Search Results (1,332)

Deep-seated tumors are challenging pathologies to treat. Currently available approaches are limited, prompting innovative solutions. Hyperthermia treatment (HT) is a thermal oncological therapy that raises tumor temperature (40–44 °C for 60 min), enhancing radio- and chemotherapy. Biomaterials loaded with magnetic particles, called magnetic scaffolds (MagSs), are used as HT agents for cancer treatment using radiofrequency (RF) heating. MagSs can be manufactured via 3D printing using fused deposition modeling to create biomimetic architectures based on triply periodic minimal surfaces (TPMSs). TPMS-based MagSs have been tested in vitro for RF HT. However, there is a lack of understanding regarding the thermal properties of TPMS MagSs for RF hyperthermia. Significant discrepancies between simulated and measured temperatures have been reported, attributed to limited knowledge of the apparent thermal conductivity of MagSs. Since planning is crucial for HT, it is fundamental to determine the thermal properties of these heterogeneous and porous composite biomaterials. Magnetic polylactic acid (PLA) scaffolds, shaped in different TPMS geometries and variable porosities, were thermally investigated in this research study. A linear relationship was found between the apparent thermal conductivity of parallelepiped and cylindrical scaffolds, and the measured values were validated using a numerical model of the RF HT test. Full article

Free form fabrication (FFF), also known as fused deposition modeling (FDM), is a widespread and accessible method for prototyping. Parts a with lattice structure having functional roles as mechanism elements is becoming more common. In the research field, the mechanical characteristics as well as optimization methods for manufacturing these parts are major points of interest. One of the major aspects of FFF is part orientation during print, as it has influence over a wide range of variables, from tensile strength to surface quality and material consumption. For parts with a lattice structure, the printing orientation is important not only as a factor that influences the characteristics of the part itself, but also as a factor that determines the support requirements. However, due to the complex lattice structure, removing supports from these parts can be a challenging task. This study focuses on analyzing the reliability of available CAD optimization methods for FFF pre-processing. The analysis is performed using the Design for Additive Manufacturing module included in the Siemens NX software, version NX2406. The efficiency of CAD optimization was observed by taking into account the material consumption, printing times, surface quality, and support requirements. The study methods were based on the comparative analysis approach. The case studies used for the comparative analysis consider two-part inner structures: the solid structure approach with a rectilinear infill and the lattice structure approach. Full article

A method to characterize the mechanical properties of cellular materials manufactured using 3D printing, specifically employing the fused deposition modeling (FDM) technique, is developed. Numerical simulations, virtual testing, and optimization based on genetic algorithms are combined in this approach to determine the anisotropic properties of the material, which are essential for biomedical applications such as tissue engineering. Homogenization using representative unit cells enabled the calculation of orthotropic properties, including elastic moduli ($E_1$, $E_2$, $E_3$), Poisson’s ratios (${\nu }_{12}$, ${\nu }_{13}$ and ${\nu }_{23}$), and shear moduli ($G_{12}$, $G_{13}$, $G_{23}$). These results validated the virtual tests using an L-shaped beam model, based on a known state of displacements and stresses. In the virtual test of the FDM model, a significant correlation with experimental results was observed, confirming the material’s anisotropy and its influence on deformations and stresses. Meanwhile, the effective medium test demonstrated over 95% agreement between simulated and experimental values, validating the accuracy of the proposed constitutive model. The optimization process, based on multi-objective genetic algorithms, allowed the determination of the material’s mechanical properties through controlled iterations, achieving a strong correlation with the results obtained from the homogenization model. These findings present a new approach for characterizing and optimizing 3D-printed materials using FDM techniques, providing an efficient and reliable method for applications in tissue engineering. Full article

This review provides a comprehensive analysis of recent developments in the additive manufacturing of green composites, with a particular focus on their mechanical behavior. A bibliometric analysis of 482 research articles indexed in the Web of Science Core Collection and published between 2015 and 2025 reveals a sharp increase in publications, with dominant contributions from countries such as China, India, and the United States, as well as strong collaboration networks centered on materials science and polymer engineering. Thematic clustering highlights a growing emphasis on natural fiber reinforcement, biodegradable matrices, and performance optimization. Despite these advances, few studies have combined bibliometric analysis with a technical evaluation of mechanical performance, leaving a gap in understanding the relationship between research trends and material or process optimization. Building on these insights, the review synthesizes current knowledge on material composition, print parameters, infill design, and post-processing, identifying their combined effects on tensile strength, stiffness, and durability. The study concludes that multi-variable optimization—encompassing fiber-matrix compatibility, print architecture, and thermal control—is essential to achieving eco-efficient and high-performance green composites in additive manufacturing. Full article

Continuous nettle fiber-reinforced PLA composites were fabricated using a custom-designed fused deposition modeling (FDM) 3D printer equipped with an in-nozzle fiber impregnation system. The influence of hatch spacing and layer thickness on fiber volume fraction, tensile strength, and fracture surface morphology was systematically examined. Fiber content increased from 7.94 vol.% to 12.21 vol.% when hatch spacing was reduced from 1.0 mm to 0.6 mm at a constant 0.4 mm layer thickness, and from 12.21 vol.% to 24.43 vol.% when layer thickness was decreased from 0.4 mm to 0.2 mm at a fixed 0.6 mm hatch spacing. When compared to neat PLA, tensile strength was improved by 18.69% for the configuration of 1_04 and 75.83% for the configuration of 06_02. SEM analysis revealed orderly fiber deposition in all samples, with 3D-printing-induced voids and fiber pull-out observed on fracture surfaces. Reduced hatch spacing and layer thickness resulted in denser fiber packing, consistent with mechanical performance trends. The results highlight the strong influence of printing parameters on the microstructural and mechanical behavior of continuous natural fiber composites produced by FDM. Full article

Due to the rapid advancements in coordinate measuring systems, data processing software, and additive manufacturing (AM) techniques, it has become possible to create copies of existing models through the reverse engineering (RE) process. However, the lack of precise estimates regarding the accuracy of the RE process—particularly at the measurement, reconstruction, and computer-aided design (CAD) modeling stages—poses significant challenges. Additionally, the assessment of dimensional and geometrical errors during the manufacturing stage using AM techniques limits the practical implementation of product replicas in the industry. This paper provides an estimation of the errors encountered in the RE process and the AM stage of various models. It includes examples of an electrical box, a lampshade for a standing lamp, a cover for a vacuum unit, and a battery cover. The geometry of these models was measured using a GOM Scan 1 (Carl Zeiss AG, Jena, Germany). Following the measurement process, data processing was performed, along with CAD modeling, which involved primitive detection, profile extraction, and auto-surface methods using Siemens NX 2406 software (Siemens Digital Industries, Plano, TX, USA). The models were produced using a Fortus 360-mc 3D printer (Stratasys, Eden Prairie, MN, USA) with ABS-M30 material. After fabrication, the models were scanned using a GOM Scan 1 scanner to identify any manufacturing errors. The research findings indicated that overall, 95% of the points representing reconstruction errors are within the maximum deviation range of ±0.6 mm to ±1 mm. The highest errors in CAD modeling were attributed to the auto-surfacing method, overall, 95% of the points are within the average range of ±0.9 mm. In contrast, the lowest errors occurred with the detect primitives method, averaging ±0.6 mm. Overall, 95% of the points representing the surface of a model made using the additive manufacturing technology fall within the deviation range ±0.2 mm on average. The findings provide crucial insights for designers utilizing RE and AM techniques in creating functional model replicas. Full article

The paper proposes a manufacturing technology for the non-woven/3D-printed (N3DP) hybrid material (HM) with improved radio-absorbing properties. We have fabricated the needle-punched non-woven felt and impregnated it with the carbon fibers containing UV-curable photopolymer resin. The functional 3D-printed layer was attached to the highly porous, deformable polymer substrate by the fused deposition modeling (FDM) technique. The preliminary bulk modification of the filament was realized with the IR- and UV-pigment microcapsules filling. The combination of additive prototyping and non-woven needle-punched fabrics surface modification (by the electrically conductive elements 2D-periodic system applying) expands the frequency range of the electromagnetic radiation effective absorption. It provides the possibility of a reversible change in the color characteristics of the hybrid material surface under the influence of the UV and IR radiation. Full article

This study investigates the influence of different surface treatments (namely, mechanical abrasion and solvent cleaning with isopropyl alcohol and acetone) on the adhesive bonding performance of polylactic acid (PLA) substrates produced by Fused Deposition Modeling (FDM). Pull-off tests revealed that the isopropanol-cleaned specimens achieved the highest bond strength, with an average pull-off value exceeding 8.5 MPa, compared to approximately 5.6 MPa for untreated PLA. Conversely, acetone cleaning resulted in the lowest performance (about 3.5 MPa), while mechanical abrasion yielded intermediate values of about 6 MPa. FTIR analysis confirmed that no chemical reactions occurred, although acetone and abrasion induced significant physical surface changes, unlike isopropanol, which acted as an effective cleaning agent. These findings demonstrate that surface cleanliness plays a dominant role over morphological alterations in enhancing the adhesion of PLA-based 3D-printed joints. Full article

This study investigates the processability—via Fused Deposition Modeling (FDM) 3D printing—and mechanical performance of biocomposites based on polylactic acid (PLA), polybutylene succinate (PBS), and their 50/50 wt% blend, each reinforced with hemp shive at 3 and 5 wt%. Blending PLA with PBS represents a straightforward and encouraging strategy to enhance both the printability and mechanical properties of the individual resins, expanding the range of their potential applications. The addition of hemp shive—a by-product of hemp processing—not only enhances the biodegradability of the composites but also improves their thermo-mechanical performance, as well as aligning with circular economy principles. The rheological characterization, performed on all the systems, evidenced that the PLA/PBS blend possesses viscoelastic properties well suited for FDM, enabling smooth extrusion through the nozzle, good shape stability after deposition, and effective interlayer adhesion. Moreover, the constrain effect of hemp shives within the polymer matrix reduced the extrudate swell, a key factor affecting the dimensional accuracy of the printed parts. Optimal processing conditions were identified at a nozzle temperature of 190 °C and a printing speed of 70 mm/s, providing a favorable compromise between print quality, final performances and production efficiency. From a mechanical perspective, the PLA/PBS blend exhibited an 8.6-fold increase in elongation at break compared to neat PLA, and its corresponding composite showed a ductility nearly three times higher than the PLA-based counterpart’s. In conclusion, the findings of this study provide new insights into the interplay between material formulation, rheological behavior and printing conditions, supporting the development of sustainable, hemp-reinforced biocomposites for additive manufacturing applications. Full article

Fused Deposition Modeling (FDM) is a commonly used 3D printing process characterized by its versatility in material selection; however, FDM’s layer-by-layer process often leads to lower strength properties. This study explores the mechanical properties of FDM 3D-printed composite materials printed with varying nozzle diameters, specifically on the influence of Carbon Fiber-reinforced Polylactic Acid (PLA-CF) on tensile and flexural strength when reinforcing Polylactic Acid (PLA) parts. Composite samples were printed with varying ratios of PLA and PLA-CF, ranging from 0% to 100% PLA-CF in 20% increments, with layer groups stacked vertically, while also using three different nozzle diameters (0.4 mm, 0.6 mm, and 0.8 mm). Tensile testing revealed a proportional increase in strength as PLA-CF content increased, indicating that carbon fiber reinforcement significantly enhances tensile performance. However, flexural testing demonstrated a decrease in bending strength with higher PLA-CF content, suggesting a trade-off between stiffness and flexibility. Mid-range ratios (40–60% PLA-CF) provided a balance between tensile and flexural properties. Finally, atomic force microscopy was utilized to provide a better understanding of the microscale morphology and surface properties of PLA and PLA-CF thin films. The results highlight the potential of PLA-CF/PLA composites to allow for more direct control over the tensile–flexural trade-off during the printing process, as opposed to manufacturing filaments with fixed fiber percentages. These results provide a path for tailoring the mechanical behavior of printed parts without requiring specialized filaments. Full article

This review investigates how process parameters and material choices influence the mechanical performance of parts produced by material extrusion additive manufacturing, with a particular focus on Material Extrusion (ME). Through a systematic bibliometric analysis of literature between 2015 and 2025, the study identifies key factors affecting mechanical strength, anisotropy, and structural reliability, including printing temperature, speed, orientation, layer thickness, and interlayer bonding. Emphasis is placed on emerging techniques such as 4D printing, fiber-reinforced composites, and novel monitoring methods like real-time vibration sensing and thermal imaging, which offer promising pathways to improve part performance and process stability. Three research questions guide the analysis: (1) how printing parameters affect micro- to macrostructure and failure behavior, (2) how optimization strategies enhance part quality, and (3) how material and process selection aligns with functional requirements. The review highlights both advances and persistent limitations in process control, material compatibility, and anisotropic strength. It concludes with a call for further integration of predictive modeling, hybrid material systems, and closed-loop process monitoring to unlock the full potential of additive manufacturing in high-performance engineering applications. Full article

Biocompatible polymers have emerged as essential materials in medical 3D printing, enabling the fabrication of scaffolds, tissue constructs, drug delivery systems, and biosensors for applications in and on the human body. This review aims to provide a comprehensive overview of the current state of 3D-printable biocompatible polymers and their composites, with an emphasis on their processing methods, properties, and biomedical uses. The scope of this work includes both natural and synthetic biocompatible polymers, polymer–nanocomposite systems, and bioinks that do not require photo initiators. The relevant literature was critically examined to classify materials by type, evaluate their compatibility with major 3D printing techniques such as stereolithography, selective laser sintering, and fused deposition modeling, and assess their performance in various medical applications. Key findings highlight that reinforced polymer composites, tailored surface chemistries, and hybrid printing strategies significantly expand the range of functional, customizable, and affordable biomedical devices. This review concludes by discussing present-day applications and emerging trends, underscoring that 3D-printable biocompatible polymers are rapidly transitioning from research to clinical practice, offering transformative potential for patient-specific healthcare solutions. Full article

Three-dimensional (3D) printing offers new opportunities in surgical planning and medical education, yet high costs and technological complexity often limit its widespread use, especially in low-resource settings. This study presents a personalized, cost-effective, and anatomically accurate liver model designed using open-source tools and affordable 3D-printing techniques. Segmentation of hepatic CT images was performed in 3D Slicer using a region-growing method, and the resulting models were optimized and exported as STL files. The external mold was printed with Fused Deposition Modeling (FDM) using PLA+, while internal structures such as vessels and tumors were fabricated via Liquid Crystal Display (LCD) printing using PLA Pro resin. The final assembly was cast in food-grade gelatin to mimic liver tissue texture. The complete model was produced for under USD 50, with an average total production time of under 128 h. An exploratory pedagogical evaluation with five medical trainees yielded high Likert scores for anatomical understanding (4.6), spatial awareness (4.4), planning confidence (4.2), and realism (4.4). This model demonstrated utility in preoperative discussions and training simulations. The proposed workflow enables the fabrication of low-cost, realistic hepatic phantoms suitable for education and surgical rehearsal, promoting the integration of 3D printing into everyday clinical practice. Full article

This study presents a simulation-driven methodology for the design and optimization of a lightweight drone frame. Starting with a CAD model developed in SolidWorks, finite element analysis (FEA) and computational fluid dynamics (CFD) which are used to evaluate stress, deformation, fatigue behavior, and aerodynamic performance. Topology optimization is then applied to reduce non-critical material and enhance the stiffness-to-weight ratio. CFD-informed refinements further help to minimize drag and improve airflow uniformity. The final design is fabricated using fused deposition modeling (FDM) with PLA, enabling rapid prototyping and experimental validation. Future work will explore advanced materials to improve fatigue resistance and structural durability. Full article

This study explores the feasibility of using 3D printing technology to fabricate reference materials for validating compressive strength measurements in construction laboratories. Polylactic acid (PLA) and polyethylene terephthalate glycol-modified (PETG) were selected due to their widespread availability and use in fused deposition modeling (FDM). A series of cubic samples with varying infill levels and dimensions were printed and tested to evaluate the influence of infill density, temperature, and storage time on compressive strength. PLA samples exhibited higher compressive strength values (from 23.5 kN for 10% infill to 70.7 kN for 50% infill) and a steeper increase in strength with rising infill density compared to PETG (from 12.4 kN for 10% infill to 44.1 kN for 50% infill). However, PETG demonstrated superior stability over time, with significantly smaller increases in result variability after 31 days. The results confirm a strong linear correlation between infill level and compressive strength and indicate that even small fluctuations in ambient temperature can influence test outcomes. Despite PLA’s initial mechanical advantage, PETG’s aging resistance makes it a promising candidate for the development of durable and repeatable reference materials (increment of StD for PLA from 0.17 kN to 0.63 kN and 0.25 kN to 0.37 for PET-G). This research contributes to closing the gap in the availability of reliable mechanical reference materials for destructive testing, offering a novel application for 3D printing in quality control in civil engineering. Full article