articles+ search results

In a world grappling with environmental challenges and the need for sustainable manufacturing practices, the convergence of 3D printing and recycling emerges as a promising solution. This research paper explores the potential of combining these two technologies and comprehensively analyses their synergistic effects. The study delves into the printability of recycled materials, evaluating their suitability for 3D printing and comparing their performance with conventional materials. The environmental impact of 3D printing with recycled materials is examined through a sustainability analysis and a life cycle assessment of recycled 3D printed objects. The findings reveal significant benefits, including enhanced resource efficiency, waste reduction, and customisation possibilities. The research also identifies challenges and opportunities for scaling up the use of recycled materials in 3D printing, highlighting the importance of collaboration, innovation, and regulations. With potential applications spanning various industries, from prototyping to construction and healthcare, the implications of this research are far-reaching. By embracing sustainable practices, industry collaboration, and innovation, the integration of 3D printing and recycling can pave the way for a more sustainable future, where resource conservation, circularity, and customised production are at the forefront of manufacturing.
Competing Interests: Declaration of competing interest The authors declare that they have no known competing for financial interests or personal relationships that could have appeared to influence the work reported in this paper.
(Copyright © 2023 The Authors. Published by Elsevier B.V. All rights reserved.)

Purpose: The reproducibility of scientific reports is crucial to advancing human knowledge. This paper is a summary of our experience in replicating a balanced SSFP half-radial dual-echo imaging technique (bSTAR) using open-source frameworks as a response to the 2023 ISMRM "repeat it with me" Challenge.
Methods: We replicated the bSTAR technique for thoracic imaging at 0.55T. The bSTAR pulse sequence is implemented in Pulseq, a vendor neutral open-source rapid sequence prototyping environment. Image reconstruction is performed with the open-source Berkeley Advanced Reconstruction Toolbox (BART). The replication of bSTAR, termed open-source bSTAR, is tested by replicating several figures from the published literature. Original bSTAR, using the pulse sequence and image reconstruction developed by the original authors, and open-source bSTAR, with pulse sequence and image reconstruction developed in this work, were performed in healthy volunteers.
Results: Both echo images obtained from open-source bSTAR contain no visible artifacts and show identical spatial resolution and image quality to those in the published literature. A direct head-to-head comparison between open-source bSTAR and original bSTAR on a healthy volunteer indicates that open-source bSTAR provides adequate SNR, spatial resolution, level of artifacts, and conspicuity of pulmonary vessels comparable to original bSTAR.
Conclusion: We have successfully replicated bSTAR lung imaging at 0.55T using two open-source frameworks. Full replication of a research method solely relying on information on a research paper is unfortunately rare in research, but our success gives greater confidence that a research methodology can be indeed replicated as described.
(© 2023 The Authors. Magnetic Resonance in Medicine published by Wiley Periodicals LLC on behalf of International Society for Magnetic Resonance in Medicine.)

Reactive Oxygen Species, Printing, Three-Dimensional, Polyesters, Acrylates, Methacrylates, and Chlorella vulgaris

3D printing represents a key enabling technology in designing photobioreactors. It allows rapid prototyping of complex geometries at an affordable price. Yet, no study dealt with the biocompatibility of 3D printing material with microalgae. Thus microalga Chlorella vulgaris was cultivated in contact with different 3D printing materials (Acrylonitrile Butadiene Styren - ABS, PolyCarbonate Blend - PC-Blend, PolyLactic acid - PLA, and acrylate methacrylate resin). Cell status was analyzed using flow cytometry, fluorometry, and pigment profiling. Results revealed that acrylate methacrylate resin material inhibits growth, a constant rise in intracellular reactive oxygen species, and a decrease in photosynthetic apparatus functioning. On the contrary, ABS, PC-Blend, and PLA led to nominal perfromances. Nevertheless, PLA was the only material that did not induce an early onset of intracellular reactive oxygen species. Therefore, resin can be ruled out as photobioreactor material, ABS and PC-Blend could be used after a curation period, and PLA induces no detectable perturbations by the means used in this study.
Competing Interests: Declaration of Competing Interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
(Copyright © 2023 Elsevier Ltd. All rights reserved.)

Humans, Cemeteries, and Cremation history

The cremation has been documented since prehistoric times and it was a common funerary custom until the advent of Catholicism. Falling into disuse, during XVII-XVIII centuries there were new movements to bring it back according to modern criteria, mainly due to hygienic reasons and cemeteries overcrowding. This also led to the prototyping of new crematory ovens to improve the ancient open-air pyre. Lodovico Brunetti was the first to carry out a crematory experimental research in the modern countries. Since Brunetti's studies were based on the study of ancient cremations, a comparison with a modern experience of reconstruction of archaeological cremation is presented to evaluate the validity of his crematorium oven. Furthermore, the social and religious aspects related to Brunetti's inventions and the revitalization of cremation shows how tools and technologies and also the cultural environment have evolved over the years, effectively accepting the cremation practice as an alternative to inhumation.
Competing Interests: Declaration of Conflicting InterestsThe author(s) declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.

Humans, Child, Child, Preschool, Carbon Dioxide, Ventilators, Mechanical, Monitoring, Physiologic methods, Respiration, Artificial methods, and Home Care Services

Introduction: Outpatient monitoring of children using invasive home mechanical ventilation (IHMV) is recommended, but access to care can be difficult. This study tested if remote (home-based) data collection was feasible and acceptable in chronic IHMV management.
Methods: A codesign study was conducted with an IHMV program, home nurses, and English- and Spanish-speaking parent-guardians of children using IHMV (0-17 years; n = 19). After prototyping, parents used a remote patient monitoring (RPM) bundle to collect patient heart rate, respiratory rate (RR), oxygen saturation, end-tidal carbon dioxide (EtCO 2 ), and ventilator pressure/volume over 8 weeks. User feedback was analyzed using qualitative methods and the System Usability Scale (SUS). Expected marginal mean differences within patient measures when awake, asleep, or after a break were calculated using mixed effects models.
Results: Patients were a median 2.9 years old and 11 (58%) took breaks off the ventilator. RPM data were entered on a mean of 83.7% (SD ± 29.1%) weeks. SUS scores were 84.8 (SD ± 10.5) for nurses and 91.8 (SD ± 10.1) for parents. Over 90% of parents agreed/strongly agreed that RPM data collection was feasible and relevant to their child's care. Within-patient comparisons revealed that EtCO 2 (break-vs-asleep 2.55 mmHg, d = 0.79 [0.42-1.15], p < .001; awake-vs-break 1.48, d = -0.49 [0.13-0.84], p = .02) and RR (break-vs-asleep 16.14, d = 2.12 [1.71-2.53], p < .001; awake-vs-break 3.44, d = 0.45 [0.10-0.04], p = .03) were significantly higher during ventilator breaks.
Conclusions: RPM data collection in children with IHMV was feasible, acceptable, and captured clinically meaningful vital sign changes during ventilator breaks, supporting the clinical utility of RPM in IHMV management.
(© 2023 The Authors. Pediatric Pulmonology published by Wiley Periodicals LLC.)

Humans, Feasibility Studies, Sports, Exercise, Sedentary Behavior, and Health Promotion

Aim: This paper describes the design of the 'Move More' study, which aims to develop and assess the feasibility of a social-prescribing intervention to increase physical activity among physically inactive Danes.
Background: Physical inactivity constitutes a public-health challenge in Denmark. Social prescribing may be a promising tool to tackle physical inactivity by linking physical activity support from general practitioners with community-based activities in sports clubs, as this may help physically inactive citizens become more physically active. Given the range of stakeholders and behaviours required for social prescribing of physical activity, an intervention that harnesses this approach may constitute a complex intervention. The methods and decisions made in the stages of developing complex interventions are seldom reported. The present study enabled us to describe how co-creation can be used in a pragmatic development process for a complex intervention that considers the needs of stakeholders and the conditions of the delivery context.
Methods: The study is based on the core elements of the development and feasibility phases of the Medical Research Council Framework for Developing and Evaluating Complex Interventions. Additionally, it is informed by a framework for the co-creation and prototyping of public-health interventions, drawing from a scoping review, stakeholder consultations and co-creation workshops. Ultimately, a feasibility study will be conducted to refine the programme theory by introducing the proposed intervention in case studies.
Perspectives: The study will result in a prototype intervention manual and recommendations for implementation of an adapted social-prescribing intervention targeting physical inactivity in Denmark.
Competing Interests: Declaration of conflicting interestsThe authors declared no potential conflicts of interest with respect to the research, authorship and/or publication of this article.

Female, Humans, Pilot Projects, Endoscopes, Fallopian Tubes, Ovarian Neoplasms diagnostic imaging, and Ovarian Neoplasms pathology

Significance: High grade serous ovarian cancer is the most deadly gynecological cancer, and it is now believed that most cases originate in the fallopian tubes (FTs). Early detection of ovarian cancer could double the 5-year survival rate compared with late-stage diagnosis. Autofluorescence imaging can detect serous-origin precancerous and cancerous lesions in ex vivo FT and ovaries with good sensitivity and specificity. Multispectral fluorescence imaging (MFI) can differentiate healthy, benign, and malignant ovarian and FT tissues. Optical coherence tomography (OCT) reveals subsurface microstructural information and can distinguish normal and cancerous structure in ovaries and FTs.
Aim: We developed an FT endoscope, the falloposcope, as a method for detecting ovarian cancer with MFI and OCT. The falloposcope clinical prototype was tested in a pilot study with 12 volunteers to date to evaluate the safety and feasibility of FT imaging prior to standard of care salpingectomy in normal-risk volunteers. In this manuscript, we describe the multiple modifications made to the falloposcope to enhance robustness, usability, and image quality based on lessons learned in the clinical setting.
Approach: The ∼ 0.8    mm diameter falloposcope was introduced via a minimally invasive approach through a commercially available hysteroscope and introducing a catheter. A navigation video, MFI, and OCT of human FTs were obtained. Feedback from stakeholders on image quality and procedural difficulty was obtained.
Results: The falloposcope successfully obtained images in vivo . Considerable feedback was obtained, motivating iterative improvements, including accommodating the operating room environment, modifying the hysteroscope accessories, decreasing endoscope fragility and fiber breaks, optimizing software, improving fiber bundle images, decreasing gradient-index lens stray light, optimizing the proximal imaging system, and improving the illumination.
Conclusions: The initial clinical prototype falloposcope was able to image the FTs, and iterative prototyping has increased its robustness, functionality, and ease of use for future trials.
(© 2023 The Authors.)

Humans, Computer Simulation, User-Computer Interface, Clinical Competence, Spinal Puncture, and Students, Medical

Background: Lumbar puncture is an essential medical procedure whose objective is to obtain cerebrospinal fluid. Lumbar puncture is considered a complex procedure, mainly for novice residents who suffer from stress and low confidence, which may result in harm to the patient.
Methods: The LPVirSim, has been developed in four stages: i) requirements analysis through user-centred design; ii) prototyping of the virtual environment and the haptic component; iii) preliminary tests with Ph.D. students and physicians using two haptic devices (Omega.7 and Sigma.7); iv) a user study where physicians evaluated the usability and user experience.
Results: The LPVirSim integrates non-technical skills and the possibility of representing different patients for training. Usability increased from 61.76 to 68.75 in the preliminary tests to 71.43 in the user study.
Conclusions: All the results showed good usability and demonstrated that the simulator arouses interest and realistically represents a Lumbar puncture, through the force and visual feedback.
(© 2023 John Wiley & Sons Ltd.)

Ti 6Al–4V alloy, Zirconia, Co–Cr–Mo alloy additive manufacturing, Osteoarthritis, Knee joint, FDM, Internal medicine, RC31-1245, Surgery, and RD1-811

Additive manufacturing (Rapid Prototyping) is a significant innovation in medical field. It allows scientists to create custom-made parts that are often more precise and robust than their standard counterparts. Osteoarthritis (OA) is very common and serious problems in aging people. It is a progressive disease that affects the cartilage, the substance that cushions the bones and joints. Artificial knee joints are being developed as a sort of replacement for the human knee joint. One of the most intricate parts of the human body is the knee joint. This complex joint comprises of a ball-and-socket relationship, which is a very difficult part of the anatomy to design. The joint consists of both the kneecap and the Cartilage, and it has been designed with the intention of having the joint supported by a bone, rather than a cartilage. In this review article the results of a recent study, which was performed by researchers from the various renowned universities of Europe & United States of America over Artificial Knee Joint by Additive Manufacturing Technology.

Post-consumer recycling, Circular economy, Metalized film, Thermal properties, Mechanical properties, Renewable energy sources, TJ807-830, Environmental engineering, and TA170-171

In the recycling point of view, the metalized plastic film is widely known to be one of the most difficult materials to be recycled due to its structural complexity. This paper investigates the effects of the ground metalized-plastic film (MF) as a filler and reinforcement in recycled polypropylene (rPP) packaging to produce a new material through circular economy. MF was incorporated to rPP from 2 to 10 wt% and it was processed by using a twin-screw extruder and an injection molding machine. For MF, elemental analysis, and x-ray diffractometer (XRD) confirmed the existence of C, O, and Al, while the differential scanning calorimetry (DSC) result evidenced the melting position of linear-low density polyethylene (LLDPE). For, rPP/MF composites, MF was found to significantly reinforce rPP with the increased tensile strength. A maximum increase of the tensile strength by around 33% was observed when MF was added at 8 wt%. Elongation at break was found to reduce with MF loading. However, there was no significant difference among rPP with 6–10 wt% MF. DSC results indicated the shifts of both crystallization and melting peaks together with the reduction of the degree of crystallinity (Xc). Based on the tensile strength, tensile elongation at break results together with the statistical analysis and waste utilization issues, the rPP with 10 wt% MF formulation was selected as a final product prototyping.

rapid prototyping, automated hardware design, corner detection codesign, MBD, HDL coder, Xilinx Zynq-7000, Engineering (General). Civil engineering (General), TA1-2040, Technology (General), T1-995, Information technology, and T58.5-58.64

Computer vision systems use corner detection to identify features in an image. In applications such as motion detection, tracking, picture registration, and object recognition, corner detection is often one of the initial steps. In this paper, a real-time image processing system based on Harris corner detection was designed and implemented using Zynq architecture and model-based design tools. The system was based on a development board containing the Zynq-7000 chip, which consists of a combination of FPGA and microprocessor, and the image taken with a high-resolution camera was processed in real-time by applying color conversion and Harris corner detection. The filter hardware designs used in the system were made using the HDL Coder tool in Matlab/Simulink without writing HDL code. The hardware that receives images from the camera was designed on a model-based basis with the Xilinx Vivado 2020. The HDL code that was implemented on the Xilinx ZedBoard using Vivado software was then validated to ensure real-time operation with the incoming video stream. The results achieved exhibited superiority compared to prior implementations in terms of area efficiency (reduced number of gates on the target FPGA) and speed performance on an identical target card. Using the rapid prototyping approach, two alternative hardware accelerator designs were created using various high-level synthesis tools. This design used less than 50% of the host FPGA's logic resources and was at least 30% faster than current implementations.

Digital mental health, Human-centered design, Methodology, Information technology, T58.5-58.64, Psychology, and BF1-990

As digital mental health interventions (DMHIs) proliferate, there is a growing need to understand the complexities of moving these tools from concept and design to service-ready products. We highlight five case studies from a center that specializes in the design and evaluation of digital mental health interventions to illustrate pragmatic approaches to the development of digital mental health interventions, and to make transparent some of the key decision points researchers encounter along the design-to-product pipeline. Case studies cover different key points in the design process and focus on partnership building, understanding the problem or opportunity, prototyping the product or service, and testing the product or service. We illustrate lessons learned and offer a series of questions researchers can use to navigate key decision points in the digital mental health intervention (DMHI) development process.

Technology, Engineering (General). Civil engineering (General), TA1-2040, Applied optics. Photonics, and TA1501-1820

Large-scale pretrained language models have been a revolution in human-machine communication. Recently, such language models also generate code for required tasks. The objective of this work is to evaluate the functionality of the codes generated by ChatGPT (version 15-Dec-2022) for point cloud processing. The programming language selected for the test was MATLAB due to the extensive use in prototyping and toolboxes for Computer Vision and LiDAR. Using the Question-Answer system, the ChatGPT was asked for codes to calculate surface normals, curvature, eigenvalues, and eigenfeatures, with specific parameters and outputs. The provided codes were compiled and executed. The results show that ChatGPT can generate functional code for very specific and short applications, however, it is not capable of generating large code involving the correct use of loops, indexes, or equations.

Nanocellulose, Alginate, Hydrogel, Films, 3D printing, Architectural design, Materials of engineering and construction. Mechanics of materials, and TA401-492

Cellulose nanofibril hydrogel mixed with an aqueous solution of sodium alginate is a novel bio-based material suitable for 3D printing of lightweight membranes with exquisite properties and sustainable traits. However, fundamental knowledge enabling its applications in architectural design is still missing. Hence, this study examines the macro-scale features of lightweight membranes from cellulose nanofibril-alginate hydrogel, relevant for the design of various interior architectural products, such as wall claddings, ceiling tiles, room partitions, tapestries, and window screens. Through iterative prototyping experiments involving robotic 3D printing of lightweight membranes, their upscaling potential is demonstrated. Correlations between toolpath designs and shrinkages are also characterized, alongside an in-depth analysis of coloration changes upon ambient drying. Further, the tunability potential of various architectural features, enabled by bespoke 3D printing toolpath design, is discussed and exemplified. The aim is to expose the wide palette of design possibilities for cellulose nanofibril-alginate membranes, encompassing variations in curvature, porosity, translucency, texture, patterning, pliability, and feature sizes. The results comprise an important knowledge foundation for the design and manufacturing of custom lightweight architectural products from cellulose nanofibril-alginate hydrogel. These products could be applied in a variety of new bio-based, sustainable interior building systems, replacing environmentally harmful, fossil-based solutions.

Hole flanging, Incremental sheet forming, Hardness, Artifiical neural network (ANN), Forming limit diagram (FLD), Numerical simulation, and Technology

In the single point incremental hole flanging (SPIHF) process, a sheet material with pre-cut holes is deformed using the SPIF technique to generate a flange, making it an effective approach for low volume manufacturing and quick prototyping. In the case of the SPIHF technique, the post-forming hardness property, the forming limit diagram (FLD), and spring-back phenomena are not completely evaluated. To this end, this paper employs experimental investigation and numerical validation to analyse the impact of SPIHF process parameters like tool diameter, feed rate, spindle speed, and initial hole diameter on these aspects for the truncated incrementally formed components made from AA1060 aluminium alloy and DC01 carbon steel. The plasticity behaviour of both sheet metals was simulated using the Workbench LS-DYNA model and ANSYS software version 18. Additionally, Cowper Symonds power-law hardening was added to the model to account for material properties. The average post-hardness of AA1060 and DC01 was evaluated using an SPIHF prediction model based on the performance of an artificial neural network (ANN). This ANN model was developed using a feed-forward back-propagation network trained using the Levenberg-Marquardt approach. The ANNs 4-n-1 were created by varying the transfer functions and the number of hidden neurons. Greater spindle speed and bigger pre-cut holes were shown to significantly increase the post-formed hardness of the truncated components, whereas the converse was seen when using a higher feed rate and a larger tool diameter. In addition, the FLD and spring-back improved dramatically with larger hole diameters. Employing correlation coefficient (R) and mean square error (MSE) as validation measures, it was shown that the established ANN models accurately predicted the SPIHF process response. Both the DC01 and AA1060 neural network models with a 4-8-1 network architecture performed very well, with MSE and R values of 0.0000105 and 1 for DC01 and 0.02613 and 0.99982 for AA1061.

Biomedical imaging, 3D printing, prototyping, material science, polymer characterization, Materials of engineering and construction. Mechanics of materials, TA401-492, Biotechnology, and TP248.13-248.65

ABSTRACTIn biomedical imaging, it is desirable that custom-made accessories for restraint, anesthesia, and monitoring can be easily cleaned and not interfere with the imaging quality or analyses. With the rise of 3D printing as a form of rapid prototyping or manufacturing for imaging tools and accessories, it is important to understand which printable materials are durable and not likely to interfere with imaging applications. Here, 15 3D printable materials were evaluated for radiodensity, optical properties, simulated wear, and capacity for repeated cleaning and disinfection. Materials that were durable, easily cleaned, and not expected to interfere with CT, PET, or optical imaging applications were identified.

3d food printing, extrusion, food waste, sustainability, dysphagia, hydrocolloids, Science, Manufactures, and TS1-2301

Food waste utilisation and zero waste approach are among the many ways of building a sustainable economy. Food waste as authentic edible food being accepted by the consumers still has many barriers to overcome. One tool to help in the valorisation of food waste to value-added products is three-dimensional food printing (3DFP). These products can lead to easier and greater acceptance of food waste by consumers, having familiar nature with respect to taste, texture and appearance as other consumables. In the present study, food ink recipes were formulated from spinach stems and kale stalks, the common green leafy vegetable wastes. These spinach and kale inks were then characterised on their rheological properties of shear thinning and yield stress. The inks were subjected to IDDSI tests meant for standardisation of soft foods for dysphagia patients. This paper demonstrates ways of converting vegetable wastes into edible diets that are aesthetically pleasing through 3DFP.

Multiple materials, additive manufacturing, wire arc additive manufacturing, Science, Manufactures, and TS1-2301

ABSTRACTThe dynamic landscape of additive manufacturing (AM) is undergoing a transformative phase with the advent of multiple wire arc AM (MWAAM) processes. This systematic review offers an exhaustive exploration of the latest advancements and multifaceted applications of these innovative techniques within the realms of AM and welding. Prominently discussed processes encompass Bi-Metallic Wire Arc Additive Manufacturing, Twin Wire Arc Additive Manufacturing, Tandem Gas Metal Arc Welding, Twin-Wire Plasma Arc Additive, and Hybrid Wire Arc Additive Manufacturing. These techniques, instrumental in fabricating an array of materials from titanium aluminides to low-carbon steel, underscore the versatility and potential of modern AM. The application breadth spans key industries such as aerospace, naval, automotive, and energy, highlighting the ubiquity and relevance of these processes. While they promise enhanced productivity, improved material attributes, and economic efficiencies, challenges persist, including the need for meticulous parameter control, an in-depth grasp of foundational physics, and the development of sophisticated predictive models. Projecting into the future of AM, this review anticipates a harmonised integration of computational advancements with automation, positioning these MWAAM processes as pivotal in the next wave of manufacturing innovations.

additive manufacturing, 3d printing, field assistance, magnetic field assistance, electric field assistance, acoustic field assistance, additive manufacturing of polymers, additive manufacturing of metals, Science, Manufactures, and TS1-2301

Additive manufacturing (AM) has emerged as a transformative technology capable of fabricating complex geometries and multi-material structures across various industries. Despite its potential, challenges persist in terms of limited material selection, anisotropic properties, and achieving functional microstructures in polymer and metal composites. Field-assisted additive manufacturing (FAAM) employs external fields like acoustic, magnetic, and electric fields. It has shown promise in addressing these limitations by controlling filler orientation and concentration in polymeric composites and improving surface finish and microstructure in metals. This review paper provides a comprehensive analysis of the state-of-the-art FAAM processes for polymer and metal composites, focusing on material compatibility, the mechanics of each field, and their integration with AM technologies as well as current applications, limitations, and potential future directions in the development of FAAM processes. Enhancing FAAM process understanding can create tailored anisotropic composites, enabling innovative applications in aerospace, automotive, biomedical fields, and beyond.

3d printing, additive manufacturing, cooperative robots, mobile robots, teams of robots, cooperative printing, Science, Manufactures, and TS1-2301

Additive manufacturing (AM) is a key enabler and technological pillar of the fourth industrial revolution (Industry 4.0) as it increases productivity and improves resource efficiency. However, current AM systems present some limitations in terms of fabrication time, versatility, and efficiency. The concept of teams of robots represents a novel approach for AM aiming to address these limitations. This review paper discusses the current state-of-the-art of the use of cooperative AM systems based on gantry systems, robotic arms, and mobile robots. The information flow, path planning and slicing strategies are discussed in detail, and several examples of the use of cooperative AM systems are provided. Finally, major research challenges and future perspectives are discussed.

3D printing, online path planning, mobile 3D printer, real-time path planning, cooperative printing, Science, Manufactures, and TS1-2301

ABSTRACTCooperative printing, where multiple printheads concurrently print a part, significantly improves printing speed. However, current literature only discussed offline path planning, in which the toolpaths are generated before the printing process starts. Offline path planning is unreliable and leads to collisions for systems with uncertainties such as mobile robots. In this paper, we developed several online path planning algorithms for cooperative printing by mobile robots that allow toolpath allocation in real time. Unlike offline path planning, it is not possible to replan the layer in case of collision in online systems. Thus, we developed a novel algorithm that guarantees collision avoidance in real time. The system was evaluated through both simulations and experiments. The mobile robots cooperatively printed several layers which showed that the system can significantly increase the speed of 3D printing. This work stands as the first in the literature that allows online path planning for cooperative printing.

material jetting, 3d inkjet printing, print parameters, printed layer height, statistical analysis, interaction effect, Science, Manufactures, and TS1-2301

3D inkjet (3D-IJ) printing is recognised for its potential in high-value applications, including printed electronics, tissue engineering and bio-inspired structures, given its precision and ability to deposit multiple materials. The quality of 3D-IJ printed parts is contingent upon meticulous control of the process governing parameters. This study experimentally investigates the influence of various parameters within the 3D-IJ process, i.e., printing resolution, coverage percentage, droplet volume, printing speed and UV-Power and their interaction effects on the printed layer height. The results were analysed statistically using ANOVA and a quadratic regression model was developed to quantitatively identify the relationship between the process response and parameters. Except UV-Power, all parameters, and their interactions with each other had noticeable effects on the printed layer height, with a distinct trend observed for each, affecting the height that ranged from 4.73 µm to 98.58 µm. Increasing printing resolution, coverage percentage and droplet volume resulted in an increase in layer height as all three parameters contribute to a larger volume of dispensed material per layer. Printing resolution was found to be the most influential parameter, evidenced by a significant p-value. Finally, the optimal printing parameters for two scenarios, highest printed layer and cost-effective printing were individually identified.

Additive manufacturing, direct ink writing, high solid loadings, rheology, characterisation, Science, Manufactures, and TS1-2301

ABSTRACTMaterial extrusion additive manufacturing is of increased interest in producing materials with very high loadings of particles, specifically through the use of the direct ink write (DIW), or robocasting, technique and the use of highly loaded particle suspensions (HLS). Applications from biomedical composites to solid rocket propellants to powder metallurgy green bodies would benefit from the complex parts enabled by additive manufacturing but require very high particle contents during processing. This leads to very high viscosity fluids and challenges in flowing and curing the inks. In this comprehensive review, we examine the main components of designing an ink formulation and a DIW process: the ink rheology, the print mechanics and the solidification/post-processing. Our expanded discussion of these elements includes an introduction to the basics as well as the latest research in the field, so serves to both introduce a new practitioner and generate new ideas for those already working in the area. We finish with a discussion of two important applications and a perspective on the future directions of DIW for highly loaded particle materials.

battery, lithium-ion, electrodes, material extrusion, composites, energy storage, Science, Manufactures, and TS1-2301

The advent of conductive extrudable materials has broadened the range of additive manufacturing applications to include smart devices, circuits, actuators and sensors – all requiring electrical power. 3D printing of components dedicated to energy storage has also gained interest, with the goal of the monolithic printing of batteries directly integrated into subsuming smart components. This review focuses on the state of the art of extrusion-based 3D printed batteries, appearing as the most widespread, inexpensive and simple additive process. The paper is intended to introduce the processes and materials of 3D printing batteries, while highlighting the main manufacturing challenges and associated solutions proposed in literature. Particular attention is dedicated to describing the extrusion-based printers being employed and the required modifications, printing parameters and multi-material capabilities, with the aim of highlighting the most promising solutions required to print composite individual components and complete rechargeable batteries in a single non-assembly step.

miniaturisation, compliant mechanisms, customization, design automation, design synthesis, Science, Manufactures, and TS1-2301

Micro-additive manufacturing techniques have the potential to meet the demand for miniaturised functional components for minimally invasive surgical instruments. These techniques create monolithic, compliant mechanisms with micro-sized free-form structures that can be tailored to patient-specific surgical procedures. The automated design synthesis of the mechanisms using building blocks results in structures that are shape-programmable. This is achieved through an algorithmic-based computational workflow, which automatically converts user-specified 2D and 3D curves into discrete curve segments. The actuated motion of the mechanisms can be designed to move in a specific way, both forwardly and inversely. The mechanisms are manufactured using micro-laser powder bed fusion and hardenable stainless steel 17-4 PH. By carefully selecting the process parameters, it is possible to 3D-print micro-sized features such as a compliant beam thickness of 80 μm and an actuation hole of 100 μm. Both 2D planar curved mechanisms and 3D spatial curved mechanisms have been implemented and experimentally validated.

laser powder bed fusion, 3d-printing, automation, compliant mechanisms, design synthesis, design freedom, Science, Manufactures, and TS1-2301

Additive manufacturing (AM) facilitates the fabrication of compliant mechanisms through its free-form and design customisation capabilities. Specifically, the properties of kinetic mechanisms such as springs can be extended with regards to their inherent (non-)linear stiffness functions. This allows for the customisation of AM springs according to user preferences. By combining the design synthesis approach of building blocks with the structural optimisation approach for AM, it is possible to define and customise spring stiffness functionalities. The optimisation process employs an automated computational framework based on a genetic algorithm scheme, which has been demonstrated through randomised and reference case studies. This framework enables the attainment of linear, progressive (stiffening), and degressive (softening) stiffness curves. The manufacturability of the springs has been validated through laser powder bed fusion using stainless-steel material 17–4 PH (H900). The springs have resulted in an accuracy error of maximum 6.48% and precision error of maximum 5% through compression testing.

bainitic crossing nose, functionally graded material (fmg), laser directed energy deposition (l-ded), microstructure, wear and rolling contact fatigue (rcf) resistance, Science, Manufactures, and TS1-2301

In this paper, 20Mn2SiCrMo bainitic crossing noses were repaired by depositing 420SS, Stellite 6, 17-4PH and 18Ni300 alloys on the rail surfaces to form functionally graded materials (FGM) using laser directed energy deposition (L-DED) technology. As a result, only 18Ni300 deposit achieves an excellent strength-toughness combination, which possesses a yield strength of ∼1120 MPa together with an impact energy of ∼85.05 J, better than those of substrates (∼1071 MPa, ∼71.34 J). Besides, the wear and rolling contact fatigue (RCF) resistance of 20Mn2SiCrMo/18Ni300 FGM is enhanced to 2.7 and 23.6 times as much as those of substrates. Massive ultrafine nanoprecipitates and a small amount of austenite make 18Ni300 deposit strong enough as well as a certain work-hardenability, ensuring good wear resistance therein; the significant RCF resistance originates from the improved shakedown limit. Therefore, all findings reveal that 18Ni300 is the most promising depositing material for repairing bainitic crossing noses by L-DED.

additive manufacturing, sensor data fusion, thermal imaging, spatter monitoring, shape agnostic monitoring, porosity, Science, Manufactures, and TS1-2301

We developed and applied a novel approach for shape agnostic detection of multiscale flaws in laser powder bed fusion (LPBF) additive manufacturing using heterogenous in-situ sensor data. Flaws in LPBF range from porosity at the micro-scale (< 100 µm), layer related inconsistencies at the meso-scale (100 µm to 1 mm) and geometry-related flaws at the macroscale (> 1 mm). Existing data-driven models are primarily focused on detecting a specific type of LPBF flaw using signals from one type of sensor. Such approaches, which are trained on data from simple cuboid and cylindrical-shaped coupons, have met limited success when used for detecting multiscale flaws in complex LPBF parts. The objective of this work is to develop a heterogenous sensor data fusion approach capable of detecting multiscale flaws across different LPBF part geometries and build conditions. Accordingly, data from an infrared camera, spatter imaging camera, and optical powder bed imaging camera were acquired across separate builds with differing part geometries and orientations (Inconel 718). Spectral graph-based process signatures were extracted from this heterogeneous thermo-optical sensor data and used as inputs to simple machine learning models. The approach detected porosity, layer-level distortion, and geometry-related flaws with statistical fidelity exceeding 93% (F-score).

negative poisson’s ratio, triply periodic minimal surfaces, auxetic structure, bone implant, hip joint, Science, Manufactures, and TS1-2301

Based on the triply periodic minimal surface (TPMS), 3D auxetic structures are successfully implemented using a dual-period function. A series of shape-controllable, dual-period deformation functions are obtained by summarising the characteristics of periodic deformation functions and applying Bezier curve fitting methods. Then, with the geometry originating from the Schwarz primitive (P) of TPMS, the periodic shape transformation of TPMS is achieved using the dual-period deformation functions. The property (negative Poisson’s ratio) of the auxetic structure is investigated based on the control parameters (the TPMS c value, periodic function η, and deformation index γ). The auxetic structures can exhibit excellent 3D negative Poisson’s ratio properties, and the Poisson’s ratio can be effectively adjusted. Moreover, a heterostructure with positive and negative Poisson’s ratio structures is obtained and applied to a stem in the hip joint. The simulation proves that the heterostructure can effectively prevent the failure of the bone implant.

Voronoi diagram, topology optimisation, lightweight structure, porous structure, additive manufacturing, Science, Manufactures, and TS1-2301

ABSTRACTThis study introduces a novel approach to design non-uniform porous structures with gradient density through the integration of the Topology Optimisation (TO) method and the Voronoi porous structure design technique. With the homogenisation method of Voronoi structures, the density data derived from the TO process is converted into seed point distribution for Voronoi diagrams. The porous structure with controlled mechanical properties is constructed based on Voronoi diagrams using the surface mesh superposition method. Compared with uniform Voronoi porous structures, TO Voronoi porous structures exhibit improved strength and stability. The proposed method for generating non-uniform Voronoi structures in this study exhibits notable advantages in terms of simplicity of implementation and robustness. The surface mesh superposition method has advantages in model generation efficiency and accuracy. In addition, the TO Voronoi porous structure design method is applied to design medical pillows, showing significant advantages in shape retention, weight reduction, and personalisation.

terahertz, metamaterials, 3d printing, mortise and tenon structures, reconfigurable multi-functional, Science, Manufactures, and TS1-2301

The emergence of metamaterial has provided an unprecedented ability to manipulate electromagnetic waves, especially in the terahertz band where there is a lack of natural response materials. However, most metamaterials are fixed single function due to the fixed structure at the beginning of design. The paper reports a reconfigurable multi-functional terahertz metamaterial with variable structures based on mortise and tenon mechanism. And a hybrid 3D printing method based on FDM and E-jet is proposed to fabricate the metamaterials, which simplifies the processing process, improves the speed, and reduces the cost compared to traditional semiconductor processing methods. Through flexible mortise and tenon connections, the metamaterial can achieve: (1) narrowband transmission and broadband absorption; (2) perfect reflection; (3) narrowband reflection and broadband absorption. Relying on ingenious design and processing, the multi-functional metamaterials are expected to be widely used in fields such as electromagnetic shielding, radar stealth, communication and so on.

design workflow, scaffolds, patient-specific, 3d printing, generative design, voronoi, scaffold-guided bone regeneration, Science, Manufactures, and TS1-2301

A streamlined design workflow that facilitates the efficient design and manufacture of patient-specific scaffolds independently applied by the surgical team has been recognised as a key step in a holistic approach towards the envisioned routine clinical translation of scaffold-guided bone regeneration (SGBR). A modular design workflow was developed to semi-automatically fill defect cavities, ensure patient specificity and ideal surgical scaffold insertion for a given surgical approach, add fixation points to secure the scaffolds to the host bone and generate scaffold based on Voronoi, periodic lattice and triply periodic minimal surface pore architectures. The adopted functional representation modelling technique produces models free from 3D printing mesh errors. It was applied to a clinical case of a complicated femoral bone defect. All models were free from mesh errors and the patient-specific fit and unobstructive insertion were validated via digital inspection and physical investigation by way of 3D printed prototypes. The real-time responsiveness of the workflow to user input allows the designer to receive real-time feedback from the surgeon, which is associated with reducing the time to finalise a patient-specific scaffold design. In summary, an efficient workflow was developed that substantially facilitates routine clinical implementation of SGBR through its ability to streamline the design of 3D printed scaffolds.

Additive manufacturing, 3D Printing, graphene, VP, graphene composites, Science, Manufactures, and TS1-2301

ABSTRACTAdditive manufacturing has revolutionised the production of intricate and complex structures, offering numerous applications across diverse industries. Among the additive manufacturing techniques, VAT photopolymerisation (VP) is a promising method for fabricating intricate structures with smooth surface finishes. However, the inherent limitations of 3D printed structures, such as compromised mechanical strength and conductivity, necessitate the incorporation of filler materials. Graphene, a remarkable two-dimensional carbon material renowned for its exceptional mechanical and electrical properties, emerges as a highly desirable filler of various applications. The review addresses the critical parameters that affect the quality and properties of graphene composites fabricated using VP, including the choice of photopolymer resin, exposure parameters, and pre and post-processing techniques. It also explores the functionalisation of graphene materials, multi-material printing and hybrid composite systems. The resulting graphene composites find applications in various fields, including electronics, aerospace, biomedicine and energy storage. This review presents a comprehensive survey of these applications, highlighting the unique advantages of VP-derived graphene composites. The challenges and future prospects in the field of VP for graphene composites are discussed. These encompass improving printability, achieving enhanced graphene dispersion, and exploring novel hybrid materials and innovative applications.

zirconium alloy, zr-4, additive manufacturing, laser powder bed fusion, annealing, Science, Manufactures, and TS1-2301

Zirconium (Zr) alloys are widely used in nuclear energy because of their excellent mechanical properties and low thermal neutron absorption cross-section. This work investigated the printability, microstructure, and mechanical properties of Zr-4 alloy additively manufactured by laser powder bed fusion (LPBF) for the first time. The effect of annealing temperature on the microstructural and the mechanical property evolution of the printed Zr-4 alloy was studied. The results exhibited that the Zr-4 alloy with a high relative density of 99.77% was obtained using optimised printing parameters. With an increase in the annealing temperature, the formed α phase of the Zr-4 alloy changed from an acicular shape to a coarse-twisted shape, and finally to an equiaxed shape. Such microstructure change endowed the alloy with a high compressive strength of 2130 MPa and compressive strain of 36%. When the annealing temperature exceeded 700°C, Zrx(Fe2Cr) compounds were precipitated, strengthening the alloy by pinning effect. These findings provide valuable guidance for the manufacture of geometrically complex Zr alloy parts for nuclear power applications.

wire and arc additive manufacturing (waam), recursive bead profile, multi-bead overlapping model, axisymmetric drop shape analysis (adsa), surface topography, Science, Manufactures, and TS1-2301

Dimension prediction of robotic wire and arc additive manufacturing (WAAM) part is fundamentally dependent on the modelling accuracy of single-bead profile and its subsequent overlapping ones. Current multi-bead overlapping models are still not capable of describing the flatten valley area of WAAM parts. This paper proposes a new recursive model, based on coordinate transformation and axisymmetric drop shape analysis (ADSA), to predict multi-bead overlapping profiles. First, a single-bead profile model for WAAM is established based on ADSA, followed by detailed description of conventional and proposed modified recursive ADSA profile model. The properties of developed recursive ADSA model are then investigated to reveal the effects of overlapping ratio and single-bead aspect ratio. Finally, multi-bead overlapping deposition experiment is carried out to validate the model feasibility. The results show that the modified recursive ADSA model is more accurate than the conventional one for its better accountability of valley areas. It is also indicated that the modified recursive ADSA model is suitable for the robotic WAAM process. The research outcome is beneficial to improving the forming accuracy of WAAM parts and geometry prediction of other additive manufactured products.

al-sc alloys, heat treatment, laser powder bed fusion (lpbf), strengthening mechanism, Science, Manufactures, and TS1-2301

According to the material nature, aluminium alloys are widely applied in aerospace, construction and automotive applications due to their characteristics, such as lightweight, good formability and good corrosion resistance. Among the aluminium alloys, scalmalloy (Al-4.49Mg-0.71Sc-0.51Mn-0.27Zr-0.07Fe-0.03Si alloy) was developed to overcome the hot crack issue during the laser powder bed fusion (LPBF) process. Hence, the degree of lightweight can be further improved by introducing this high-specific strength material with a structure of the lightweight design. However, the strengthening mechanism of the heat-treated 3D printed scalmalloy has not been sufficiently explored. In this study, the synergistic effect of the strengthening mechanisms is explored through detailed microstructure analysis. The grain size, size and spacing of the precipitate and coherent phase contribute to the strengthening of scalmalloy. Through the observation of the microstructure feature, the theoretical strength of the heat-treated 3D printed scalmalloy can thus be calculated by three strengthening mechanisms and match the experimental results perfectly.

mechanical alloying, selective laser melting, amorphous/crystalline, zn60zr40 alloys, mechanical properties, Science, Manufactures, and TS1-2301

In the present study, mechanical alloying (MA) was employed for synthesising non-equilibrium Zn60Zr40 amorphous powders, and then consolidated into amorphous/crystalline Zn60Zr40 alloys using selective laser melting (SLM). The results showed that the MA process destabilised the atomic periodicity of Zn and Zr powders and induced crystalline-to-amorphous transformation due to atomic size mismatch and negative heat of mixing. Moreover, the amorphisation trend of as-milled powders was intensified with increasing milling time and attained almost fully amorphous structure after 30 h of milling. During SLM, the ultra-high cooling rate restricted the long-range atomic diffusion of the amorphous powders and enabled successful survival of amorphous phase, leading to amorphous/crystalline Zn60Zr40 alloys. The alloys exhibited a maximum compressive yield strength and microhardness of 160.9 ± 9.1 MPa and 3.73 ± 0.8 GPa, respectively. These findings demonstrated that the developed MA-SLM process might be a promising strategy for the preparation of amorphous/crystalline alloys with superior properties.

invar 36 alloy, laser powder bed fusion, high cycle fatigue, microstructures, defects, Science, Manufactures, and TS1-2301

The Invar 36 alloy was additively manufactured by laser powder bed fusion (PBF-LB), and systematical observations and experiments for microstructure, defects, metallography, especially high cycle fatigue behaviour and fractography were conducted. Inadequate laser energy density results in hardly overlapping melting traces, generating numerous defects. Accordingly, the fabricated Invar 36 alloy presents an inferior high cycle fatigue life, as it failures from the rapid aggregation of the defects. In contrast, an adequate laser energy density remarkably enlarges the overlapping between adjacent melting traces. The large molten pools with steady boundaries are beneficially to generate favourable microstructures and low porosity. Consequently, the Invar 36 alloy shows superior high cycle fatigue life, completely generated from small crack propagation, long crack propagation and final fracture stages. Above experimental results and analysis primarily link up the PBF-LB process, microstructures (defects) and high cycle fatigue performance for PBF-LB Invar 36 alloy.

4d printing, additive manufacturing, energy absorption, shape memory materials, recoverability, crashworthiness performance, Science, Manufactures, and TS1-2301

The emergence of 4D printing from additive manufacturing has opened new frontiers in crashworthiness application. Energy-absorbing structures with fixed geometrical shapes and irreversible deformation stages can be programmed such that after mild or extreme deformation, their initial shapes, properties and functionalities can be recovered with time when actuated by external stimuli. This survey delves into the recently-accelerated progress of shape memory/recovery energy-absorbing metamaterials (EAMM) and energy-absorbing smart/intelligent structures (EASS). First, the introduction gives some fundamental concepts of metamaterials and their application to energy-absorbing structures. Next, some common 3D printing technologies that have led to 4D printed EAMM and EASS are succinctly described. Shape memory materials, their functional properties and recovery process, are then discussed. Finally, various recoverable/reversible energy absorbers with their future challenges and perspectives, are presented. With well-tailored 4D printed EAMM and EASS, reusability with minimal maintenance and higher energy absorption capacity can be retained.

In-plane crushing, crashworthiness performance, additive manufacturing, polymer-based, polymer-fibre reinforcement, honeycomb structures, Science, Manufactures, and TS1-2301

ABSTRACTAdditive manufacturing technology is suitable for producing energy-absorbing devices with tunable mechanical properties and improved crashworthiness performance. In this study, the mechanical properties and macrostructural crushing behaviour of five additively manufactured polymer-based honeycomb structures (HS) are investigated. Subjected to in-plane loading, the experimental results of the HS are compared with numerical findings and theoretical predictions. Results indicate that deformation modes and overall crushing performance are influenced by utilising different parent materials. The polymer HS made from polyethylene terephthalate glycol gives the best overall crushing performance over the other polymers and polymer-fibre reinforcement HS. However, the crush force efficiency of HS made from polylactic acid is the least promising. The polymer-fibre reinforced HS outperforms some of the pure polymer-based ones in terms of specific energy absorption and shows a characteristic lightweight advantage. Hence, spotting it as a promising energy absorber utilised for crashworthiness application especially where ultra-lightweight property is highly desired.

laser powder bed fusion, overhang, downskin, high-speed thermal imaging, homography, parameter optimization, Science, Manufactures, and TS1-2301

One of the most revolutionary aspects of Laser Powder Bed Fusion (LPBF) is to be able to lift the design constraints from conventional manufacturing. However, as a rule of thumb, any surfaces lower than 45° with respect to the horizontal plane would still require sacrificial supports in order to complete the printing. Fundamentally, it is unclear whether it is feasible to print a 1st layer 0° overhang nor how the print parameters for the 1st layer can be optimised. This research demonstrates that large 1st layer 0° overhangs can be printed with a coverage above 90%. For the first time, the parameter space of laser power, scan speed and hatch spacing for the 1st layer has been simultaneously explored efficiently. The use of the rate of change of the mushy zone is proposed for the parameter selection instead of the average melt pool temperature. Adaptive Parameter 28 (AP28: 250W_4000 mm/s_50 µm) is the best choice. Several surface morphological phenomena are discussed. The core parameter (285W_960 mm/s_110 µm) causes severe balling and its mechanism is revealed. The average melt pool temperature of the 1st layer by the core parameter is lower than that of the bulk. The ramifications beyond the 1st layer are also illustrated.

hybrid rocket engine, additive manufacturing/three-dimensional printing, breathable blade, composite fuel grain, mechanical and combustion properties, porous structure, Science, Manufactures, and TS1-2301

Hybrid rocket engines suffer from the restricted mechanical properties and low regression rates of current polymeric fuel grains. We propose a three-dimensional printed aluminium (Al) nested composite fuel grain with millimetre-scale lattice pores (referred to as Al-L). In this study, breathable Al blades with micrometer-scale interconnected pores (Al-B) and blades combining millimetre-scale and micrometer-scale pores (Al-B&L) are designed. The formation mechanisms, characteristics, and effects of the breathable blades are analysed in simulations, micro-computed tomography, and cyclic compression tests. The mechanical properties of the composite fuel grains are investigated numerically and in compression tests. Al-B has the highest Young’s modulus at more than 15 times that of a paraffin-based fuel grain and Al-B&L has the highest yield stress at 4 times that of the paraffin-based fuel grain. Referring to combustion properties, the regression rates of the Al-B and Al-B&L grains are respectively 63.3% and 58.2% greater than the regression rate of the paraffin-based fuel grain.

wire arc additive manufacturing, mg-gd-y-zr alloy, heat treatment, microstructure evolution, mechanical properties, Science, Manufactures, and TS1-2301

A detailed and systematic investigation on the effect post heat treatment has on the microstructure evolution and the resultant mechanical properties of the wire arc additive manufacturing processed Mg-5.9Gd-2.8Y-0.7Zr alloy is conducted in this work. The microstructure of the as-built sample is composed mainly of fine equiaxed α-Mg grain and Mg24(Gd, Y)5 phase. The solution heat treatment (400°C × 1 h) has relatively little effect on grain size, but it can effectively reduce the content of the Mg24(Gd, Y)5 phase, which leads to a significantly improved elongation with slightly decreased strength. Further ageing heat treatment at 200°C induces prismatic βʹ precipitates formation and does not influence other phases and grain size. The samples directly following the peak ageing heat treatment process demonstrate the best tensile properties with yield strength of 227 ± 9 MPa, ultimate tensile strength of 350 ± 4 MPa and elongation of 5.5 ± 0.6%.

multi-photon photopolymerisation, laser direct writing, order of absorption, tunable wavelength, group delay dispersion, resolution bridges, Science, Manufactures, and TS1-2301

Multiphoton photopolymerisation (MPP), also known as 3D nanoprinting, was studied using a wavelength-tunable femtosecond laser. The possibility of using any colour of the spectrum from 500 to 1200 nm with a fixed pulse width of 100 fs revealed an interplay of photophysical mechanisms more delicate than just two-photon photopolymerisation. An effective order of absorption, i.e. the X-photon absorption, as well as optimal exposure conditions were assessed for photosensitised and pure SZ2080$^{{\rm TM}}$ pre-polymer. The tunability of wavelength greatly influenced the dynamic fabrication window (DFW), optimised conditions resulting in a 10-fold increase. Furthermore, a non-trivial energy deposition by X-photon absorption was noted with an onset of a strong lateral size increase at longer wavelengths and can be understood as due to reaching epsilon-near-zero conditions. Such a control over the voxel aspect ratio and, consequently, the photopolymerised volume, may boost 3D nanoprinting efficiency. Overall, the results reveal wavelength being an important degree of freedom to tailor the MPP process and, if optimised, benefiting broad applications in areas of micro-optics, nanophotonic devices, metamaterials and tissue engineering.

additive manufacturing, cellular materials, lattice structures, metamaterials, fused filament fabrication, Science, Manufactures, and TS1-2301

One of the areas that have benefited the most from the advent of additive manufacturing is the development of customized cellular materials, scaffolds and lattices. Although these different groups of materials are typically considered separately, they can be categorized as mechanical metamaterials. Among the different additive manufacturing techniques, perhaps the most popular is that of Fused Filament Fabrication. Numerous works have been reported in the literature in which this fabrication technique has been used to produce such materials. Inspired by the increasing volume of work dealing with the subject, we present a review of the manufacturing and characterization of cellular and lattice-based mechanical metamaterials using Fused Filament Fabrication. An overview of the topologies, their effective mechanical properties and intrinsic manufacturing aspects are presented. The methods for failure analysis at different scales are also discussed. Finally, studies comparing the production of mechanical metamaterials using Fused Filament Fabrication and other additive manufacturing techniques are presented, in addition to recommendations and current trends in the production of these structures by Fused Filament Fabrication.

Triply periodic minimum surfaces, additive manufacturing, energy absorption, strain-rate effects, constitutive model, Science, Manufactures, and TS1-2301

ABSTRACTMetallic lattice structures based on triply periodic minimum surfaces (TPMS) have attracted extensive attention for their potential application in lightweight and energy absorption. The underlying phenomena, mechanisms and modelling under the crushing responses from quasi-static to shock conditions still remain to be revealed. This work systematically investigates the mechanical behaviour of graded additively Schoen-F-RD (FRD) lattice structures under various loading rates. Under dynamic compression, FRD lattices exhibit the ability to withstand larger densification strains at higher plateau strengths, thus, holding enhanced energy absorption capabilities. At medium strain rates, it is the rate-dependence of lattice base material dominates in the strength enhancement, while, at higher strain rates, the role of inertia effect becomes notable. Furthermore, an empirical formula is introduced to predict the shock stress responses. Finally, constitutive models with strain-rates are proposed for the uniform and graded lattices. These findings can provide excellent guidance on the design of energy-absorbing structures.

Directed energy deposition, 2319 aluminum alloy, ultrasonic vibration, Zro2 particles, microstructure control, Science, Manufactures, and TS1-2301

ABSTRACTInhibiting unhomogenised microstructure during the directed energy deposition process with the electric arc energy source (DED-Arc) has become a significant challenge. Ultrasonic vibration leads to the severe stirring of liquid metal and break down dendrites in the inner-layer zone, which promotes the formation of fine grains after rapid solidification. In contrast, the grain refinement effect is not obvious in the semi-melting zone. The addition of ZrO2 particles in the 2319 Al-Cu alloy during the DED-Arc process can drag and pin the grain boundary to prevent grain coarsening in the semi-melting zone. Under the integrated effect of ultrasound and particles, ZrO2 particles can be evenly distributed in different regions, which is beneficial to enhance the microstructure uniformity of the deposition layer and ultimately achieving significant improvement in mechanical properties. The intergrated effect of ultrasonic vibration and particles on strength and elongation reach 13.8% and 92.4%, respectively.

cationic photoinitiators, photopolymerisation, photopolymerisation kinetics, 3d printing, photo-cured composites, photoinitiating systems, Science, Manufactures, and TS1-2301

In this article, the application of 10 new amino-m-terphenyls in 3D-VAT printing was described. New compounds have specially designed D-π-A structure, where the central phenyl ring with nitrile and amino groups is the acceptor and the modifiable amino group is donor. Such design eliminates problem with acid scavenging and guaranteed desire properties and photoactivity as well as it allows further development of such system for 3D-VAT printing. Efficient excitation with intramolecular charge transfer provides excellent absorption and electrochemical properties, which can be tuned by modification of the amino group. The design allows photoinitiation of free radical, hybrid and especially cationic polymerisation even at 455 nm with more than 70% of monomer conversion. Such properties allow to use the developed compounds as efficient visible light photoinitiators for 3D printing of nanocomposite materials. The terphenyls can efficiently cure resins containing CuO and Al2O3 nano additives leading to high-resolution 3D prints.

topology optimisation, human in the loop design, length scale, Science, Manufactures, and TS1-2301

Topology optimisation is a computational design approach that generates high-performing, efficient structures uniquely suited to a design engineer’s goal. However, there exist two major obstacles to the accessibility, or ease of use, of topology optimisation: expensive computational costs and users’ binary decision between personal intuition and the algorithm’s result. Human-informed topology optimisation, or HiTop, presents an alternative approach to topology optimisation when a user lacks access to a high-performance computer or knowledge of code parameters. HiTop 2.0 prompts users to interactively identify a region of interest in the preliminary design and modify the size of the solid and/or void features. The novel contribution of this paper implements multi-phase minimum and maximum solid feature size controls in HiTop 2.0, and demonstrates 2D and 3D benchmark examples, including test cases that show how the user can interactively enhance issues related to eigenvalues, stress, and energy absorption, while solving the minimum compliance problem.

titanium, β-tricalcium phosphate, direct ink writing, composite porous scaffold, Science, Manufactures, and TS1-2301

A Ti/β-TCP composite porous scaffold with a hierarchical pore structure composed of 3D printed interconnected macroscopic pores and sintered microscopic pores was prepared by direct ink writing (DIW) 3D printing technology. This method can control the extrusion of composite ink at room temperature and produce a 3D scaffold using layer-by-layer deposition. We studied the effects of the β-TCP powder particle size, β-TCP/Ti powder ratio and solid loading on the rheological properties of the ink and optimised the DIW printing process parameters. After sintering, the compressive strength and elastic modulus of the composite scaffold reached 45 MPa and 1 GPa, which is close to the strength of human cancellous bone. The cell culture experiment confirmed that the composite scaffold had better biological properties than the pure titanium scaffold. The composite scaffold has satisfactory mechanical and biological properties, meeting the requirements for orthopaedic implants.