Search Results (46)

Intervertebral disk pathology, including disk herniation and degeneration, is a major contributor to chronic low back pain, and when conservative treatment fails, surgical management often involves discectomy-based procedures that leave residual annulus fibrosus (AF) defects associated with reherniation and progressive degeneration. These limitations have motivated interest in regenerative strategies using biomaterial scaffolds; however, reproducing the hierarchical, angle-ply architecture of the AF remains challenging. Here, we present a single-step extrusion-based 3D-printing approach to fabricate polycaprolactone (PCL) scaffolds with aligned microscale surface grooves that promote AF-like organization. Patterned nozzles with circumferential peaks generated uniaxial concave microgrooves (10–17 µm wide) directly during printing, enabling formation of multilamellar angle-ply constructs. Human bone marrow-derived mesenchymal stem cells cultured on patterned scaffolds aligned longitudinally within concave grooves, forming end-to-end arrays that guided extracellular matrix deposition. Gene expression analysis showed that topographical cues governed cellular organization without significantly altering gene expression profiles, while TGF-β3 supplementation upregulated outer AF-associated markers, including COL1, COL12, SFRP2, MKX, MCAM, and SCX. TAGLN expression increased specifically on patterned scaffolds in the absence of TGF-β3, indicating an association between microgroove-guided cellular organization and TAGLN expression, warranting further investigation into potential tension-related mechanisms. This novel single-step extrusion-printing approach leverages custom nozzle geometry to impart concave microgrooves, facilitating scalable fabrication of multilamellar angle-ply scaffolds that induce aligned cellular organization and support potential applications in annulus fibrosus repair, as well as mechanobiological studies of anisotropic musculoskeletal tissues. Full article

This study presents a practical and tunable 3D printing-based approach for manufacturing oral controlled-release bilayer tablets by modulating drug release solely through layer ratio control within a single dosage form. Theophylline-loaded filaments were prepared via hot-melt extrusion (HME) using Kollicoat^® IR or hydroxypropyl cellulose as polymer matrices. The mechanical properties of the manufactured filaments were evaluated and compared with commercial filaments to confirm their suitability for fused deposition modeling (FDM) printing. Physicochemical characterization using scanning electron microscopy, differential scanning calorimetry, X-ray diffraction, and Fourier transform infrared spectroscopy indicated partial crystallinity and molecular dispersion of the drug within the polymer matrices. Using a dual-nozzle FDM 3D printer, five bilayer tablets composed of two drug-loaded filaments at different layer ratios were successfully fabricated without altering formulation composition or processing conditions. Drug release studies revealed distinct dissolution behaviors that were strongly dependent on the bilayer composition. Overall, this study demonstrates that controlled drug release can be effectively achieved through geometric modulation of bilayer structures using a combined HME–FDM 3D printing approach, providing a practical platform for personalized oral drug delivery without increasing formulation complexity. Full article

The growing interest in sustainable additive manufacturing has driven research into customized biocomposite filaments reinforced with natural fibers. This study evaluates the influence of flax fiber content (5–15 wt%) on the thermal, rheological, morphological, and mechanical properties of fully bio-based polyamide PA10.10 filaments intended for fused deposition modeling (FDM). Filaments containing up to 15 wt% flax fibers were produced using both conventional single-screw extrusion and the METEOR^® elongational mixer to compare shear- and elongation-dominated dispersive mechanisms. Increasing flax loading enhanced stiffness (up to +84% tensile modulus at 15 wt%) but also significantly increased porosity, particularly in METEOR-processed materials, leading to reduced strength and intrinsic viscosity. Microscopy confirmed fiber shortening during compounding and revealed porosity arising from moisture release and insufficient fiber wetting. Rheological analysis showed the onset of a pseudo-percolated fiber network from 10 wt%, while excessive porosity at higher loadings impeded melt flow and printability. Based on the combined evaluation of the mechanical performance, dimensional stability, and processability, a 5 wt% flax formulation was identified as the optimal compromise for FDM. A functional automotive demonstrator (Fiat 500 dashboard fascia) was successfully printed using optimized FDM parameters (nozzle 240 °C, bed 75 °C, speed 20 mm s⁻¹, 0.6 mm nozzle, 0.20 mm layer height, and 100% infill). The part exhibited controlled shrinkage and limited warpage (maximum 1.8 mm across a 165 × 180 × 45 mm geometry with a 3 mm wall thickness). Dimensional accuracy remained within ±0.7 mm relative to the CAD geometry. These results confirm the suitability of PA10.10/flax biocomposites for sustainable, lightweight automotive components and provide key structure–processing–property relationships supporting the development of next-generation bio-based FDM feedstocks. Full article

Isolating the mechanical properties of an FDM joint by performing a direct tensile test on it is something that has yet to be achieved. Developing a methodology for isolating the properties of a single joint could help to inform simulations and achieve a better understanding of the mechanisms affecting the bond strength between FDM-printed materials. In this work, a cruciform single-joint test (CSJT) of a cross-shaped specimen and a fast mechanical clamping protocol are introduced to evaluate the apparent tensile strength and fracture mechanisms of a single FDM-printed joint between two PLA filaments. First, a discussion of different approaches for obtaining a fast, reproducible, and reliable test of the samples is presented. Then, nozzle temperature (180–215 °C) and bed temperature (30–120 °C) were systematically varied, producing a minimum of n = 12 samples per condition. Samples were classified after failure, depending on the fracture mechanism (type 1 = joint failure; type 2 = filament failure), and the apparent tensile strength (ATS) of the joint was computed from the tensile tests and optical micrographs. The detachment probability of the joints decreased sharply above 210 °C, while the ATS increased, approaching a plateau near ~50 MPa. The influence of bed temperature was smoother, with a stable decrease in the detachment ratio as the ATS increased, indicating that nozzle temperature is the main factor contributing to the joint strength. These results map a temperature-driven transition from joint-controlled to filament-controlled failure. The method proposed also provides a minimal-material, high-throughput route to quantify FDM interlayer bonding and inform process simulations. Additional tests are performed to contextualize the results presented. Full article

Edible hydrogels are the central material class in 3D food printing because they reconcile two competing needs: (i) low resistance to flow under nozzle shear and (ii) fast recovery of elastic structure after deposition to preserve geometry. This review consolidates the recent years of progress on hydrogel formulations—gelatin, alginate, pectin, carrageenan, agar, starch-based gels, gellan, and cellulose derivatives, xanthan/konjac blends, protein–polysaccharide composites, and emulsion gels alongside a critical analysis of printing technologies relevant to food: extrusion, inkjet, binder jetting, and laser-based approaches. For each material, this review connects gelation triggers and compositional variables to rheology signatures that govern printability and then maps these to process windows and post-processing routes. This review consolidates a decision-oriented workflow for edible-hydrogel printability that links formulation variables, process parameters, and geometric fidelity through standardized test constructs (single line, bridge, thin wall) and rheology-anchored gates (e.g., yield stress and recovery). Building on these elements, a “printability map/window” is formalized to position inks within actionable operating regions, enabling recipe screening and process transfer. Compared with prior reviews, the emphasis is on decisions: what to measure, how to interpret it, and how to adjust inks and post-set enablers to meet target fidelity and texture. Reporting minima and a stability checklist are identified to close the loop from design to shelf. Full article

In this study, the effect of various parameters of a single screw extruder on the rheology and mechanical properties of a polylactic acid (PLA) filament with a 1.75 mm diameter was investigated. The barrel temperature, nozzle and cooling bath temperature, screw speed, nozzle diameter, water bath length, and distance to the nozzle were the process variables. A Taguchi experimental design was implemented using an L8 orthogonal matrix with seven factors and two levels, and their influence on roundness and diameter were evaluated. Among the various processing parameters, the temperature of the cooling bath affected the roundness the most. The mechanical properties and surface roughness of the PLA filament were examined using a tensile test and nanofocus optical system, respectively. Moreover, to assess the filament’s reliability and investigate its behavior further, the filament was used to print 0° plates, and then dog-bone samples were cut from them to evaluate the mechanical properties of the printed specimens. Finally, the results indicate that improved-roundness filaments of 0.004 mm can lead to enhanced mechanical properties in 3D-printed samples with 3.54 MPa. Full article

Fused deposition modeling (FDM) 3D printing has the advantages of a simple molding principle, convenient operation, and low cost, making it suitable for the production and fabrication of complex structural parts. Moving forward to mass production using 3D printing, the major hurdle to overcome is the achievement of high dimensional stability and adequate mechanical properties. In particular, engineering plastics require precise dimensional accuracy. In this study, we overcame the issues of FDM 3D printing in terms of ternary material compounds for polyamides with gradient structures. Using multi-walled carbon nanotubes (MWCNTs) and boron nitride (BN) as fillers, polyamide 6 (PA6)-based 3D-printed parts with high dimensional stability were prepared using a single-nozzle, two-component composite fused deposition modeling (FDM) 3D printing technology to construct a gradient structure. The ternary composites were characterized via DSC and XRD to determine the optimal crystallinity. The warpage and shrinkage of the printed samples were measured to ensure the dimensional properties. The mechanical properties were analyzed to determine the influence of the gradient structures on the composites. The experimental results show that the warpage of pure polymer 3D-printed parts is as high as 72.64%, and the introduction of a gradient structure can reduce the warpage to 3.40% by offsetting the shrinkage internal stress between layers. In addition, the tensile strength of the gradient material reaches up to 42.91 MPa, and the increasing filler content improves the interlayer bonding of the composites, with the bending strength reaching up to 60.91 MPa and the interlayer shear strength reaching up to 10.23 MPa. Therefore, gradient structure design can be used to produce PA6 3D-printed composites with high dimensional stability without sacrificing the mechanical properties of PA6 composites. Full article

This article proposes a simulation-based hierarchical heuristic (SHH) method to optimize nozzle assignment, feeder assignment, and component sequencing in a single spin-head gantry type surface mounter. Spin-head surface mounters are widely used in assembling printed circuit boards (PCBs) for consumer electronics but present a challenging non-deterministic polynomial-time hard (NP-hard) problem. The SHH method introduces multiple heuristics for the three sub-problems and evaluates their combinations in the FlexSim simulation environment. Through case studies using industrial and artificial PCB samples, the optimal combination scheme is identified, demonstrating significant improvements in the operational efficiency. This research not only provides a novel solution for optimizing spin-head surface mounters but also contributes to operations research by addressing complex NP-hard problems. Full article

This study utilizes a lab-developed pneumatic-extrusion condensing 3D food printer to prepare astragalus–starch mixed gels by blending different ratios of astragalus polysaccharide and wheat starch and applies these gels to 3D printing experiments. The aim of this paper is to investigate the impacts of mixed-gel concentrations on printing outcomes in order to identify the optimal blending ratio. Under this rationale, the effects of printing layer height and nozzle diameter on print quality were studied. Single-factor analysis and response surface methodology were employed to optimize the experiments and determine the optimal printing process parameters for the astragalus–starch mixed gels. The results indicate that an increase in astragalus polysaccharide content leads to a decrease in the sedimentation rate of the mixed gels and a tendency towards a more fluid consistency. After storage of samples in a sealed space for equal durations, it was found that an increase in astragalus polysaccharide content enhances the textural properties of the mixed gels, with optimal printing effects achieved at a 2% polysaccharide content. The optimal print quality is achieved when the ratio of nozzle diameter to layer height is between 0.5 and 0.55. The influence order of printing process parameters on the overall completion rate of the samples is nozzle diameter > printing speed > fill rate. The predicted optimal printing parameters are a nozzle diameter of 0.6 mm, a printing speed of 767 mm/min, and a fill rate of 83%, with a predicted overall completion rate of the printed samples at 99.45%. Experimental validation revealed an actual overall completion rate of the printed samples at 99.52%, slightly higher than the predicted value. This discrepancy was attributed to the precision of the measurement methods and the variability in the printing process. The study demonstrates that the addition of astragalus polysaccharide significantly improves the 3D printing molding effect of wheat starch, and the printing parameter settings obtained by response surface optimization effectively enhance printing accuracy. This research provides experimental evidence and parameter optimization references for the application of non-starch polysaccharides in starch-based 3D food printing. Full article

The structure and composition of natural bone show gradient changes. Most bone scaffolds prepared by bone tissue engineering with single materials and structures present difficulties in meeting the needs of bone defect repair. Based on the structure and composition of natural long bones, this study proposed a new bone scaffold preparation technology, the dual-phase composite forming process. Based on the composite use of multiple biomaterials, a bionic natural long bone structure bone scaffold model with bone scaffold pore structure gradient and material concentration gradient changes along the radial direction was designed. Different from the traditional method of using multiple nozzles to achieve material concentration gradient in the scaffold, the dual-phase composite forming process in this study achieved continuous 3D printing preparation of bone scaffolds with gradual material concentration gradient by controlling the speed of extruding materials from two feed barrels into a closed mixing chamber with one nozzle. Through morphological characterization and mechanical property analysis, the results showed that BS-G (radial gradient long bone scaffolds prepared by the dual-phase composite forming process) had obvious pore structure gradient changes and material concentration gradient changes, while BS-T (radial gradient long bone scaffolds prepared by printing three concentrations of material in separate regions) had a discontinuous gradient with obvious boundaries between the parts. The compressive strength of BS-G was 1.00 ± 0.19 MPa, which was higher than the compressive strength of BS-T, and the compressive strength of BS-G also met the needs of bone defect repair. The results of in vitro cell culture tests showed that BS-G had no cytotoxicity. In a Sprague–Dawley rat experimental model, blood tests and key organ sections showed no significant difference between the experimental group and the control group. The prepared BS-G was verified to have good biocompatibility and lays a foundation for the subsequent study of the bone repair effect of radial gradient long bone scaffolds in large animals. Full article

The trade-off between resolution and speed represents a significant challenge when extrusion-based additive manufacturing (AM) is used for large-format additive manufacturing (LFAM). This paper presents an analysis of a new material extrusion process, named selective sheet extrusion (SSE), that aims to decouple these parameters. Unlike traditional single-nozzle material extrusion processes, SSE utilizes a single, very wide nozzle through which extrusion is controlled by an array of dynamically actuated teeth at the nozzle outlet. This allows the system to deposit a selectively structured sheet of material with each pass, potentially enabling the deposition of an entire layer of a part in a single pass. An analysis of the theoretical performance of the SSE technology, in terms of speed and material efficiency in comparison with single-nozzle extrusion systems, predicted speed increases of 2–3 times for the geometries that were explored. The analysis was then validated through experimental work that indicated a normalized improvement in print speed of between 2.3 and 2.5 times using a proof-of-concept SSE prototype. The SSE concept expands the opportunity frontier of LFAM technologies by enabling enhanced print speeds, while maintaining higher resolutions at scale. This enhancement in speed and/or resolution could have significant benefits, especially in large-scale prints that benefit from enhanced internal resolution. Full article

The print head is one of the most critical components in an additive manufacturing (AM) system. It can significantly affect the quality of printed parts. Recently, because continuous carbon fiber-reinforced composites can have excellent mechanical properties, a relevant AM technique, fused filament fabrication (FFF), has been attracting increasing attention. This has extended the requirements demanded of print heads. To this end, different FFF extrusion methods have been rapidly developed based on various methods of impregnating fibers into the matrix for the corresponding print heads. Generally, these extrusion methods are of three types: single extrusion, in situ extrusion, and dual extrusion. All these methods face substantial challenges, such as the nozzle clogging and damage to the continuous carbon fibers during extrusion. These common issues still need to be fully addressed. This study’s aim is to summarize and discuss the different extrusion methods and their FFF specific components in terms of their advantages and disadvantages for continuous carbon fiber-reinforced composites. Full article

We report a fusedly deposited frequency-selective composite (FD-FSCs), fabricated with a dual-nozzle 3D printer using a conductive carbon black (CB) polylactic acid (PLA) composite filament and a pure PLA polymer filament. The square frequency-selective pattern was constructed by the conductive CB/PLA nanocomposite, and the apertures of the pattern were filled with the pure dielectric PLA material, which allows the FD-FSC to maintain one single plane, even under bending, and also affects the resonating frequency due to the characteristic impedance of PLA (ε_r′ ≈ 2.0). The number of the deposition layer and the printing direction were observed to affect electrical conductivity, complex permittivity, and the frequency selectivity of the FD-FSCs. In addition, the FD-FSCs designed for an X-band showed partial transmission around the resonant frequency and was observed to, quite uniformly, transmit microwaves in the decibel level of −2.17~−2.83 dB in the whole X-band, unlike a metallic frequency selective surface with full transmission at the resonance frequency. FD-FSCs embedded radar absorbing structure (RAS) demonstrates an excellent microwave absorption and a wide effective bandwidth. At a thickness of 4.3 mm, the 10 dB bandwidth covered the entire X-band (8.2~12.4 GHz) range of 4.2 GHz. Therefore, the proposed FD-FSCs fabricated by dual-nozzle 3D printing can be an impedance modifier to expand the design space and the application of radar absorbing materials and structures. Full article

In this study, a multiwalled carbon nanotube (MWCNT) dispersion is used as an ink for a single-nozzle inkjet printing system to produce a planar coil that can be used to determine strain wirelessly. The MWCNT dispersion is non-covalently functionalized by dispersing the CNTs in an anionic surfactant, namely sodium dodecyl sulfate (SDS). The fabrication parameters, such as sonication energy and centrifugation time, are optimized to obtain an aqueous suspension suitable for an inkjet printer. Planar coils with different design parameters are printed on a flexible polyethylene terephthalate (PET) polymer substrate. The design parameters include a different number of windings, inner diameter, outer diameter, and deposited layers. The electrical impedance spectroscopy (EIS) analysis is employed to characterize the printed planar coils, and an equivalent electrical circuit model is derived based on the results. Additionally, the radio frequency identification technique is utilized to wirelessly investigate the read-out mechanism of the printed planar MWCNT coils. The complex impedance of the inductively coupled sensor undergoes a shift under strain, allowing for the monitoring of changes in resonance frequency and bandwidth (i.e., amplitude). The proposed wireless strain sensor exhibits a remarkable gauge factor of 22.5, which is nearly 15 times higher than that of the wireless strain sensors based on conventional metallic strain gauges. The high gauge factor of the proposed sensor suggests its high potential in a wide range of applications, such as structural health monitoring, wearable devices, and soft robotics. Full article

This article proposes the integration of two novel aspects into the production of 3D-printed customized wrist-hand orthoses. One aspect involves the material, particularly Colorfabb varioShore thermoplastic polyurethane (TPU) filament with an active foaming agent, which allows adjusting the 3D-printed orthoses’ mechanical properties via process parameters such as printing temperature. Consequently, within the same printing process, by using a single extrusion nozzle, orthoses with varying stiffness levels can be produced, aiming at both immobilization rigidity and skin-comfortable softness. This capability is harnessed by 3D-printing the orthosis in a flat shape via material extrusion-based additive manufacturing, which represents the other novel aspect. Subsequently, the orthosis conforms to the user’s upper limb shape after secure attachment, or by thermoforming in the case of a bi-material solution. A dedicated design web app, which relies on key patient hand measurement input, is also proposed, differing from the 3D scanning and modeling approach that requires engineering expertise and 3D scan data processing. The evaluation of varioShore TPU orthoses with diverse designs was conducted considering printing time, cost, maximum flexion angle, comfort, and perceived wrist stability as criteria. As some of the produced TPU orthoses lacked the necessary stiffness around the wrist or did not properly fit the palm shape, bi-material orthoses including polylactic acid (PLA) inserts of varying sizes were 3D-printed and assessed, showing an improved stiffness around the wrist and a better hand shape conformity. The findings demonstrated the potential of this innovative approach in creating bi-material upper limb orthoses, capitalizing on various characteristics such as varioShore properties, PLA thermoforming capabilities, and the design flexibility provided by additive manufacturing technology. Full article