Internal 3D Printing of Intricate Structures

International audienceAdditive technologies are increasingly used in Cultural Heritage process , for example in order to reproduce, complete, study or exhibit artefacts. 3D copies are based on digitization techniques such as laser scan or photogramme-try. In this case, the 3d copy remains limited to the external surface of objects. Medical images based digitization such as MRI or CT scan are also increasingly used in CH as they provide information on the internal structure of archaeological material. Different previous works illustrated the interest of combining 3D printing and CT scan in order to extract concealed artefacts from larger archaeological material. The method was based on 3D segmentation techniques within volume data obtained by CT scan to isolate nested objects. This approach was useful to perform a digital extraction, but in some case it is also interesting to observe the internal spatial organization of an intricate object in order to understand its production process. We propose a method for the representation of a complex internal structure based on a combination of CT scan and emerging 3D printing techniques mixing colored and transparent parts. This method was successfully applied to visualize the interior of a funeral urn and is currently applied on a set of tools agglomerated in a gangue of corrosion

Automated Design of Tissue Engineering Scaffolds by Advanced CAD

The design of scaffolds with an intricate and controlled internal structure represents a challenge for Tissue Engineering. Several scaffold manufacturing techniques allow the creation of complex and random architectures, but have little or no control over geometrical parameters such as pore size, shape and interconnectivity- things that are essential for tissue regeneration. The combined use of CAD software and layer manufacturing techniques allow a high degree of control over those parameters, resulting in reproducible geometrical architectures. However, the design of the complex and intricate network of channels that are required in conventional CAD, is extremely time consuming: manually setting thousands of different geometrical parameters may require several days in which to design the individual scaffold structures. This research proposes an automated design methodology in order to overcome those limitations. The combined use of Object Oriented Programming and advanced CAD software, allows the rapid generation of thousands of different geometrical elements. Each has a different set of parameters that can be changed by the software, either randomly or according to a given mathematical formula, so that they match the different distribution of geometrical elements such as pore size and pore interconnectivity. This work describes a methodology that has been used to design five cubic scaffolds with pore size ranging from about 200 to 800 µm, each with an increased complexity of the internal geometry.Mechanical Engineerin

Fabrication of Nonplanar Surfaces Via 5-Axis 3D Printing

The advancements in manufacturing have always played a vital role in human life. One of the most recent and growing manufacturing methods is additive manufacturing (AM). AM has been in focus for its ability to manufacture intricate parts with internal features which are not possible with traditional manufacturing processes. Making parts lighter and stronger has been the goal for most AM processes. The advancements in AM have made it possible to produce parts with high strength internal structures. The overall strength of the manufactured plastic parts depends on several variables. The part’s strength is determined by the material, the build direction, the infill settings, and the printing parameters. Optimization of each of these variables is critical for obtaining the desired result for the intended application of the printed part. One of the major drawbacks of these parts is the weak interlayer bonding within parts which are susceptible to failure under high loads. Similarly, the stair stepping effect compromises the surface finish of a part. This is prominently seen when the angle of inclination is less than 30 degrees. Previous research shows that the mixture of non-planar and planar layers in a 3DP part can improve its surface finish. Non-Planar 3D printing done using a 3-axis machine is limited by the angle of the nozzle with respect to the previously printed layers. This study will focus on incorporating 5-axis 3D printer toolpath motions to print nonplanar surfaces. It will also shed some light on the enhanced mechanical properties of the parts which have non-planar layers as compared to conventionally 3D printed parts

Recent advances in 3D printing of biomaterials.

3D Printing promises to produce complex biomedical devices according to computer design using patient-specific anatomical data. Since its initial use as pre-surgical visualization models and tooling molds, 3D Printing has slowly evolved to create one-of-a-kind devices, implants, scaffolds for tissue engineering, diagnostic platforms, and drug delivery systems. Fueled by the recent explosion in public interest and access to affordable printers, there is renewed interest to combine stem cells with custom 3D scaffolds for personalized regenerative medicine. Before 3D Printing can be used routinely for the regeneration of complex tissues (e.g. bone, cartilage, muscles, vessels, nerves in the craniomaxillofacial complex), and complex organs with intricate 3D microarchitecture (e.g. liver, lymphoid organs), several technological limitations must be addressed. In this review, the major materials and technology advances within the last five years for each of the common 3D Printing technologies (Three Dimensional Printing, Fused Deposition Modeling, Selective Laser Sintering, Stereolithography, and 3D Plotting/Direct-Write/Bioprinting) are described. Examples are highlighted to illustrate progress of each technology in tissue engineering, and key limitations are identified to motivate future research and advance this fascinating field of advanced manufacturing

Combining X-ray CT and 3D printing technology to produce microcosms with replicable, complex pore geometries

Measurements in soils have been traditionally used to demonstrate that soil architecture is one of the key drivers of soil processes. Major advances in the use of X-ray Computed Tomography (CT) afford significant insight into the pore geometry of soils, but until recently no experimental techniques were available to reproduce this complexity in microcosms. This article describes a 3D additive manufacturing technology that can print physical structures with pore geometries reflecting those of soils. The process enables printing of replicated structures, and the printing materials are suitable to study fungal growth. This technology is argued to open up a wealth of opportunities for soil biological studies

3D printing of cement composites

The aims of this study were to investigate the feasibility of generating 3D structures directly in rapid-hardening Portland cement (RHPC) using 3D Printing (3DP) technology. 3DP is a Additive Layer Manufacturing (ALM) process that generates parts directly from CAD in a layer-wise manner. 3D structures were successfully printed using a polyvinylalcohol: RHPC ratio of 3:97 w/w, with print resolutions of better than 1mm. The test components demonstrated the manufacture of features, including off-axis holes, overhangs / undercuts etc that would not be manufacturable using simple mould tools. Samples hardened by 1 day post-build immersion in water at RT offered Modulus of Rupture (MOR) values of up to 0.8±0.1MPa, and, after 26 days immersion in water at RT, offered MOR values of 2.2±0.2MPa, similar to bassanite-based materials more typically used in 3DP (1-3 MPa). Post-curing by water immersion restructured the structure, removing the layering typical of ALM processes, and infilling porosity

Biomimetic Design and Fabrication of Interior Architecture of Tissue Scaffolds Using Solid Freeform Fabrication

Modeling, design and fabrication of tissue scaffolds with intricate architecture, porosity and pore size for desired tissue properties presents a challenge in tissue engineering. This paper will present the details of our development in designing and fabrication of the interior architecture of scaffolds using a novel design approach. The Interior Architecture Design (IAD) approach seeks to generate scaffold layered freeform fabrication tool path without forming complicated 3D CAD scaffold models. This involves: applying the principle of layered manufacturing to determine the scaffold individual layered process planes and layered contour; defining the 2D characteristic patterns of the scaffold building blocks (unit cells) to form the Interior Scaffold Pattern; and the generation of process tool path for freeform fabrication of these scaffolds with the specified interior architecture. Feasibility studies applying the IAD algorithm to example models and the generation of fabrication planning instructions will be presented.Mechanical Engineerin

Investigating the potential of electroless nickel plating for fabricating Ultra-porous metal-based lattice structures using polyHIPE templates

The use of polymerized high internal phase emulsions (polyHIPEs) as templates for electroless nickel plating is a promising method for producing ultra-porous metallic lattice structures with consistent wall thickness. These structures have desirable properties such as low density, high specific strength, resilience, and absorbency, making them suitable for various applications including battery electrodes, catalyst supports, and acoustic or vibration damping. This study aimed to optimize and investigate the electroless nickel plating process on polyHIPEs. Initially, a surfactant (Hypermer)-stabilized water-in-oil emulsion based on 2-ethylhexyl-acrylate and isobornyl-acrylate was used as a 3D printing resin to create polyHIPE structures. Then, the electroless nickel plating process was optimized using polyHIPE discs. The study also examined the effects of air, argon, and reducing atmospheres during the heating process to remove the polyHIPE template using metallized 3D-printed polyHIPE lattice structures. The findings indicated that different atmospheres led to the formation of distinct compounds. While nickel-coated polyHIPEs were fully oxidized in an air atmosphere, nickel phosphide (Ni3P) structures occurred in argon and reducing atmospheres along Ni metal. Moreover, in argon and reducing atmospheres, the porous structure of the polyHIPEs was retained as the internal structure was completely carbonized. Overall, the study demonstrated that intricate polyHIPE structures can be used as templates to create ultra-porous metal-based lattices for a wide range of applications

Layered Fabrication of Branched Networks Using Lindenmayer Systems

A current challenge impeding the growth of bone tissue engineering is the lack of functional scaffolds of geometric sizes greater than 10mm due to the inability of cells to survive deep within the scaffold. It is hypothesized that these scaffolds must have an inbuilt nutrient distribution network to sustain the uniform growth of cells. In this paper, we seek to enhance the design and layered fabrication of scaffold internal architecture through the development of Lindenmayer systems, a graphical language based theory to create nutrient delivery networks. The scaffolds are fabricated using the Texas Instruments DLP™ system through UV‐photopolymerization to produce polyethylene glycol hydrogels with internal branch structures. The paper will discuss the Lindenmayer system, process planning algorithms, layered fabrication of samples, challenges and future tasks.Mechanical Engineerin