PCL/HA and PCL/TCP bone bricks. Furthermore, the degradation kinetics of rectangular scaffolds increased by increasing the pore size from 500 μm to 200 μm. The results also indicate that, for the same material composition, bone bricks degrade slower compared with rectangular scaffolds. The scanning electron microscopy (SEM) images show that the degradation process was faster on the external regions of the bone brick scaffolds (600 μm pore size) compared with the internal regions (200 μm pore size). The thermal gravimetric analysis (TGA) results show that the ceramic concentration remained constant throughout the degradation process, while differential scanning calorimetry (DSC) results show that all scaffolds exhibited a reduction in crystallinity (Xc), enthalpy (Δm) and melting temperature (Tm) throughout the degradation process, while the glass transition temperature (Tg) slightly increased. Finally, the compression results show that the mechanical properties decreased during the degradation process, with PCL/bioglass bone bricks and rectangular scaffolds presenting higher mechanical properties with the same design in comparison with the other materials.

Microcellular injection moulding is an important injection moulding technique to create foaming plastic parts. However, there are no consistent conclusions on the impact of processing parameters on the cell morphology of microcellular injection moulded parts. This paper investigates the influence of the main processing parameters, such as melt temperature, mould temperature, injection pressure, flow rate, shot volume and gas dosage amount, on the average cell size and weight reduction of a talc-reinforced polypropylene square part (165 mm × 165 mm × 3.2 mm), using the commercial software Moldex 3D. The effect of each parameter is investigated considering a range of values and the simulation results were compared with published experimental results. The differences between numerical and experimental trends are discussed.

Honey was used in traditional medicine to treat wounds until the advent of modern medicine. The rising global antibiotic resistance has forced the development of novel therapies as alternatives to combat infections. Consequently, honey is experiencing a resurgence in evaluation for antimicrobial and wound healing applications. A range of both Gram-positive and Gram-negative bacteria, including antibiotic-resistant strains and biofilms, are inhibited by honey. Furthermore, susceptibility to antibiotics can be restored when used synergistically with honey. Honey's antimicrobial activity also includes antifungal and antiviral properties, and in most varieties of honey, its activity is attributed to the enzymatic generation of hydrogen peroxide, a reactive oxygen species. Non-peroxide factors include low water activity, acidity, phenolic content, defensin-1, and methylglyoxal ( Leptospermum honeys). Honey has also been widely explored as a tissue-regenerative agent. It can contribute to all stages of wound healing, and thus has been used in direct application and in dressings. The difficulty of the sustained delivery of honey's active ingredients to the wound site has driven the development of tissue engineering approaches (e.g., electrospinning and hydrogels). This review presents the most in-depth and up-to-date comprehensive overview of honey's antimicrobial and wound healing properties, commercial and medical uses, and its growing experimental use in tissue-engineered scaffolds.

Melanoma is a potentially fatal cancer with rising incidence over the last 50 years, associated with enhanced sun exposure and ultraviolet radiation. Its incidence is highest in people of European descent and the ageing population. There are multiple clinical and epidemiological variables affecting melanoma incidence and mortality, such as sex, ethnicity, UV exposure, anatomic site, and age. Although survival has improved in recent years due to advances in targeted and immunotherapies, new understanding of melanoma biology and disease progression is vital to improving clinical outcomes. Efforts to develop three-dimensional human skin equivalent models using biofabrication techniques, such as bioprinting, promise to deliver a better understanding of the complexity of melanoma and associated risk factors. These 3D skin models can be used as a platform for patient specific models and testing therapeutics.

The advancement of additive manufacturing (AM) for metal matrix nanocomposites (MMNCs) is gaining enormous attention due to their potential improvement of physical and mechanical performance. When using nanostructured additives as reinforcements in 3D printed metal composites and with the aid of selective laser melting (SLM), the mechanical properties of the composites can be tailored. The nanostructured additive AEROSIL ® fumed silica is both cost-effective and beneficial in the production of MMNCs using SLM. In this study, both hydrophobic and hydrophilic fumed silicas were shown to successfully achieve homogenous blends with commercial 316L stainless steel powder. The powder blends, which exhibited better flow, were then used to fabricate samples using SLM. The samples' microstructure demonstrated that smaller grains were present in the composites, resulting in improvements in mechanical properties by grain refinement compared to those of 316L stainless steel samples.

The design of scaffolds with optimal biomechanical properties for load-bearing applications is an important topic of research. Most studies have addressed this problem by focusing on the material composition and not on the coupled effect between the material composition and the scaffold architecture. Polymer-bioglass scaffolds have been investigated due to the excellent bioactivity properties of bioglass, which release ions that activate osteogenesis. However, material preparation methods usually require the use of organic solvents that induce surface modifications on the bioglass particles, compromising the adhesion with the polymeric material thus compromising mechanical properties. In this paper, we used a simple melt blending approach to produce polycaprolactone/bioglass pellets to construct scaffolds with pore size gradient. The results show that the addition of bioglass particles improved the mechanical properties of the scaffolds and, due to the selected architecture, all scaffolds presented mechanical properties in the cortical bone region. Moreover, the addition of bioglass indicated a positive long-term effect on the biological performance of the scaffolds. The pore size gradient also induced a cell spreading gradient.

Conformal cooling channels (CCCs) are widely used in the plastic injection molding process to improve the product quality and operational performance. Tooling that incorporates CCCs can be fabricated through metal additive manufacturing (MAM). The present work focuses on the MAM of a plastic injection mold insert with different CCC types that are circular, serpentine, and tapered channels with/without body-centered cubic (BCC) lattices. The entire manufacturing process of the mold insert is explained from the design step to the final printing step including the computational thermal & mechanical simulations, performance assessments, and multiobjective optimization. Compared to the traditional channels, conformal cooling channels achieved up to 62.9% better cooling performance with a better thermal uniformity on the mold surface. The optimum mold geometry is decided using the multiobjective optimization procedure according to the multiple objectives of cooling time, temperature non-uniformity, and pressure drop in the channel. Direct Metal Laser Sintering (DMLS) method is used for manufacturing the molds and the quality of the printed molds are analyzed with the X-ray Computed Tomography (X-ray CT) technique. The errors between the design and the printed parameters are less than 5% for the circular and tapered channels while the maximum deviation of the strut diameters of the BCC is 0.06 mm.

Critical bone defects are a major clinical challenge in reconstructive bone surgery. Polycaprolactone (PCL) mixed with bioceramics, such as hydroxyapatite (HA) and tricalcium phosphate (TCP), create composite scaffolds with improved biological recognition and bioactivity. Electrical stimulation (ES) aims to compensate the compromised endogenous electrical signals and to stimulate cell proliferation and differentiation. We investigated the effects of composite scaffolds (PCL with HA; and PCL with β-TCP) and the use of ES on critical bone defects in Wistar rats using eight experimental groups: untreated, ES, PCL, PCL/ES, HA, HA/ES, TCP, and TCP/ES. The investigation was based on histomorphometry, immunohistochemistry, and gene expression analysis. The vascular area was greater in the HA/ES group on days 30 and 60. Tissue mineralization was greater in the HA, HA/ES, and TCP groups at day 30, and TCP/ES at day 60. Bmp-2 gene expression was higher in the HA, TCP, and TCP/ES groups at day 30, and in the TCP/ES and PCL/ES groups at day 60. Runx-2, Osterix, and Osteopontin gene expression were also higher in the TCP/ES group at day 60. These results suggest that scaffolds printed with PCL and TCP, when paired with electrical therapy application, improve bone regeneration.

Skin is a hierarchical and multi-cellular organ exposed to the external environment with a key protective and regulatory role. Wounds caused by disease and trauma can lead to a loss of function, which can be debilitating and even cause death. Accelerating the natural skin healing process and minimizing the risk of infection is a clinical challenge. Electrospinning is a key technology in the development of wound dressings and skin substitutes as it enables extracellular matrix-mimicking fibrous structures and delivery of bioactive materials. Honey is a promising biomaterial for use in skin tissue engineering applications and has antimicrobial properties and potential tissue regenerative properties. This preliminary study investigates a solution electrospun composite nanofibrous mesh based on polycaprolactone and a medical grade honey, SurgihoneyRO. The processing conditions were optimized and assessed by scanning electron microscopy to fabricate meshes with uniform fiber diameters and minimal presence of beads. The chemistry of the composite meshes was examined using Fourier transform infrared spectroscopy and X-ray photon spectroscopy showing incorporation of honey into the polymer matrix. Meshes incorporating honey had lower mechanical properties due to lower polymer content but were more hydrophilic, resulting in an increase in swelling and an accelerated degradation profile. The biocompatibility of the meshes was assessed using human dermal fibroblasts and adipose-derived stem cells, which showed comparable or higher cell metabolic activity and viability for SurgihoneyRO-containing meshes compared to polycaprolactone only meshes. The meshes showed no antibacterial properties in a disk diffusion test due to a lack of hydrogen peroxide production and release. The developed polycaprolactone-honey nanofibrous meshes have potential for use in skin applications.

Multi Jet Fusion (MJF) is a recently developed polymeric powder bed fusion (PBF) additive manufacturing technique that has received considerable attention in the industrial and scientific community due to its ability to fabricate functional and complex polymeric parts efficiently. In this work, a systematic characterization of the physicochemical properties of MJF-certified polyamide 11 (PA11) and thermoplastic polyurethane (TPU) powder was conducted. The mechanical performance and print quality of the specimens printed using both powders were then evaluated. Both PA11 and TPU powders showed irregular morphology with sharp features and had broad particle size distribution, but such features did not impair their printability significantly. According to the DSC scans, the PA11 specimen exhibited two endothermic peaks, while the TPU specimen exhibited a broad endothermic peak (116-150 °C). The PA11 specimens possessed the highest tensile strength in the Z orientation, as opposed to the TPU specimens which possessed the lowest tensile strength along the same orientation. The flexural properties of the PA11 and TPU specimens displayed a similar anisotropy where the flexural strength was highest in the Z orientation and lowest in the X orientation. The porosity values of both the PA11 and the TPU specimens were observed to be the lowest in the Z orientation and highest in the X orientation, which was the opposite of the trend observed for the flexural strength of the specimens. The PA11 specimen possessed a low coefficient of friction (COF) of 0.13 and wear rate of 8.68 × 10 -5 mm 3 /Nm as compared to the TPU specimen, which had a COF of 0.55 and wear rate of 0.012 mm 3 /Nm. The PA11 specimens generally had lower roughness values on their surfaces ( R a < 25 μm), while the TPU specimens had much rougher surfaces ( R a > 40 μm). This investigation aims to uncover and explain phenomena that are unique to the MJF process of PA11 and TPU while also serving as a benchmark against similar polymeric parts printed using other PBF processes.

Fused filament fabrication (FFF) is increasingly adopted for direct manufacturing of end use parts in an aviation industry. However, the application of FFF technique is still restricted to manufacturing low criticality lightly loaded parts, due to poor mechanical performance. To alleviate the mechanical performance issue, thermal annealing process is frequently utilized. However, problems such as distortion issues and the need for jigs and fixtures limit the effectiveness of the thermal annealing process, especially for low volume complex FFF parts. In this research, a novel low temperature thermal annealing is proposed to address the limitations in conventional annealing. A modified orthogonal array design is applied to investigate the performance of ULTEM™ 9085 FFF coupons. Further, the coupons are annealed with specialized support structures, which are co-printed with the coupons during the manufacturing process. Once the annealing process is completed, multiscale characterizations are performed to identify the mechanical properties of the specimens. Geometrical measurement of post annealed specimens indicates an expansion in the layering direction, which indicates relief of thermal stresses. Moreover, annealed coupons show an improvement in tensile strength and reduction in strain concentration. Mesostructure and fracture surface analysis indicate an increase in ductility and enhanced coalescence. This research shows that the proposed annealing methodology can be applied to enhance the mechanical performance of FFF parts without significant distortion.

Aerosol jet printing of electronic devices is increasingly attracting interest in recent years. However, low capability and high resistance are still limitations of the printed electronic devices. In this paper, we introduce a novel post-treatment method to achieve a high-performance electric circuit. The electric circuit was printed with aerosol jet printing method on an ULTEM substrate. The ULTEM substrate was fabricated by the Fused Deposition Modelling method. After post-treatment, the electrical resistance of the printed electric circuit was changed from 236 mΩ to 47 mΩ and the electric property was enhanced. It was found that the reduction of electric resistance was caused by surface property changes. Different surface analysis methods including scanning electron microscopy (SEM) and x-ray photoelectron spectroscopy (XPS) were used to understand the effectiveness of the proposed method. The results showed that the microsurface structure remained the same original structure before and after treatment. It was found that the surface carbon concentration was significantly increased after treatment. Detailed analysis showed that the C-C bond increased obviously after treatment. The change of electrical resistance was found to be limited to the material's surface. After polishing, the circuit resistance was changed back to its original value. As the electric circuit is the basic element of electric devices, the proposed method enables the fabrication of high performance devices such as capacitors, strain gauge, and other sensors, which has potential applications in many areas such as industrial, aerospace, and military usage.

Osteoarthritis of the knee with meniscal pathologies is a severe meniscal pathology suffered by the aging population worldwide. However, conventional meniscal substitutes are not 3D-printable and lack the customizability of 3D printed implants and are not mechanically robust enough for human implantation. Similarly, 3D printed hydrogel scaffolds suffer from drawbacks of being mechanically weak and as a result patients are unable to execute immediate post-surgical weight-bearing ambulation and rehabilitation. To solve this problem, we have developed a 3D silicone meniscus implant which is (1) cytocompatible, (2) resistant to cyclic loading and mechanically similar to native meniscus, and (3) directly 3D printable. The main focus of this study is to determine whether the purity, composition, structure, dimensions and mechanical properties of silicone implants are affected by the use of a custom-made in-house 3D-printer. We have used the phosphate buffer saline (PBS) absorption test, Fourier transform infrared (FTIR) spectroscopy, surface profilometry, thermo-gravimetric analysis (TGA), X-ray photoelectron spectroscopy (XPS), differential scanning calorimetry (DSC), and scanning electron microscopy (SEM) to effectively assess and compare material properties between molded and 3D printed silicone samples.

The first successful direct 3D printing, or additive manufacturing (AM), of heat-cured silicone meniscal implants, using biocompatible and bio-implantable silicone resins is reported. Silicone implants have conventionally been manufactured by indirect silicone casting and molding methods which are expensive and time-consuming. A novel custom-made heat-curing extrusion-based silicone 3D printer which is capable of directly 3D printing medical silicone implants is introduced. The rheological study of silicone resins and the optimization of critical process parameters are described in detail. The surface and cross-sectional morphologies of the printed silicone meniscus implant were also included. A time-lapsed simulation study of the heated silicone resin within the nozzle using computational fluid dynamics (CFD) was done and the results obtained closely resembled real time 3D printing. Solidworks one-convection model simulation, when compared to the on-off model, more closely correlated with the actual probed temperature. Finally, comparative mechanical study between 3D printed and heat-molded meniscus is conducted. The novel 3D printing process opens up the opportunities for rapid 3D printing of various customizable medical silicone implants and devices for patients and fills the current gap in the additive manufacturing industry.

In this paper, we studied the crack-repair by spraying bacteria-based liquid around the cracks in concrete. To enhance the repair efficiency and speed up the repair process, the transposon mutagenesis method was employed to modify the genes of Bacillus halodurans and create a mutant bacterial strain with higher efficiency of calcium carbonate productivity by catalyzing the combination of carbonate and calcium ion. The efficiency of crack-repairing in concrete by spraying two kinds of bacterial liquid was evaluated via image analysis, X-ray computed tomography (X-CT) scanning technology and the sorptivity test. The results show that the crack-repair efficiency was enhanced very evidently by spraying genetically modified bacterial-liquid as no microbiologically induced calcite precipitation (MICP) was found within the cracks for concrete samples sprayed using wild type bacterial-liquid. In addition, the crack-repair process was also shortened significantly in the case of genetically modified bacteria.

The advent of digital concrete fabrication calls for advancing our understanding of the interaction of 3D printing with material rheology and print parameters, in addition to developing new measurement and control techniques. Thixotropy is the main challenge associated with printable material, which offers high yield strength and low viscosity. The higher the thixotropy, the better the shape stability and the higher buildability. However, exceeding a minimum value of thixotropy can cause high extrusion pressure and poor interface bond strength if the printing parameters are not optimized to the part design. This paper aims to investigate the effects of both material and process parameters on the buildability and inter-layer adhesion properties of 3D printed cementitious materials, produced with different thixotropy and print head standoff distances. Nano particles are used to increase the thixotropy and, in this context, a lower standoff distance is found to be useful for improving the bond strength. The low viscosity "control" sample is unaffected by the variation in standoff distances, which is attributed to its flowability and low yield stress characteristics that lead to strong interfacial bonding. This is supported by our microscopic observations.

Selective Laser Melting (SLM) has been implemented to address the difficulties in manufacturing complex nickel titanium (NiTi) structures. However, the SLM production of NiTi is much more challenging than the fabrication of conventional metals. Other than the need to have a high density that leads to excellent mechanical properties, strict chemical compositional control is required as well for the SLM NiTi parts to exhibit desirable phase transformation characteristics. In addition, acquiring a high transformation strain from the produced specimens is another challenging task. In the prior research, a new approach-repetitive scanning-was implemented to achieve these objectives. The repetitively scanned samples demonstrated an average of 4.61% transformation strain when subjected to the tensile test. Nevertheless, there is still room for improvement as the conventionally-produced NiTi can exhibit a transformation strain of about 6%. Hence, post-process heat treatment was introduced to improve the shape memory properties of the samples. The results showed an improvement when the samples were heat treated at a temperature of 400 °C for a period of 5 min. The enhancement in the shape memory behavior of the repetitively scanned samples was mainly attributed to the formation of fine Ni₄Ti₃ metastable precipitates.

NiTi shape memory alloys (SMAs) have the best combination of properties among the different SMAs. However, the limitations of conventional manufacturing processes and the poor manufacturability of NiTi have critically limited its full potential applicability. Thus, additive manufacturing, commonly known as 3D printing, has the potential to be a solution in fabricating complex NiTi smart structures. Recently, a number of studies on Selective Laser Melting (SLM) of NiTi were conducted to explore the various aspects of SLM-produced NiTi. Compared to producing conventional metals through the SLM process, the fabrication of NiTi SMA is much more challenging. Not only do the produced parts require a high density that leads to good mechanical properties, strict composition control is needed as well for the SLM NiTi to possess suitable phase transformation characteristics. Additionally, obtaining a good shape memory effect from the SLM NiTi samples is another challenging task that requires further understanding. This paper presents the results of the effects of energy density and SLM process parameters on the properties of SLM NiTi. Its shape memory properties and potential applications were then reviewed and discussed., Competing Interests: The authors declare no conflict of interest.

In 4D printing research, different types of complex structure folding and unfolding have been investigated. However, research on cross-folding of origami structures (defined as a folding structure with at least two overlapping folds) has not been reported. This research focuses on the investigation of cross-folding structures using multi-material components along different axes and different horizontal hinge thickness with single homogeneous material. Tensile tests were conducted to determine the impact of multi-material components and horizontal hinge thickness. In the case of multi-material structures, the hybrid material composition has a significant impact on the overall maximum strain and Young's modulus properties. In the case of single material structures, the shape recovery speed is inversely proportional to the horizontal hinge thickness, while the flexural or bending strength is proportional to the horizontal hinge thickness. A hinge with a thickness of 0.5 mm could be folded three times prior to fracture whilst a hinge with a thickness of 0.3 mm could be folded only once prior to fracture. A hinge with a thickness of 0.1 mm could not even be folded without cracking. The introduction of a physical hole in the center of the folding/unfolding line provided stress relief and prevented fracture. A complex flower petal shape was used to successfully demonstrate the implementation of overlapping and non-overlapping folding lines using both single material segments and multi-material segments. Design guidelines for establishing cross-folding structures using multi-material components along different axes and different horizontal hinge thicknesses with single or homogeneous material were established. These guidelines can be used to design and implement complex origami structures with overlapping and non-overlapping folding lines. Combined overlapping folding structures could be implemented and allocating specific hole locations in the overall designs could be further explored. In addition, creating a more precise prediction by investigating sets of in between hinge thicknesses and comparing the folding times before fracture, will be the subject of future work., Competing Interests: The authors declare no conflict of interest.

Additive manufacturing (AM) has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing., Competing Interests: The authors declare no conflict of interest.

Orthopedic implants first started out as an all-metal hip joint replacement. However, poor design and machinability as well as unsatisfactory surface finish subjected the all-metal joint replacement to being superseded by a polyethylene bearing. Continued improvement in manufacturing techniques together with the reality that polyethylene wear debris can cause hazardous reactions in the human body has brought about the revival of metal-on-metal (MOM) hip joints in recent years. This has also led to a relatively new research area that links tribology and corrosion together. This article aims at reviewing the commonly used tribochemical methods adopted in the analysis of tribocorrosion and putting forward some of the models and environmental factors affecting the tribocorrosive behavior of CoCrMo alloys, a widely-used class of biomaterial for orthopedic implants., Competing Interests: The authors declare no conflict of interest.

The objective of this investigation was to determine the quasi-static indentation response and failure mode in three-dimensional (3D) printed trapezoidal core structures, and to characterize the energy absorbed by the structures. In this work, the trapezoidal sandwich structure was designed in the following two ways. Firstly, the trapezoidal core along with its facesheet was 3D printed as a single element comprising a single material for both core and facesheet (type A); Secondly, the trapezoidal core along with facesheet was 3D printed, but with variation in facesheet materials (type B). Quasi-static indentation was carried out using three different indenters, namely standard hemispherical, conical, and flat indenters. Acoustic emission (AE) technique was used to capture brittle cracking in the specimens during indentation. The major failure modes were found to be brittle failure and quasi-brittle fractures. The measured indentation energy was at a maximum when using a conical indenter at 9.40 J and 9.66 J and was at a minimum when using a hemispherical indenter at 6.87 J and 8.82 J for type A and type B series specimens respectively. The observed maximum indenter displacements at failure were the effect of material variations and composite configurations in the facesheet.

Drop-on-demand (DOD) bioprinting has attracted huge attention for numerous biological applications due to its precise control over material volume and deposition pattern in a contactless printing approach. 3D bioprinting is still an emerging field and more work is required to improve the viability and homogeneity of printed cells during the printing process. Here, a general purpose bio-ink was developed using polyvinylpyrrolidone (PVP) macromolecules. Different PVP-based bio-inks (0%-3% w/v) were prepared and evaluated for their printability; the short-term and long-term viability of the printed cells were first investigated. The Z value of a bio-ink determines its printability; it is the inverse of the Ohnesorge number (Oh), which is the ratio between the Reynolds number and a square root of the Weber number, and is independent of the bio-ink velocity. The viability of printed cells is dependent on the Z values of the bio-inks; the results indicated that the cells can be printed without any significant impairment using a bio-ink with a threshold Z value of ≤9.30 (2% and 2.5% w/v). Next, the cell output was evaluated over a period of 30 min. The results indicated that PVP molecules mitigate the cell adhesion and sedimentation during the printing process; the 2.5% w/v PVP bio-ink demonstrated the most consistent cell output over a period of 30 min. Hence, PVP macromolecules can play a critical role in improving the cell viability and homogeneity during the bioprinting process.

Accumulation of particles in a high concentration on a microchannel wall is a common phenomenon in a colloidal fluid. Gradual accumulation/deposition of particles can eventually obstruct the fluid flow and lead to clogging, which seriously affects the accuracy and reliability of nozzle-based printing and causes damage to the nozzle. Particle accumulation in a 100 μm microchannel was investigated by light microscopy, and its area growth in an exponential format was used to quantify this phenomenon. The effects of the constriction angle and alginate concentration on particle accumulation were also studied. In order to reduce the clogging problem, an acoustic method was proposed and evaluated here. Numerical simulation was first conducted to predict the acoustic radiation force on the particles in the fluid with different viscosities. Interdigital transducers (IDTs) were fabricated on the LiNbO₃ wafer to produce standing surface acoustic waves (SSAW) in the microchannel. It was found that the actuation of SSAW can reduce the accumulation area in the microchannel by 2 to 3.7-fold. In summary, the particle accumulation becomes significant with the increase of the constriction angle and fluid viscosity. The SSAW can effectively reduce the particle accumulation and postpone clogging., Competing Interests: The authors declare no conflict of interest.

Polymeric fibrous scaffolds for guiding cell growth are designed to be potentially used for the tissue engineering (TE) of tubular organs including esophagi, blood vessels, tracheas, etc. Tubular scaffolds were fabricated via melt-drawing of highly elastic poly(l-lactide-co-ε-caprolactone) (PLC) fibers layer-by-layer on a cylindrical mandrel. The diameter and length of the scaffolds are customizable via 3D printing of the mandrel. Thickness of the scaffolds was varied by changing the number of layers of the melt-drawing process. The morphology and tensile properties of the PLC fibers were investigated. The fibers were highly aligned with a uniform diameter. Their diameters and tensile properties were tunable by varying the melt-drawing speeds. These tailorable topographies and tensile properties show that the additive-based scaffold fabrication technique is customizable at the micro- and macro-scale for different tubular tissues. The merits of these scaffolds in TE were further shown by the finding that myoblast and fibroblast cells seeded onto the scaffolds in vitro showed appropriate cell proliferation and distribution. Human mesenchymal stem cells (hMSCs) differentiated to smooth muscle lineage on the microfibrous scaffolds in the absence of soluble induction factors, showing cellular shape modulation and scaffold elasticity may encourage the myogenic differentiation of stem cells.

Multi-walled carbon nanotubes (CNTs) as nano-reinforcements were introduced to facilitate the laser sintering process and enhance the thermal and mechanical properties of polymeric composites. A dual experimental-theoretical method was proposed to evaluate the processability and predict the process parameters of newly developed CNT-coated polyamide 12 (CNTs/PA12) powders. The thermal conductivity, melt viscosity, phase transition and temperature-dependent density and heat capacity of PA12 and CNTs/PA12 powders were characterized for material evaluation. The composite powders exhibited improved heat conduction and heat absorption compared with virgin polymer powders, and the stable sintering range of composite powders was extended and found to be favourable for the sintering process. The microstructures of sintered composites revealed that the CNTs remained at the powder boundaries and formed network architectures, which instantaneously induced the significant enhancements in tensile strength, elongation at break and toughness without sacrificing tensile modulus.

Gelatin methacryloyl (GelMA) has been increasingly considered as an important bioink material due to its tailorable mechanical properties, good biocompatibility, and ability to be photopolymerized in situ as well as printability. GelMA can be classified into two types: type A GelMA (a product from acid treatment) and type B GelMA (a product from alkali treatment). In current literature, there is little research on the comparison of type A GelMA and type B GelMA in terms of synthesis, rheological properties, and printability for bioink applications. Here, we report the synthesis, rheological properties, and printability of types A and B GelMA. Types A and B GelMA samples with different degrees of substitution (DS) were prepared in a controllable manner by a time-lapse loading method of methacrylic anhydride (MAA) and different feed ratios of MAA to gelatin. Type B GelMA tended to have a slightly higher DS compared to type A GelMA, especially in a lower feed ratio of MAA to gelatin. All the type A and type B GelMA solutions with different DS exhibited shear thinning behaviours at 37 °C. However, only GelMA with a high DS had an easy-to-extrude feature at room temperature. The cell-laden printed constructs of types A and B GelMA at 20% w / v showed around 75% cell viability.

Pneumatic extrusion-based bioprinting is a recent and interesting technology that is very useful for biomedical applications. However, many process parameters in the bioprinter need to be fully understood in order to print at an adequate resolution. In this paper, a simple yet accurate mathematical model to predict the printed width of a continuous hydrogel line is proposed, in which the resolution is expressed as a function of nozzle size, pressure, and printing speed. A thermo-responsive hydrogel, pluronic F127, is used to validate the model predictions. This model could provide a platform for future correlation studies on pneumatic extrusion-based bioprinting as well as for developing new bioink formulations.

Three-dimensional (3D) bioprinting is an emerging and promising technology in tissue engineering to construct tissues and organs for implantation. Alignment of self-assembly cell spheroids that are used as bioink could be very accurate after droplet ejection from bioprinter. Complex and heterogeneous tissue structures could be built using rapid additive manufacture technology and multiple cell lines. Effective vascularization in the engineered tissue samples is critical in any clinical application. In this review paper, the current technologies and processing steps (such as printing, preparation of bioink, cross-linking, tissue fusion and maturation) in 3D bio-printing are introduced, and their specifications are compared with each other. In addition, the application of ultrasound in this novel field is also introduced. Cells experience acoustic radiation force in ultrasound standing wave field (USWF) and then accumulate at the pressure node at low acoustic pressure. Formation of cell spheroids by this method is within minutes with uniform size and homogeneous cell distribution. Neovessel formation from USWF-induced endothelial cell spheroids is significant. Low-intensity ultrasound could enhance the proliferation and differentiation of stem cells. Its use is at low cost and compatible with current bioreactor. In summary, ultrasound application in 3D bio-printing may solve some challenges and enhance the outcomes.

In tissue engineering, there is limited availability of a simple, fast and solvent-free process for fabricating micro-porous thin membrane scaffolds. This paper presents the first report of a novel surface suspension melt technique to fabricate a micro-porous thin membrane scaffolds without using any organic solvent. Briefly, a layer of polycaprolactone (PCL) particles is directly spread on top of water in the form of a suspension. After that, with the use of heat, the powder layer is transformed into a melted layer, and following cooling, a thin membrane is obtained. Two different sizes of PCL powder particles (100 µm and 500 µm) are used. Results show that membranes made from 100 µm powders have lower thickness, smaller pore size, smoother surface, higher value of stiffness but lower ultimate tensile load compared to membranes made from 500 µm powder. C2C12 cell culture results indicate that the membrane supports cell growth and differentiation. Thus, this novel membrane generation method holds great promise for tissue engineering.