A level set based method for fixing overhangs in 3D printing

3D printers based on the Fused Decomposition Modeling create objects layer-by-layer dropping fused material. As a consequence, strong overhangs cannot be printed because the new-come material does not find a suitable support over the last deposed layer. In these cases, one can add some support structures (scaffolds) which make the object printable, to be removed at the end. In this paper we propose a level set method to create object-dependent support structures, specifically conceived to reduce both the amount of additional material and the printing time. We also review some open problems about 3D printing which can be of interests for the mathematical community

MicroRNAs delivery into human cells grown on 3D-printed PLA scaffolds coated with a novel fluorescent PAMAM dendrimer for biomedical applications

Many advanced synthetic, natural, degradable or non-degradable materials have been employed to create scaffolds for cell culture for biomedical or tissue engineering applications. One of the most versatile material is poly-lactide (PLA), commonly used as 3D printing filament. Manufacturing of multifunctional scaffolds with improved cell growth proliferation and able to deliver oligonucleotides represents an innovative strategy for controlled and localized gene modulation that hold great promise and could increase the number of applications in biomedicine. Here we report for the first time the synthesis of a novel Rhodamine derivative of a poly-amidoamine dendrimer (G = 5) able to transfect cells and to be monitored by confocal microscopy that we also employed to coat a 3D-printed PLA scaffold. The coating do not modify the oligonucleotide binding ability, toxicity or transfection properties of the scaffold that is able to increase cell proliferation and deliver miRNA mimics (i.e., pre-mir-503) into human cells. Although further experiments are required to optimize the dendrimer/miRNA ratio and improve transfection efficiency, we demonstrated the effectiveness of this promising and innovative 3D-printed transfection system to transfer miRNAs into human cells for future biomedical applications. © 2018, The Author(s)

Cosmic Sculpture: A new way to visualise the Cosmic Microwave Background

3D printing presents an attractive alternative to visual representation of physical datasets such as astronomical images that can be used for research, outreach or teaching purposes, and is especially relevant to people with a visual disability. We here report the use of 3D printing technology to produce a representation of the all-sky Cosmic Microwave Background (CMB) intensity anisotropy maps produced by the Planck mission. The success of this work in representing key features of the CMB is discussed as is the potential of this approach for representing other astrophysical data sets. 3D printing such datasets represents a highly complementary approach to the usual 2D projections used in teaching and outreach work, and can also form the basis of undergraduate projects. The CAD files used to produce the models discussed in this paper are made available.Comment: Accepted for publication in the European Journal of Physic

A numerical study on the design trade-offs of a thin-film thermoelectric generator for large-area applications

Thin-film thermoelectric generators with a novel folding scheme are proposed for large-area, low energy-density applications. Both the electrical current and heat transfer are in the plane of the thermoelectric thin-film, yet the heat transfer is across the plane of the module - similar to conventional bulk thermoelectric modules. With such designs, the heat leakage through the module itself can be minimized and the available temperature gradient maximized. Different from the previously reported corrugated thermoelectric generators, the proposed folding scheme enables high packing densities without compromising the thermal contact area to the heat source and sink. The significance of various thermal transport, or leakage, mechanisms in relation to power production is demonstrated for different packing densities and thicknesses of the module under heat sink-limited conditions. It is shown that the power factor is more important than ZT for predicting the power output of such thin-film devices. As very thin thermoelectric films are employed with modest temperature gradients, high aspect-ratio elements are needed to meet the - usually ignored - requirements of practical applications for the current. With the design trade-offs considered, the proposed devices may enable the exploitation of thermoelectric energy harvesting in new - large-area - applications at reasonable cost.Comment: 26 pages,5 figures, post-peer-review, pre-copyedit version of an article published in Renewable Energ

Development of a 3D printer using scanning projection stereolithography

We have developed a system for the rapid fabrication of low cost 3D devices and systems in the laboratory with micro-scale features yet cm-scale objects. Our system is inspired by maskless lithography, where a digital micromirror device (DMD) is used to project patterns with resolution up to 10 µm onto a layer of photoresist. Large area objects can be fabricated by stitching projected images over a 5cm2 area. The addition of a z-stage allows multiple layers to be stacked to create 3D objects, removing the need for any developing or etching steps but at the same time leading to true 3D devices which are robust, configurable and scalable. We demonstrate the applications of the system by printing a range of micro-scale objects as well as a fully functioning microfluidic droplet device and test its integrity by pumping dye through the channels

From 3D Models to 3D Prints: an Overview of the Processing Pipeline

Due to the wide diffusion of 3D printing technologies, geometric algorithms for Additive Manufacturing are being invented at an impressive speed. Each single step, in particular along the Process Planning pipeline, can now count on dozens of methods that prepare the 3D model for fabrication, while analysing and optimizing geometry and machine instructions for various objectives. This report provides a classification of this huge state of the art, and elicits the relation between each single algorithm and a list of desirable objectives during Process Planning. The objectives themselves are listed and discussed, along with possible needs for tradeoffs. Additive Manufacturing technologies are broadly categorized to explicitly relate classes of devices and supported features. Finally, this report offers an analysis of the state of the art while discussing open and challenging problems from both an academic and an industrial perspective.Comment: European Union (EU); Horizon 2020; H2020-FoF-2015; RIA - Research and Innovation action; Grant agreement N. 68044

Nanoroughness, Surface Chemistry and Drug Delivery Control by Atmospheric Plasma Jet on Implantable Devices

Implantable devices need specific tailored surface morphologies and chemistries to interact with the living systems or to actively induce a biological response also by the release of drugs or proteins. These customised requirements foster technologies that can be implemented in additive manufacturing systems. Here we present a novel approach based on spraying processes that allows to control separately topographic features in the submicron range ( 3d 60 nm - 2 \ub5m), ammine or carboxylic chemistry and fluorophore release even on temperature sensitive biodegradable polymers such as polycaprolactone (PCL). We developed a two-steps process with a first deposition of 220 nm silica and poly(lactic-co-glycolide) (PLGA) fluorescent nanoparticles by aerosol followed by the deposition of a fixing layer by atmospheric pressure plasma jet (APPJ). The nanoparticles can be used to create the nano-roughness and to include active molecule release, while the capping layer ensures stability and the chemical functionalities. The process is enabled by a novel APPJ which allows deposition rates of 10 - 20 nm\ub7s-1 at temperatures lower than 50 \ub0C using argon as process gas. This approach was assessed on titanium alloys for dental implants and on PCL films. The surfaces were characterized by FT-IR, AFM and SEM. Titanium alloys were tested with pre-osteoblasts murine cells line, while PCL film with fibroblasts. Cell behaviour was evaluated by viability and adhesion assays, protein adsorption, cell proliferation, focal adhesion formation and SEM. The release of a fluorophore molecule was assessed in the cell growing media, simulating a drug release. Osteoblast adhesion on the plasma treated materials increased by 20% with respect to commercial titanium alloys implants. Fibroblast adhesion increased by a 100% compared to smooth PCL substrate. The release of the fluorophore by the dissolution of the PLGA nanoparticles was verified and the integrity of the encapsulated drug model confirmed