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Polymeric biomaterials such as polylactic acid (PLA) play a prominent role in the advancement of biomedical additive manufacturing (AM). PLA offers indeed a very advantageous combination of thermo-mechanical properties and functional attributes, as it is biobased, biodegradable, biocompatible and easy to print. However, PLA can be damaged by common sterilization methods and is sensitive to most chemical disinfectants, and this may impair its widespread usage. One of the most promising ways to overcome this shortcoming is to provide PLA with embedded antibacterial activity by the addition of appropriate fillers such as ZnO nanoparticles. After a detailed introduction to the basic properties of PLA and ZnO nanoparticles, the present review analyzes the main variables that govern the antibacterial activity of PLA-ZnO nanocomposites. Current applications and related manufacturing processes are also presented to showcase the importance of having embedded antibacterial functions in demanding fields such as food packaging and wound dressing. Emphasis is then placed on the emerging literature of the AM of PLA-ZnO nanocomposites, with a focus on fused filament fabrication (also known as fused deposition modeling). Existing gaps and hurdles related to the development and 3D printing of such composites are critically discussed. It is envisioned that a deeper understanding of the processability, thermo-mechanical behavior, biocompatibility and anti-bacterial efficacy of additively manufactured PLA-ZnO nanocomposites will foster their adoption in the biomedical field and, ultimately, in all circumstances where it is crucial to limit infection transmission.

Over the last few years, the effectiveness of textile-reinforced mortar (TRM) composite systems for structural retrofitting has led to the widespread adoption of these materials in the practice and to the issue of up-to-date design guidelines. Nonetheless, the weak interfacial bonding that is frequently observed between matrix and fibres is likely to cause inconsistent failure modes and, generally speaking, to severely limit the reinforcing potential of the textile. A promising solution to tackle this issue consists in treating the surface of the reinforcing fibres with a functional coating to improve the adhesion at the interphase. In this paper, a pilot study is presented to assess the effectiveness of a fully sustainable polymer coating, consisting in polyvinyl alcohol (PVA) loaded with with rice husk ash (RHA) or with a 50/50 mixture of RHA and silica fume (SF). The coating was applied on basalt fabrics to reinforce TRM coupons that were mechanically tested under uni-axial tensile loads. The mechanical properties of the TRM samples were significantly increased by up to 20%, and the peak load was attained at a higher deformability level, which is a clue of the enhanced ductility of the reinforced elements.

Cement and lime currently are the most common binders in building materials. However, alternative materials and methods are needed to overcome the functional limitations and environmental footprint of conventional products. This Special Issue is entirely dedicated to “New frontiers in cementitious and lime-based materials and composites” and gathers selected reviews and experimental articles that showcase the most recent trends in this multidisciplinary field. Authoritative contributions from all around the world provide important insights into all areas of research related to cementitious and lime-based materials and composites, spanning from structural engineering to geotechnics, including materials science and processing technology. This topical cross-disciplinary collection is intended to foster innovation and help researchers and developers to identify new solutions for a more sustainable and functional built environment.

The extreme personalization of the sports car industry requires the development of reliable and affordable techniques for the in-house set-up and control of processing conditions in deep dr...

Additive manufacturing (AM) of orthopedic implants is growing in popularity as it offers almost complete design flexibility and freedom, meaning complex geometries mimicking specific body parts can be easily produced. Novel composite materials with optimized functionalities present opportunities for 3D printing osteoconductive implants with desirable mechanical properties. Standard metals for bone implants, such as titanium and its alloys, are durable and nontoxic but lack bioactivity. Bioactive glasses promote strong bone formation but are susceptible to brittle failure. Metal-bioactive glass composites, however, may combine the mechanical reliability of metals with the bone-bonding ability of bioactive glasses, potentially reducing the incidence of implant failure. Processing such composites by AM paves the way for producing unprecedented bespoke parts with highly porous lattices, whose stiffness can be tailored to meet the mechanical properties of natural bone tissue. This Perspective focuses on titanium-bioactive glass composites, critically discussing their processability by AM and highlighting their potential as a next-generation implantable biomaterial.

Lattice materials represent one of the utmost applications of additive manufacturing. The promising synergy between additive processes and topology optimization finds full development in achieving components that comprise bulky and hollow areas, as well as intermediate zones. Yet, the potential to design innovative shapes can be hindered by technological limits. The article tackles the manufacturability by laser-based powder bed fusion (L-PBF) of aluminum-based lattice materials by varying the beam diameter and thus the relative density. The printing accuracy is evaluated against the distinctive building phenomena in L-PBF of metals. The main finding consists in identification of a feasibility window that can be used for development of lightweight industrial components. A relative density of 20% compared with fully solid material (aluminum alloy A357.0) is found as the lowest boundary for a 3-mm cell dimension for a body-centered cubic structure with struts along the cube edges (BCCXYZ) and built with the vertical edges parallel to the growth direction to account for the worst-case scenario. Lighter structures of this kind, even if theoretically compliant with technical specifications of the machine, result in unstable frameworks.

The preparation and thermo-mechanical characterization of composites based on polyamide 11 (PA11) filled with various amounts of both expandable and expanded graphites are presented. Investigation conducted using X-ray diffraction (XRD), scanning electron microscopy and surface area analyses indicated how graphite expanded under the selected processing conditions. The XRD analysis on PA11/graphite composites revealed no change in the crystal form of the PA11, while the presence of diffraction peaks associated to the graphite-stacked lamellae can be still detected. All the investigated composites showed an improvement of the thermal stability and mechanical properties (elastic and storage moduli).

Additive manufacturing (AM) is rapidly evolving from “rapid prototyping” to “industrial production”. AM enables the fabrication of bespoke components with complicated geometries in the high-performance areas of aerospace, defence and biomedicine. Providing AM parts with a tagging feature that allows them to be identified like a fingerprint can be crucial for logistics, certification and anti-counterfeiting purposes. Whereas the implementation of an overarching strategy for the complete traceability of AM components downstream from designer to end user is, by nature, a cross-disciplinary task that involves legal, digital and technological issues, materials engineers are on the front line of research to understand what kind of tag is preferred for each kind of object and how existing materials and 3D printing hardware should be synergistically modified to create such tag. This review provides a critical analysis of the main requirements and properties of tagging features for authentication and identification of AM parts, of the strategies that have been put in place so far, and of the future challenges that are emerging to make these systems efficient and suitable for digitalisation. It is envisaged that this literature survey will help scientists and developers answer the challenging question: “How can we embed a tagging feature in an AM part?”.

The composition of a CaO-rich silicate bioglass (BG_Ca-Mix, in mol%: 2.3 Na2O; 2.3 K2O; 45.6 CaO; 2.6 P2O5; 47.2 SiO2) was modified by replacing a fixed 10 mol% of CaO with MgO or SrO or fifty-fifty MgO-SrO. The thermal behaviour of the modified glasses was accurately evaluated via differential thermal analysis (DTA), heating microscopy and direct sintering tests. The presence of MgO and/or SrO didn't interfere with the thermal stability of the parent glass, since all the new glasses remained completely amorphous after sintering (treatment performed at 753 °C for the glass with MgO; at 750 °C with SrO; at 759 °C with MgO and SrO). The sintered samples achieved good mechanical properties, with a Young's modulus ranging between 57.9 ± 6.7 for the MgO-SrO modified composition and 112.6 ± 8.0 GPa for the MgO-modified one. If immersed in a simulated body fluid (SBF), the modified glasses after sintering retained the strong apatite forming ability of the parent glass, in spite of the presence of MgO and/or SrO. Moreover, the sintered glasses, tested with MLO-Y4 osteocytes by means of a multi-parametrical approach, showed a good bioactivity in vitro, since neither the glasses nor their extracts caused any negative effect on cell viability or any inhibition on cell growth. The best results were achieved by the MgO-modified glasses, both BGMIX_Mg and BGMIX_MgSr, which were able to exert a strong stimulating effect on the cell growth, thus confirming the beneficial effect of MgO on the glass bioactivity.

An analytical model was applied in order to understand the distribution depth of cured stone consolidants. The model is grounded on a case study of Vienna’s St. Stephen’s Cathedral and was verified against drilled cores examined by SEM and image analysis, on-site drilling resistance measurements and laboratory-based mechanical tests. The results reveal that the variation of the concentration gradient with penetration depth resembles an exponential decline. The deposition of the cured consolidant is governed by capillary forces upon drying within water-based nano-zirconia dispersions and water/alcohol-based colloidal silica. This effect is less pronounced within reactive consolidants, which undergo polycondensation reactions, as with alkoxysilanes.

Electron beam melting (EBM) is an additive manufacturing technique that uses an electron beam to selectively fuse and consolidate the metal powder. The final object is built up layer-by-layer according to a computer-aided design or, in case of customized biomedical implants, according to a computed tomography of the patient. This chapter introduces the basic concepts of EBM and the advantages and limitations of applying this technique in biomedical manufacturing. Subsequently, the chapter is describing the processing steps of EBM, the consolidation mechanisms, and the potential microstructural defects of the finished parts. A thorough discussion is provided about the EBM capability of producing cellular structures, dental implants, and orthopedic prostheses, with an emphasis on customized parts. The chapter closes with a survey of the challenges and the future developments of EBM to fabricate biomedical devices.

This work investigates the effect of a fast, acid-catalysed sol-gel silica nano-coating on the mechanical performance of draw-wire Polypropylene (PP) fibres used as dispersed reinforcement in Fibre Reinforced Concrete (FRC). The failure mechanism is investigated. To this aim, the role of curing time is also considered. Mechanical performance is assessed in pull-out and three-point bending tests of un-notched beams. Coating deeply affects the post-cracking behaviour of FRC, which shifts from brittle (plain concrete), to softening (uncoated) and finally to plastic-softening (coated fibres). Remarkably, 28-day curing improves over 8-day curing in terms of energy dissipation capability for coated fibres only. This suggests that fibre-to-matrix bond enhancement moves the failure mechanism from delamination at the interface to failure in the interphase zone. In the former case, failure is inconsistent and occurs independently from the curing time while in the latter failure depends on the matrix quality.

The effect of epoxy dilution with acetone on the mechanical performance of epoxy-coated alkali-resistant glass (ARG) fabric embedded in a lime-based mortar is studied experimentally. The mechanical behaviour of the composite system is assessed in uni-axial tensile tests, according to the ICC guidelines. Epoxy is diluted in acetone and several concentrations, namely 10%, 25%, 50%, 75% and 90%, are considered in an attempt to define a decay law for strength, ductility and dissipated energy at failure. Although epoxy-coating promotes a striking improvement of the mechanical performance with respect to the uncoated specimens, epoxy dilution appears to little affect the global response, even at very low epoxy-to-solvent ratios. Actually, a notable increase in the ultimate strength and strain as well as dissipation capacity are evidenced for 75% dilution. Indeed, epoxy resin is able to uniformly impregnate the bundles of the yarns in a very thin layer, still preserving its contribution to the mechanical performance. In fact, wettability of the yarns plays a fundamental role in the mechanical performance of the laminate for it limitates telescopic failure. A threshold of viscosity is identified. Above this limit, the high quality of impregnation overcomes the issue of the reduction of the amount of epoxy resin in the coating. Besides, dilution strongly promotes the ease of application, as a result of the resin viscosity being sharply reduced. Most remarkably and contrarily to common expectation, the specific energy dissipated at failure exhibits a maximum point, whence an optimal dilution ratio exists which best balances interphase strength and ductility.

Preliminary epoxy coating of the reinforcing fabric provides an effective approach for improving matrix-to-fabric strength in inorganic matrix composites. We investigate the effect of epoxy resin dilution in acetone on uni-axial tensile performance of coated alkali-resistant (AR) glass fabric embedded in a lime-based matrix. Remarkably, it is found that dilution has a mixed effect on performance and this trend is consistently retrieved for strength, ductility and energy dissipation. Indeed, performance initially decays and then it suddenly raises to a level close to or even exceeding that of the undiluted specimens. It is postulated that this behaviour is caused by resin viscosity, that falls off exponentially with the dilution degree. Once a viscosity threshold is breached, epoxy is capable of penetrating inside the yarn and thereby prevents telescopic failure, that is the sliding of the outer over the inner glass filaments. Furthermore, the interphase surface area increases dramatically and this enhances performance and narrows scattering. Besides, optimal viscosity is reached at an unexpectedly high dilution degree, whence material cost is significantly reduced. A cost-to-performance comparison of common strengthening technologies is presented, which shows that diluted epoxy composites score comparably to FRPs. It is concluded that epoxy coating optimization plays an important role in designing inorganic matrix composites.

Functionally graded materials (FGMs) are innovative materials whose composition and/or microstructure gradually vary in space according to a designed law. As a result, also the properties gradually vary in space, so as to meet specific non-homogeneous service requirements without any abrupt interface at the macroscale. FGMs are emerging materials for orthopedic prostheses, since the functional gradient can be adapted to reproduce the local properties of the original bone, which helps to minimize the stress shielding effect and, at the same time, to reduce the shear stress between the implant and the surrounding bone tissue, two critical prerequisites for a longer lifespan of the graft. After a brief introduction to the origin of the FGM concept, the review surveys some representative examples of graded systems which are present in nature and, in particular, in the human body, with a focus on bone tissue. Then the rationale for using FGMs in orthopedic devices is discussed more in detail, taking into account both biological and biomechanical requirements. The core of the paper is dedicated to two fundamental topics, which are essential to benefit from the use of FGMs for orthopedic applications, namely (1) the computational tools for materials design and geometry optimization, and (2) the manufacturing techniques currently available to produce FGM-based grafts. This second part, in its turn, is structured to consider the production of functionally graded coatings (FGCs), of functionally graded 3D parts, and of special devices with a gradient in porosity (functionally graded scaffolds). The inspection of the literature on the argument clearly shows that the integration of design and manufacturing remains a critical step to overpass in order to achieve effective FGM-based implants.

Additive manufacturing (AM) has shown promise to process parts for end-use applications, however stringent requirements must be fulfilled in terms of reliability and predictability. The expensiveness of raw materials for AM, especially for metal-based Powder Bed Fusion (PBF), brings about the need for a careful recycling of powder, but the effect of powder reuse on both processing conditions and final part performance is still the focus of intensive research in the open literature. Although ASTM F2924-14 specifies the virgin-to-used powder ratio to be introduced to manufacture titanium-6aluminum-4vanadium (Ti-6Al-4V) components by PBF, a deeper understanding of the effect of powder recycling on the mechanical properties of finished parts is expected to foster a more efficient and safe reuse. The present contribution is therefore addressed to investigate the consequence of Ti-6Al-4V powder recycling on the flowability, particle size distribution and morphology of the feedstock material as well as on the density and tensile performance of built parts. In order to quantify the recyclability of powders, a new "average usage time" (AUT) parameter is defined to account for both the real usage time of the powder and the virgin-to-used powder mixing ratio. The new parameter, whose applicability can be readily extended to any kind of feedstock powder, offers a significant contribution to achieve a more consistent and economical recycling of raw materials for PBF processing.

Background: Lack of interphase compatibility between the fabric and the matrix significantly impairs the load-bearing capacity of textile reinforced mortar (TRM). In this study, we consider the application of two inorganic surface coatings for enhancing the interphase bond properties. Methods: Either of two silica-based coatings, namely nano- and micro-silica, were applied to alkali-resistant glass (ARG) and to hybrid carbon–ARG woven fabric. Mechanical performance of TRM reinforced with the uncoated and the coated fabric was compared in uniaxial tensile tests. Results: Mechanical testing provides evidence of a remarkable enhancement in terms of ultimate strength and deformability for the coated specimens. This effect can be ascribed to the improved hydrophilicity of the fibers’ surface and to the activation of pozzolanic reaction at the interphase. In addition, penetration of nano- and microparticles in the bundle of the textile yarns reduces the occurrence of telescopic failure.

Laser Powder Bed Fusion (LPBF) technology was used to produce samples based on the Ti&ndash, 6Al&ndash, 4V alloy for biomedical applications. Solid-state phase transformations induced by thermal treatments were studied by neutron diffraction (ND), X-ray diffraction (XRD), scanning transmission electron microscopy (STEM) and energy-dispersive spectroscopy (EDS). Although, ND analysis is rather uncommon in such studies, this technique allowed evidencing the presence of retained &beta, in &alpha, &rsquo, martensite of the as-produced (#AP) sample. The retained &beta, was not detectable by XRD analysis, nor by STEM observations. Martensite contains a high number of defects, mainly dislocations, that anneal during the thermal treatment. Element diffusion and partitioning are the main mechanisms in the &alpha, &harr, &beta, transformation that causes lattice expansion during heating and determines the final shape and size of phases. The retained &beta, phase plays a key role in the &alpha, &rarr, transformation kinetics.