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This review paper explores the cutting-edge advancements in hydrogel design for articular cartilage regeneration (CR). Articular cartilage (AC) defects are a common occurrence worldwide that can lead to joint breakdown at a later stage of the disease, necessitating immediate intervention to prevent progressive degeneration of cartilage. Decades of research into the biomedical applications of hydrogels have revealed their tremendous potential, particularly in soft tissue engineering, including CR. Hydrogels are highly tunable and can be designed to meet the key criteria needed for a template in CR. This paper aims to identify those criteria, including the hydrogel components, mechanical properties, biodegradability, structural design, and integration capability with the adjacent native tissue and delves into the benefits that CR can obtain through appropriate design. Stratified-structural hydrogels that emulate the native cartilage structure, as well as the impact of environmental stimuli on the regeneration outcome, have also been discussed. By examining recent advances and emerging techniques, this paper offers valuable insights into developing effective hydrogel-based therapies for AC repair.

Steel bearings have been commonly used to counteract induced loading from thermal and traffic conditions in numerous bridges. However, their effectiveness has been compromised due to aging and maintenance limitations, potentially impacting the overall bridge system performance. Existing monitoring techniques for detecting malfunctioning steel bearings lack automation and precision, making them inadequate for long-term and real-time bridge dynamics assessment. This study proposes a response-based approach to identify bearing malfunction by analyzing the traffic-induced response in the bearing vicinity. To implement this approach, laser displacement sensors and wireless acceleration sensors were employed to monitor both malfunctioning and well-functioning steel bridge bearings. Significant differences in bearing performance were observed through response analysis and comparison. Laser sensor measurements revealed larger vertical deflections in the girder at malfunctioned bearing under traffic loading. Moreover, the investigation of the acceleration response in the bearing locality indicated that bearing malfunction could alter the vibrational characteristics of the vicinity, significantly affecting Cross Power Spectral Density (CPSD) and cross-correlation. To quantitatively evaluate the performance of steel bearings, a Condition Score (CS) was introduced. The CS exhibited a strong correlation with bearing damage, providing valuable insights for maintenance and decision-making processes in bridge asset management. This study offers a comprehensive and automated method for identifying steel bridge bearing malfunction by utilizing advanced monitoring techniques and introducing the CS for assessment. The results obtained from this approach can enhance bridge maintenance strategies and contribute to effective bridge asset management.

Within the healthy human body, cells reside within the physiological environment of a tissue compound. Here, they are subject to constant low levels of mechanical stress that can influence the growth and differentiation of the cells. The liposuction of adipose tissue and the subsequent isolation of mesenchymal stem/stromal cells (MSCs), for example, are procedures that induce a high level of mechanical shear stress. As MSCs play a central role in tissue regeneration by migrating into regenerating areas and driving regeneration through proliferation and tissue-specific differentiation, they are increasingly used in therapeutic applications. Consequently, there is a strong interest in investigating the effects of shear stress on MSCs. In this study, we present a set-up for applying high shear rates to cells based on a rotational rheometer with a small-angle cone–plate configuration. This set-up was used to investigate the effect of various shear stresses on human adipose-derived MSCs in suspension. The results of the study show that the viability of the cells remained unaffected up to 18.38 Pa for an exposure time of 5 min. However, it was observed that intense shear stress damaged the cells, with longer treatment durations increasing the percentage of cell debris.

Background: Preserving residual hearing after cochlear implant (CI) surgery remains a crucial challenge. The application of dexamethasone (DEX) has been proven to positively affect residual hearing. To deliver DEX in a localized and controlled way, a round window niche implant (RNI), allowing drug diffusion via the round window membrane into the cochlea, may be used. To prove this concept, an RNI for guinea pigs as a CI-trauma model was manufactured by molding and tested for its drug release in vitro and biological effects in vivo. Methods: The RNIs were molded using silicone containing 10% DEX. Release was analyzed over time using high-performance liquid chromatography (HPLC). Fourteen adult guinea pigs were randomly assigned to two groups (CI or CI + RNI group). All animals received a unilateral CI electrode insertion trauma followed by CI insertion. The CI + RNI group was additionally implanted with an RNI containing 10% DEX. Animals were followed up for 4 weeks. Acoustically evoked auditory brainstem response and impedance measurement, micro-computed tomography (µCT) imaging, and histology were performed for evaluation. Results: DEX was released for more than 250 days in vitro, with an initial burst followed by a slower release over time. Comparing the hearing threshold shift (from day 0 to day 28) of the CI and CI + RNI groups, significant differences were observed at 32 and 40 kHz. The impedance shift at basal contacts was lower in the CI + RNI group than in the CI group. Moreover, the fibrosis in the lower basal turn was reduced in the CI + RNI group in contrast to the CI group. Conclusions: The RNI containing 10% DEX has anti-inflammatory potential concerning fibrosis inhibition and has beneficial effects on hearing preservation at high frequencies.

New developments in the field of artificial intelligence (AI) are increasingly finding their way into industrial areas such as additive manufacturing (AM). Generative AI (GAI) applications in particular offer interesting possibilities here, for example, to generate texts, images or computer codes with the help of algorithms and to integrate these as useful supports in various AM processes. This paper examines the opportunities that GAI offers specifically for additive manufacturing. There are currently relatively few publications that deal with the topic of GAI in AM. Much of the information has only been published in preprints. There, the focus has been on algorithms for Natural Language Processing (NLP), Large Language Models (LLMs) and generative adversarial networks (GANs). This summarised presentation of the state of the art of GAI in AM is new and the link to specific use cases is this first comprehensive case study on GAI in AM processes. Building on this, three specific use cases are then developed in which generative AI tools are used to optimise AM processes. Finally, a Strengths, Weaknesses, Opportunities and Threats (SWOT) analysis is carried out on the general possibilities of GAI, which forms the basis for an in-depth discussion on the sensible use of GAI tools in AM. The key findings of this work are that GAI can be integrated into AM processes as a useful support, making these processes faster and more creative, as well as to make the process information digitally recordable and usable. This current and future potential, as well as the technical implementation of GAI into AM, is also presented and explained visually. It is also shown where the use of generative AI tools can be useful and where current or future potential risks may arise.

In ultrashort-pulsed laser processing, surface modification is subject to complex laser and scanning parameter studies. In addition, quality assurance systems for monitoring surface modification are still lacking. Automated laser processing routines featuring machine learning (ML) can help overcome these limitations, but they are largely absent in the literature and still lack practical applications. This paper presents a new methodology for machine learning classification of self-organized surface structures based on light microscopic images. For this purpose, three application-relevant types of self-organized surface structures are fabricated using a 300 fs laser system on hot working tool steel and stainless-steel substrates. Optical images of the hot working tool steel substrates were used to learn a classification algorithm based on the open-source tool Teachable Machine from Google. The trained classification algorithm achieved very high accuracy in distinguishing the surface types for the hot working steel substrate learned on, as well as for surface structures on the stainless-steel substrate. In addition, the algorithm also achieved very high accuracy in classifying the images of a specific structure class captured at different optical magnifications. Thus, the methodology proposed represents a simple and robust automated classification of surface structures that can be used as a basis for further development of quality assurance systems, automated process parameter recommendation, and inline laser parameter control.

3D-structured hydrogel scaffolds are frequently used in tissue engineering applications as they can provide a supportive and biocompatible environment for the growth and regeneration of new tissue. Hydrogel scaffolds seeded with human mesenchymal stem cells (MSCs) can be mechanically stimulated in bioreactors to promote the formation of cartilage or bone tissue. Although in vitro and in vivo experiments are necessary to understand the biological response of cells and tissues to mechanical stimulation, in silico methods are cost-effective and powerful approaches that can support these experimental investigations. In this study, we simulated the fluid-structure interaction (FSI) to predict cell differentiation on the entire surface of a 3D-structured hydrogel scaffold seeded with cells due to dynamic compressive load stimulation. The computational FSI model made it possible to simultaneously investigate the influence of both mechanical deformation and flow of the culture medium on the cells on the scaffold surface during stimulation. The transient one-way FSI model thus opens up significantly more possibilities for predicting cell differentiation in mechanically stimulated scaffolds than previous static microscale computational approaches used in mechanobiology. In a first parameter study, the impact of the amplitude of a sinusoidal compression ranging from 1% to 10% on the phenotype of cells seeded on a porous hydrogel scaffold was analyzed. The simulation results show that the number of cells differentiating into bone tissue gradually decreases with increasing compression amplitude, while differentiation into cartilage cells initially multiplied with increasing compression amplitude in the range of 2% up to 7% and then decreased. Fibrous cell differentiation was predicted from a compression of 5% and increased moderately up to a compression of 10%. At high compression amplitudes of 9% and 10%, negligible areas on the scaffold surface experienced high stimuli where no cell differentiation could occur. In summary, this study shows that simulation of the FSI system is a versatile approach in computational mechanobiology that can be used to study the effects of, for example, different scaffold designs and stimulation parameters on cell differentiation in mechanically stimulated 3D-structured scaffolds.

Bone healing is a complex process orchestrated by various factors, such as mechanical, chemical and electrical cues. Creating synthetic biomaterials that combine several of these factors leading to tailored and controlled tissue regeneration, is the goal of scientists worldwide. Among those factors is piezoelectricity which creates a physiological electrical microenvironment that plays an important role in stimulating bone cells and fostering bone regeneration. However, only a limited number of studies have addressed the potential of combining piezoelectric biomaterials with state-of-the-art fabrication methods to fabricate tailored scaffolds for bone tissue engineering. Here, we present an approach that takes advantage of modern additive manufacturing techniques to create macroporous biomaterial scaffolds based on a piezoelectric and bioactive ceramic-crystallised glass composite. Using binder jetting, scaffolds made of barium titanate and 45S5 bioactive glass are fabricated and extensively characterised with respect to their physical and functional properties. The 3D-printed ceramic-crystallised glass composite scaffolds show both suitable mechanical strength and bioactive behaviour, as represented by the accumulation of bone-like calcium phosphate on the surface. Piezoelectric scaffolds that mimic or even surpass bone with piezoelectric constants ranging from 1 to 21 pC/N are achieved, depending on the composition of the composite. Using MC3T3-E1 osteoblast precursor cells, the scaffolds show high cytocompatibility coupled with cell attachment and proliferation, rendering the barium titanate/45S5 ceramic-crystallised glass composites promising candidates for bone tissue engineering.

This paper delves into the application of vibration-based energy harvesting to power environmental sensor nodes, a critical component of modern data collection systems. These sensor nodes play a crucial role in structural health monitoring, providing essential data on external conditions that can affect the health and performance of structures. We investigate the feasibility and efficiency of utilizing piezoelectric vibration energy harvesters to sustainably power environmental wireless sensor nodes on the one hand. On the other hand, we exploit different approaches to minimize the sensor node’s power consumption and maximize its efficiency. The investigations consider various sensor node platforms and assess their performance under different voltage levels and broadcast frequencies. The findings reveal that optimized harvester designs enable real-time data broadcasting with short intervals, ranging from 1 to 3 s, expanding the horizons of environmental monitoring, and show that in case the system includes a battery as a backup plan, the battery’s lifetime can be extended up to 9 times. This work underscores the potential of vibration energy harvesting as a viable solution for powering sensor nodes, enhancing their autonomy, and reducing maintenance costs in remote and challenging environments. It opens doors to broader applications of sustainable energy sources in environmental monitoring and data collection systems.

Composite Extrusion Modeling (CEM) is a screw-based material extrusion (MEX) additive manufacturing process that can produce plastic, metal and ceramic parts based on standard injection molding feedstocks. In this work, an aluminum oxide feedstock (Al2O3) originally developed for injection molding is processed via a screw-based MEX process for the first time by depositing the plasticized material in layers on the build platform. In order to identify appropriate process parameters, the feedstock is first characterized to estimate the printable temperature processing window. Initially, the best printable extrusion values were estimated in terms of green part density and dimensional accuracy. Afterwards, different nozzle diameters and layer heights are investigated to further improve the green part density and shape accuracy. An extrusion multiplier of 0.14, nozzle diameter of 0.4 mm and a layer height of 0.1 mm were found to be the optimum process parameters to achieve highly dense green parts with a density of 2.791 ± 0.001 g/cm3. The optimized parts were also debound and sintered and the shrinkage was investigated. A shrinkage of 17.43% in the z direction and 14.08% in the x-y direction was observed, and a density of 3.92 ± 0.0025 g/cm3 was achieved for the sintered parts.

Summary: To use regeneratively active cells for cell therapeutic applications, the cells must be isolated from their resident tissues. Different isolation procedures subject these cells to varying degrees of mechanical strain, which can affect the yield of cell number and viability. Knowledge of cell volumetric mass density is important for experimental and numerical optimization of these procedures. Although methods for measuring cell volumetric mass density already exist, they either consume much time and cell material or require a special setup. Therefore, we developed a user-friendly method that is based on the use of readily available instrumentation. The newly developed method is predicated on the linear relationship between the volumetric mass density of the cell suspension and the volumetric mass density, number, and diameter of the cells in the suspension. We used this method to determine the volumetric mass density of mesenchymal stem cells (MSCs) and compared it to results from the established density centrifugation.

A critical-size bone defect in load-bearing areas is a challenging clinical problem in orthopaedic surgery. Titanium alloy (Ti6Al4V) scaffolds have advantages because of their biomechanical stability but lack electrical activity, which hinders their further use. This work is focused on the fabrication of Ti6Al4V-Barium Titanate (BaTiO3) bulk composite scaffolds to combine the biomechanical stability of Ti6Al4V with electrical activity through BaTiO3. For the first time, a hollow cylindrical Ti6Al4V is additively manufactured by electron beam melting and combined with piezoelectric BaTiO3 powder for joint processing in field-assisted sintering. Scanning electron microscope images on the interface of the Ti6Al4V-BaTiO3 composite scaffold showed that after sintering, the Ti6Al4V lattice structure bounded with BaTiO3 matrix without its major deformation. The Ti6Al4V-BaTiO3 scaffold had average piezoelectric constants of (0.63 ± 0.12) pC/N directly after sintering due to partial dipole alignment of the BaTiO3 tetragonal phase, which increased to (4.92 ± 0.75) pC/N after a successful corona poling. Moreover, the nanoindentation values of Ti6Al4V exhibited an average hardness and Young’s modulus of (5.9 ± 0.9) GPa and (130 ± 14) GPa, and BaTiO3 showed (4.0 ± 0.6) GPa and (106 ± 10) GPa, respectively. It reveals that the Ti6Al4V is the harder and stiffer part in the Ti6Al4V-BaTiO3 composite scaffold. Such a scaffold has the potential to treat critical-size bone defects in load-bearing areas and guide tissue regeneration by physical stimulation.

A novel approach to manufacture components with integrated conductor paths involves embedding and sintering an isotropic conductive adhesive (ICA) during fused filament fabrication (FFF). However, the molten plastic is deposited directly onto the adhesive path which causes an inhomogeneous displacement of the uncured ICA. This paper presents a 3D printing strategy to achieve a homogeneous cross-section of the conductor path. The approach involves embedding the ICA into a printed groove and sealing it with a wide extruded plastic strand. Three parameter studies are conducted to obtain a consistent cavity for uniform formation of the ICA path. Specimens made of polylactic acid (PLA) with embedded ICA paths are printed and evaluated. The optimal parameters include a groove printed with a layer height of 0.1 mm, depth of 0.4 mm, and sealed with a PLA strand of 700 µm diameter. This resulted in a conductor path with a homogeneous cross-section, measuring 660 µm ± 22 µm in width (relative standard deviation: 3.3%) and a cross-sectional area of 0.108 mm2 ± 0.008 mm2 (relative standard deviation 7.2%). This is the first study to demonstrate the successful implementation of a printing strategy for embedding conductive traces with a homogeneous cross-sectional area in FFF 3D printing.

Composite Extrusion Modeling (CEM) is an advanced material extrusion additive manufacturing technique for low-cost rapid production of complex parts. In this work, a conventional Metal Injection Moulding (MIM) feedstock is used for 3D printing of low alloy-steel AISI 8740 via CEM. This steel is widely used in aircraft, aerospace, and MIM industries. However, it has, so far, not been processed using CEM-based 3D printing. The influence of four printing parameters, extrusion multiplier, extrusion temperature, nozzle velocity, and layer thickness on green density and surface roughness was explored following the feedstock's investigation. Full-factorial and face-centered response designs were utilized to study the influence of printing parameters and their optimization to achieve maximum green density and minimum surface roughness. The optimized parameters were found to be an extrusion multiplier of 107.6 %, extrusion temperature of 180 °C, nozzle velocity of 20 mm/s and layer thickness of 0.050 mm through a multiple response optimization process. The dense green part with relative densities of ≥ 98 % was achieved with minimum surface roughness of Ra = (2.3 ± 0.1) μm and Rz = (16.1 ± 1.1) μm. Moreover, a scanning electron microscope was utilized to study the surfaces of green parts. The parts printed with optimized printing parameters showed the best quality with minimized printing voids and smooth extrusion.

Three-dimensional (3D) printing technology enables the design of personalized scaffolds with tunable pore size and composition. Combining decellularization and 3D printing techniques provides the opportunity to fabricate scaffolds with high potential to mimic native tissue. The aim of this study is to produce novel decellularized bone extracellular matrix (dbECM)-reinforced composite-scaffold that can be used as a biomaterial for bone tissue engineering. Decellularized bone particles (dbPTs, ∼100 ​μm diameter) were obtained from rabbit femur and used as a reinforcement agent by mixing with gelatin (GEL) in different concentrations. 3D scaffolds were fabricated by using an extrusion-based bioprinter and crosslinking with microbial transglutaminase (mTG) enzyme, followed by freeze-drying to obtain porous structures. Fabricated 3D scaffolds were characterized morphologically, mechanically, and chemically. Furthermore, MC3T3-E1 mouse pre-osteoblast cells were seeded on the dbPTs reinforced GEL scaffolds (GEL/dbPTs) and cultured for 21 days to assess cytocompatibility and cell attachment. We demonstrate the 3D-printability of dbPTs-reinforced GEL hydrogels and the achievement of homogenous distribution of the dbPTs in the whole scaffold structure, as well as bioactivity and cytocompatibility of GEL/dbPTs scaffolds. It was shown that Young's modulus and degradation rate of scaffolds were enhanced with increasing dbPTs content. Multiphoton microscopy imaging displayed the interaction of cells with dbPTs, indicating attachment and proliferation of cells around the particles as well as into the GEL-particle hydrogels. Our results demonstrate that GEL/dbPTs hydrogel formulations have potential for bone tissue engineering.

A novel approach for the long-term medical treatment of the inner ear is the diffusion of drugs through the round window membrane from a patient-individualized, drug-eluting implant, which is inserted in the middle ear. In this study, drug-loaded (10 wt% Dexamethasone) guinea pig round window niche implants (GP-RNIs, ~1.30 mm × 0.95 mm × 0.60 mm) were manufactured with high precision via micro injection molding (µIM, Tmold = 160 °C, crosslinking time of 120 s). Each implant has a handle (~3.00 mm × 1.00 mm × 0.30 mm) that can be used to hold the implant. A medical-grade silicone elastomer was used as implant material. Molds for µIM were 3D printed from a commercially available resin (TG = 84 °C) via a high-resolution DLP process (xy resolution of 32 µm, z resolution of 10 µm, 3D printing time of about 6 h). Drug release, biocompatibility, and bioefficacy of the GP-RNIs were investigated in vitro. GP-RNIs could be successfully produced. The wear of the molds due to thermal stress was observed. However, the molds are suitable for single use in the µIM process. About 10% of the drug load (8.2 ± 0.6 µg) was released after 6 weeks (medium: isotonic saline). The implants showed high biocompatibility over 28 days (lowest cell viability ~80%). Moreover, we found anti-inflammatory effects over 28 days in a TNF-α-reduction test. These results are promising for the development of long-term drug-releasing implants for human inner ear therapy.

Novel 3D printing techniques enable the development of medical devices with drug delivery systems that are tailored to the patient in terms of scaffold shape and the desired pharmaceutically active substance release. Gentle curing methods such as photopolymerization are also relevant for the incorporation of potent and sensitive drugs including proteins. However, retaining the pharmaceutical functions of proteins remains challenging due to the possible crosslinking between the functional groups of proteins, and the used photopolymers such as acrylates. In this work, the in vitro release of the model protein drug, albumin–fluorescein isothiocyanate conjugate (BSA–FITC) from differently composed, photopolymerized poly(ethylene) glycol diacrylate (PEGDA), an often employed, nontoxic, easily curable resin, was investigated. Different PEGDA concentrations in water (20, 30, and 40 wt %) and their different molecular masses (4000, 10,000, and 20,000 g/mol) were used to prepare a protein carrier with photopolymerization and molding. The viscosity measurements of photomonomer solutions revealed exponentially increasing values with increasing PEGDA concentration and molecular mass. Polymerized samples showed increasing medium uptake with an increasing molecular mass and decreasing uptake with increasing PEGDA content. Therefore, the modification of the inner network resulted in the most swollen samples (20 wt %) also releasing the highest amount of incorporated BSA–FITC for all PEGDA molecular masses.

The culverts are used to safely convey water under railways, highways, and overpasses. They are utilized in drainage areas or water channels and in areas where the bearing capacity of soil is low. The design and construction of this crucial infrastructure need to be improved to meet contemporary demands of reliability and affordability. Precast reinforced box culverts are popular alternatives as they ensure strength, durability, rigidity, and economy. This research seeks to develop an effective and affordable design improvement procedure for a precast box culvert using modern numerical tools. The Finite Element Method (FEM) based approach is used in studying the effects of haunch geometry and additional steel reinforcement on the load-bearing capacity of box culverts. A conventional box culvert is analyzed to create the numerical models in the Abaqus FEM code and to investigate the load-bearing capacity of culverts with an expanded span. The outcomes of the study reveal the critical places for stress concentration as well as the location of maximum damage. It is found that haunch geometry and additional reinforcement at these critical places significantly affect the load-carrying capacity of a culvert. From the comparison of capacity curves of models with and without haunches and diagonal reinforcement, it is found that a 25% increase in load-carrying capacity is achievable with the recommended changes. The proposed design improvement technique can be employed for the cost-effective and safe design of a concrete box culvert with larger span lengths and high water-flowing capacities. The findings of this study are expected to assist practitioners in strength enhancement tasks of box culverts for increased structural stability and drainage efficiency.

Drop-on-demand (DOD) inkjet printing enables exact dispensing and positioning of single droplets in the picoliter range. In this study, we investigate the long-term reproducibility of droplet formation of piezoelectric inkjet printed drug solutions using solvents with different volatilities. We found inkjet printability of EtOH/ASA drug solutions is limited, as there is a rapid forming of drug deposits on the nozzle of the printhead because of fast solvent evaporation. Droplet formation of c = 100 g/L EtOH/ASA solution was affected after only a few seconds by little drug deposits, whereas for c = 10 g/L EtOH/ASA solution, a negative affection was observed only after t = 15 min, while prominent drug deposits form at the printhead tip. Due to the creeping effect, the crystallizing structures of ASA spread around the nozzle but do not clog it necessarily. When there is a negative affection, the droplet trajectory is affected the most, while the droplet volume and droplet velocity are influenced less. In contrast, no formation of drug deposits could be observed for highly concentrated, low volatile DMSO-based drug solution of c = 100 g/L even after a dispensing time of t = 30 min. Therefore, low volatile solvents are preferable to highly volatile solvents to ensure a reproducible droplet formation in long-term inkjet printing of highly concentrated drug solutions. Highly volatile solvents require relatively low drug concentrations and frequent printhead cleaning. The findings of this study are especially relevant when high droplet positioning precision is desired, e.g., drug loading of microreservoirs or drug-coating of microneedle devices.

Enhanced multipoint moulding with additive attachments (EMMA) is a process combining vacuum-assisted multipoint moulding (VAMM) and additively manufactured moulding attachments for carbon fibre reinforced plastics (CFRP) component production. The aim of this initial study is to investigate the mouldability of the additively manufactured attachments on the multipoint tool. For this purpose, two different test specimens were defined, the VAMM machine was adjusted, the attachments were additively built with the robot on the curved silicone interpolation layer and lastly, the CFRP specimens were moulded. The fabrication results were analysed with surface comparisons to check that there was no displacement of the attachments during moulding. A visual evaluation of the manufactured components was carried out, and the overall dimensional accuracy was assessed by comparing the surface with the target geometry. The results showed a very good agreement between the shapes before and after the moulding and thus prove that the attachments were not postponed in the moulding process. The optical evaluation confirms good moulding results for the parts manufactured with the enhanced multipoint moulding with additive attachments. Moreover, the evaluation shows that the major parts of the specimens comply with the permissible tolerance of t = 6 mm defined in ISO 20457. To the authors’ best knowledge, this is the first study that has investigated the entire EMMA process and systematically proved the mouldability of the additively manufactured attachments on multipoint tools.

Beam–column connections are the most critical components of reinforced concrete (RC) structures. They serve as a load transfer path and take a significant portion of the overall shear. Joints in RC structures constructed with no seismic provisions have an insufficient capacity and ductility under lateral loading and can cause the progressive failure of the entire structure. The joint may fail in the shear prior to the connecting beam and column elements. Therefore, several modeling techniques have been devised in the past to capture the non-linear response of such joints. Modeling techniques used to capture the non-linear response of reinforced-concrete-beam–column joints range from simplified lumped plasticity models to detailed fiber-based finite element (FE) models. The macro-modeling technique for joint modeling is highly efficient in terms of the computational effort, analysis time, and computer memory requirements, and is one of the most widely used modeling techniques. The non-linear shear response of the joint panel and interface bond–slip mechanism are concentrated in zero-length linear and rotational springs while the connecting elements are modeled through elastic elements. The shear response of joint panels has also been captured through rigid panel boundary elements with rotational springs. The computational efficiency of these models is significantly high compared to continuum models, as each joint act as a separate supe-element. This paper aims to provide an up-to-date review of macro-modeling techniques for the analysis and assessment of RC-beam–column connections subjected to lateral loads. A thorough understanding of existing models is necessary for developing new mechanically adequate and computationally efficient joint models for the analysis and assessment of deficient RC connections. This paper will provide a basis for further research on the topic and will assist in the modification and optimization of existing models. As each model is critically evaluated, and their respective capabilities and limitations are explored, it should help researchers to improve and build on modeling techniques both in terms of accuracy and computational efficiency.

The objective of this study is the investigation of the transferability of the material extrusion process from conventional to robotic fabrication on silicone build plates for use in Enhanced Multipoint Moulding with Additive Attachments. Therefore, the study is based on two series of experiments. The first series of tests used a conventional plant extended by a silicone construction platform. In comparison, a six-axis industrial robot was chosen to produce the test specimens in the second series of tests. The comparisons of adhesion strengths and relative shape deviations are used to validate the transferability. The results of the tests show a very good transferability of the process from conventional to robotic production. Whilst angular specimen geometries can be transferred directly, for round specimen geometries, the results show a need for further adaptation to the robot kinematics. The round specimen geometries showed deviations in the surface quality caused by an over-extrusion in the robotic manufacturing. This over-extrusion results from the slicing process in combination with the robot control and may be avoided through further optimisation of the process parameters. Overall, to the best of our knowledge, this study is the first that successfully demonstrates the transfer of Fused Filament Fabrication (FFF) from a conventional system to manufacturing using robots on silicone build plates for the use in Enhanced Multipoint Moulding with Additive Attachments.

Blockchain solutions offer efficient approaches for trustworthy data management, especially in the medical field when storing and processing sensitive patient data. Many institutional and industrial facilities have already recognized the importance of the technology for the health sector and have also formulated basic ideas, concepts and main use cases, but concrete implementations and executions are comparatively rare. This mini review examines current research on specific blockchain implementations in healthcare that go beyond the state of concept studies or theoretical implementation ideas and describes the most promising systems based on systematic literature research. The review shows that secure storage and easy access to complete patient data is becoming increasingly important. Blockchain technology can be used as a secure, transparent and digital way to meet these needs. Hybrid solutions consisting of conventional data storage and blockchain-based access management are increasingly being developed and implemented. The automation of blockchain processes through smart contracts is also recommended. The review further reveals ambiguities in the use of permissioned and permissionless blockchain frameworks, machine learning (ML) integration as well as the question of which data should be stored in the blockchain and how this should be viewed legally. Therefore, there is still a need for further research, especially on these aspects, in order to further establish the use of blockchains in healthcare.

Novel fabrication techniques based on photopolymerization enable the preparation of complex multi-material constructs for biomedical applications. This requires an understanding of the influence of the used reaction components on the properties of the generated copolymers. The identification of fundamental characteristics of these copolymers is necessary to evaluate their potential for biomaterial applications. Additionally, knowledge of the properties of the starting materials enables subsequent tailoring of the biomaterials to meet individual implantation needs. In our study, we have analyzed the biological, chemical, mechanical and thermal properties of photopolymerized poly(ethyleneglycol) diacrylate (PEGDA) and specific copolymers with different photoinitiator (PI) concentrations before and after applying a post treatment washing process. As comonomers, 1,3-butanediol diacrylate, pentaerythritol triacrylate and pentaerythritol tetraacrylate were used. The in vitro studies confirm the biocompatibility of all investigated copolymers. Uniaxial tensile tests show significantly lower tensile strength (82% decrease) and elongation at break (76% decrease) values for washed samples. Altered tensile strength is also observed for different PI concentrations: on average, 6.2 MPa for 1.25% PI and 3.1 MPa for 0.5% PI. The addition of comonomers lowers elongation at break on average by 45%. Moreover, our observations show glass transition temperatures (Tg) ranging from 27 °C to 56 °C, which significantly increase with higher comonomer content. These results confirm the ability to generate biocompatible PEGDA copolymers with specific thermal and mechanical properties. These can be considered as resins for various additive manufacturing-based applications to obtain personalized medical devices, such as drug delivery systems (DDS). Therefore, our study has advanced the understanding of PEGDA multi-materials and will contribute to the future development of tools ensuring safe and effective individual therapy for patients.

Critical size bone defects are regularly treated by auto- and allograft transplantation. However, such treatments require to harvest bone from patient donor sites, with often limited tissue availability or risk of donor site morbidity. Not requiring bone donation, three-dimensionally (3D) printed implants and biomaterial-based tissue engineering (TE) strategies promise to be the next generation therapies for bone regeneration. We present here polylactic acid (PLA)-bioactive glass (BG) composite scaffolds manufactured by fused deposition modeling (FDM), involving the fabrication of PLA-BG composite filaments which are used to 3D print controlled open-porous and osteoinductive scaffolds. We demonstrated the printability of PLA-BG filaments as well as the bioactivity and cytocompatibility of PLA-BG scaffolds using pre-osteoblast MC3T3E1 cells. Gene expression analyses indicated the beneficial impact of BG inclusions in FDM scaffolds regarding osteoinduction, as BG inclusions lead to increased osteogenic differentiation of human adipose-derived stem cells in comparison to pristine PLA. Our findings confirm that FDM is a convenient additive manufacturing technology to develop PLA-BG composite scaffolds suitable for bone tissue engineering.

CaTiO3 is a promising candidate as a pseudo-piezoelectric scaffold material for bone implantation. In this study, pure and magnesium/iron doped CaTiO3 are synthesized by sol-gel method and spark plasma sintering. Energy dispersive X-ray mapping confirm the homogenous distribution of doping elements in sintered samples. High-energy X-ray diffraction investigations reveal that doping of nanostructured CaTiO3 increased the strain and defects in the structure of CaTiO3 compared to the pure one. This led to a stronger pseudo-piezoelectric effect in the doped samples. The charge produced in magnesium doped CaTiO3 due to the direct piezoelectric effect is (2.9 ± 0.1) pC which was larger than the one produced in pure CaTiO3 (2.1 ± 0.3) pC, whereas the maximum charge was generated by iron doped CaTiO3 with (3.6 ± 0.2) pC. Therefore, the pseudo-piezoelectric behavior can be tuned by doping. This tuning of pseudo-piezoelectric response provides the possibility to systematically study the bone response using different piezoelectric strengths and possibly adjust for bone tissue engineering.

In cell-based therapies for cartilage lesions, the main problem is still the formation of fibrous cartilage, caused by underlying de-differentiation processes ex vivo. Biophysical stimulation is a promising approach to optimize cell-based procedures and to adapt them more closely to physiological conditions. The occurrence of mechano-electrical transduction phenomena within cartilage tissue is physiological and based on streaming and diffusion potentials. The application of exogenous electric fields can be used to mimic endogenous fields and, thus, support the differentiation of chondrocytes in vitro. For this purpose, we have developed a new device for electrical stimulation of chondrocytes, which operates on the basis of capacitive coupling of alternating electric fields. The reusable and sterilizable stimulation device allows the simultaneous use of 12 cavities with independently applicable fields using only one main supply. The first parameter settings for the stimulation of human non-degenerative chondrocytes, seeded on collagen type I elastin-based scaffolds, were derived from numerical electric field simulations. Our first results suggest that applied alternating electric fields induce chondrogenic re-differentiation at the gene and especially at the protein level of human de-differentiated chondrocytes in a frequency-dependent manner. In future studies, further parameter optimizations will be performed to improve the differentiation capacity of human cartilage cells.

A method of computer modeling of a surface relief is proposed, and its efficiency and high accuracy are proven. The method is based on the mathematical model of surface microrelief, using titanium alloy Ti6Al4V subjected to processing with femtosecond pulses as an example. When modeling the examples of microrelief, changes in the shape of segments-cycles of the studied surface processes, which correspond to separate morphological formations, were taken into account. The proposed algorithms were realized in the form of a computer simulation program, which provides for a more accurate description of the geometry of the microrelief segments. It was proven that the new method significantly increases the efficiency of the analysis procedure and processing of signals that characterize self-organized relief formations.

The effect of chemical solvents on the wetting state of laser-structured surfaces over time is systematically examined in this paper. By using a 300-fs laser, nanostructures were generated on Ti6Al4V, subsequently cleaned in an ultrasonic bath with different solvents and stored in ambient air. The static contact angle showed significant differences for cleaning with various solvents, which, depending on the applied cleaning and time, amounted up to 100°. X-ray photoelectron spectroscopy analyses reveal that the cleaning of the laser-structured surfaces affects the surface chemistry and the aging behavior of the surfaces, even with highly volatile solvents. The effect of the chemical surface modification is particularly noticeable when using alcohols for cleaning, which, due to their OH groups, cause highly hydrophilic behavior of the surface after one day of storage. Over the course of 14 days, enrichment with organic groups from the atmosphere occurs on the surface, which leads to poorer wetting on almost every structured surface. In contrast, the cleaning in hexane leads to a fast saturation of the surface with long-chain carbon groups and thus to a time-independent hydrophobic behavior.

The prevalence of large bone defects is still a major problem in surgical clinics. It is, thus, not a surprise that bone-related research, especially in the field of bone tissue engineering, is a major issue in medical research. Researchers worldwide are searching for the missing link in engineering bone graft materials that mimic bones, and foster osteogenesis and bone remodeling. One approach is the combination of additive manufacturing technology with smart and additionally electrically active biomaterials. In this study, we performed a three-dimensional (3D) printing process to fabricate piezoelectric, porous barium titanate (BaTiO3) and hydroxyapatite (HA) composite scaffolds. The printed scaffolds indicate good cytocompatibility and cell attachment as well as bone mimicking piezoelectric properties with a piezoelectric constant of 3 pC/N. This work represents a promising first approach to creating an implant material with improved bone regenerating potential, in combination with an interconnected porous network and a microporosity, known to enhance bone growth and vascularization.

The microstructuring of surfaces is a highly researched field that is aimed at enhancing the tribological behavior of sliding surfaces such as artificial joints, which are subject to wear. Lubrication of the joint interface plays a key role in the wear process, although the mechanisms of lubrication are quite complex. In order to improve the lubrication, the surfaces of the articulating components can be modified by pulsed femtosecond-laser microstructuring. Through microstructuring, the apparent dynamic viscosity of the synovial fluid between the artificial joint can be increased due to its non-Newtonian properties. This may lead to better hydrodynamic lubrication and, therefore, reduced particle abrasion. Femtosecond laser-induced microstructures were investigated in a modified rheometer setup featuring a reduced gap size in order to reproduce and measure the interface between fluid and implant surface more accurately. As a test fluid, a synovial fluid substitute was used. The study has shown that an increase in the viscosity of the synovial fluid substitute can be achieved by microstructuring. Compared to a smooth implant surface, the apparent viscosity of the synovial fluid substitute increased by over 30% when ring-shaped microstructures of 100 µm diameter with an aspect ratio of 0.66 were implemented.

Surface structuring is a key factor for the tailoring of proper cell attachment and the improvement of the bone-implant interface anchorage. Femtosecond laser machining is especially suited to the structuring of implants due to the possibility of creating surfaces with a wide variety of nano- and microstructures. To achieve a desired surface topography, different laser structuring parameters can be adjusted. The scanning strategy, or rather the laser pulse overlap and scanning line overlap, affect the surface topography in an essential way, which is demonstrated in this study. Ti6Al4V samples were structured using a 300 fs laser source with a wavelength of 1030 nm. Laser pulse overlap and scanning line overlap were varied between 40% and 90% over a wide range of fluences (F from 0.49 to 12.28 J/cm²), respectively. Four different main types of surface structures were obtained depending on the applied laser parameters: femtosecond laser-induced periodic surface structures (FLIPSS), micrometric ripples (MR), micro-craters, and pillared microstructures. It could also be demonstrated that the exceedance of the strong ablation threshold of Ti6Al4V strongly depends on the scanning strategy. The formation of microstructures can be achieved at lower levels of laser pulse overlap compared to the corresponding value of scanning line overlap due to higher heat accumulation in the irradiated area during laser machining.

The propensity to manufacture functional and geometrically sophisticated parts from a wide range of metals provides the metal additive manufacturing (AM) processes superior advantages over traditional methods. The field of metal AM is currently dominated by beam-based technologies such as selective laser sintering (SLM) or electron beam melting (EBM) which have some limitations such as high production cost, residual stress and anisotropic mechanical properties induced by melting of metal powders followed by rapid solidification. So, there exist a significant gap between industrial production requirements and the qualities offered by well-established beam-based AM technologies. Therefore, beamless metal AM techniques (known as non-beam metal AM) have gained increasing attention in recent years as they have been found to be able to fill the gap and bring new possibilities. There exist a number of beamless processes with distinctively various characteristics that are either under development or already available on the market. Since this is a very promising field and there is currently no high-quality review on this topic yet, this paper aims to review the key beamless processes and their latest developments.

3D printing is a promising method for the fabrication of scaffolds in the field of bone tissue engineering. To date, the mechanical strength of 3D printed ceramic scaffolds is not sufficient for a variety of applications in the reconstructive surgery. Mechanical strength is directly in relation with the porosity of the 3D printed scaffolds. The porosity is directly influenced by particle size and particle-size distribution of the raw material. To investigate this impact, a hydroxyapatite granule blend with a wide particle size distribution was fractioned by sieving. The specific fractions and bimodal mixtures of the sieved granule blend were used to 3D print specimens. It has been shown that an optimized arrangement of fractions with large and small particles can provide 3D printed specimens with good mechanical strength due to a higher packing density. An increase of mechanical strength can possibly expand the application area of 3D printed hydroxyapatite scaffolds.

Functional magnetic resonance imaging (fMRI) in neonates has been introduced as a non-invasive method for studying sensorimotor processing in the developing brain. However, previous neonatal studies have delivered conflicting results regarding localization, lateralization, and directionality of blood oxygenation level dependent (BOLD) responses in sensorimotor cortex (SMC). Amongst the confounding factors in interpreting neonatal fMRI studies include the use of standard adult MR-coils providing insufficient signal to noise, and liberal statistical thresholds, compromising clinical interpretation at the single subject level.Here, we employed a custom-designed neonatal MR-coil adapted and optimized to the head size of a newborn in order to improve robustness, reliability and validity of neonatal sensorimotor fMRI. Thirteen preterm infants with a median gestational age of 26 weeks were scanned at term-corrected age using a prototype 8-channel neonatal head coil at 3T (Achieva, Philips, Best, NL). Sensorimotor stimulation was elicited by passive extension/flexion of the elbow at 1 Hz in a block design. Analysis of temporal signal to noise ratio (tSNR) was performed on the whole brain and the SMC, and was compared to data acquired with an 'adult' 8 channel head coil published previously. Task-evoked activation was determined by single-subject SPM8 analyses, thresholded at p < 0.05, whole-brain FWE-corrected.Using a custom-designed neonatal MR-coil, we found significant positive BOLD responses in contralateral SMC after unilateral passive sensorimotor stimulation in all neonates (analyses restricted to artifact-free data sets = 8/13). Improved imaging characteristics of the neonatal MR-coil were evidenced by additional phantom and in vivo tSNR measurements: phantom studies revealed a 240% global increase in tSNR; in vivo studies revealed a 73% global and a 55% local (SMC) increase in tSNR, as compared to the 'adult' MR-coil.Our findings strengthen the importance of using optimized coil settings for neonatal fMRI, yielding robust and reproducible SMC activation at the single subject level. We conclude that functional lateralization of SMC activation, as found in children and adults, is already present in the newborn period.

This study investigated the wetting behavior of Ti6Al4V surfaces that were groove-structured by means of femtosecond laser irradiation. The material was treated under ambient air conditions by use of a laser wavelength of 1030 nm and a pulse duration of 300 fs. Highly accurate structures with a gap width of 20 µm, a gap depth of 10 µm, and varying strut widths (1−300 µm) were generated and the contact angles in parallel and perpendicular direction were determined using sessile drop method with ultrapure water 1, 8, and 15 days after irradiation. All deterministic surfaces exhibited a pronounced contact angle change over time. The structures showed a strong anisotropic wetting behavior with a maximum contact angle aspect ratio of 2.47 at a strut width of 40 µm and a maximum difference between the parallel and perpendicular contact angle of 47.9° after 1 day.

The performance of two selective electron beam melting operation modes, namely the manual mode and the automatic ‘build theme mode’, have been investigated for the case of a Ti-6Al-4V alloy (45−105 μm average particle size of the powder) in terms of porosity, microstructure, and mechanical properties. The two operation modes produced notable differences in terms of build quality (porosity), microstructure, and properties over the sample thickness. The number and the average size of the pores were measured using a light microscope over the entire build height. A density measurement provided a quantitative index of the global porosity throughout the builds. The selective-electron-beam-melted microstructure was mainly composed of a columnar prior β-grain structure, delineated by α-phase boundaries, oriented along the build direction. A nearly equilibrium α + β mixture structure, formed from the original β-phase, arranged inside the prior β-grains as an α-colony or α-basket weave pattern, whereas the β-phase enveloped α-lamellae. The microstructure was finer with increasing distance from the build plate regardless of the selected build mode. Optical measurements of the α-plate width showed that it varied as the distance from the build plate varied. This microstructure parameter was correlated at the sample core with the mechanical properties measured by means of a macro-instrumented indentation test, thereby confirming Hall-Petch law behavior for strength at a local scale for the various process conditions. The tensile properties, while attesting to the mechanical performance of the builds over a macro scale, also validated the indentation property measurement at the core of the samples. Thus, a direct correlation between the process parameters, microstructure, porosity, and mechanical properties was established at the micro and macro scales. The macro-instrumented indentation test has emerged as a reliable, easy, quick, and yet non-destructive alternate means to the tensile test to measure tensile-like properties of selective-electron-beam-melted specimens. Furthermore, the macro-instrumented indentation test can be used effectively in additive manufacturing for a rapid setting up of the process, that is, by controlling the microscopic scale properties of the samples, or to quantitatively determine a product quality index of the final builds, by taking advantage of its intrinsic relationship with the tensile properties.

Nano- and microstructured titanium surfaces have recently attracted attention in the field of regenerative medicine because of the influence which surface characteristics such as roughness and wettability can have on cellular processes. This study focuses on the correlation of surface properties (wettability and nano/micro texture) of laser-structured Ti6Al4V samples with pronounced cell adhesion. Samples were structured with multiple laser parameters in order to create a range of surface properties. Surface characterization was performed by contact angle measurements 1 and 7 days after laser processing. The arithmetic mean roughness of the material surface in an area (Sa) was determined by means of confocal laser scanning microscopy (CLSM). Immediately after wettability tests of the laser-structured surfaces, in vitro experiments with human MG-63 osteoblasts were carried out. For this purpose, the cell morphology and actin cytoskeleton organization were analyzed using CLSM and scanning electron microscopy. On rough microstructures with deep cavities, the cell growth and spreading were inhibited. An improved cellular adhesion and growth on nanostructured and sinusoidal microstructured surfaces could be demonstrated, regardless of hydrophilicity of the surfaces.

In current therapeutic strategies, bone defects are filled up by bone auto- or allografts. Since they are limited by insufficient availability and donor site morbidity, it is necessary to find an appropriate alternative of synthetic porous bone materials. Because of their osteoconductive characteristics, ceramic materials like tricalciumphosphate (TCP) are suitable to fill up bone defects. Another advantage of TCP implants is the ability of patient-specific engineering. Objective of the present in-vitro study was to analyze the migration capacity and viability of human primary osteoblasts in porous three-dimensional TCP scaffolds in a static cell culture. To obtain data of the cellular supply with nutrients and oxygen, we determined the oxygen concentration and the pH value within the 3D scaffold compared to the surrounding medium using microsensors. After eight days of cultivation we found cells on all four planes. During incubation, the oxygen concentration within the scaffold decreased by approximately 8%. Furthermore, we could not demonstrate an increasing acidification in the core of the TCP scaffold. Our results suggest that osteoblasts could migrate and survive within the macroporous TCP scaffolds. The selected size of the macropores prevents overgrowth of cells, whereby the oxygen and nutrients supply is sufficiently guaranteed.

Additive manufacturing of lightweight or functional structures by selective laser beam (SLM) or electron beam melting (EBM) is widespread, especially in the field of medical applications. SLM and EBM processes were applied to prepare Ti6Al4V test specimens with different surface orientations (0°, 45° and 90°). Roughness measurements of the surfaces were conducted and cell behavior on these surfaces was analyzed. Hence, human osteoblasts were seeded on test specimens to determine cell viability (metabolic activity, live-dead staining) and gene expression of collagen type 1 (Col1A1), matrix metalloprotease (MMP) 1 and its natural inhibitor, TIMP1, after 3 and 7 days. The surface orientation of specimens during the manufacturing process significantly influenced the roughness. Surface roughness showed significant impact on cellular viability, whereas differences between the time points day 3 and 7 were not found. Collagen type 1 mRNA synthesis rates in human osteoblasts were enhanced with increasing roughness. Both manufacturing techniques further influenced the induction of bone formation process in the cell culture. Moreover, the relationship between osteoblastic collagen type 1 mRNA synthesis rates and specimen orientation during the building process could be characterized by functional formulas. These findings are useful in the designing of biomedical applications and medical devices.

Electrolytic plasma polishing (EPP) is an emerging technology for polishing, cleaning, deburring and smoothing of free-formed metal surfaces. The electrolytic plasma polishing of outer metal surfaces is state-of-the-art, whereas the polishing of pipe inner surfaces has only recently been reported by the authors. A prototype system and first experimental results were presented. It was found in the previous study that the average surface roughness Sa reaches a range from 0.065 µm to 0.090 µm. The current study systematically investigates the influence of the velocity v as well as the number n of polishing passages on the average surface roughness Sa . The polishing of the pipe inner surface and weld seam are considered separately. The results show that the average roughness Sa is mainly dependent on the effective polishing time t e p t of the polishing process. The average surface roughness Sa of the pipe inner surface can reach a range from 0.030 µm to 0.034 µm starting from an initial surface roughness S a 0 of 0.719 µm, whereas the average surface roughness Sa of the weld seam can reach a range from 0.088 µm to 0.096 µm starting from an initial surface roughness Sa 0 of 0.282 µm. These ranges are achieved after an effective polishing time of approximately 25 s for both the inner pipe surface and the weld seam.

Optical flow analysis methods such as particle image velocimetry can only be performed in fluid systems or components with optical access. Many fluidic components, such as metallic tubes, do not typically feature optical accessibility. A new silicone-based molding technique is presented that makes it possible to replicate non-transparent fluidic components as models with optical accessibility that can be used to perform optical flow analysis. Furthermore, to avoid errors due to refraction, a test fluid is presented whose refractive index matches that of the silicone material of the replication. This new method allows flows to be analyzed in tubes or similar components with diameters in the range of only a few millimeters. An initial test was performed demonstrating the proof of concept and the velocity field of the flow inside a manifold was measured using a micro-particle image velocimetry setup. The study showed that both simple parts like tubes and complex parts such as manifolds can be replicated and investigated.

Composite Extrusion Modelling (CEM) is a new additive manufacturing process for metal that uses Metal Injection Moulding (MIM) materials. The MIM material is printed on a build plate using a moveable extruder. Subsequently, the printed greenparts are debinded and sintered in a two-step oven process. In contrast to beam-based additive processes, the microstructure of the part is not generated layer-wise by melting and solidifying small areas, but in a steady manner during sintering from the outside of the part to the inside, in order to create dense metal parts. In this study, various structures were printed and sintered in order to investigate the mechanical properties and dimensional properties of the resulting stainless-steel structures, and their dependence on the infill percentage. The measured density of the dense sintered parts is 7.47 g/cm3 and the sintering shrinkage is in the range from 14.6 to 16.8%. The compressive strength (σdm50) of the specimens varies in the range from 1220 to 2345 MPa dependent on the infill percentage. The measured density and the sintering shrinkage are very close to the values specified by the manufacturer of the MIM material.

Smooth surfaces are becoming increasingly important in many industries, such as medical, chemical or food. In some industrial areas, the mechanical treatment of surfaces (grinding and polishing) does not fulfil desired specifications. Non-abrasive methods (chemical and electrochemical) have the advantage that even complex geometries and free-form shapes can be polished. In the context of this paper, electrochemical surface treatment is considered in more detail. Both electro polishing, which is state of the art, and the novel electrolytic plasma polishing (EPP) process are presented. This paper focusses on the electrolytic plasma polishing because it has many advantages compared to the process of electro polishing. The theoretical operation of the electrolytic plasma polishing is shown. A prototype system for plasma polishing of internal surfaces of pipes was installed and a polishing head was developed. Several parameters are investigated, such as the width of the adjustable polishing head gap and different velocities v or different applied potential differences U, and first results of the average surface roughness Sa as function of the various parameters were evaluated. It can be seen that a stable polishing process can be achieved at the highest potential difference of 320 V and that the average surface roughness Sa reaches a range from 0.065 to 0.090 µm. At the same time, it has been shown that with increasing potential difference, the average surface roughness becomes independent of the width of the adjustable polishing head gap.

The use of additive manufacturing technologies to produce lightweight or functional structures is widespread. Especially Ti6Al4V plays an important role in this development field and parts are manufactured and analyzed with the aim to characterize the mechanical properties of open-porous structures and to generate scaffolds with properties specific to their intended application. An SLM and an EBM process were used respectively to fabricate the Ti6Al4V single struts. For mechanical characterization, uniaxial compression tests and hardness measurements were conducted. Furthermore, the struts were manufactured in different orientations for the determination of the mechanical properties. Roughness measurements and a microscopic characterization of the struts were also carried out. Some parts were characterized following heat treatment (hot isostatic pressing). A functional correlation was found between the compressive strength and the slenderness ratio (λ) as well as the equivalent diameter (d) and the height (L) of EBM and SLM parts. Hardness investigations revealed considerable differences related to the microstructure. An influence of heat treatment as well as of orientation could be determined. In this work, we demonstrate the influence of the fabrication quality of single struts, the roughness and the microstructure on mechanical properties as a function of orientation.

Selective electron beam melting (SEBM) is a relatively new additive manufacturing technology for metallic materials. Specific to this technology is the sintering of the metal powder prior to the melting process. The sintering process has disadvantages for post-processing. The post-processing of parts produced by SEBM typically involves the removal of semi-sintered powder through the use of a powder blasting system. Furthermore, the sintering of large areas before melting decreases productivity. Current investigations are aimed at improving the sintering process in order to achieve better productivity, geometric accuracy, and resolution. In this study, the focus lies on the modification of the sintering process. In order to investigate and improve the sintering process, highly porous titanium test specimens with various scan speeds were built. The aim of this study was to decrease build time with comparable mechanical properties of the components and to remove the residual powder more easily after a build. By only sintering the area in which the melt pool for the components is created, an average productivity improvement of approx. 20% was achieved. Tensile tests were carried out, and the measured mechanical properties show comparatively or slightly improved values compared with the reference.