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The article provides readers with a detailed overview of the AutoMedPrint technology, its advantages and opportunities, based on a number of studies and case examples. The AutoMedPrint system represents a significant advancement in the field of orthopedics, offering a comprehensive solution for the automated design and rapid production of personalized orthopedic and prosthetic devices through 3D printing technology. This paper details the system's capabilities and methodologies behind it, which include the design and manufacturing of various devices such as wrist hand orthoses (WHO) and ankle foot orthoses (AFO), among others. These devices are crafted using data obtained from precise anthropometric measurements, allowing for high customization to meet individual patient needs. The AutoMedPrint system enhances the quality of life for patients by providing devices that are not only functional and cost-effective but also rapidly produced, ensuring timely intervention. Case studies demonstrate the system's effectiveness in practical scenarios, highlighting its potential to revolutionize orthopedic care by integrating new materials and technologies that adapt to changing medical and patient requirements. The discussion extends to the lifecycle of the produced devices, emphasizing sustainability and continuous improvement, ensuring the system's relevance and efficacy in modern medical practice.

The article presents analysis of mechanical properties of specimens fabricated by fused deposition modeling (FDM). The four of considered materials are the well-known 3D printing filaments i.e., polylactide (PLA), Nylon 12 (PA12), acrylonitrile butadiene styrene (ABS), polyethylene terephthalate glycol (PET-G). The other four of the considered materials are composites with carbon i.e. polylactide with carbon fiber (PLA-CF), Nylon 12 with carbon fiber (PA12-CF), acrylonitrile butadiene styrene with carbon fiber (ABS-CF), polyethylene terephthalate glycol with carbon fiber (PETG-CF). The paper describes how the specimens were designed, printed, subjected to tensile testing, and examined using microscopy. The obtained data will be used to select the optimum material for the rapid manufacture of lower limb orthoses. Carbon composites were found to have better mechanical properties of their base material, but the fabrication of composite samples is much more time consuming, for the reason that the manufacturing process is not stable.

Additive manufacturing is a technology that can be successfully used in pharmacy and medicine. One of the examples of products that can be additively manufactured are microneedle systems. The specificity of these products, which are used for transdermal drug delivery, makes additive manufacturing a perfect choice for related research. However, the dimensions of microneedles usually do not exceed 2 mm, which means that manufacturing them using the most widely available additive manufacturing method, Fused Deposition Modelling (FDM), is problematic. In this study, the authors decided to investigate the possibilities of manufacturing microneedle systems using the FDM method in such a way as to minimize or exclude the need for post-processing. Five types of microneedle geometries were tested in four sizes, examining how changing the values of FDM process parameters would affect the accuracy of reproducing the digital geometry of the microneedles. From the point of view of the application of microneedle systems, it is not only necessary to obtain the designed shape of the microneedles, but also to maintain their appropriate strength. The study presents the results of the bending and compression strength of microneedles made of polylactic acid.

The aim of the study was to investigate the effect of ethanol on the properties of acrylic-urethane resin products obtained by vat photopolymerization using the masked stereolithography method. The effect of alcohol at concentrations of 15, 25, and 35% in the resin on the chemical structure, weight, thickness of the samples, and mechanical properties in static tabltensile tests performed immediately after printing and one month later were studied. The results obtained were evaluated in terms of the use of ethanol as a cosolvent to help load the resin with agomelatine for the potential of obtaining microneedle transdermal systems. It was shown that in terms of stability of properties, the most favorable system was resin with the addition of alcohol at a concentration of 15%. The greatest changes induced by the presence of the solvent in the resin were observed in the case of tensile properties, where the alcohol caused a decrease in the plasticity of the material, reducing the relative elongation at break from 14% for the pure resin to 4% when the alcohol concentration was 35%. Young’s modulus and tensile strength also decreased with the addition of alcohol by 18% and 31%, respectively, for testable samples with the maximum amount of alcohol in the resin. The deterioration in properties is most likely related to the effect of the solvent on the radical polymerization process of the resin, particularly the phenomenon of chain transfer to the solvent, which is important in view of the intended application of the developed material.

The manufacturing process relies heavily on production scheduling to guarantee effective production schedules, reduce costs and product shortages, and get away from delays, interruptions, and waste products. Scheduling issues have been effectively solved via constraint programming. In this paper, we consider a constraint programming formulation of the flexible flow shop scheduling problem with repeated jobs and operations repetitions. We also implemented seven fast heuristics and compared the results with the constraint programming solution. The results from using the CPLEX solver as a solution tool were satisfactory. Computational experiments demonstrate that using constraint programming can be significantly more advantageous than using heuristics.

Advancements in materials science and 3D printing technologies have opened up new avenues for developing low-cost robotic grippers with high-performance capabilities, making them suitable for various biomechatronic applications. In this research, it has been explored the utilization of high-performance polymer materials, such as Polyetherketoneketone (PEKK), Polyethylene Terephthalate Glycol (PET-G) and MED 857 (DraftWhite), in the designing and developing of customized robotic grippers. The primary focus of made analyses was oriented on materials characterization, both experimentally and analytically. Computer-Aided Engineering (CAE) methods were employed to simulate bending experiments, allowing for a comprehensive analysis of the mechanical behavior of the selected materials. These simulations were validated through physical bending experiments using samples fabricated via 3D printing technologies, including Fused Filament Fabrication (FFF) for PET-G and PEKK, as well as Jetted Photopolymer (PolyJet) technology employing UV Resin for MED 857. The findings of this research provided advantages of utilizing advanced materials like PEKK in low-cost robotic grippers for biomechatronic applications. The experimental and analytical approaches offer valuable insights into material selection, design optimization, and the development of cost-effective high-performing robotic systems with a wide range of applications in the field of biomechatronics.

This paper presents the results of research on the influence of the moisture content in a filament made of ABS polymer on the properties of products manufactured using FDM (fused deposition modeling). Tests were carried out on a standard printer, using the parameters recommended by the manufacturer and the literature on the subject. A special climatic chamber was used to condition the material. A negative impact of ABS filament moisture on the strength and dimensional accuracy of printed products and on the structure of their surface is demonstrated. When the range of the filament moisture is between 0.17% and 0.75%, the strength decreases by 25% and the sample thickness increases by 10%. It is also shown that this effect does not depend on the history of the polymer reaching a given moisture level, i.e., by absorbing moisture in the absorption process or releasing moisture in the desorption process.

This study investigated the relationship between the parameters of the DLP manufacturing process and the structure of photopolymerizable acrylic resins. Four different process parameters were established to produce different thin-walled acrylic sample series: exposure time, layer thickness, area offset, and number of transition layers. The structure and the surface of the obtained samples were examined with the use of the FTIR–ATR method and an optical microscope, respectively. It was proved that extension of the exposure time increases the density of crosslinking and sample thickness. A decreasing crosslinking density due to rising layer thickness is observed. The area offset affects only the dimensions of the sample, predictably reducing the dimensions of the sample as the compensation increases. The absence of transition layers proved unfavorable in many respects, both structurally and geometrically.

In this study, caffeine-loaded photoresin composites with homogeneous structures, suitable for additive manufacturing of transdermal microneedle systems, were obtained. The properties of the composites with varying caffeine concentrations (0.1–0.4% w/w) were investigated for carbon–carbon double bond conversion using Fourier Transform Infrared Spectroscopy, surface wettability and mechanical properties using a static tensile test and nanoindentation, and caffeine release in ethanol using UV-Vis. The caffeine concentration did not affect the final degree of double bond conversion, which was confirmed in tensile tests, where the strength and Young’s modulus of caffeine-loaded samples had comparable values to control ones. Samples with 0.1 and 0.2% caffeine content showed an increase in nanohardness and reduced elastic modulus of 50 MPa and 1.5 MPa, respectively. The good wettability of the samples with water and the increase in surface energy is a favorable aspect for the dedicated application of the obtained composite materials. The amount of caffeine released into the ethanol solution at 1, 3 and 7 days reached a maximum value of 81%, was higher for the lower concentration of caffeine in the sample and increased over time. The conducted research may enhance the potential application of composite materials obtained through the digital light processing method in additive manufacturing.

This paper presents the outcomes of investigations conducted on the development procedure of a personalized prosthetic device for an adult patient. The individualization is achieved through 3D scanning, followed by semi-automated design using the AutoMedPrint system, and low-cost fused deposition modelling (FDM) technology for 3D printing. The prosthesis is aimed for use during bicycle riding and other sport activities. During the conducted experiments outlined in this manuscript, the prosthesis is equipped with force and movement sensors. The purpose is to collect data on its functionality across different scenarios and dynamic activities, aiming to assess potential harm, refine the design, and serve as an initial step before activating the prosthesis end effector. This article describes the methodology in detail, including the process of designing, producing, and programming, as well as laboratory and field test results (including testing performed with and without a patient). Overall, the design and prototype are implemented successfully. A discussion about the need for particular improvements in both the mechanical and electrical areas is finally presented.

The necessity for undertaking this research is driven by the prevailing challenges encountered in logistic centers. This study addresses a logistic order-picking issue involving unidirectional conveyors and buffers, which are assigned to racks and pickers with the objective of minimizing the makespan. Subsequently, two variations of a two-step matheuristic approach are proposed as solution methodologies. These matheuristics entail decomposing the primary order-picking problem into two subproblems. In the initial step, the problem of minimizing the free time for pickers/buffers is solved, followed by an investigation into minimizing order picking makespan. An experimentation phase is carried out across three versions of a distribution center layout, wherein one or more pickers are allocated to one or more buffers, spanning 120 test instances. The research findings indicate that employing a mathematical programming-based technique holds promise for yielding solutions within reasonable computational timeframes, particularly when distributing products to consumers with limited product variety within the order. Furthermore, the proposed technique offers the advantages of expediency and simplicity, rendering it suitable for adoption in the process of designing and selecting order-picking systems.

The Special Issue, entitled “Bioactive Materials for Additive Manufacturing”, aims to cover cutting-edge research regarding the production, characterization and application of bioactive materials that can be processed using additive manufacturing technology [...]

The aim of this research was to determine the possibility of applying alternative techniques for the production of prototypes for spare parts in agriculture and to determine the possible directions of development of their applications in the engineering industry. Then, to determine which spare parts could be produced using the FDM technique, comparisons of the most important parameters of spare parts produced independently (using the FDM technique) and obtained from producers (produced using traditional methods in professional factories) were made. A number of factors were analysed, from technical parameters such as machine type, processed material and its consumption including required as support structures, to economic issues such as manufacturing or purchase delivery total time and cost. The FDM technique has proven itself in many ways in the production of spare parts for agricultural machinery.

Materials based on photocurable resins and pharmaceutically active agents (APIs) are gaining interest as a composite drug delivery system. In this study, a composite of caffeine with acrylic resin was obtained using an additive manufacturing method of digital light processing (DLP) as a potential material for transdermal drug delivery. The mechanical properties of the composites and the ability to release caffeine from the resin volume in an aqueous environment were investigated. The amount of caffeine in the resulting samples before and after release was evaluated using a gravimetric method. The global thresholding method was also evaluated for its applicability in examining caffeine release from the composite. It was shown that as the caffeine content increased, the strength properties worsened and the ability to release the drug from the composite increased, which was caused by negligible interfacial interactions between the hydrophilic filler and the hydrophobic matrix. The global thresholding method resulted in similar caffeine release rate values compared to the gravimetric method but only for samples in which the caffeine was mainly located near the sample surface. The distribution of caffeine throughout the sample volume made it impossible to assess the caffeine content of the sample using global thresholding.

Designing individualized medical devices requires the collection of anthropometric data from the patient. This can be done by using the 3D scanning process. Despite many advantages, it has significant drawbacks, limiting the suitability of its use for many types of medical devices. This paper presents the design of measuring station that allows to increase the quality of anthropometric data obtained in the scanning process of humans limbs. Accuracy and repeatability of data obtained on the station is presented and compared to reference scans. What's more, thanks to the automatisation of certain activities in the scanning process, operating the device requires the operator to have much lower competencies and workload.

The paper presents experimental process of manufacturing individualized prosthetic sockets out of thermoplastic material, using an additive manufacturing technology of Fused Deposition Modelling. The patient is an adult male with an amputated forearm. His stump was 3D scanned using a low-cost 3D scanner in a semi-automated manner. Then, the anthropometric data was used for creation of a model of a prosthetic socket, which was then manufactured. Three different 3D printers were used, with three different materials (ABS, nylon and PC) and three different sets of process parameters. The paper contains descriptions of the process, its results and opinions by the patient, leading to selection of an optimal process course variant.

The article presents the results of research on the influence of the natural moisture of a filament made of acrylonitrile–butadiene–styrene terpolymer (ABS) on the mechanical properties and quality of products fabricated with fused filament fabrication (FFF). The concept of the natural moisture of the filament was defined, and the range of its variability was identified in reference to the range of the natural ambient humidity. It is shown that a change in the ambient humidity by 10% resulted in a change in filament moisture by about 0.05%. The results of the research on the moisture variability of an ABS filament stored in a package, an airtight container, or a container with a moisture absorber are also discussed. The last part of the article presents the results of the research on the impact of the moisture of the filament in its natural range of variability on select mechanical properties of filaments and products made using FFT. It is shown that this impact was significant and had a value of 1 MPa on 0.1% filament moisture.

Pre-operative preparation of the surgeon is more and more often extended to individual patient's anatomical models depicting the ill organ and the existing change in relation to the surrounding structures (e.g. blood vessels). Among the models there are models of the skeletal system, to which the FFF technology is used. Models of parenchymal organs are more difficult to reproduce due to material limitations in FFF technology, which is why alternative technologies such as PolyJet and SLA are used. Due to the high price of models, they are less frequently used in, especially in Polish hospitals. The research presented in the article deals with the subject of modification of the existing methodology of rapid production of pre-operative models with the use of various low-budget techniques of rapid manufacturing, which use materials of low hardness, similar to human soft tissues. The aim is to create a methodology and determine the parameters of materials that allow for the cheap production of functional pre-operational aids.

The paper presents design and manufacturing process of an individualized wrist orthosis. The patient’s upper limb was 3D scanned and the orthosis was design using a CAD system. Each part of the orthosis consists of two different materials, that fulfill different functions. By using the double-head Fused Deposition Modelling machine it was possible to produce theses parts in a single process without the need for additional assembly operations. The orthosis has been tested for mutual fit of parts, strength and comfort of use.

Growing age and different conditions often require the replacement of orthoses, and FDM-based 3D printing can produce them quickly with less investment. In today’s market for orthotics, these characteristics are highly desired. Therefore, this study is fully focused on the optimization and strength analysis of FDM 3D-printed ankle–foot orthoses (AFO) fabricated using PLA and PLA reinforced with carbon fiber (PLA-C). An increase in ankle plantar-flexor force can be achieved by reinforcing thermoplastic AFOs with CFs. Specially designed mechanical strength tests were conducted at the UTM to generate force–displacement curves for stored elastic energy and fracture studies. The mechanical behavior of both AFOs was predicted with the help of an FEA. The model predictions were validated by comparing them with mechanical strength testing conducted under the same loading and boundary conditions as the FEA. In both the prediction and experimental analysis, the PLA-C-based AFOs were stiffer and could withstand greater loads than the PLA-based AFOs. An area of high stress in the simulation and a fracture point in experimentation were both found at the same location. Furthermore, these highly accurate models will allow the fabrication of AFOs to be improved without investing time and resources on trials.

The paper presents the results of research on the influence of the parameters of Fused Deposition Modelling (FDM) on the mechanical properties and geometric accuracy of angle-shaped parts. The samples were manufactured from acrylonitrile butadiene styrene (ABS) on a universal machine. A complete factorial experiment was conducted. The results indicated that the critical technological parameter was the angular orientation of the sample in the working chamber of the machine. The results were compared with the results of research performed on simple rectangular samples. A significant similarity was found in the relationships between the FDM parameters and properties for both sample types.

Inter-operational surgery supplies manufactured additively using the FDM (Fused Deposition Modelling) technology are required to be sterilized before use. After manufacturing, the part should be sterilized using one of commonly used processes, without losing its dimensions and shape. The paper presents studies on manufacturing and sterilizing samples made out of ABS material and influence of the sterilization process on the dimensional accuracy of these samples.

A new approach to product quality assessment taken by manufacturers integrates environmental aspects. Design for the environment, also referred to as ecodesign or sustainable design, is an innovative approach to the traditional design process. It focuses on compliance with ecological standards at an early stage of design in CAD 3D environment. In this paper, main objectives of the ecodesign process automation method based on a CAD 3D system are presented. The ecodesign process of a small household appliance is analyzed. The main features of a dedicated software application with a graphical interface, which runs independently of the CAD 3D system, are presented.

Realism of a Virtual Reality simulation can be improved by use of physical objects tracked in real time. The paper presents possibility of using low-cost FDM process, realized by MakerBot Replicator 2X machine, in comparison with a professional one to build tooling for a simulation of ultrasound examination procedure. The objects were manufactured on two different machines out of ABS material, 3D scanned for accuracy testing and finally possibilities of their use in a VR system were evaluated.

This paper presents the results of experiments conducted on a batch of additively manufactured customized prosthetic sockets for upper limbs, made of thermoplastics and designed automatically on the basis of a 3D-scanned limb of a 3-year-old patient. The aim of this work was to compare sockets made of two different materials—rigid PLA and elastic TPE. Two distinct socket designs with various mounting systems were prepared. To find a reliable set of parameters for cheap and stable manufacturing of usable prostheses using 3D printers, realizing the fused deposition modeling (FDM) process, sets of sockets were manufactured with various process parameters. This paper presents the methodology of the design, the plan of the experiments and the obtained results in terms of process stability, fit and assessment by patient, as well as strength of the obtained sockets and their measured surface roughness. The results are promising, as most of the obtained products fulfil the strength criteria, although not all of them meet the fitting and use comfort criteria. As a result, recommendations of materials and process parameters were determined. These parameters were included in a prototype of the automated design and production system developed by the authors, and prostheses for several other patients were manufactured.

The paper presents design and manufacturing process of an individualized ankle orthosis using additive manufacturing technologies and reverse engineering. Conventional processes of manufacturing of orthosesareexpensive and time consuming -an alternative method was proposed. The patient’s leg was 3D scanned and the orthosis was designed using a CAD system. It was then manufactured using the Fused Deposition Modelling technology, assembled and fully tested. Positive results were obtained.

This paper describes prototyping of an individualized cosmetic arm prosthesis. Aim of the studies was to obtain an anatomically correct, lightweight prosthesis. It was accomplished using additive manufacturing technology of fused deposition modeling. The data was obtained by 3D scanning. An experimental concept of dual extrusion of two different materials was applied – the prosthesis was divided into an elastic shell and a rigid core, manufactured in one process. Obtained results were positive.

This paper presents assessment of the Rapid Prototyping finishing techniques for the printed components. The aim of the study was to compare the element printed with FDM technology before and after the treatment, using 3D scanning techniques. The object was scanned right after manufacturing, then was subjected to finishing treatment and was 3D scanned once again. Assessment of the results was performed using the GOM Inspect software, based on a comparison between scans and nominal model.

The paper presents results of tests conducted on the elements of medical devices - slings used with medical lifts - manufactured using additive technologies. Project assumptions were: to produce 100 samples of clips with varying design, material and orientation parameter. Samples were manufactured using FDM and SLA processes and then tested for mechanical strength, load transmission and functionality, using certified equipment. Paper shows full methodology and obtained test results.

The paper presents results of studies undertaken by the authors, aimed at determination of character of influence of marker arrangement on real-time measurement of position and orientation of an object, using an exemplary optical tracking system PST-55. Such a system can be used for interaction in immersive Virtual Reality applications. To ensure better immersion of a user in a virtual environment, it is necessary to directly translate its actions into 3D image presented by the VR application. It is possible, among other things, by the application of systems for tracking user’s movements. During the presented studies, an object with infrared-reflective markers deployed on its surface was placed in the center of a rotary table, then it was measured by the tracking system to determine the influence of the object angular position on the accuracy of determination of its position and orientation by the examined device. The measurements were performed for several different arrangements of markers, to formulate guidelines for their deployment on objects used for work in a virtual environment.

The article describes the experimental and simulation research on the material properties of the individualized wrist orthoses produced in the additive manufacturing (AM) process by the fused filament fabrication (FFF) method. The authors produced a series of standard (normalized) samples for three-point bending from acrylonitrile butadiene styrene (ABS) filament on a low-budget 3D printer and a series of samples in the shape of a fragment of the orthosis and the entire orthosis. All types of samples were subjected to experimental tests on a universal testing machine, which allowed us to determine the modulus of elasticity of the produced materials by comparing it with finite element method (FEM) simulation models in the ABAQUS environment. The adopted research methodology allowed us to compare the material properties of the material of the entire product—wrist hand orthosis (WHO)—with the material properties of standard bending samples. The obtained values of Young’s modulus are characterized by a large discrepancy between the standard samples and the entire orthosis. On the other hand, the samples with the shape of the middle part of the orthosis were similar in the value of Young’s modulus to the results obtained during the examination of the complete orthosis.

The paper presents results of research conducted on a batch of additively manufactured individualized openwork wrist–hand orthoses made of thermoplastics and designed automatically based on 3D-scanned geometry of a given patient. The aim of the work was to establish an automated design process and find a reliable set of parameters for rapid and affordable manufacturing of usable orthoses on popular 3D printers, with little or no supervision of the process. The paper presents motivations, methodology of automated design, plan of manufacturing and testing, the obtained results in terms of process stability, fit and assessment by patient and strength of the obtained orthoses. Almost 100 manufacturing processes of ready-to-use orthosis parts were carried out in a controlled environment and their results were analyzed thoroughly. The results are promising, as most of the obtained products fulfil the strength criteria, although not all of them meet the economic criteria. As a result, a recommended set of process parameters was determined. These parameters were included in a prototype of the automated design and in a production system developed by the authors.

The paper presents a method, developed by the authors, for manufacturing polymer composites with the matrix manufactured in a layered manner (via 3D printing – Fused Deposition Modeling) out of a thermoplastic material. As an example of practical application of this method, functional prototypes are presented, which were used as elements of foundry tooling – patterns for sand molding. In case of manufacturing prototype castings or short series of products, foundries usually cooperate with modeling studios, which produce patterns by conventional, subtractive manufacturing technologies. If patterns have complex shapes, this results in high manufacturing costs and significantly longer time of tooling preparation. The method proposed by the authors allows manufacturing functional prototypes in a short time thanks to utilizing capabilities of additive manufacturing (3D printing) technology. Thanks to using two types of materials simultaneously (ABS combined with chemically hardened resins), the produced prototypes are capable of carrying increased loads. Moreover, the method developed by the authors is characterized by manufacturing costs lower than in the basic technology of Fused Deposition Modeling. During the presented studies, the pattern was produced as a polymer composite and it was used to prepare a mold and a set of metal castings.

Numerous experimental studies, including experiments performed by the authors, have shown that the part orientation during layer deposition has a very strong influence on final strength of a product manufactured by additive Fused Deposition Technology. The paper presents the results of tensile, bending and impact strength tests performed on samples of various orientations, made out of ABS material using FDM technology. The results of these tests allowed discovering a unique phenomenon – with the changing orientation, not only the values of strength indexes change, but macroscopic material behavior under load as well. The transition between a “yield point” and “brittle” material usually happens in a certain range of orientation values, named a critical orientation by the authors. The paper indicates supposed ranges of critical orientation for various types of loads.

The paper presents the results of experimental study – part of research of additive technology using thermoplastics as a build material, namely Fused Deposition Modelling (FDM). Aim of the study was to identify the relation between basic parameter of the FDM process – model orientation during manufacturing – and a dimensional accuracy and repeatability of obtained products. A set of samples was prepared – they were manufactured with variable process parameters and they were measured using 3D scanner. Significant differences in accuracy of products of the same geometry, but manufactured with different set of process parameters were observed.

The paper presents an application of additive method of Fused Deposition Modeling for manufacturing of small series of elastic models. Additive FDM technology is used to produce a casting mould for multiple use. Process of manufacturing of small series of products consists in casting a two-component silicone rubber degassed using vacuum chamber into a multiple use mould. The paper shows the course of the process and related problems on the example of industrial product – a cylindrical seal. The casting mould was produced out of ABS material using BST 1200 machine, whereas casted elastic models were made out of XTX 45 silicone rubber.