Geometric Modeling of Cellular Materials for Additive Manufacturing in Biomedical Field: A Review

Advances in additive manufacturing technologies facilitate the fabrication of cellular materials that have tailored functional characteristics. The application of solid freeform fabrication techniques is especially exploited in designing scaffolds for tissue engineering. In this review, firstly, a classification of cellular materials from a geometric point of view is proposed; then, the main approaches on geometric modeling of cellular materials are discussed. Finally, an investigation on porous scaffolds fabricated by additive manufacturing technologies is pointed out. Perspectives in geometric modeling of scaffolds for tissue engineering are also proposed

Functionally heterogeneous porous scaffold design for tissue engineering

Most of the current tissue scaffolds are mainly designed with homogeneous porosity which does not represent the spatial heterogeneity found in actual tissues. Therefore engineering a realistic tissue scaffolds with properly graded properties to facilitate the mimicry of the complex elegance of native tissues are critical for the successful tissue regeneration. In this work, novel bio-mimetic heterogeneous porous scaffolds have been modeled. First, the geometry of the scaffold is extracted along with its internal regional heterogeneity. Then the model has been discretized with planner slices suitable for layer based fabrication. An optimum filament deposition angle has been determined for each slice based on the contour geometry and the internal heterogeneity. The internal region has been discritized considering the homogeneity factor along the deposition direction. Finally, an area weight based approach has been used to generate the spatial porosity function that determines the filament deposition location for desired biomimetic porosity. The proposed methodology has been implemented and illustrative examples are provided. The effective porosity has been compared between the proposed design and the conventional homogeneous scaffolds. The result shows a significant error reduction towards achieving the biomimetic porosity in the scaffold design and provides better control over the desired porosity level. Moreover, sample designed structures have also been fabricated with a NC motion controlled micro-nozzle biomaterial deposition system

Functionally gradient tissue scaffold design and deposition path planning for bio-additive processes

A layer-based tissue scaffold is designed with heterogeneous internal architecture. The proposed layer-based design uses a bi-layer pattern of radial and spiral layer consecutively to generate functionally gradient porosity following the geometry of the scaffold. Medial region is constructed from medial axis and used as an internal geometric feature for each layer. The radial layers are generated with sub-region channels by connecting the boundaries of the medial region and the layer’s outer contour. Proper connections with allowable geometric properties are ensured by applying optimization algorithms. Iso-porosity regions are determined by dividing the sub-regions into pore cells. The combination of consecutive layers generates the pore cells with desired pore sizes. To ensure the fabrication of the designed scaffolds, both contours have been optimized for a continuous, interconnected, and smooth deposition path-planning. The proposed methodologies can generate the structure with gradient (linear or non-linear), variational or constant porosity that can provide localized control of variational porosity along the scaffold architecture. The designed porous structures can be fabricated using bio-additive fabrication processes

Functionally graded material: an overview

Functionally Graded Material (FGM) belongs to a class of advanced material characterized by variation in properties as the dimension varies. The overall properties of FMG are unique and different from any of the individual material that forms it. There is a wide range of applications for FGM and it is expected to increase as the cost of material processing and fabrication processes are reduced by improving these processes. In this study, an overview of fabrication processes, area of application, some recent research studies and the need to focus more research effort on improving the most promising FGM fabrication method (solid freeform SFF) is presented. Improving the performance of SFF processes and extensive studies on material characterization on components produced will go a long way in bringing down the manufacturing cost of FGM and increase productivity in this regard

Designing heterogeneous porous tissue scaffolds for additive manufacturing processes

A novel tissue scaffold design technique has been proposed with controllable heterogeneous architecture design suitable for additive manufacturing processes. The proposed layer-based design uses a bi-layer pattern of radial and spiral layers consecutively to generate functionally gradient porosity, which follows the geometry of the scaffold. The proposed approach constructs the medial region from the medial axis of each corresponding layer, which represents the geometric internal feature or the spine. The radial layers of the scaffold are then generated by connecting the boundaries of the medial region and the layer's outer contour. To avoid the twisting of the internal channels, reorientation and relaxation techniques are introduced to establish the point matching of ruling lines. An optimization algorithm is developed to construct sub-regions from these ruling lines. Gradient porosity is changed between the medial region and the layer's outer contour. Iso-porosity regions are determined by dividing the subregions peripherally into pore cells and consecutive iso-porosity curves are generated using the isopoints from those pore cells. The combination of consecutive layers generates the pore cells with desired pore sizes. To ensure the fabrication of the designed scaffolds, the generated contours are optimized for a continuous, interconnected, and smooth deposition path-planning. A continuous zig-zag pattern deposition path crossing through the medial region is used for the initial layer and a biarc fitted isoporosity curve is generated for the consecutive layer with C-1 continuity. The proposed methodologies can generate the structure with gradient (linear or non-linear), variational or constant porosity that can provide localized control of variational porosity along the scaffold architecture. The designed porous structures can be fabricated using additive manufacturing processes

Optimal Design of Functionally Graded Parts

Several additive manufacturing processes are capable of fabricating three-dimensional parts with complex distribution of material composition to achieve desired local properties and functions. This unique advantage could be exploited by developing and implementing methodologies capable of optimizing the distribution of material composition for one-, two-, and three-dimensional parts. This paper is the first effort to review the research works on developing these methods. The underlying components (i.e., building blocks) in all of these methods include the homogenization approach, material representation technique, finite element analysis approach, and the choice of optimization algorithm. The overall performance of each method mainly depends on these components and how they work together. For instance, if a simple one-dimensional analytical equation is used to represent the material composition distribution, the finite element analysis and optimization would be straightforward, but it does not have the versatility of a method which uses an advanced representation technique. In this paper, evolution of these methods is followed; noteworthy homogenization approaches, representation techniques, finite element analysis approaches, and optimization algorithms used/developed in these studies are described; and most powerful design methods are identified, explained, and compared against each other. Also, manufacturing techniques, capable of producing functionally graded materials with complex material distribution, are reviewed; and future research directions are discussed

Specifying a hybrid, multiple material CAD system for next-generation prosthetic design

For many years, the biggest issue that causes discomfort and hygiene issues for patients with lower limb amputations have been the interface between body and prosthetic, the socket. Often made of an inflexible, solid polymer that does not allow the residual limb to breathe or perspire and with no consideration for the changes in size and shape of the human body caused by changes in temperature or environment, inflammation, irritation and discomfort often cause reduced usage or outright rejection of the prosthetic by the patient in their day to day lives. To address these issues and move towards a future of improved quality of life for patients who suffer amputations, Loughborough University formed the Next Generation Prosthetics research cluster. This work is one of four multidisciplinary research studies conducted by members of this research cluster, focusing on the area of Computer Aided Design (CAD) for improving the interface with Additive Manufacture (AM) to solve some of the challenges presented with improving prosthetic socket design, with an aim to improve and streamline the process to enable the involvement of clinicians and patients in the design process. The research presented in this thesis is based on three primary studies. The first study involved the conception of a CAD criteria, deciding what features are needed to represent the various properties the future socket outlined by the research cluster needs. These criteria were then used for testing three CAD systems, one each from the Parametric, Non Uniform Rational Basis Spline (NURBS) and Polygon archetypes respectively. The result of these tests led to the creation of a hybrid control workflow, used as the basis for finding improvements. The second study explored emerging CAD solutions, various new systems or plug-ins that had opportunities to improve the control model. These solutions were tested individually in areas where they could improve the workflow, and the successful solutions were added to the hybrid workflow to improve and reduce the workflow further. The final study involved taking the knowledge gained from the literature and the first two studies in order to theorise how an ideal CAD system for producing future prosthetic sockets would work, with considerations for user interface issues as well as background CAD applications. The third study was then used to inform the final deliverable of this research, a software design specification that defines how the system would work. This specification was written as a challenge to the CAD community, hoping to inform and aid future advancements in CAD software. As a final stage of research validation, a number of members of the CAD community were contacted and interviewed about their feelings of the work produced and their feedback was taken in order to inform future research in this area

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

Fibre-reinforced additive manufacturing: from design guidelines to advanced lattice structures

In pursuit of achieving ultimate lightweight designs with additive manufacturing (AM), engineers across industries are increasingly gravitating towards composites and architected cellular solids; more precisely, fibre-reinforced polymers and functionally graded lattices (FGLs). Control over material anisotropy and the cell topology in design for AM (DfAM) offer immense scope for customising a part’s properties and for the efficient use of material. This research expands the knowledge on the design with fibre-reinforced AM (FRAM) and the elastic-plastic performance of FGLs. Novel toolpath strategies, design guidelines and assessment criteria for FRAM were developed. For this purpose, an open-source solution was proposed, successfully overcoming the limitations of commercial printers. The effect of infill patterns on structural performance, economy, and manufacturability was examined. It was demonstrated how print paths informed by stress trajectories and key geometric features can outperform conventional patterns, laying the groundwork for more sophisticated process planning. A compilation of the first comprehensive database on fibre-reinforced FGLs provided insights into the effect of grading on the elastic performance and energy absorption capability, subject to strut-and surface-based lattices, build direction and fibre volume fraction. It was elucidated how grading the unit cell density within a lattice offers the possibility of tailoring the stiffness and achieving higher energy absorption than ungraded lattices. Vice versa, grading the unit cell size of lattices yielded no effect on the performance and is thus exclusively governed by the density. These findings help exploit the lightweight potential of FGLs through better informed DfAM. A new and efficient methodology for predicting the elastic-plastic characteristics of FGLs under large strain deformation, assuming homogenised material properties, was presented. A phenomenological constitutive model that was calibrated based upon interpolated material data of uniform density lattices facilitated a computationally inexpensive simulation approach and thus helps streamline the design workflow with architected lattices.Open Acces

Radial Basis Functions: Biomedical Applications and Parallelization

Radial basis function (RBF) is a real-valued function whose values depend only on the distances between an interpolation point and a set of user-specified points called centers. RBF interpolation is one of the primary methods to reconstruct functions from multi-dimensional scattered data. Its abilities to generalize arbitrary space dimensions and to provide spectral accuracy have made it particularly popular in different application areas, including but not limited to: finding numerical solutions of partial differential equations (PDEs), image processing, computer vision and graphics, deep learning and neural networks, etc. The present thesis discusses three applications of RBF interpolation in biomedical engineering areas: (1) Calcium dynamics modeling, in which we numerically solve a set of PDEs by using meshless numerical methods and RBF-based interpolation techniques; (2) Image restoration and transformation, where an image is restored from its triangular mesh representation or transformed under translation, rotation, and scaling, etc. from its original form; (3) Porous structure design, in which the RBF interpolation used to reconstruct a 3D volume containing porous structures from a set of regularly or randomly placed points inside a user-provided surface shape. All these three applications have been investigated and their effectiveness has been supported with numerous experimental results. In particular, we innovatively utilize anisotropic distance metrics to define the distance in RBF interpolation and apply them to the aforementioned second and third applications, which show significant improvement in preserving image features or capturing connected porous structures over the isotropic distance-based RBF method. Beside the algorithm designs and their applications in biomedical areas, we also explore several common parallelization techniques (including OpenMP and CUDA-based GPU programming) to accelerate the performance of the present algorithms. In particular, we analyze how parallel programming can help RBF interpolation to speed up the meshless PDE solver as well as image processing. While RBF has been widely used in various science and engineering fields, the current thesis is expected to trigger some more interest from computational scientists or students into this fast-growing area and specifically apply these techniques to biomedical problems such as the ones investigated in the present work