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The growth behavior of stress corrosion cracking (SCC) of Alloy 600 with different cold-work levels was investigated in simulated boiling water reactors water environments. In addition, a correlation of cold-work levels, grain boundary characteristic, and the SCC growth behavior of Alloy 600 were studied. The results show that grains with high residual strain caused by cold work provide transgranular crack growth paths. The SCC growth rates of the specimens also increase with an increase in the degree of cold work and decrease remarkably after switching to the hydrogen water chemistry environment. Grain boundary character proves to be a factor more important than the localized strain concentration at the grain boundary in terms of its role in the intergranular crack growth rate of the Alloy 600 with a cold-work degree from 20% to 30%.

Orthopedic bone plates are most commonly used for bone fracture fixation for more than 100 years. The bone plate design had evolved over time overcoming many challenges such as insufficient strength and excessive plate–bone contact affecting the blood circulation. However, it is only made of two materials, either stainless steel (AISI 316L) or titanium (Ti–6Al–4V). There are two main limitations of metallic bone implants, namely stress shielding and the problem of malocclusion caused by the displacement of the fracture site during healing. To overcome the two problems, a new bone plate design with the incorporation of auxetic structures is proposed in this work. This study aims to use auxetic structure section in the bone plate that would decrease the stiffness of the region, thereby mitigating the stress-shielding effect and at the same time act as a deformable section to enable intra-operative bending for effective alignment while having enough bending strength and stiffness. Two different auxetic structures namely re-entrant honeycomb and missing rib structures were considered. The auxetic structure incorporated bone plates were designed, finite element analysis was done, fabricated using direct metal laser sintering technique, and tested. The results indicate that the re-entrant honeycomb structure incorporated bone plates serve as an effective bone design compared to the conventional bone plate design, in terms of stress shielding and intra-operative bending while offering similar mechanical and bending strength.

Additive manufacturing enables the fabrication of periodic ceramic lattices with controllable micro-architectures. Many studies reported their catastrophic brittle fracture behaviour. However, ceramic lattices may fail by a layer-by-layer pseudo-ductile fracture mode, by controlling micro-architectures and porosities. Moreover, their fracture behaviour can be optimised by introducing strut/wall thickness gradients. This paper investigates the fracture behaviour and the fracture mode transition of ceramic triply periodic minimal surface (TPMS) structures. Alumina TPMS structures with relative densities of 0.14-0.37 are fabricated by ceramic stereolithography. Quasi-static compression tests validate a transition density range for non-graded samples: low ( 0.25) relative density samples show layer-by-layer pseudo-ductile and catastrophic brittle fracture modes, respectively. The pseudo-ductile failure mode increases the energy absorption performance, enabling load-bearing capacity for a compressive strain up to 50%. With appropriate thickness gradients, graded structures exhibit significant increase of energy absorption without a decrease of fracture strength compared to their non-graded counterparts.

Chromia-forming ferritic stainless steel (FSS) is a highly promising interconnect material for application in solid oxide fuel cells. In this study, initial oxidation of chromium oxides was performed at 500–800 °C to understand the evolution of materials at an early stage. The structural variations in oxide scales were analyzed through scanning electron microscopy, energy dispersive spectroscopy (EDS), transmission electron microscopy (TEM), X-ray diffractometry (XRD), laser confocal microscopy (LSCM), X-ray photoelectron spectroscopy (XPS), and Raman spectroscopy. Surface electrochemical properties were investigated through electrochemical impedance spectroscopy to understand how the heat treatment temperature affected surface impedance. Treatment temperatures higher than 700 °C facilitate the diffusion of Cr and Mn, thus allowing ferritic spinels to form on the surface and leading to high electrical conductivity.

Additively manufactured lattice structures enable the realisation of light-weight, multi-functional, structures. For example, lattices can be used for high stiffness and buckling resistance in sandwich structures or as support material for additive manufacturing. Topology optimisation and additive manufacturing are two technologies that allow the design, optimisation and manufacture of complex lattice designs. In this work, a new lattice optimisation methodology is presented that tailors the size, shape and orientation of individual lattice trusses in three-dimensional space by using principal strain fields obtained from topology optimisation. This new method of generating functionally graded lattices is shown both numerically and experimentally to be capable of generating lattice structures with greatly improved stiffness and strength when compared to lattice structures with a uniform lattice infill. Upper and lower relative density thresholds and minimum truss member sizes are included in the optimisation workflow to ensure that the optimised lattice designs are compatible with additive manufacturing process constraints. The functional grading method is also shown to be capable of generating conformal lattice structures in three dimensions, even for complex loading conditions and arbitrary volume boundaries.

3D printing and particularly fused deposition modelling (FDM) is widely used for prototyping and fabricating low-cost customised parts. However, present fused deposition modelling 3D printers have limited nozzle condition monitoring techniques to minimize nozzle clogging errors. Nozzle clogging is one of the significant process errors in fused deposition modelling 3D printers, and it affects the quality of prototyped parts in terms of mechanical properties and geometrical accuracy. This paper proposes a dynamic model for current-based nozzle condition monitoring in fused deposition modelling, which is briefly described as follows. First, all the process forces in filament extrusion of the fused deposition modelling were identified and derived theoretically, and theoretical equations of the feed rolling forces and flow-through-nozzle forces were derived. In addition, the effect of the nozzle clogging on the current of extruding motor were identified. Second, based on the proposed dynamic model, current-based nozzle condition monitoring method was proposed. Next, sets of experiments on FDM machine using polylactic acid (PLA) material were carried out to verify the proposed theoretical model, and the results were analysed and evaluated. Findings of the present study indicate that nozzle clogging in FDM 3D printing can be monitored by sensing the current of the filament extruding motor. The proposed model can be used efficiently for monitoring nozzle clogging conditions in fused deposition modelling 3D printers as it is based on the fundamental process modelling.

Specific structures of esophagus play an important role in specific functions. However, current esophageal tissue engineering scaffolds replicate them poorly. To address this issue, the objective of this study is to fabricate a hierarchical PCL/F127 scaffold inspired by the natural esophageal structure. The hierarchical scaffold consists of aligned fibers in micro-size and thin film with nano-sized pores through combining E-jetting and E-spraying. The aligned fibers of scaffold guide the orientation and induce the elongation of fibroblasts, mimicking the uniformly oriented esophageal muscles. Furthermore, the film functioned as a protective barrier to replicate the esophageal mucosa. Meanwhile, the film also increases cell adhesion area, hence, improving cell proliferation. These two features of the fabricated hierarchical scaffold mimic the structure of natural esophagus. Moreover, fabricated hierarchical scaffold possesses comparable mechanical properties to natural esophagus. These results prove the potential of fabricated scaffold for esophagus tissue repair.

NGCs are considered as an alternative treatment method for treating peripheral nerve injuries in place of nerve autografts. Biomimicry, conductivity, and biodegradability are the properties expected of an ideal NGC. PCL/PAA NGCs with three different concentrations of PAA (2.5, 5 and 7.5%) were fabricated using EHD-jet 3D printing. The mechanical properties of the PCL/PAA NGCs mimic the native human nerve properties (ultimate tensile strength of 6.5 to 11.7 MPa) and the conductivity match that of the amphibian motor nerve fiber myelin sheath (10−6 S/cm). The in vitro degradation studies reveal that they are biodegradable and injury/site-specific biodegradability can be obtained by tuning the PCL/PAA concentration ratio. In addition, PAA being a polyanionic polymer has the potential to act as a cation-exchanger, mimicking the functions of the nerve cortical gel layer, thereby influencing the electrophysiological phenomena called nerve excitation and conduction. Neural differentiation studies with PC12 cells assessed by the Reverse Transcription-Polymerase Chain Reaction (RT-PCR) and immunocytochemistry showed enhanced gene expression with the presence of PAA. Our results suggest that the EHD-jet 3D printed porous conductive PCL/PAA NGCs has the potential to be used in the treatment of peripheral nerve injuries. Keywords: 3D printing, Tissue engineering scaffolds, Peripheral nerve injury, Nerve guide conduits, Electrohydrodynamic jet, Conductive scaffolds

3D printing and particularly fused filament fabrication is widely used for prototyping and fabricating low-cost customized parts. However, current fused filament fabrication 3D printers have limited nozzle condition monitoring techniques to minimize nozzle clogging errors. Nozzle clogging is one of the most significant process errors in current fused filament fabrication 3D printers, and it affects the quality of the prototyped parts in terms of geometry tolerance, surface roughness, and mechanical properties. This paper proposes a nozzle condition monitoring technique in fused filament fabrication 3D printing using a vibration sensor, which is briefly described as follows. First, a bar mount that supports the liquefier in fused filament fabrication extruder was modeled as a beam excited by a system of process forces. The boundary conditions were identified, and the applied forces were analyzed for Direct and Bowden types of fused filament fabrication extruders. Second, a new 3D printer with a fixed extruder and a moving platform was designed and built for conducting nozzle condition monitoring experiments. Third, nozzle clogging was simulated by reducing the nozzle extrusion temperature, which caused partial solidification of the filament around inner walls of the nozzle. Fourth, sets of experiments were performed by measuring the vibrations of a bar mount during extrusion of polylactic acid, acrylonitrile butadiene styrene, and SemiFlex filaments via Direct and Bowden types of fused filament fabrication extruders. Findings of the current study show that nozzle clogging in fused filament fabrication 3D printers can be monitored using an accelerometer sensor by measuring extruder’s bar mount vibrations. The proposed technique can be used efficiently for monitoring nozzle clogging in fused filament fabrication 3D printers as it is based on the fundamental process modeling.

Bioprinting three-dimensional (3D) tissue equivalents have progressed tremendously over the last decade. 3D bioprinting is currently being employed to develop larger and more physiologic tissues, and it is of particular interest to generate vasculature in biofabricated tissues to aid better perfusion and transport of nutrition. Having an advantage over manual culture systems by bringing together biological scaffold materials and cells in precise 3D spatial orientation, bioprinting could assist in placing endothelial cells in specific spatial locations within a 3D matrix to promote vessel formation at these predefined areas. Hence, in the present study, we investigated the use of bioprinting to generate tissue-level capillary-like networks in biofabricated tissue constructs. First, we developed a bioink using collagen type-1 supplemented with xanthan gum (XG) as a thickening agent. Using a commercial extrusion-based multi-head bioprinter and collagen-XG bioink, the component cells were spatially assembled, wherein the endothelial cells were bioprinted in a lattice pattern and sandwiched between bioprinted fibroblasts layers. 3D bioprinted constructs thus generated were stable, and maintained structural shape and form. Post-print culture of the bioprinted tissues resulted in endothelial sprouting and formation of interconnected capillary-like networks within the lattice pattern and between the fibroblast layers. Bioprinter-assisted spatial placement of endothelial cells resulted in fabrication of patterned prevascularized constructs that enable potential regenerative applications in the future.

Among different treatments of critical-sized bone defects, bone tissue engineering (BTE) is a fast-developing strategy centering around the fabrication of scaffolds that can stimulate tissue regeneration and provide mechanical support at the same time. This area has seen an extensive application of bioceramics, such as calcium phosphate, for their bioactivity and resemblance to the composition of natural bones. Moreover, recent advances in additive manufacturing (AM) have unleashed enormous potential in the fabrication of BTE scaffolds with tailored porous structure as well as desired biological and mechanical properties. Robocasting is an AM technique that has been widely applied to fabricate calcium phosphate scaffolds, but most of these scaffolds do not meet the mechanical requirements for load-bearing BTE scaffolds. In light of this challenge, various approaches have been utilized to mechanically strengthen the scaffolds. In this review, the current state of knowledge and existing research on robocasting of calcium phosphate scaffolds are presented. Applying the Gibson-Ashby model, this review provides a meta-analysis from the published literature of the compressive strength of robocast calcium phosphate scaffolds. Furthermore, this review evaluates different approaches to the mechanical strengthening of robocast calcium phosphate scaffolds. The aim of this review is to provide insightful data and analysis for future research on mechanical strengthening of robocast calcium phosphate scaffolds and ultimately for their clinical applications.

Overlapping melting trajectories and partially-melted powders result in poor surface morphology and high surface roughness values (Ra = ~13.34 μm) of selective laser melted (SLMed) Ti6Al4V alloy. Secondary processing of SLMed components is thus an essential finishing operation to produce functional SLMed parts in precision engineering. This paper investigates the effects of laser scanning strategies (0°, 67.5° and 90° laser scanning schemes) and machining surfaces (top and front surfaces) on the machining performance of SLMed Ti6Al4V alloy in milling, compared with that of annealed ASTM B265 Ti6Al4V alloy. High degree of anisotropy of SLMed Ti6Al4V alloy is reflected in cutting force, surface morphology and surface roughness on different machining surfaces. The machining anisotropy is dominated by the anisotropy of microstructure and mechanical properties of SLMed Ti6Al4V alloy, where the anisotropy weakens following the sequence of 0°, 90° and 67.5° SLMed samples. It is verified that high cutting speed can improve machining anisotropy features of SLMed titanium alloy. The chip shape of SLMed Ti6Al4V alloy is a typical conical spiral chip, and the bending degree and length of chips produced by SLMed Ti6Al4V alloy are larger than those produced by annealed Ti6Al4V alloy.

This paper aims to improve the surface quality of 316L stainless steel parts manufactured by selective laser melting (SLM) using dry mechanical-electrochemical polishing (DMECP). DMECP is an advanced surface finishing method combining the advantages of both mechanical and electrochemical polishing techniques in a more environmentally friendly manner. In this paper, the SLM process-related defects causing poor surface quality are analysed first. The material removal mechanism of DMECP is investigated to continuously remove the oxide layers formed during polishing. Surface morphology and roughness evolution under different polishing conditions are characterised. The top surface roughness can be reduced by over 91% from 8.72 μm to 0.75 μm compared to side surface by over 93% from 12.10 to 0.80 μm. The material removal on the top surface is more efficient than that on the side surface under the same polishing condition. The secondary defects formed during polishing can be removed using mechanical polishing mode. The chemical element composition of the polished surface exhibits almost identical content to the initial 316L powders. Compared with the initial dark and rough surfaces, the results validate the capability of DMECP as an effective tool to improve the SLM surface quality and achieve a mirror finish.

Stress shielding is one of the main problems that lead to bone resorption and revision surgery after implantation. Most of the commercially available metallic non-porous bone implants have a much greater stiffness than the native human bones and are prone to cause stress-shielding. With an open cell structure and intricate architecture, hyperbolic minimal surfaces offer several advantages such as less stress concentration, high permeability and high surface area to volume ratio, thus providing an ideal environment for cell adhesion, migration, and proliferation. This paper explores the use of porous bone implant design based on Triply Periodic Minimal Surfaces (TPMS) which is additively manufactured with ceramic material (Alumina) using Lithography-based Ceramics Manufacturing (LCM) technology. A total of 12 different primitive surface structure unit cells with pore size in the range of 500–1000 μm and porosity above 50% were considered. This is one of the earliest studies reporting the 3D printing of TPMS-based structures using ceramic material. Our results suggest that the choice of material and a porous TPMS-based design led to fabrication of structures with a much lesser compressive modulus comparable with the native bone and hence could potentially be adopted for bone implant design to mitigate the stress-shielding effect.

Apparent anisotropies have been found in the microstructure and mechanical properties of selective laser melted (SLM) Ti–6Al–4V alloy, which will significantly influence the comprehensive performance of the SLM parts. In this study, the effect of scanning strategies on material anisotropy, including surface morphology, microstructure, microhardness, quasi-static and dynamic mechanical properties, were comprehensively investigated with 0°, 67.5°, and 90° scanning strategies. The SLM Ti6Al4V alloy prepared by the 0° scanning strategy exhibited the most pronounced anisotropy. The size of the primary columnar crystals on the front surface (158–173 μm) is approximately 1.8–3.2 times larger than that of the top surface (54–88 μm), and the microhardness at the top surface is ∼30% higher than that of the front surface. In addition, the modified Johnson-Cook constitutive model for the SLM Ti6Al4V alloy was developed based on the results of quasi-static compression and dynamic compression with the average absolute relative error controlled within 10%. This provides a reliable solution and an effective material constitutive model for modeling and simulation of the machining SLM parts with higher accuracy and enhanced physical meaning.

The incidence of peripheral nerve injuries is on the rise and the current gold standard for treatment of such injuries is nerve autografting. Given the severe limitations of nerve autografts which include donor site morbidity and limited supply, neural guide conduits (NGCs) are considered as an effective alternative treatment. Conductivity is a desired property of an ideal NGC. Reduced graphene oxide (rGO) possesses several advantages in addition to its conductive nature such as high surface area to volume ratio due to its nanostructure and has been explored for its use in tissue engineering. However, most of the works reported are on traditional 2D culture with a layer of rGO coating, while the native tissue microenvironment is three-dimensional. In this study, PCL/rGO scaffolds are fabricated using electrohydrodynamic jet (EHD-jet) 3D printing method as a proof of concept study. Mechanical and material characterization of the printed PCL/rGO scaffolds and PCL scaffolds was done. The addition of rGO results in softer scaffolds which is favorable for neural differentiation. In vitro neural differentiation studies using PC12 cells were also performed. Cell proliferation was higher in the PCL/rGO scaffolds than the PCL scaffolds. Reverse transcription polymerase chain reaction and immunocytochemistry results reveal that PCL/rGO scaffolds support neural differentiation of PC12 cells.

The rapid development of additive manufacturing technology provides a more flexible and efficient manufacturing solution for the high value-added parts with a complex topology. However, the poor surface finish poses a major obstacle for the wide application of the additively manufactured components when their functionality and tolerance are benchmarked with those produced by the conventional process. In selective laser melting, visible pattern and texture of the printed layers and unmolten particles cannot be avoided although research works have been conducted to improve the surface finish by optimising the selective laser melting strategy and process parameters. Therefore, a dedicated post-processing technique is generally required to improve the surface finish of the additively manufactured products in terms of various levels of geometric complexity. In this study, a vibration-assisted conformal polishing tool is developed to finish a representative v-groove structure fabricated by selective laser melting. Experiments are conducted to investigate the effects of abrasive size and polishing time on the improvement in surface roughness. The developed technique in this paper can be applied to finish the additively manufactured internal structures such as honeycomb structure and irregular holes that have linear projection along a single axis.

The design and fabrication of tissue engineering scaffolds is a highly complex process. In order to provide a proper architecture for cells to grow, proliferate, and differentiate to form tissues, scaffolds have to be made with suitable properties. However, the limited structural designs and conventional fabrication techniques severely cripple the improvement of scaffold properties. To overcome these limitations, many researchers have recently adopted computational methods combined with 3D printing techniques as a new approach for scaffold design and fabrication. This approach allows scaffolds to be designed and fabricated with highly complex microstructures and good control and accuracy. Previous works have also shown this approach to be a very useful tool to predict the scaffold properties and to optimize the scaffold designs with a great reduction of experimental iterations. As this approach combining computational methods and 3D printing techniques for scaffold design and fabrication has many advantages over the conventional trial-and-error based approach, it is imperative to provide a state-of-the-art review on the topic. To this end, this article reviews the various applications of computational methods in scaffold design and simulation; it also briefly reviews the application of 3D printing techniques to fabricate the computationally designed scaffolds. Finally, the limitations and future trends of this approach are discussed. Overall, this review will enable readers to understand the benefits of using computational methods coupled with 3D printing to design and fabricate scaffolds, and thus help researchers to improve and optimize the scaffold properties for future tissue engineering research. © 2018 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater 107B: 1329-1351, 2019.

Designing metallic cellular structures with triply periodic minimal surface (TPMS) sheet cores is a novel approach for lightweight and multi-functional structural applications. Different from current honeycombs and lattices, TPMS sheet structures are composed of continuous and smooth shells, allowing for large surface areas and continuous internal channels. In this paper, we investigate the mechanical properties and energy absorption abilities of three types of TPMS sheet structures (Primitive, Diamond, and Gyroid) fabricated by selective laser melting (SLM) with 316 L stainless steel under compression loading and classify their failure mechanisms and printing accuracy with the help of numerical analysis. Experimental results reveal the superior stiffness, plateau stress and energy absorption ability of TPMS sheet structures compared to body-centred cubic lattices, with Diamond-type sheet structures performing best. Nonlinear finite element simulation results also show that Diamond and Gyroid sheet structures display relatively uniform stress distributions across all lattice cells under compression, leading to stable collapse mechanisms and desired energy absorption performance. In contrast, Primitive-type structures display rapid diagonal shear band development followed by localized wall buckling. Lastly, an energy absorption diagram is developed to facilitate a systematic way to select optimal densities of TPMS structures for energy absorbing applications.

Biomimetic scaffold design is gaining attention in the field of tissue engineering lately. Recently, triply periodic minimal surfaces (TPMSs) have attracted the attention of tissue engineering scientists for fabrication of biomimetic porous scaffolds. TPMS scaffolds offer several advantages, which include a high surface area to volume ratio, less stress concentration, and increased permeability compared to the traditional lattice structures, thereby aiding in better cell adhesion, migration, and proliferation. In literature, several design methods for TPMS scaffolds have been developed, which considered some of the important tissue-specific requirements, such as porosity, Young's modulus, and pore size. However, only one of the requirements of a tissue engineering scaffold was investigated in these studies, and not all of the requirements were satisfied simultaneously. In this work, we develop a design method for TPMS sheet scaffolds, which is able to satisfy multiple requirements including the porosity, Young's modulus, and pore size, based on a parametric optimization approach. Three TPMSs, namely, the primitive (P), gyroid (G), and diamond (D) surfaces, with cubic symmetry are considered. The versatility of the proposed design method is demonstrated by three different applications, namely, tissue-specific scaffolds, scaffolds for stem cell differentiation, and functionally graded scaffolds with biomimetic functional gradients.

Biomimicry is a desirable quality of tissue engineering scaffolds. While most of the scaffolds reported in the literature contain a single pore size or porosity, the native biological tissues such as cartilage and skin have a layered architecture with zone-specific pore size and mechanical properties. Thus, there is a need for functionally graded scaffolds (FGS). EHD-jet 3D printing is a high-resolution process and a variety of polymer solutions can be processed into 3D porous scaffolds at ease, overcoming the limitations of other 3D printing methods (SLS, stereolithography, and FDM) in terms of resolution and limited material choice. In this paper, a novel proof of concept study on fabrication of porous polycaprolactone-based FGS by using EHD-jet 3D printing technology is presented. Organomorphic scaffolds, multiculture systems, interfacial tissue engineering, and in vitro cancer metastasis models are some of the futuristic applications of these polymeric FGS.

Lightweight lattice structures are an important class of cellular structures with high potentials for multi-functional applications. Considering load-bearing requirements, truss buckling is one of the main failure mechanisms for low density and slender lattice structures. Critical buckling loads can be increased by modifying the profile of a truss. In this paper, we present a shape design method to optimize the critical buckling loads for lattice cores with free-form trusses. The free-form truss is represented by Fourier series and implicit surfaces, having smooth truss diameter variations and truss joints. The optimized truss profile is obtained by solving a parametric shape optimization problem with Fourier series coefficients as design variables. The method is used for designing optimized 1D columns and 3D Kagome lattice cores for sandwich panels. The numerical results predict 26.8% and 20.4% improvements of the critical buckling loads for 1D columns and 3D Kagome lattice cores compared to their uniform counterparts of the same mass, respectively. The optimized structures include complex smooth and curved geometries that are well suited for additive manufacturing because of the greater design freedom. Finally, the initial and optimized lattice cores are additively manufactured and tested. The experimental results validate the effectiveness of the proposed method. Keywords: Additive manufacturing, Shape design, Buckling failure, Kagome lattice core, Free-form truss

For negative Poisson's ratio (NPR) cellular structures, most previous research focus on the design of unit cells, and then repeat the unit cell to construct uniform cellular structures. However, there is a disadvantage that these structures do not have much design freedom to achieve high-level functions, such as performing a desired deformation. As a solution, an evolutionary design method is proposed to develop nonuniform cellular structures. To conduct this method, the design domain is divided into finite unit cells with tunable Poisson's ratio (PR). With a given objective deformation, the value of each unit cell's PR is optimized using evolutionary algorithm (EA). In order to reduce the computational cost of the algorithm, discrete cosine transform (DCT) is applied to encode the structure for evolving. Considering the geometrical complexity of the optimized nonuniform cellular structures, additive manufacturing (AM) is chosen to build them physically. Both two-dimensional (2D) and three-dimensional (3D) design cases were developed and analyzed to validate the proposed method. The computational and experimental results showed good conformation with each other. Most importantly, this novel design method brings huge potential to NPR cellular structures with high-level functions and much wider applications. Keywords: Nonuniform cellular structure, Poisson's ratio, Evolutionary algorithm, Re-entrant structure, Additive manufacturing

Thin-walled tubes have long been used as energy absorbing structures, owing to their high specific energy absorption (SEA) capacity. But, they are associated with substantial high values of peak cr...

Functionally graded lattice core structures show a gradual and localised variation in their mechanical properties with the aim of improving structural performance whilst minimising weight. We present a novel approach to generate optimised functionally graded lattice core structures. Firstly, topology optimisation is performed to return the optimal core density distribution to minimise the structure's compliance subject to a mass constraint. A series of isostatic lines are then constructed with respect to the local principal stresses to generate a lattice structure spatially graded with respect to lattice cell size, aspect ratio and orientation. To validate this novel approach, optimisation is performed on a sandwich core structure subject to three point bending. Experimental tests confirm the greatly improved stiffness and strength properties (101% and 172% respectively) of the core as a result of spatially grading the lattice cells when compared to a benchmark core with uniform cell size of the same density. The new approach also significantly outperforms lattice structures with graded diameters as optimised by state-of-the-art commercial software packages. Non-dimensional core performance indices are formulated to express the relative specific stiffness and strength properties of the core for the three design approaches. Keywords: Topology optimisation, Lattice structures, Finite element analysis, Functionally graded materials, Sandwich structures

Biocompatible tissue engineering (TE) scaffolds were used to closure the leakage area in gastro intestinal (GI) tract as patches; they could induce the regeneration of defected tissue and degraded steadily. However, some disadvantages, such as small and uncontrolled pore size, hinder the application of existed TE scaffolds. In this study, PCL/F127 composite scaffolds were fabricated through electrohydrodynamic jetting (E-jetting) technique. And the E-jetted scaffolds were cultured with esophageal fibroblast cells (the most important cell type in wound healing process) to evaluate their biocompatibility. The results show that E-jetted PCL/F127 scaffold has potential to be an alternative GI tract regeneration tool.

Conductivity is a desirable property of an ideal nerve guide conduit (NGC) that is being considered for peripheral nerve regeneration. Most of the conductive polymers reported in use for fabrication of tissue engineering scaffolds such as polypyrrole (PPy), polyaniline, polythiophene, and poly(3,4-ethylenedioxythiophene) are non-biodegradable and possess weak mechanical properties to be fabricated into 3D structures. In this study, a biodegradable and conductive block copolymer of PPy and Polycaprolactone (PPy-b-PCL) was used to fabricate 3D porous NGCs using a novel electrohydrodynamic jet 3D printing process which offers superior control over fiber diameter, pore size, porosity, and fiber alignment. PCL/PPy scaffolds with three different concentrations of PPy-b-PCL (0.5, 1, and 2% v/v) were fabricated as a mesh (pore size 125 ± 15 μm) and the effect of incorporation of PPy-b-PCL on mechanical properties, biodegradability, and conductivity of the NGCs were studied. The mechanical properties of the scaffolds decreased with the addition of PPy-b-PCL which aided the ability to fabricate softer scaffolds that are closer to the properties of the native human peripheral nerve. With increasing concentrations of PPy-b-PCL, the scaffolds displayed a marked increase in conductivity (ranging from 0.28 to 1.15 mS/cm depending on concentration of PPy). Human embryonic stem cell-derived neural crest stem cells (hESC-NCSCs) were used to investigate the impact of PPy-b-PCL based conductive scaffolds on the growth and differentiation to peripheral neuronal cells. The hESC-NCSCs were able to attach and differentiate to peripheral neurons on PCL and PCL/PPy scaffolds, in particular the PCL/PPy (1% v/v) scaffolds supported higher growth of neural cells and a stronger maturation of hESC-NCSCs to peripheral neuronal cells. Overall, these results suggest that PPy-based conductive scaffolds have potential clinical value as cell-free or cell-laden NGCs for peripheral neuronal regeneration.

Bioprinting is increasingly being used for fabrication of engineered tissues for regenerative medicine, drug testing, and other biomedical applications. The success of this technology lies with the development of suitable bioinks and hydrogels that are specific to the intended tissue application. For applications such as neural tissue engineering, conductivity plays an important role in determining the neural differentiation and neural tissue regeneration. Although several conductive hydrogels based on metal nanoparticles (NPs) such as gold and silver, carbon-based materials such as graphene and carbon nanotubes and conducting polymers such as polypyrrole (PPy) and polyaniline were used, they possess several disadvantages. The long-term cytotoxicity of metal nanoparticles (NPs) and carbon-based materials restricts their use in regenerative medicine. The conductive polymers, on the other hand, are non-biodegradable and possess weak mechanical properties limiting their printability into three-dimensional constructs. The aim of this study is to develop a biodegradable, conductive, and printable hydrogel based on collagen and a block copolymer of PPy and polycaprolactone (PCL) (PPy-block-poly(caprolactone) [PPy-b-PCL]) for bioprinting of neural tissue constructs. The printability, including the influence of the printing speed and material flow rate on the printed fiber width; rheological properties; and cytotoxicity of these hydrogels were studied. The results prove that the collagen/PPy-b-PCL hydrogels possessed better printability and biocompatibility. Thus, the collagen/PPy-b-PCL hydrogels reported this study has the potential to be used in the bioprinting of neural tissue constructs for the repair of damaged neural tissues and drug testing or precision medicine applications.

Stainless steel 304L (SS304L) has been selected as the material for canisters for spent fuel storage from three nuclear power plants in Taiwan. A crucial issue is extending the spent fuel storage safety standards of the canisters. The anti-saline corrosion abilities of three thermal spray coatings (i.e., Al, ZnAl, and 625 Inconel alloys) on the SS304L were evaluated by immersion in 3.5 wt % aqueous NaCl and with 0.025 g/cm2 NaCl deposition at 80 &deg, C and 80% relative humidity (RH) for 1000 h. The pristine thermal spray coatings were examined using the pull-off adhesion test to understand the adhesion strength, and Vickers hardness was measured for the mechanical properties of the three coatings. Confocal laser scanning microscopy (CLSM) was used to identify the porosities of the coatings. Furthermore, the surfaces of the specimens before and after corrosion were investigated using scanning electron microscopy (SEM), X-ray diffraction (XRD), and energy dispersive spectroscopy (EDS). The composition and distribution of the oxide layers formed on the coating surfaces during corrosion were evaluated. Electrochemical measurement was also performed with the polarization method to quantify the corrosion property of the three thermal spray coatings. The results showed that the corrosion rate of Al coating was lowest from the Tafel analysis after the 1000 h corrosion test in 3.5% aqueous NaCl. In contrast, the corrosion rate of Inconel 625 was lowest after 1000 h of the NaCl deposition corrosion test in a controlled environment. Therefore, the ZnAl thermal spray coating is a potential protection layer, keeping in mind economic considerations, of SS304L for anti-corrosion in saline environments.

Metallic lattice structures are well known for having high specific elastic moduli and strength. However, very little is understood about their resistance to fracture. In this work Ti–6Al–4V lattice structures are additively manufactured by selective laser melting and their fracture toughness characteristics are investigated. Resistance to fracture was determined under Mode-I loading at static rates using an extended compact tension (EC(T)) specimen, modified to contain lattice cells. The lattices consist of octet cells with a 3.5 mm edge length and relative densities ranging from 25% to 56%. Toughness is shown to increase by a power law with relative density and this trend was also obtained with finite element models. A new functional grading optimisation methodology is also presented for increasing fracture toughness. The size optimisation results in a functionally graded lattice whereby lattice truss diameters become the design variables. After size optimisation, initiation fracture toughness increases by up to 37%.

Selective laser melting processes deposit and join metal powders to near net shape in a layer-by-layer manner. The process of melting and re-solidification of several layers of deposited material can result in geometric deviations, and the impact is particularly significant for sub-millimetre structures oriented at a wide range of overhang angles with respect to the building platform. This paper assesses and benchmarks the capabilities of a neural network-based geometric compensation approach for truss lattice structures with circular cross-sections. The neural network method is capable to generate free-form cross-sections with enhanced geometric freedom for compensation compared to more established analytical compensation approaches limited to predefined geometric shapes. For neural network training, lattice dome structures composed of trusses with different overhang angles were designed and printed by selective laser melting and measured via X-ray computed tomography, resulting in point cloud data sets containing more than 20,000 data points for each overhang angle. For experimental validation, neural network-compensated dome structures were benchmarked against dome structures with elliptical parameter compensation. Results show that the neural network compensated lattice trusses achieve higher printing dimensional accuracy compared to the uncompensated structures and those compensated based on elliptical parameter estimates.

Selective laser melting (SLM) is generally characterized by the brief laser-powder interaction time, highly localized heat intensity and input distributions, steep temperature gradients and high cooling rate. It was admitted that the mechanical properties of as-built SLMed components exhibit significantly anisotropic due to different heat history and microstructures in different directions. Post-processing of additively manufactured parts is generally considered an essential operation due to poor surface quality and dimensional accuracy. In this paper, comprehensive research is conducted about the influence of material anisotropy of additively manufactured Ti-6Al-4V alloys on machining performance in ultra-precision micromachining. The machining performance of SLMed Ti-6Al-4V alloys was derived from two cutting directions (parallel/perpendicular to the laser scanning direction), two machining surfaces (top/front surface) and three laser scanning strategies (0°-line scanning, 67.5°/90°- rotation scanning). Surface topography, roughness, microstructure and microhardness were assessed to characterize the material anisotropy of SLMed titanium alloy. The machining results showed that the anisotropic mechanical properties and microstructure feature of the Ti-6Al-4V alloys are the fundamental reasons for the anisotropic machining performance in terms of cutting force and surface roughness. The machining properties of SLMed Ti-6Al-4V alloys are affected by the microstructure, machining surfaces, cutting directions and cutting parameters. Both the magnitude and fluctuation of dynamic cutting force produced on the front surfaces are obviously larger than those generated on the top surfaces. Significant improvement in surface roughness ranging from Sa = 80–100 nm could be achieved along the laser scanning direction for 0°-line SLMed Ti-6Al-4V sample when cutting depth was from 1 to 15 μm at vc = 50 mm/min. In addition, some typical SLMed defects appear on the machined surface and produced chips. This research is applicable to assist manufacturers in choosing the appropriate machining method for SLMed components in ultra-precision machining.

Surface roughness is often considered as one of the most important technical requirements for a machined part in production. Traditional selection of conservative process parameters neither guarantees part surface quality nor attains high metal removal rates. An accurate prediction and effective control of surface roughness is of vital importance for improving machining efficiency and reducing machining cost. In this paper, a novel model is presented for predicting surface roughness when slot milling Al-7075. The model is developed using a hybrid approach combining analytical calculation of specific cutting energy consumption (SCEC) and empirical characterization of the relationship between the surface roughness and SCEC. The proposed model has been validated by experiments under various cutting conditions. Compared to Taguchi methodology for predicting surface roughness, the proposed model is more accurate and reliable. From a novel viewpoint of SCEC, the model may provide valuable information regarding the effects of the cutting parameters on the surface roughness. Besides, the implementation of this model is straightforward, thus providing great potential for surface roughness control in real production.

The effects of trace MoSi2 addition on the microstructure evolution, mechanical properties and fracture behavior of Ti–6Al–4V wall via cold metal transfer additive manufacturing (CMTAM) were investigated. After the addition of trace MoSi2 powder, trace (β-Ti, Mo) phase and SiO2 particles were obtained and partly prior-β→α’ phase transformation was suppressed. Compared with the as-built Ti–6Al–4V wall, the prior-β grains changed from columnar to the equiaxed or near-equiaxed after the addition of trace MoSi2. The tensile analysis result revealed that the addition of trace MoSi2 could improve the average strain while reduce anisotropy. All specimens showed dimples corresponding to ductile failure mode. The possible thermal cycles for the trace-MoSi2-addition specimens during the CMTAM process were analyzed.

This study investigated the effects of dendrite axis and fusion boundary (FB) on the stress corrosion cracking (SCC) of 308 L/304 L welds by using an alternating current potential drop (ACPD) technique to measure the SCC growth rates in a simulated boiling water reactor environment. The results show that the ferrite/austenite interfaces are more susceptible to SCC in the SS 308 L welds. Furthermore, the angle between the applied load and the dendrite axis affects the SCC growth rate, and as this angle approached 90°, the SCC crack growth rate increases. The SCC cracks in the heat affected zone (HAZ) are mainly intergranular and some cracks propagate transgranularly. Furthermore, the primary crack in the HAZ propagates along the FB; when reaching FB, some secondary cracks are arrested at the FB. The residual strain caused by weld shrinkage is the crucial factor for the increase in SCC susceptibility in HAZ.

Nerve guidance conduits (NGCs) are tubular tissue engineering scaffolds used for nerve regeneration. The poor mechanical properties and porosity have always compromised their performances for guiding and supporting axonal growth. Therefore, in order to improve the properties of NGCs, the computational design approach was adopted to investigate the effects of different NGC structural features on their various properties, and finally, design an ideal NGC with mechanical properties matching human nerves and high porosity and permeability. Three common NGC designs, namely hollow luminal, multichannel, and microgrooved, were chosen in this study. Simulations were conducted to study the mechanical properties and permeability. The results show that pore size is the most influential structural feature for NGC tensile modulus. Multichannel NGCs have higher mechanical strength but lower permeability compared to other designs. Square pores lead to higher permeability but lower mechanical strength than circular pores. The study finally selected an optimized hollow luminal NGC with a porosity of 71% and a tensile modulus of 8 MPa to achieve multiple design requirements. The use of computational design and optimization was shown to be promising in future NGC design and nerve tissue engineering research.

Stent implantation at a highly curved artery has always been a challenge, considering the relatively high chance of in-stent restenosis (ISR) caused by severe straightening effect and high strain energy over the vessel wall. In this paper, a novel optimization based design method was proposed to manipulate the deformation behavior of the common ring-and-link stent. By changing the location of the connection point between rings and links, traditional ring-and-link structure was modified to achiever tunable Poisson's ratio (PR). With the nonuniform cellular structure design method proposed in a previous study, PR distribution of the stent structure was optimized to achieve the desired curvature. As a result, the obtained stent structure with nonuniform PR could perfectly fit into the curved artery after expansion, without causing any obvious vessel straightening. To validate the proposed method, two different vessel models were introduced. Firstly, a short vessel with a constant curvature was set as the design objective, and both numerical and experimental tests were conducted. Further, a patient-specific vessel was applied. Both test results showed that optimized stents would cause much smaller vessel straightening. Moreover, vessels stented by the optimized structures had much lower stress concentration and strain energy. All those properties will decrease the possibility of ISR significantly.

Several attempts have been made to fabricate esophageal tissue engineering scaffolds. However, most of these scaffolds possess randomly oriented fibres and uncontrollable pore sizes. In order to mimic the native esophageal tissue structure, electro-hydrodynamic jetting (e-jetting) was used in this study to fabricate scaffolds with aligned fibres and controlled pore size. A hydrophilic additive, Pluronic F127 (F127), was blended with polycaprolactone (PCL) to improve the wettability of the scaffolds and hence the cell adhesion. PCL/F127 composite scaffolds with different weight ratios (0–12%) were fabricated. The wettability, phase composition, and the mechanical properties of the fabricated scaffolds were investigated. The results show that the e-jetted scaffolds have controllable fibres orientated in two perpendicular directions, which are similar to the human esophagus structure and suitable pore size for cell infiltration. In addition, the scaffolds with 8% F127 exhibited better wettability (contact angle of 14°) and an ultimate tensile strength (1.2 MPa) that mimics the native esophageal tissue. Furthermore, primary human esophageal fibroblasts were seeded on the e-jetted scaffolds. PCL/F127 scaffolds showed enhanced cell proliferation and expression of the vascular endothelial growth factor (VEGF) compared to pristine PCL scaffolds (1.5- and 25.8- fold increase, respectively; P

The slow strain rate tests (SSRT) at a nominal strain rate 1× 10−6/s were conducted to evaluate the mechanical properties of CF8A cast austenitic stainless steel (CASS) in air and high-temperature water environments. CF8A CASS is mainly composed of a matrix of γ phase dispersed with δ ferrites and is affected slightly by aging heat treatment. The hardness value of γ phase did not change with aging time, while that of δ ferrite increased with increasing the aging time. The SSRT results showed that a loss in elongation of a high δ-ferrite specimen was more significant than that of the low δ-ferrite specimens. The SCC paths of the low δ-ferrite specimen were along the links between δ ferrites dispersed in the matrix. For the high δ-ferrite specimen, most of the cracks were observed to propagate through the chromium depletion regions in the ferrite grains, which were preferentially oxidized during the SSR test in water. However, the elongation did not decrease further after aging time was longer than 2,400 h,...

In tissue engineering, cell-laden scaffold has gradually replaced cell-less scaffold due to better biological performance. However, manual pipetting, the traditional cell seeding for cell-laden scaffold, leads to an imprecise and inhomogeneous cell distribution. As an alternative, micro-extrusion of cell-laden hydrogel achieves homogenous cell distribution, but causes high shear stress which is harmful to cells. To address this challenge, the objective of this study is to print cells on porous scaffold precisely without causing high shear stress to produce homogeneous cell-laden hybrid scaffold. Porous polycaprolactone scaffold fabricated through electro-hydrodynamic jetting was used as a representation. To improve scaffold hydrophilicity for better cell adhesion, 6% (w/w) Pluronic F127 was blended with polycaprolactone. HeLa cells, as a demonstration, were ejected on the scaffold fibers through piezoelectric inkjet printing. As a result, inkjet printing showed a more precise and homogeneous cell distribution and enhanced cell proliferation compared to manual pipetting (1.34- fold increase after 7 days). Furthermore, due to the low viscosity of cell solution, the average shear stress caused during inkjet printing was 1.79 kPa as opposed to 18 kPa of micro-extrusion, which is friendly to cells. In summary, through inkjet printing, homogeneous cell-laden hybrid scaffold could be fabricated with lower shear stress.

The prevalence of peripheral nerve injuries resulting in loss of motor function, sensory function, or both, is on the rise. Artificial Nerve Guide Conduits (NGCs) are considered an effective alternative treatment for autologous nerve grafts, which is the current gold-standard for treating peripheral nerve injuries. In this study, Polycaprolactone-based three-dimensional porous NGCs are fabricated using Electrohydrodynamic jet 3D printing (EHD-jetting) for the first time. The main advantage of this technique is that all the scaffold properties, namely fibre diameter, pore size, porosity, and fibre alignment, can be controlled by tuning the process parameters. In addition, EHD-jetting has the advantages of customizability, repeatability, and scalability. Scaffolds with five different pore sizes (125 to 550 μm) and porosities (65 to 88%) are fabricated and the effect of pore size on the mechanical properties is evaluated. In vitro degradation studies are carried out to investigate the degradation profile of the scaffolds and determine the influence of pore size on the degradation rate and mechanical properties at various degradation time points. Scaffolds with a pore size of 125 ± 15 μm meet the requirements of an optimal NGC structure with a porosity greater than 60%, mechanical properties closer to those of the native peripheral nerves, and an optimal degradation rate matching the nerve regeneration rate post-injury. The in vitro neural differentiation studies also corroborate the same results. Cell proliferation was highest in the scaffolds with a pore size of 125 ± 15 μm assessed by the PrestoBlue assay. The Reverse Transcription-Polymerase Chain Reaction (RT-PCR) results involving the three most important genes concerning neural differentiation, namely β3-tubulin, NF-H, and GAP-43, confirm that the scaffolds with a pore size of 125 ± 15 μm have the highest gene expression of all the other pore sizes and also outperform the electrospun Polycaprolactone (PCL) scaffold. The immunocytochemistry results, expressing the two important nerve proteins β3-tubulin and NF200, showed directional alignment of the neurite growth along the fibre direction in EHD-jet 3D printed scaffolds.

Tissue engineering is a multi-disciplinary area of research bringing together the fields of engineering and life sciences with the aim of fabricating tissue constructs aiding in the regeneration of damaged tissues and organs. Scaffolds play a key role in tissue engineering, acting as the templates for tissue regeneration and guiding the growth of new tissue. The use of stem cells in tissue engineering and regenerative medicine becomes indispensable, especially for applications involving successful long-term restoration of continuously self-renewing tissues, such as skin. The differentiation of stem cells is controlled by a number of cues, of which the nature of the substrate and its innate stiffness plays a vital role in stem cell fate determination. By tuning the substrate stiffness, the differentiation of stem cells can be directed to the desired lineage. Many studies on the effect of substrate stiffness on stem cell differentiation has been reported, but most of those studies are conducted with two-dimensional (2D) substrates. However, the native in vivo tissue microenvironment is three-dimensional (3D) and life science researchers are moving towards 3D cell cultures. Porous 3D scaffolds are widely used by the researchers for 3D cell culture and the properties of such scaffolds affects the cell attachment, proliferation, and differentiation. To this end, the design of porous scaffolds directly influences the stem cell fate determination. There exists a need to have 3D scaffolds with tunable stiffness for directing the differentiation of stem cells into the desired lineage. Given the limited number of biomaterials with all the desired properties, the design of the scaffolds themselves could be used to tune the matrix stiffness. This paper is an in silico study, investigating the effect of various scaffold parameter, namely fiber width, porosity, number of unit cells per layer, number of layers, and material selection, on the matrix stiffness, thereby offering a guideline for design of porous tissue engineering scaffolds with tunable matrix stiffness for directing stem cell lineage specification.

In this study, polycaprolactone/mineral trioxide aggregate (PCL/MTA) scaffolds were successfully fabricated via an electrohydrodynamic jet (or E-jet) 3D printing system developed by our group. The viscosity of the composited solutions and the key process parameters (i.e. applied voltage and feed rate) were investigated to achieve an optimal process condition. To investigate the potential of PCL/MTA scaffolds to support regeneration ability for dentin related tissue, we seeded dental pulp stem cells on the scaffolds, and compared the results with cell-seeded PCL scaffolds. Assessment of cell viability and proliferation using live/dead cell staining and MTS assay showed compatibility of PCL and PCL/MTA scaffolds for cellular attachment and growth. These scaffolds could be used for fabrication of three-dimensional tissues and in future could be applied to dentin and periodontal tissue engineering applications.