Search Results (923)

Resin 3D-printed molds are being increasingly favored for PDMS microfluidics across many disciplines. However, resin diversity, as well as secret manufacturer formulations, leads to a lack of standardization when using 3D printing for microscale applications. The impact of physical resin properties, both in its monomeric concoction and polymerized lattices at 100 µm or lower scales, needs quantification. We tested the performance of locally available resin formulations, isolating the impact of resin pigments and how it impacted the resin’s properties and performance. Lower resin viscosity improved feature fidelity (edge filleting < 25 µm) and improved resolution limit for recessed features, while cured polymer mechanical strength impacted the limit for positive mold features. We combined our findings to fabricate quality negative and positive mold structures in the mold and determined the best protocols associated with limitations during the fabrication of such structures. The methodologies in this study are expected to be widely applicable across various resin types and simplify the adoption of 3D printing protocols for specific feature fabrication in microscale molds for PDMS devices. Full article

This study comparatively evaluated the influence of processing routes on the optical stability of three dental resin composites: a light-cured direct composite—G-ænial A’CHORD (LCC), a CAD-CAM milled composite—BreCAM.HIPC (MC), and a 3D-printed composite—Saremco Print Crowntec (PC). Specimens were analyzed before (T0) and after hydrothermal aging for 5000 (T1), 10,000 (T2), and 30,000 cycles (T3). Optical stability was assessed through the change in color (ΔE₀₀) and translucency parameter (TP) after aging and immersion in beverages. Surface topography was evaluated using atomic force microscopy (AFM), while Raman spectroscopy was employed to detect aging-induced molecular changes. After aging and staining, all composites exceeded the acceptability threshold for color change. ΔE₀₀ values of 6.8 ± 1.1 (PC), 4.6 ± 0.9 (MC), and 2.1 ± 0.9 (LCC), obtained after initial aging, further increased following prolonged immersion in coffee. After 1 day of immersion in Coca-Cola, MC exhibited the highest ΔE₀₀ values, which slightly exceeded the clinically acceptable threshold. Prolonged immersion (7 days) significantly increased staining for all materials. TP values significantly differed among materials, with the highest values detected for LCC (20.6 ± 3.6) and PC (19.1 ± 1.5) and the lowest values detected for MC (4.9 ± 0.8). Overall, the results demonstrated that ΔE₀₀ was strongly influenced by the processing route and surface topography, whereas changes in translucency parameter (TP) were predominantly governed by the intrinsic properties of the resin composites. Full article

Electrically conductive photopolymers enable the fabrication of functional 3D-printed components with customized electrical properties, expanding additive manufacturing applications beyond traditional structural uses. This study reports the formulation and characterization of electrically conductive, water-washable photopolymer resins for masked stereolithography (MSLA) through the incorporation of nano-graphite, PEDOT:PSS, and dimethyl sulfoxide (DMSO) as a secondary dopant. Single filler and hybrid resin systems were prepared and processed via MSLA printing, then subjected to sequential thermal treatments, 25 °C curing for 48 h followed by annealing at 80 °C and 120 °C, to investigate conductivity enhancement and microstructural evolution. Electrical characterization via current–voltage (I–V) measurements, referenced to the transversal conductivity (${\sigma }_{TRA}$), showed that the hybrid formulation containing PEDOT:PSS, graphite, and DMSO achieved the highest conductivity (9.40 × 10⁻² S·cm⁻¹), outperforming PEDOT:PSS/graphite systems (2.6 × 10⁻³ S·cm⁻¹) and graphite-only samples (9.76 × 10⁻⁴ S·cm⁻¹). Conductivity increased consistently after each thermal step, indicating enhanced charge transport. Scanning electron microscopy further revealed improved filler dispersion and interconnectivity within the polymer matrix. The synergistic combination of PEDOT:PSS, graphite nanofillers, and DMSO enables MSLA printed components with tunable and reproducible electrical performance. This work demonstrates a scalable strategy for producing functional, water-washable photopolymer resins suitable for applications in sensors, soft electronics, and lightweight conductive structures. Full article

Luminescent organic–inorganic Cu(I) halide hybrid molecular crystals exhibit remarkable structural diversity and photophysical properties, but their application in aqueous environments is often limited by insufficient stability. Herein, we report portable and reusable photoluminescent sensors based on Cu(I)–I triethylenediamine derivatives [Cu₄I₆(pr-ted)₂] and [Cu₃I₅(bz-ted)₂] (pr-ted = 1-propyl-1,4-diazabicyclo[2.2.2]octan-1-ium; bz-ted = 1-benzyl-1,4-diazabicyclo[2.2.2]octan-1-ium). Their submicrometric particles exhibit intense UV-excited emissions and high photoluminescence quantum yields but limited water stability. To address this limitation, ultrasound sonication was employed to control particle size and produce stable suspensions that can be incorporated into polymeric matrices via 3D printing with photocurable resins or polylactic acid (PLA) films by drop-casting, yielding mechanically robust composites that retain their structural and optical properties. The devices used act as selective turn-off luminescent sensors for Fe³⁺ in aqueous media, with nanomolar detection limits (1.33–1.58 nM) below regulatory thresholds for drinking water. Moreover, [Cu₃I₅(bz-ted)₂] enables tetracycline detection in river water with a limit of detection of 0.038 nM. Mechanistic studies indicate that reversible photoinduced electron transfer is the primary quenching pathway, while composites maintain sensing performance over multiple reuse cycles. Full article

Soft magnetic composite materials have a low total loss and high magnetic conductivity and are highly desirable for high-frequency motors, semiconductors, and 5G communication technologies. However, these composites often contain a high-volume fraction of soft magnetic metallic powders and are difficult to process into complex shapes. Herein, iron-based amorphous powders were surface-modified with silane coupling agents (DTMS and KH570) and applied in 3D direct ink writing (DIW). The modified powders exhibit improved compatibility and dispersion in epoxy resin. The optimized 92.3 wt% FeSiB@3.35 wt% KH570/EP slurry shows favorable rheological properties and a dense interfacial microstructure. The printed composite achieves the best magnetic performance (M_s: 137.02 ± 1.2 emu/g, H_c: 6.63 ± 0.2 Oe) and stable permeability up to 1 GHz. The surface modification enhanced slurry fluidity, preventing nozzle blockage and increasing powder loading. Various shaped magnetic cores were successfully fabricated with excellent magnetic properties and printing quality. Our work paves a new way for realizing the high processibility of soft magnetic composites, which lays a foundation for a technique for the wide applications of these materials in various electronic devices. Full article

This study evaluated the effects of thermocycling on surface roughness (Ra), gloss (GU), color stability (ΔE₀₀), and water sorption of interim materials manufactured by three methods. Disc specimens (n = 20/group) were fabricated from a conventional bis-acryl (PreVISION^® Temp), a computer-aided design/computer-aided manufacturing (CAD/CAM)-milled methacrylate-based composite (StructurCAD Disc^®), and a 3D-printed resin composite (Alias Dental Temp C&B^®). Two disc dimensions were used: 10 × 2 mm for Ra, GU, and color, and 15 × 1 mm for water sorption. Measurements were performed before and after thermocycling (10,000 cycles; 5–55 °C). Nonparametric tests were used (α = 0.05). After thermocycling, Ra increased in the conventional and 3D-printed groups, whereas the milled group demonstrated a decrease (p < 0.05). GU decreased across all groups (p < 0.001) and differed among materials (p = 0.021), with a significant difference only between milled and 3D-printed groups. Color stability differed among materials (p < 0.001): the milled group showed the lowest ΔE₀₀ perceptibility threshold (below PT₀₀ = 0.81), whereas conventional and 3D-printed groups exceeded the acceptability threshold (AT₀₀ = 1.81). Water sorption differed among groups (p < 0.001), with a significant difference between the milled and 3D-printed groups (p < 0.001). The tested 3D-printed material exhibited less favorable post-thermocycling optical properties, whereas the evaluated CAD/CAM-milled material demonstrated more favorable overall surface and optical performance under the applied aging conditions. Full article

Hybrid metal–polymer components are used in many industries, such as in aerospace, automotives, and electronics, due to the possibility of reducing the weight of the final part while maintaining mechanical properties comparable to components made entirely of metal. Conventional 3D printing processes do not enable the direct fabrication of hybrid structures consisting of solid metal and polymer parts due to the significant differences in the processing temperatures of both materials. A solution to this problem is the integration of two processes, electrodeposition and photopolymerization, which allow fabrication to be carried out at room temperature. This paper presents preparatory studies aimed at developing a new 3D printing technology that uses the simultaneous application of electrodeposition and photopolymerization to manufacture hybrid metal–polymer elements in a single, integrated 3D printing process. Here, a hybrid metal–polymer element is defined as a component composed of at least two bonded parts, including at least one metal part fabricated by electrodeposition and at least one polymer part produced by photopolymerization. Thus, it is not a polymer component merely coated with an electrodeposited metal layer, but a true hybrid structure consisting of functional metallic and polymeric parts. Such components can be manufactured using the world’s first hybrid 3D printer, which integrates electrodeposition and photopolymerization to produce metal–polymer hybrid parts within a single 3D printing process (the device has been submitted to the Polish Patent Office). However, its design and operating principle are beyond the scope of this paper. The presented research focuses on initial study of selected feedstock materials for this printer, namely photocurable resins and electroplating baths. Since the entire hybrid printing process occurs in an electroplating bath environment, studies of these materials for 3D printing under such conditions were essential. This work includes a screening study of photocurable formulations with respect to rheological properties, 3D printing tests in a model copper electroplating bath, and selection of a suitable bath brightener to maximize the quality (fine grain size, homogeneous grain distribution) of additively deposited copper layers. The study was conducted using copper electrodeposition and acrylate resin photopolymerization as model processes for evaluating the proposed hybrid metal–polymer 3D printing technology. Finally, the most suitable feedstock materials for producing metal–polymer hybrid parts via the proposed 3D printing method were selected. Full article

This study presents a predictive manufacturing framework for customizing the biomechanical response of a 3D printed ergonomic armrest based on relaxed Voronoi metamaterials. A double curved armrest geometry was combined with parametric lattice generation, stereolithography printing in BioMed Elastic 50A resin, uniaxial compression testing of cylindrical lattice specimens, and homogenized finite element simulations using a CT derived forearm model under 15, 30, and 45 N loading. The results showed that both cell size and ligament thickness strongly affected compressive behavior, with smaller cells and thicker ligaments producing higher stiffness and earlier densification. Among the uniform configurations selected for simulation, the E-9-1.5 lattice provided the most balanced response, maintaining contact pressure below about 70 kPa up to 45 N, whereas the stiffer E-7-1.5 configuration exceeded 160 kPa and the E-7-1 configuration surpassed 100 kPa at higher load. Based on these findings, a functionally graded Voronoi concept was developed to combine a more compliant central zone with a stiffer peripheral support region while preserving conformity to the complex armrest boundary. Overall, the results show that relaxed Voronoi lattices offer a computationally efficient route toward anatomically conforming and mechanically tunable cushioning interfaces. Full article

In veterinary education, many exercises are performed on animals. Palpating the mucosa of the Ruminoreticulum in ruminants is a necessary preparatory exercise for future surgery. However, there are legal and ethical obligations to reduce the use of animals and improve animal welfare. This can be achieved using 3D models and simulators. To allow students to practice palpating the goat’s forestomach, a simulator is being developed. The aim of the present study was to produce replicas of the mucosal surface of the Ruminoreticulum for the inner lining of this simulator. Two methods were applied and compared: 3D printing and surface casting. For 3D printing, computed tomography-based virtual templates were created and printed after appropriate post-processing. For the surface cast, a negative mold of the mucosal surfaces was created using epoxy resin. The positive mucosal cast was then created using silicone. The results showed a clear advantage of surface casting compared to 3D printing. The virtual templates and 3D prints lacked fine anatomical structures. In contrast, the surface casting method yielded detailed replicas of the mucosal surfaces of Rumen and Reticulum, including even finer anatomical structures. Since the silicone casts also allowed for haptic differentiation of mucosal formations, they can be considered a suitable inner lining for the planned simulator. Full article

Accelerated industrial development demands the search for efficient remediation technologies. Microbial fuel cells (MFCs) have the capacity to remediate organic matter-rich effluent by utilizing bacteria as biocatalysts capable of oxidizing organic material while simultaneously producing electricity. In this paper, a novel electrode is prepared through the carbonization of a tailored photopolymer with iron nanoparticles and carbon black (C-iNPCB) and its performance tested as an anode using dual chamber MFCs for the remediation of paper recycling plant effluent. Its efficiency is compared to a graphite rod (GR) and a carbon black-coated 3D-printed structure (3D-CB). The paper effluent containing chemical oxygen demand 5.0 g/L was used as feedstock in the MFCs. The GR anode (0.91 A/m²; 0.32 W/m²) and 3D-CB anode (0.88 A/m²; 0.30 W/m²) both achieved 56% COD removal, while the C-iNPCB-anode (5.71 A/m²; 3.75 W/m²) was the best performing, with over 80% COD removal. The photopolymerized doped anode exhibited superior performance in terms of both organic matter oxidation and conductivity, indicating higher effectiveness of this type of electrode in MFC technology. Full article

In the continuous development of additive technologies and light-sensitive resins, the biological performance of 3D-printed resins is strongly dependent on photopolymerization efficiency and post-processing conditions. This study evaluated the effect of post-curing duration on the cellular response to two denture base resins using direct contact and indirect eluate-based pathways. Human gingival fibroblasts were assessed through viability, membrane integrity, nitric oxide production, fluorescence live/dead staining, and caspase-3/7 activity. As a result of contact between the cells and the surface interface of the specimen disks, reduced metabolic activity was noticed compared with the control under direct exposure, indicating cellular stress. Extended polymerization has been demonstrated to improve metabolic activity and reduce apoptotic signals for the V-Print dentbase resin, whereas FotoDent Denture presented a less uniform response under the same parameters. Therefore, for evaluating the cytotoxicity of light-sensitive resins, it is not sufficient to assess only the saliva-soluble substances released from the resin, such as residual monomers, but also the 3D printing parameters. Full article

Background/Objectives: Resin 3D printing is widely used to fabricate orthodontic diagnostic models, but the practical performance of commercial desktop workflows compared to dental-certified workflows is still debated. This study compared the dimensional accuracy and 7-day stability of maxillary orthodontic models printed from the same master STL file using a dental-certified workflow versus two commercial desktop workflows. Methods: An ISO 20896-1:2019-based reference cast with four 6 mm calibration spheres was used to generate a master STL file. Fifteen models were printed (n = 5 per workflow) using Primeprint™ (dental-certified workflow) and two commercial desktop printers (Anycubic Photon Mono M5s; Phrozen Sonic Mighty 14K REVO). The models were digitized at baseline (T0, ≤48 h) and after 7 days (T7) using a laboratory scanner. Surface superimposition in CloudCompare^® calculated the RMS (root mean square) surface deviation and mean signed deviation, and two calibrated operators performed independent extractions. Results: The mean RMS deviations were <0.10 mm for all workflows at both time points. No between-workflow differences were detected at T0 (H = 2.000; p = 0.368) or T7 (H = 1.520; p = 0.468), no within-workflow T0–T7 changes were significant (all p > 0.05), and the inter-operator agreement was excellent (ICC 0.991–0.999). Conclusions: Under the tested workflows, dental-certified and commercial desktop resin printing produced orthodontic models with a comparable global surface accuracy and short-term dimensional stability. Full article

Introduction: Recent advancements in technologies, such as 3D printing, have been adopted in prosthodontics to streamline clinical procedures and provide high-quality prosthetic devices to patients within a reduced timeframe. Aim of the study: This study primarily aimed to determine the color change levels of 3D-printed dental resins for temporary and long-term intraoral applications. We also evaluated the effectiveness of post-processing procedures such as polishing or glazing on color stability. Materials and methods: Three types of dental resins were tested in distilled water, coffee, and wine environments for 2, 7, 30, and 60 days. A spectrophotometric analysis was conducted, and the Ciede2000 formula was used to determine the DE. Results: The material type, conditioning method, and storage time significantly affected the color changes of the tested materials. The post-processing technique had the most remarkable impact on color stability over time. Conclusions: Glazing of the 3D-printed material surface appears to be the most effective approach to prolong its clinical applicability by maintaining color stability. Full article

Biofilm formation on denture base materials may contribute to oral diseases such as denture stomatitis and therefore represents an important factor in prosthodontic treatment. This in vitro study investigated biofilm formation on dental prosthetic materials manufactured by additive, subtractive, and conventional techniques. Disc-shaped specimens were fabricated from 3D-printed Denture Base Resin (Formlabs), milled Lucitone Digital Fit (Dentsply Sirona), and conventionally processed cold-polymerized PALAPress (Kulzer). Biofilm formation by Streptococcus mutans and Streptococcus sanguinis was assessed separately over a 21-day incubation period using crystal violet staining and photometric determination of optical density at eight predefined time points. Surface characteristics before and after microbial colonization were qualitatively evaluated by scanning electron microscopy. For S. mutans, significant material-dependent differences were observed only at selected time points, while overall biofilm accumulation remained low. In contrast, S. sanguinis exhibited pronounced and repeated differences, with milled PMMA generally showing lower biofilm accumulation compared with additively manufactured and conventionally processed materials. Overall, S. sanguinis formed significantly more biofilm than S. mutans across all materials and time points. These findings indicate that both manufacturing technique and bacterial species influence biofilm formation on denture base materials. Full article

Background: Additively manufactured surgical guides require post-processing and subsequent decontamination prior to intraoral use. Steam sterilization and chemical disinfection protocols may influence the dimensional stability of polymer-based guide materials and potentially affect clinical fit and accuracy. Objectives: This in vitro study evaluated the dimensional changes of SLA 3D-printed Surgical Guide Resin V1 (Formlabs) after steam sterilization at 121 °C (AUT121) and 134 °C (AUT134) and after disinfection using 70% isopropyl alcohol (IPA70), compared with an untreated control group. Methods: Forty standardized specimens were fabricated using SLA technology and divided into four groups (n = 10/group): Control (CT), 121 °C steam sterilization (AUT121), 134 °C steam sterilization (AUT134), and IPA70 disinfection. Two linear measurement zones (L1 and L2) were assessed per specimen. Baseline measurements were recorded with a caliper (mm). Post-treatment measurements were obtained using microscopic evaluation, recorded in µm, and converted to mm for analysis. Dimensional change was calculated as ΔL = L_after − L_before. Within-group comparisons and between-group analyses were performed with a significance level of α = 0.05. Results: Steam sterilization at 134 °C (AUT 134) produced statistically significant dimensional changes in both zones (L1: p = 0.036; L2: p = 0.042). No statistically significant differences were observed in the AUT121 group (L1: p = 0.437; L2: p = 0.682) or the IPA70 group (L1: p = 0.164; L2: p = 0.086). Between-group analysis showed no significant differences for ΔL1 (p = 0.345), whereas ΔL2 differed significantly among groups (p = 0.021). Conclusions: Under the conditions of this study, AUT134 steam sterilization significantly affected the dimensional stability of SLA-printed Surgical Guide Resin V1 specimens. The AUT121 protocol and IPA70 disinfection did not result in statistically significant dimensional changes compared with baseline. Full article