Journal articles: 'Freeform 3d printing'

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Lee, Hyun, Tae-Sik Jang, Ginam Han, Hae-Won Kim, and Hyun-Do Jung. "Freeform 3D printing of vascularized tissues: Challenges and strategies." Journal of Tissue Engineering 12 (January 2021): 204173142110572. http://dx.doi.org/10.1177/20417314211057236.

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In recent years, freeform three-dimensional (3D) printing has led to significant advances in the fabrication of artificial tissues with vascularized structures. This technique utilizes a supporting matrix that holds the extruded printing ink and ensures shape maintenance of the printed 3D constructs within the prescribed spatial precision. Since the printing nozzle can be translated omnidirectionally within the supporting matrix, freeform 3D printing is potentially applicable for the fabrication of complex 3D objects, incorporating curved, and irregular shaped vascular networks. To optimize freeform 3D printing quality and performance, the rheological properties of the printing ink and supporting matrix, and the material matching between them are of paramount importance. In this review, we shall compare conventional 3D printing and freeform 3D printing technologies for the fabrication of vascular constructs, and critically discuss their working principles and their advantages and disadvantages. We also provide the detailed material information of emerging printing inks and supporting matrices in recent freeform 3D printing studies. The accompanying challenges are further discussed, aiming to guide freeform 3D printing by the effective design and selection of the most appropriate materials/processes for the development of full-scale functional vascularized artificial tissues.

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Rodriguez, Maria J., Thomas A. Dixon, Eliad Cohen, Wenwen Huang, Fiorenzo G. Omenetto, and David L. Kaplan. "3D freeform printing of silk fibroin." Acta Biomaterialia 71 (April 2018): 379–87. http://dx.doi.org/10.1016/j.actbio.2018.02.035.

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Guo, Shuang-zhuang, Xuelu Yang, Marie-Claude Heuzey, and Daniel Therriault. "3D printing of a multifunctional nanocomposite helical liquid sensor." Nanoscale 7, no. 15 (2015): 6451–56. http://dx.doi.org/10.1039/c5nr00278h.

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Shen, Hongyao, Bing Liu, Senxin Liu, and Jianzhong Fu. "Five-Axis Freeform Surface Color Printing Technology Based on Offset Curve Path Planning Method." Applied Sciences 10, no. 5 (March 3, 2020): 1716. http://dx.doi.org/10.3390/app10051716.

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Great progress has been made in 2D color printing with inkjet technology, and mature related products have come out, but there still exists great developmental space in 3D color printing. Therefore, a new path planning method based on the offset curve for 3D inkjet technology is proposed in this paper. Offset curves are generated on a freeform surface with geodesic equidistance, and then points for color printing are generated along the offset curves. In this paper, the principle of color printing technology with a 5-axis platform and the offset curve path planning (OCPP) method are presented. In addition, comparisons between the OCPP and adaptive filling algorithm based on the section method (AFSM) have been implemented. The OCPP significantly increased the rate of the theoretical filling area from 0.89 to 0.99 on a freeform surface.

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Lee, Dongyoun, and Junho Hong. "Development of an Adaptive Slicing Algorithm of Laminated Object Manufacturing Based 3D Printing for Freeform Formwork." Buildings 12, no. 9 (August 30, 2022): 1335. http://dx.doi.org/10.3390/buildings12091335.

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Recently, as “Freeform buildings” have increased in number, studies on ways to increase productivity in the construction of freeform buildings are increasing. In the case of 3D printing in construction, many studies are being conducted using the material extrusion method; among the 3D printing methods, manufacturing freeform forms using laminated object manufacturing (LOM) can overcome the limitation presented above. However, there is a lack of cases used in LOM construction sites, so it is necessary to increase the productivity of construction work and study the slicing method suitable for construction. Therefore, in this paper, we propose using study criteria and adaptive slicing methods to combine both the shape error and the manufacturing time of freeform construction. A case study was conducted to verify the results of this study; the freeform concrete form manufacturing with the algorithm that proposed this study could save 66.1% of the manufacturing time compared with CNC milling, and it needs 19.8% less manufacturing time than the existing uniform slicing method. This is a result of the production of one freeform form, and it can be expected to have a greater effect if applied to many freeform forms used in construction sites. In addition, the results of this study can be used as a decision-making tool that can determine the shape and manufacturing time of production according to the on-site situation.

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Blachowicz, Tomasz, Guido Ehrmann, and Andrea Ehrmann. "Optical elements from 3D printed polymers." e-Polymers 21, no. 1 (January 1, 2021): 549–65. http://dx.doi.org/10.1515/epoly-2021-0061.

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Abstract 3D printing belongs to the emerging technologies of our time. Describing diverse specific techniques, 3D printing enables rapid production of individual objects and creating shapes that would not be produced with other techniques. One of the drawbacks of typical 3D printing processes, however, is the layered structure of the created parts. This is especially problematic in the production of optical elements, which in most cases necessitate highly even surfaces. To meet this challenge, advanced 3D printing techniques as well as other sophisticated solutions can be applied. Here, we give an overview of 3D printed optical elements, such as lenses, mirrors, and waveguides, with a focus on freeform optics and other elements for which 3D printing is especially well suited.

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Patrício, Sónia G., Liliana R. Sousa, Tiago R. Correia, Vítor M. Gaspar, Liliana S. Pires, Jorge L. Luís, José M. Oliveira, and João F. Mano. "Freeform 3D printing using a continuous viscoelastic supporting matrix." Biofabrication 12, no. 3 (May 15, 2020): 035017. http://dx.doi.org/10.1088/1758-5090/ab8bc3.

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Luo, Guanyi, Yafeng Yu, Yuxue Yuan, Xue Chen, Zhou Liu, and Tiantian Kong. "Freeform, Reconfigurable Embedded Printing of All‐Aqueous 3D Architectures." Advanced Materials 31, no. 49 (October 14, 2019): 1904631. http://dx.doi.org/10.1002/adma.201904631.

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Sher, Praveen, Clara R. Correia, Rui R. Costa, and João F. Mano. "Compartmentalized bioencapsulated liquefied 3D macro-construct by perfusion-based layer-by-layer technique." RSC Advances 5, no. 4 (2015): 2511–16. http://dx.doi.org/10.1039/c4ra11674g.

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A novel biofabrication process via perfusion-based LbL technique for bioencapsulated hydrogel beads as building blocks to produce freeform 3D construct with controllable switching of a solid to liquefied microenvironment for use in TE/organ printing.

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Štumberger, Gabriela, and Boštjan Vihar. "Freeform Perfusable Microfluidics Embedded in Hydrogel Matrices." Materials 11, no. 12 (December 12, 2018): 2529. http://dx.doi.org/10.3390/ma11122529.

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We report a modification of the freeform reversible embedding of suspended hydrogels (FRESH) 3D printing method for the fabrication of freeform perfusable microfluidics inside a hydrogel matrix. Xanthan gum is deposited into a CaCl2 infused gelatine slurry to form filaments, which are consequently rinsed to produce hollow channels. This provides a simple method for rapid prototyping of microfluidic devices based on biopolymers and potentially a new approach to the construction of vascular grafts for tissue engineering.

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Jeong, Hoon Yeub, Eunsongyi Lee, Soo-Chan An, Yeonsoo Lim, and Young Chul Jun. "3D and 4D printing for optics and metaphotonics." Nanophotonics 9, no. 5 (February 4, 2020): 1139–60. http://dx.doi.org/10.1515/nanoph-2019-0483.

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AbstractThree-dimensional (3D) printing is a new paradigm in customized manufacturing and allows the fabrication of complex optical components and metaphotonic structures that are difficult to realize via traditional methods. Conventional lithography techniques are usually limited to planar patterning, but 3D printing can allow the fabrication and integration of complex shapes or multiple parts along the out-of-plane direction. Additionally, 3D printing can allow printing on curved surfaces. Four-dimensional (4D) printing adds active, responsive functions to 3D-printed structures and provides new avenues for active, reconfigurable optical and microwave structures. This review introduces recent developments in 3D and 4D printing, with emphasis on topics that are interesting for the nanophotonics and metaphotonics communities. In this article, we have first discussed functional materials for 3D and 4D printing. Then, we have presented the various designs and applications of 3D and 4D printing in the optical, terahertz, and microwave domains. 3D printing can be ideal for customized, nonconventional optical components and complex metaphotonic structures. Furthermore, with various printable smart materials, 4D printing might provide a unique platform for active and reconfigurable structures. Therefore, 3D and 4D printing can introduce unprecedented opportunities in optics and metaphotonics and may have applications in freeform optics, integrated optical and optoelectronic devices, displays, optical sensors, antennas, active and tunable photonic devices, and biomedicine. Abundant new opportunities exist for exploration.

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Kong, Zhiyuan, and Xiaohong Wang. "Bioprinting Technologies and Bioinks for Vascular Model Establishment." International Journal of Molecular Sciences 24, no. 1 (January 3, 2023): 891. http://dx.doi.org/10.3390/ijms24010891.

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Clinically, large diameter artery defects (diameter larger than 6 mm) can be substituted by unbiodegradable polymers, such as polytetrafluoroethylene. There are many problems in the construction of small diameter blood vessels (diameter between 1 and 3 mm) and microvessels (diameter less than 1 mm), especially in the establishment of complex vascular models with multi-scale branched networks. Throughout history, the vascularization strategies have been divided into three major groups, including self-generated capillaries from implantation, pre-constructed vascular channels, and three-dimensional (3D) printed cell-laden hydrogels. The first group is based on the spontaneous angiogenesis behaviour of cells in the host tissues, which also lays the foundation of capillary angiogenesis in tissue engineering scaffolds. The second group is to vascularize the polymeric vessels (or scaffolds) with endothelial cells. It is hoped that the pre-constructed vessels can be connected with the vascular networks of host tissues with rapid blood perfusion. With the development of bioprinting technologies, various fabrication methods have been achieved to build hierarchical vascular networks with high-precision 3D control. In this review, the latest advances in 3D bioprinting of vascularized tissues/organs are discussed, including new printing techniques and researches on bioinks for promoting angiogenesis, especially coaxial printing, freeform reversible embedded in suspended hydrogel printing, and acoustic assisted printing technologies, and freeform reversible embedded in suspended hydrogel (flash) technology.

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Sieber, Ingo, Richard Thelen, and Ulrich Gengenbach. "Enhancement of High-Resolution 3D Inkjet-Printing of Optical Freeform Surfaces Using Digital Twins." Micromachines 12, no. 1 (December 30, 2020): 35. http://dx.doi.org/10.3390/mi12010035.

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3D-inkjet-printing is just beginning to take off in the optical field. Advantages of this technique include its fast and cost-efficient fabrication without tooling costs. However, there are still obstacles preventing 3D inkjet-printing from a broad usage in optics, e.g., insufficient form fidelity. In this article, we present the formulation of a digital twin by the enhancement of an optical model by integrating geometrical measurement data. This approach strengthens the high-precision 3D printing process to fulfil optical precision requirements. A process flow between the design of freeform components, fabrication by inkjet printing, the geometrical measurement of the fabricated optical surface, and the feedback of the measurement data into the simulation model was developed, and its interfaces were defined. The evaluation of the measurements allowed for the adaptation of the printing process to compensate for process errors and tolerances. Furthermore, the performance of the manufactured component was simulated and compared with the nominal performance, and the enhanced model could be used for sensitivity analysis. The method was applied to a highly complex helical surface that allowed for the adjustment of the optical power by rotation. We show that sensitivity analysis could be used to define acceptable tolerance budgets of the process.

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Jeon, Seunggyu, Se-Hwan Lee, Saeed B. Ahmed, Jonghyeuk Han, Su-Jin Heo, and Hyun-Wook Kang. "3D cell aggregate printing technology and its applications." Essays in Biochemistry 65, no. 3 (August 2021): 467–80. http://dx.doi.org/10.1042/ebc20200128.

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Abstract Various cell aggregate culture technologies have been developed and actively applied to tissue engineering and organ-on-a-chip. However, the conventional culture technologies are labor-intensive, and their outcomes are highly user dependent. In addition, the technologies cannot be used to produce three-dimensional (3D) complex tissues. In this regard, 3D cell aggregate printing technology has attracted increased attention from many researchers owing to its 3D processability. The technology allows the fabrication of 3D freeform constructs using multiple types of cell aggregates in an automated manner. Technological advancement has resulted in the development of a printing technology with a high resolution of approximately 20 μm in 3D space. A high-speed printing technology that can print a cell aggregate in milliseconds has also been introduced. The developed aggregate printing technologies are being actively applied to produce various types of engineered tissues. Although various types of high-performance printing technologies have been developed, there are still some technical obstacles in the fabrication of engineered tissues that mimic the structure and function of native tissues. This review highlights the central importance and current technical level of 3D cell aggregate printing technology, and their applications to tissue/disease models, artificial tissues, and drug-screening platforms. The paper also discusses the remaining hurdles and future directions of the printing processes.

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Calais, Théo, Naresh D. Sanandiya, Snehal Jain, Elgar V. Kanhere, Siddharth Kumar, Raye Chen-Hua Yeow, and Pablo Valdivia y Alvarado. "Freeform Liquid 3D Printing of Soft Functional Components for Soft Robotics." ACS Applied Materials & Interfaces 14, no. 1 (December 28, 2021): 2301–15. http://dx.doi.org/10.1021/acsami.1c20209.

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Shaw, Dein, and Juei-Yuan Wu. "CAD/CAM System for 3D Inkjet Printing on a Freeform Surface." Advanced Science Letters 8, no. 1 (April 15, 2012): 89–94. http://dx.doi.org/10.1166/asl.2012.2389.

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An, Hyeon Seok, Young‐Geun Park, Kukjoo Kim, Yun Seok Nam, Myoung Hoon Song, and Jang‐Ung Park. "High‐Resolution 3D Printing of Freeform, Transparent Displays in Ambient Air." Advanced Science 6, no. 23 (October 4, 2019): 1901603. http://dx.doi.org/10.1002/advs.201901603.

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Zhao, Huo Ping, Chun Sheng Ye, and Zi Tian Fan. "3D Printing of Calcia-Based Ceramic Core Composites." Advances in Science and Technology 88 (October 2014): 65–69. http://dx.doi.org/10.4028/www.scientific.net/ast.88.65.

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Three-dimensional printing has been used as a rapid freeform fabrication process to fabricate a wider range of green ceramic components with complex structures difficult to obtain using traditional ceramic fabrication process. In this study, calcia-based ceramic core composites were fabricated by three dimensional printing and sintering operation. The green bodies were printed using a CaO/TiO2powder mixture as a precursor material and ethylene glycol as a binder. They were sintered at 1400-1500 °C for 2 h. The phases and microstructures of these samples were characterized by X-ray diffraction and scanning electron microscopy. The effect of TiO2content and the sintering temperature on the density, hydration resistance and bending strength of the sintered bodies was investigated. It was found that increment of TiO2content and sintering temperature would result in an increase of density of the sintered bodies and then increase of hydration resistance and bending strength.

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Garg, Akash, Saigopalakrishna S. Yerneni, Phil Campbell, Philip R. LeDuc, and O. Burak Ozdoganlar. "Freeform 3D Ice Printing (3D‐ICE) at the Micro Scale (Adv. Sci. 27/2022)." Advanced Science 9, no. 27 (September 2022): 2270170. http://dx.doi.org/10.1002/advs.202270170.

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Mair, Vincent, Ilona Paulus, Jürgen Groll, and Matthias Ryma. "Freeform printing of thermoresponsive poly(2-cyclopropyl-oxazoline) as cytocompatible and on-demand dissolving template of hollow channel networks in cell-laden hydrogels." Biofabrication 14, no. 2 (March 9, 2022): 025019. http://dx.doi.org/10.1088/1758-5090/ac57a7.

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Abstract Conventional additive-manufacturing technologies rely on the vertical stacking of layers, whereas each layer provides the structural integrity for the upcoming one. This inherently gives rise to limitations in freedom of design especially when structures containing large voids or truly 3D pathways for printed filaments are aspired. An especially interesting technique, which overcomes these layer limitations, is freeform printing, where thermoplastic materials are printed in 3D through controlling the temperature profile such that the polymer melt solidifies right when it exits the nozzle. In this study, we introduce freeform printing for thermoresponsive polymers at the example of poly(2-cyclopropyl-oxazoline) (PcycloPrOx). This material is especially interesting for biofabrication, as poly(oxazoline)s are known to provide excellent cytocompatibility. Furthermore, (PcycloPrOx) scaffolds provide adequate stability, so that the printed structures can be embedded in cell-laden hydrogels and sufficient time remains for the gel to form around the scaffold before dissolution via temperature reduction. This ensures accuracy and prevents channel collapse for the creation of cell-laden hydrogels with an embedded three-dimensionally interconnected channel network without the need of any additional processing step such as coating.

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Hinton, Thomas J., Quentin Jallerat, Rachelle N. Palchesko, Joon Hyung Park, Martin S. Grodzicki, Hao-Jan Shue, Mohamed H. Ramadan, Andrew R. Hudson, and Adam W. Feinberg. "Three-dimensional printing of complex biological structures by freeform reversible embedding of suspended hydrogels." Science Advances 1, no. 9 (October 2015): e1500758. http://dx.doi.org/10.1126/sciadv.1500758.

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We demonstrate the additive manufacturing of complex three-dimensional (3D) biological structures using soft protein and polysaccharide hydrogels that are challenging or impossible to create using traditional fabrication approaches. These structures are built by embedding the printed hydrogel within a secondary hydrogel that serves as a temporary, thermoreversible, and biocompatible support. This process, termed freeform reversible embedding of suspended hydrogels, enables 3D printing of hydrated materials with an elastic modulus <500 kPa including alginate, collagen, and fibrin. Computer-aided design models of 3D optical, computed tomography, and magnetic resonance imaging data were 3D printed at a resolution of ~200 μm and at low cost by leveraging open-source hardware and software tools. Proof-of-concept structures based on femurs, branched coronary arteries, trabeculated embryonic hearts, and human brains were mechanically robust and recreated complex 3D internal and external anatomical architectures.

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Yoon, Hyung Sun, Kyungjik Yang, Young Min Kim, Keonwook Nam, and Young Hoon Roh. "Cellulose nanocrystals as support nanomaterials for dual droplet-based freeform 3D printing." Carbohydrate Polymers 272 (November 2021): 118469. http://dx.doi.org/10.1016/j.carbpol.2021.118469.

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Xiong, Ruitong, Zhengyi Zhang, Wenxuan Chai, Yong Huang, and Douglas B. Chrisey. "Freeform drop-on-demand laser printing of 3D alginate and cellular constructs." Biofabrication 7, no. 4 (December 22, 2015): 045011. http://dx.doi.org/10.1088/1758-5090/7/4/045011.

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Savoji, Houman, Locke Davenport Huyer, Mohammad Hossein Mohammadi, Benjamin Fook Lun Lai, Naimeh Rafatian, Dawn Bannerman, Mohammad Shoaib, Erin R. Bobicki, Arun Ramachandran, and Milica Radisic. "3D Printing of Vascular Tubes Using Bioelastomer Prepolymers by Freeform Reversible Embedding." ACS Biomaterials Science & Engineering 6, no. 3 (January 16, 2020): 1333–43. http://dx.doi.org/10.1021/acsbiomaterials.9b00676.

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Yoon, Sejeong, Ju An Park, Hwa-Rim Lee, Woong Hee Yoon, Dong Soo Hwang, and Sungjune Jung. "Inkjet-Spray Hybrid Printing for 3D Freeform Fabrication of Multilayered Hydrogel Structures." Advanced Healthcare Materials 7, no. 14 (April 30, 2018): 1800050. http://dx.doi.org/10.1002/adhm.201800050.

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Singamneni, Sarat, Dawn Smith, Marie-Joo LeGuen, and Derryn Truong. "Extrusion 3D Printing of Polybutyrate-Adipate-Terephthalate-Polymer Composites in the Pellet Form." Polymers 10, no. 8 (August 17, 2018): 922. http://dx.doi.org/10.3390/polym10080922.

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Fused deposition modelling is a common 3D printing technique used for the freeform fabrication of complex shapes based on polymers. Acrylonitrile butadiene styrene (ABS) is the common material option, though polylactide (PLA) has also proved to be a successful candidate. There is an ever increasing demand to harness new materials as possible candidates for fused deposition. The current research is focused on evaluating polybutyrate-adipate-terephthalate–polymer (PBAT) for fused deposition modelling. Both neat and composite PBAT filled with varying wood flour fillers were experimentally analyzed for 3D printing by extrusion from the pellet forms. The results are positive and the addition of small quantities of the wood flour filler material was found to improve the thixotropic nature of the polymer composite and consequently the inter-strand and inter-layer coalescence.

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Zhu, Zhijie, Shuang-Zhuang Guo, Tessa Hirdler, Cindy Eide, Xiaoxiao Fan, Jakub Tolar, and Michael C. McAlpine. "3D Printing: 3D Printed Functional and Biological Materials on Moving Freeform Surfaces (Adv. Mater. 23/2018)." Advanced Materials 30, no. 23 (June 2018): 1870165. http://dx.doi.org/10.1002/adma.201870165.

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Zain, N. M., N. H. Hassan, M. Ibrahim, and M. S. Wahab. "Solid Freeform Fabrication of Prototypes Using Palm Oil Fly Ash via 3D Printing." Journal of Applied Sciences 11, no. 9 (April 15, 2011): 1648–52. http://dx.doi.org/10.3923/jas.2011.1648.1652.

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Hinton, Thomas J., Andrew Hudson, Kira Pusch, Andrew Lee, and Adam W. Feinberg. "3D Printing PDMS Elastomer in a Hydrophilic Support Bath via Freeform Reversible Embedding." ACS Biomaterials Science & Engineering 2, no. 10 (May 20, 2016): 1781–86. http://dx.doi.org/10.1021/acsbiomaterials.6b00170.

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Lowmunkong, Rungnapa, Taiji Sohmura, Yumiko Suzuki, Shigeki Matsuya, and Kunio Ishikawa. "Fabrication of freeform bone-filling calcium phosphate ceramics by gypsum 3D printing method." Journal of Biomedical Materials Research Part B: Applied Biomaterials 90B, no. 2 (August 2009): 531–39. http://dx.doi.org/10.1002/jbm.b.31314.

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Chen, Shengyang, Wen See Tan, Muhammad Aidil Bin Juhari, Qian Shi, Xue Shirley Cheng, Wai Lee Chan, and Juha Song. "Freeform 3D printing of soft matters: recent advances in technology for biomedical engineering." Biomedical Engineering Letters 10, no. 4 (September 29, 2020): 453–79. http://dx.doi.org/10.1007/s13534-020-00171-8.

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Montero, Javier, Alicia Becerro, Beatriz Pardal-Peláez, Norberto Quispe-López, Juan-Francisco Blanco, and Cristina Gómez-Polo. "Main 3D Manufacturing Techniques for Customized Bone Substitutes. A Systematic Review." Materials 14, no. 10 (May 12, 2021): 2524. http://dx.doi.org/10.3390/ma14102524.

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Clinicians should be aware of the main methods and materials to face the challenge of bone shortage by manufacturing customized grafts, in order to repair defects. This study aims to carry out a bibliographic review of the existing methods to manufacture customized bone scaffolds through 3D technology and to identify their current situation based on the published papers. A literature search was carried out using “3D scaffold”, “bone regeneration”, “robocasting” and “3D printing” as descriptors. This search strategy was performed on PubMed (MEDLINE), Scopus and Cochrane Library, but also by hand search in relevant journals and throughout the selected papers. All the papers focusing on techniques for manufacturing customized bone scaffolds were reviewed. The 62 articles identified described 14 techniques (4 subtraction + 10 addition techniques). Scaffold fabrication techniques can be also be classified according to the time at which they are developed, into Conventional techniques and Solid Freeform Fabrication techniques. The conventional techniques are unable to control the architecture of the pore and the pore interconnection. However, current Solid Freeform Fabrication techniques allow individualizing and generating complex geometries of porosity. To conclude, currently SLA (Stereolithography), Robocasting and FDM (Fused deposition modeling) are promising options in customized bone regeneration.

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Chi, Baihong, Zhiwei Jiao, and Weimin Yang. "Design and experimental study on the freeform fabrication with polymer melt droplet deposition." Rapid Prototyping Journal 23, no. 3 (April 18, 2017): 633–41. http://dx.doi.org/10.1108/rpj-03-2015-0028.

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Purpose 3D printing based on additive manufacturing has advantages in manufacturing products with high geometrical complexity. However, there are many limitations to print plastic products with the existing commercial 3D printers. The polymer materials processing industry needs new devices which can satisfy the trend of processing individual units and small batch sizes of plastic parts. Design/methodology/approach In this study, a freeform fabrication system with the method of polymer melt droplet deposition is proposed. The performance of this system under different conditions was studied by changing the operating parameters. Furthermore, the dimensional uniformity of droplets and their deposition process are analyzed, and a plastic sample was fabricated with this system as an example. Findings The results show a clear correlation between the processing parameters and the droplet diameter. In the experiment for examining the dimensional uniformity of the droplet, the droplets become spindles, and there appears a melt filament between the droplets. The variation of the droplet’s diameters is within 5 per cent. Furthermore, a successfully processed rectangular plastic sample verified the feasibility of this technology for the printing of plastic products. Originality/value A freeform fabrication system with polymer melt droplet deposition is proposed, which can process a wide variety of materials in the form of standard granulates like injection molding or extrusion. Based on the principle of droplet deposition, multi-component or colorful materials can be printed.

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Fu, Guoqiang, Tengda Gu, Hongli Gao, and Caijiang Lu. "A postprocessing and path optimization based on nonlinear error for multijoint industrial robot-based 3D printing." International Journal of Advanced Robotic Systems 17, no. 5 (September 1, 2020): 172988142095224. http://dx.doi.org/10.1177/1729881420952249.

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Multijoint industrial robots can be used for 3D printing to manufacture the complex freeform surfaces. The postprocessing is the basis of the precise printing. Due to the nonlinear motion of the rotational joint, nonlinear error is inevitable in multijoint industrial robots. In this article, the postprocessing and the path optimization based on the nonlinear errors are proposed to improve the accuracy of the multijoint industrial robots-based 3D printing. Firstly, the kinematics of the multijoint industrial robot for 3D printing is analyzed briefly based on product of exponential (POE) theory by considering the structure parameters. All possible groups of joint angles for one tool pose in the joint range are obtained in the inverse kinematics. Secondly, the nonlinear error evaluation based on the interpolation is derived according to the kinematics. The nonlinear error of one numerical control (NC) code or one tool pose is obtained. The principle of minimum nonlinear error of joint angle is proposed to select the appropriate solution of joint angle for the postprocessing. Thirdly, a path smoothing method by inserting new tool poses adaptively is proposed to reduce the nonlinear error of the whole printing path. The smooth level in the smoothing is proposed to avoid the endless insertion near the singular area. Finally, simulation and experiments are carried out to testify the effectiveness of the proposed postprocessing and path optimization method.

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Sakai, Shinji, Ryohei Harada, and Takashi Kotani. "Freeform 3D Bioprinting Involving Ink Gelation by Cascade Reaction of Oxidase and Peroxidase: A Feasibility Study Using Hyaluronic Acid-Based Ink." Biomolecules 11, no. 12 (December 20, 2021): 1908. http://dx.doi.org/10.3390/biom11121908.

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Freeform bioprinting, realized by extruding ink-containing cells into supporting materials to provide physical support during printing, has fostered significant advances toward the fabrication of cell-laden soft hydrogel constructs with desired spatial control. For further advancement of freeform bioprinting, we aimed to propose a method in which the ink embedded in supporting materials gelate through a cytocompatible and rapid cascade reaction between oxidase and peroxidase. To demonstrate the feasibility of the proposed method, we extruded ink containing choline, horseradish peroxidase (HRP), and a hyaluronic acid derivative, cross-linkable by HRP-catalyzed reaction, into a supporting material containing choline oxidase and successfully obtained three-dimensional hyaluronic acid-based hydrogel constructs with good shape fidelity to blueprints. Cytocompatibility of the bioprinting method was confirmed by the comparable growth of mouse fibroblast cells, released from the printed hydrogels through degradation on cell culture dishes, with those not exposed to the printing process, and considering more than 85% viability of the enclosed cells during 10 days of culture. Owing to the presence of derivatives of the various biocompatible polymers that are cross-linkable through HRP-mediated cross-linking, our results demonstrate that the novel 3D bioprinting method has great potential in tissue engineering applications.

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Rocca, Marco, Alessio Fragasso, Wanjun Liu, Marcel A. Heinrich, and Yu Shrike Zhang. "Embedded Multimaterial Extrusion Bioprinting." SLAS TECHNOLOGY: Translating Life Sciences Innovation 23, no. 2 (November 13, 2017): 154–63. http://dx.doi.org/10.1177/2472630317742071.

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Embedded extrusion bioprinting allows for the generation of complex structures that otherwise cannot be achieved with conventional layer-by-layer deposition from the bottom, by overcoming the limits imposed by gravitational force. By taking advantage of a hydrogel bath, serving as a sacrificial printing environment, it is feasible to extrude a bioink in freeform until the entire structure is deposited and crosslinked. The bioprinted structure can be subsequently released from the supporting hydrogel and used for further applications. Combining this advanced three-dimensional (3D) bioprinting technique with a multimaterial extrusion printhead setup enables the fabrication of complex volumetric structures built from multiple bioinks. The work described in this paper focuses on the optimization of the experimental setup and proposes a workflow to automate the bioprinting process, resulting in a fast and efficient conversion of a virtual 3D model into a physical, extruded structure in freeform using the multimaterial embedded bioprinting system. It is anticipated that further development of this technology will likely lead to widespread applications in areas such as tissue engineering, pharmaceutical testing, and organs-on-chips.

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Strauß, L., J. Montero, S. Weber, S. Brenner, P. Höfer, K. Paetzold, and G. Löwisch. "Effect of Heat Treatment on the Hardness of Unconventional Geometrical Features for Laser Powder Bed Fused AlSi10Mg." Proceedings of the Design Society 2 (May 2022): 603–12. http://dx.doi.org/10.1017/pds.2022.62.

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AbstractThe adoption of Design for Additive Manufacturing (DfAM) practices brought new industrial components embedding unconventional shapes such as lattice structures or freeform surfaces resulting from topological optimisations. As a drawback of design freedom, designers need to use thermal post-processing to achieve homogeneous properties in metal 3D printing. This contribution analyses the effect of T6-like heat treatment on the hardness of a complex component. Hardness values are reported along with good design practices for effective thermal post-processing to complement the DfAM knowledge base.

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Liu, Yigong, Qudus Hamid, Jessica Snyder, Chengyang Wang, and Wei Sun. "Evaluating fabrication feasibility and biomedical application potential of in situ 3D printing technology." Rapid Prototyping Journal 22, no. 6 (October 17, 2016): 947–55. http://dx.doi.org/10.1108/rpj-07-2015-0090.

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Purpose This paper aims to present a solid freeform fabrication-based in situ three-dimensional (3D) printing method. This method enables simultaneous cross-linking alginate at ambient environmental conditions (temperature and pressure) for 3D-laden construct fabrication. The fabrication feasibility and potentials in biomedical applications were evaluated. Design/methodology/approach Fabrication feasibility was evaluated as the investigation of fabrication parameters on strut formability (the capability to fabricate a cylindrical strut in the same diameter as dispensing tip) and structural stability (the capability to hold the fabricated 3D-laden construct against mechanical disturbance). Potentials in biomedical application was evaluated as the investigation on structural integrity (the capability to preserve the fabricated 3D-laden construct in cell culture condition). Findings Strut formability can be achieved when the flow rate of alginate suspension and nozzle travel speed are set according to the dispensing tip size, and extruded alginate was cross-linked sufficiently. A range of cross-linking-related fabrication parameters was determined for sufficient cross-link. The structural stability and structural integrity were found to be controlled by alginate composition. An optimized setting of the alginate composition and the fabrication parameters was determined for the fabrication of a desired stable scaffold with structural integrity for 14 days. Originality/value This paper reports that in situ 3D printing is an efficient method for 3D-laden construct fabrication and its potentials in biomedical application.

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Charalampous, Paschalis, Ioannis Kostavelis, Theodora Kontodina, and Dimitrios Tzovaras. "Learning-based error modeling in FDM 3D printing process." Rapid Prototyping Journal 27, no. 3 (February 23, 2021): 507–17. http://dx.doi.org/10.1108/rpj-03-2020-0046.

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Purpose Additive manufacturing (AM) technologies are gaining immense popularity in the manufacturing sector because of their undisputed ability to construct geometrically complex prototypes and functional parts. However, the reliability of AM processes in providing high-quality products remains an open and challenging task, as it necessitates a deep understanding of the impact of process-related parameters on certain characteristics of the manufactured part. The purpose of this study is to develop a novel method for process parameter selection in order to improve the dimensional accuracy of manufactured specimens via the fused deposition modeling (FDM) process and ensure the efficiency of the procedure. Design/methodology/approach The introduced methodology uses regression-based machine learning algorithms to predict the dimensional deviations between the nominal computer aided design (CAD) model and the produced physical part. To achieve this, a database with measurements of three-dimensional (3D) printed parts possessing primitive geometry was created for the formulation of the predictive models. Additionally, adjustments on the dimensions of the 3D model are also considered to compensate for the overall shape deviations and further improve the accuracy of the process. Findings The validity of the suggested strategy is evaluated in a real-life manufacturing scenario with a complex benchmark model and a freeform shape manufactured in different scaling factors, where various sets of printing conditions have been applied. The experimental results exhibited that the developed regressive models can be effectively used for printing conditions recommendation and compensation of the errors as well. Originality/value The present research paper is the first to apply machine learning-based regression models and compensation strategies to assess the quality of the FDM process.

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Godlinski, Dirk, and Stéphane Morvan. "Steel Parts with Tailored Material Gradients by 3D-Printing Using Nano-Particulate Ink." Materials Science Forum 492-493 (August 2005): 679–84. http://dx.doi.org/10.4028/www.scientific.net/msf.492-493.679.

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It is difficult to generate any user-defined three dimensional gradient to tailor the functional properties of a component. Problems are not only the lack of local material design tools, but also a suitable manufacturing process. The implementation of the concept of local composition control into the Solid Freeform Fabrication (SFF) process 3D-Printing is described, which leads to geometrical complex parts out of tailored materials. Suspensions of different functional inks containing a binder and carbon black nano-particles are dispensed into droplets through multiple jets – like inkjet printing a halftone image on a paper – but into a metal powder bed to generate layer by layer graded green parts. In this case the tailored preforms are then sintered, while the nano-particle additions from the functional ink act locally as alloying elements in the steel matrix to combine e.g. both, toughness and hardness in the part. This work concentrates on the realisation of the new process and shows first results taking the generation of carbon-graded steel parts as an example.

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Ghosh, Samannoy, Marshall V. Johnson, Rajan Neupane, James Hardin, John Daniel Berrigan, Surya R. Kalidindi, and Yong Lin Kong. "Machine learning-enabled feature classification of evaporation-driven multi-scale 3D printing." Flexible and Printed Electronics 7, no. 1 (March 1, 2022): 014011. http://dx.doi.org/10.1088/2058-8585/ac518a.

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Abstract The freeform generation of active electronics can impart advanced optical, computational, or sensing capabilities to an otherwise passive construct by overcoming the geometrical and mechanical dichotomies between conventional electronics manufacturing technologies and a broad range of three-dimensional (3D) systems. Previous work has demonstrated the capability to entirely 3D print active electronics such as photodetectors and light-emitting diodes by leveraging an evaporation-driven multi-scale 3D printing approach. However, the evaporative patterning process is highly sensitive to print parameters such as concentration and ink composition. The assembly process is governed by the multiphase interactions between solutes, solvents, and the microenvironment. The process is susceptible to environmental perturbations and instability, which can cause unexpected deviation from targeted print patterns. The ability to print consistently is particularly important for the printing of active electronics, which require the integration of multiple functional layers. Here we demonstrate a synergistic integration of a microfluidics-driven multi-scale 3D printer with a machine learning algorithm that can precisely tune colloidal ink composition and classify complex internal features. Specifically, the microfluidic-driven 3D printer can rapidly modulate ink composition, such as concentration and solvent-to-cosolvent ratio, to explore multi-dimensional parameter space. The integration of the printer with an image-processing algorithm and a support vector machine-guided classification model enables automated, in situ pattern classification. We envision that such integration will provide valuable insights in understanding the complex evaporative-driven assembly process and ultimately enable an autonomous optimisation of printing parameters that can robustly adapt to unexpected perturbations.

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Tan, Wen See, Qian Shi, Shengyang Chen, Muhammad Aidil Bin Juhari, and Juha Song. "Recyclable and biocompatible microgel-based supporting system for positive 3D freeform printing of silicone rubber." Biomedical Engineering Letters 10, no. 4 (September 29, 2020): 517–32. http://dx.doi.org/10.1007/s13534-020-00173-6.

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Wangler, Timothy, Ena Lloret, Lex Reiter, Norman Hack, Fabio Gramazio, Matthias Kohler, Mathias Bernhard, et al. "Digital Concrete: Opportunities and Challenges." RILEM Technical Letters 1 (October 31, 2016): 67. http://dx.doi.org/10.21809/rilemtechlett.2016.16.

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Digital fabrication has been termed the “third industrial revolution” in recent years, and promises to revolutionize the construction industry with the potential of freeform architecture, less material waste, reduced construction costs, and increased worker safety. Digital fabrication techniques and cementitious materials have only intersected in a significant way within recent years. In this letter, we review the methods of digital fabrication with concrete, including 3D printing, under the encompassing term “digital concrete”, identifying major challenges for concrete technology within this field. We additionally provide an analysis of layered extrusion, the most popular digital fabrication technique in concrete technology, identifying the importance of hydration control in its implementation.

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Kreuels, Klaus, David Bosma, Nadine Nottrodt, and Arnold Gillner. "Utilizing direct-initiation of thiols for photoinitiator-free stereolithographic 3D printing of mechanically stable scaffolds." Current Directions in Biomedical Engineering 7, no. 2 (October 1, 2021): 847–50. http://dx.doi.org/10.1515/cdbme-2021-2216.

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Abstract The automated production of artificial biological structures for biomedical applications continues to gather interest. Different fields of science are combined to find solutions for the arising multidimensional problems. Additive manufacturing in combination with material science provides one solution for the biological issues around 3D cell culture and construction of living tissues. Here, we present the photoinitiator-free stereolithographic fabrication of thiol-ene polymers with microarchitectures in the range of tens of microns for scaffolds up to the millimeter scale. Scaffolds composed of cubic unit cells were designed using computer-aided design (CAD) and subsequently 3D printed with a custom-made laser stereolithography setup. The process parameters were determined step by step with increasing complexity and number of parameters. Gained insights were applied to the fabrication of 3D printed test specimens. The quality of the 3D printed parts was evaluated by measuring the porosity and optical microscopy images. Furthermore, the mechanical properties of the scaffold structures were characterized using compression testing and compared with the bulk material revealing a lower capacity to bear load but higher flexibility. In this study, we demonstrate the advantages of combining the high-precision, freeform fabrication of stereolithography with a biocompatible material for the fabrication of complex microarchitectures for biomedical applications

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Singh, Gurminder, and Pulak Mohan Pandey. "Rapid manufacturing of copper-graphene composites using a novel rapid tooling technique." Rapid Prototyping Journal 26, no. 4 (March 31, 2020): 765–76. http://dx.doi.org/10.1108/rpj-10-2019-0258.

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Purpose The purpose of this study is to study the mechanical, tribological and electrical properties of the copper-graphene (Cu-Gn) composites fabricated by a novel rapid tooling technique consist of three-dimensional printing and ultrasonic-assisted pressureless sintering (UAPS). Design/methodology/approach Four different Cu-Gn compositions with 0.25, 0.5, 1 and 1.5 per cent of graphene were fabricated using an amalgamation of three-dimensional printing and UAPS. The polymer 3d printed parts were used to prepare mould cavity and later the UAPS process was used to sinter Cu-Gn powder to acquire free-form shape. The density, hardness, wear rate, coefficient of friction and electrical conductivity were evaluated for the different compositions of graphene and compared with the pure copper. Besides, the comparison was performed with the conventional method. Findings Cu-Gn composites revealed excellent wear properties due to higher hardness, and the lubrication provided by the graphene. The electrical conductivity of the fabricated Cu-Gn composites started increasing initially but decreased afterwards with increasing the content of graphene. The UAPS fabricated composites outperformed the conventional method manufactured samples with better properties such as density, hardness, wear rate, coefficient of friction and electrical conductivity due to homogeneous mixing of metal particles and graphene. Originality/value The fabrication of Cu-Gn composite freeform shapes was found to be difficult using conventional methods. The novel technique using a combination of polymer three-dimensional printing and UAPS as rapid tooling was introduced for the fabrication of freeform shapes of Cu-Gn composites and mechanical, tribological and electrical properties were studied. The method can be used to fabricate optimized complex Cu-Gn structures with improved wear and electrical applications.

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Sheng, Yu-Ting, Sze-Teng Liong, Shih-Yuan Wang, and Yee-Siang Gan. "3D printing on freeform surface: Real-time and accurate 3D dynamic dense surface reconstruction with HoloLens and displacement measurement sensors." Advances in Mechanical Engineering 15, no. 1 (January 2023): 168781322211484. http://dx.doi.org/10.1177/16878132221148404.

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This paper attempts to print irregular 3D objects on a freeform surface. Notably, it is inevitable to cause errors when creating a specific object shape in simulated and real-life scenarios. This is mainly attributed to the unique characteristics of the materials adopted, which tend to develop different deformations properties. Nevertheless, since the simulated model provides a clue regarding the coordinates of the deformed shape, it is adopted as an essential indicator in estimating accurate real-world coordinates. Concretely, this paper presents a complete system that is capable of reconstructing the detailed surface coordinates in real-time conditions. To verify the effectiveness of the proposed method, a metal board is used as the primary material to create different curvatures physically and virtually. In particular, the real-time performance of the overall 3D surface reconstruction has been experimentally evaluated using several tools, such as KUKA KR90 R3100 robots, HoloLens 2, displacement sensor, and ArUco markers. Consequently, both the quantitative and qualitative results are presented to demonstrate the feasibility of the proposed method. Furthermore, the experimental data obtained manifest that there are significant differences between the simulated and the real-world coordinates. Thus, the findings of this study provide an insightful outlook and lay down several important implications for future practice.

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Jin, Jie, Huachao Mao, and Yong Chen. "Photocuring-while-writing: A 3D printing strategy to build free space structure and freeform surface texture." Manufacturing Letters 29 (August 2021): 113–16. http://dx.doi.org/10.1016/j.mfglet.2021.07.016.

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Nguyen, Khanh T. T., Franca F. M. Heijningen, Daan Zillen, Kjeld J. C. van Bommel, Renz J. van Ee, Henderik W. Frijlink, and Wouter L. J. Hinrichs. "Formulation of a 3D Printed Biopharmaceutical: The Development of an Alkaline Phosphatase Containing Tablet with Ileo-Colonic Release Profile to Treat Ulcerative Colitis." Pharmaceutics 14, no. 10 (October 13, 2022): 2179. http://dx.doi.org/10.3390/pharmaceutics14102179.

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Powder bed printing is a 3D-printing process that creates freeform geometries from powders, with increasing traction for personalized medicine potential. Little is known about its applications for biopharmaceuticals. In this study, the production of tablets containing alkaline phosphatase using powder bed printing for the potential treatment of ulcerative colitis (UC) was investigated, as was the coating of these tablets to obtain ileo-colonic targeting. The printing process was studied, revealing line spacing as a critical factor affecting tablet physical properties when using hydroxypropyl cellulose as the binder. Increasing line spacing yielded tablets with higher porosity. The enzymatic activity of alkaline phosphatase (formulated in inulin glass) remained over 95% after 2 weeks of storage at 45 °C. The subsequent application of a colonic targeting coating required a PEG 1500 sub-coating. In vitro release experiments, using a gastrointestinal simulated system, indicated that the desired ileo-colonic release was achieved. Less than 8% of the methylene blue, a release marker, was released in the terminal ileum phase, followed by a fast release in the colon phase. No significant impact from the coating process on the enzymatic activity was found. These tablets are the first to achieve both biopharmaceutical incorporation in powder bed printed tablets and ileo-colonic targeting, thus might be suitable for on-demand patient-centric treatment of UC.

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Stender, Benedikt, Fabian Hilbert, Yannick Dupuis, Alexander Krupp, Willi Mantei, and Ruth Houbertz. "Manufacturing strategies for scalable high-precision 3D printing of structures from the micro to the macro range." Advanced Optical Technologies 8, no. 3-4 (June 26, 2019): 225–31. http://dx.doi.org/10.1515/aot-2019-0022.

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Abstract Industrial high-precision 3D Printing (HP3DP) via two-photon absorption (TPA) provides freedom in design for the fabrication of novel products that are not feasible with conventional techniques. Up to now, 2PP-fabrication has only been used for structures on the micrometer scale due to limited traveling ranges of the translation stages and the field-of-view (FoV) of microscope objectives (diameters below 0.5 mm). For industrial applications, not only high throughput but also scalability in size is essential. For this purpose, this contribution gives insights into different manufacturing strategies composed of varying exposure modes, fabrication modes, and structuring modes, which enable the generation of large-scale optical elements without relying on stitching. With strategies like stage-only mode or synchronized movement of galvoscanners and translation stages, optical elements with several millimeters in diameter and freeform shape can be fabricated with optical surface quality.

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Tan, Wen See, Muhammad Aidil Bin Juhari, Qian Shi, Shengyang Chen, Domenico Campolo, and Juha Song. "Development of a new additive manufacturing platform for direct freeform 3D printing of intrinsically curved flexible membranes." Additive Manufacturing 36 (December 2020): 101563. http://dx.doi.org/10.1016/j.addma.2020.101563.

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Journal articles on the topic 'Freeform 3d printing'

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