Search Results (49)

Introduction: Three-dimensional (3D) printing technology has rapidly evolved across various fields of medicine and dentistry, particularly in orthodontics. One key application in orthodontics is the fabrication of dental models. Numerous parameters throughout the dental cast fabrication workflow can influence the accuracy of 3D-printed models. This review aims to evaluate the influence of post-processing procedures, specifically post-curing and post-rinsing, on the dimensional accuracy of 3D-printed dental casts. Materials and Methods: An initial data search was conducted using specific keywords across four databases (PubMed, Scopus, Web of Science, and Google Scholar). A secondary search of references and citations was also performed. This systematic review ultimately identified five studies that met the inclusion criteria (in vitro studies and studies referred to post-processing only of 3D-printed models) for further evaluation and analysis, whereas reviews, opinion studies, and papers in languages other than English were excluded. Based on the QUIN tool, all studies were assessed for their risk of bias. Because of the studies’ heterogeneity, a qualitative descriptive synthesis was conducted. Results: All five included studies were in vitro investigations. One study examined the influence of the post-curing process on dimensional accuracy, while the remaining four explored the impact of post-rinsing procedures on both dimensional accuracy and other surface characteristics of 3D-printed dental casts. Conclusions: According to the findings of the included studies, both post-curing and post-rinsing procedures had statistically significant effects on the dimensional accuracy of 3D-printed dental models. Nevertheless, all five studies concluded that the observed deviations remained within clinically acceptable limits, rendering the casts suitable for diagnostic orthodontic purposes or device fabrication. However, further research is needed to reinforce current findings and to enhance our understanding of the optimal post-processing protocols of additively manufactured dental casts. Full article

Bio-based polymeric composites were prepared by dispersing different amounts of olive pit (OP) powder within an acrylate epoxidized soybean oil (AESO) photocurable resin using tetrahydrofurfuryl acrylate (THFA) as diluent and (2,4,6-trimethylbenzoyl), phosphine oxide (BAPO) as photo-initiator, and they were photocured by Vat Photopolymerization (VP) using a Liquid Crystal Display (LCD) 3D printer. Formulation viscosity was studied because of its important role in a VP process able to influence the printability of the final parts. Different 3D printed architectures were successfully realized with good resolution and accuracy, high level of detail, and flexibility. The effect of OP addition was investigated by thermal (TGA and DSC), morphological (SEM and PSD), viscoelastic (DMA), and mechanical (tensile testing) characterization. The filler led to an increase in the T_g, storage modulus, and tensile properties, underlining the stiffening effect induced by the OP particles onto the polymeric starting resin. This underlines the possibility to apply these bio-based composites in many application fields by valorizing agro-wastes, developing more sustainable materials, and taking advantages of VP 3D printing, such as low costs, minimal wastage, and customized geometry. Biocompatibility tests were also successfully carried out. The results clearly indicate that the AESO-based composites promote cell adhesion and viability. Full article

The present study evaluates the viability of fabricating unmanned aerial vehicle (UAV) propellers using fused filament fabrication (FFF), with an emphasis on low-cost, desktop-scale production. The study’s backdrop is the recent adoption of UAVs and advancements in additive manufacturing. While the scope targets accessibility for individual and small-scale users, the results have broader implications for scalable UAV propulsion systems. The research was conducted within an experimental UAV development framework aimed at optimizing propeller performance through strategic material selection, geometrical design optimization, and additive manufacturing processes. Six propeller variants were manufactured using widely available thermoplastic polymers, including polyethylene terephthalate glycol-modified (PETG) and thermoplastic polyurethane (TPU), as well as photopolymer-based propellers fabricated using vat photopolymerization, also known as digital light processing (DLP). Mechanical and aerodynamic characterizations were performed to assess the structural integrity, flexibility, and performance of each material under dynamic conditions. Two blade configurations, a toroidal propeller with anticipated aerodynamic advantages and a conventional tri-blade propeller (Gemfan 51466-3)—were comparatively analyzed. The primary contribution of this work is the systematic evaluation of performance metrics such as thrust generation, acoustic signature, mechanical strength, and thermal stress imposed on the electrical motor, thereby establishing a benchmark for polymer-based propeller fabrication via additive manufacturing. The findings underscore the potential of polymeric materials and layer-based manufacturing techniques in advancing the design and production of UAV propulsion components. Full article

3D printing has garnered significant attention across academia and industry due to its capability to design and fabricate complex architectures. Applications such as those requiring intricate geometries or custom designs, including footwear, healthcare, energy storage, and electronics applications, greatly benefit from exploiting 3D printing processes. Despite the recent advancement of structural 3D printing, its use in functional devices remains limited, requiring the need for the development of functional materials suitable for 3D printing in device fabrication. In this review, we briefly introduce various 3D printing techniques, including material extrusion and vat polymerization, and highlight the recent advances in 3D printing for energy and biomedical devices. A summary of future perspectives in this area is also presented. By highlighting recent developments and addressing key challenges, this review aims to inspire future directions in the development of functional devices. Full article

Background: Gold nanoparticles can generate heat upon exposure to radiation due to their plasmonic properties, which depend on particle size and shape. This enables precise control over the release of active substances from polymeric pharmaceutical formulations, minimizing side effects and premature release. The technology of 3D printing, especially vat photopolymerization, is valuable for integrating nanoparticles into complex formulations. Method: This study aimed to incorporate gold nanospheres (AuNSs) and nanorods (AuNRs) into polymeric matrices using vat photopolymerization, allowing for controlled drug release with exposure to 532 nm and 1064 nm wavelengths. Results: The AuNSs (27 nm) responded to 532 nm and the NRs (60 nm length, 10 nm width) responded to 1064 nm. Niclosamide was used as the drug model. Ternary blends of Polyethylene Glycol Diacrylate 250 (PEGDA 250), Polyethylene Glycol 400 (PEG 400), and water were optimized using DesignExpert 11 software for controlled drug release upon specific wavelength exposure. Three matrices, selected based on solubility and printability, underwent rigorous characterization. Two materials achieved controlled drug release with specific wavelengths. Bilayer devices combining AuNSs and AuNRs demonstrated selective drug release based on irradiation wavelength. Conclusions: A pharmaceutical device was developed, capable of controlling drug release upon irradiation, with potential applications in treatments requiring delayed administration. Full article

The aim of the study was to investigate the effect of ethanol on the properties of acrylic-urethane resin products obtained by vat photopolymerization using the masked stereolithography method. The effect of alcohol at concentrations of 15, 25, and 35% in the resin on the chemical structure, weight, thickness of the samples, and mechanical properties in static tabltensile tests performed immediately after printing and one month later were studied. The results obtained were evaluated in terms of the use of ethanol as a cosolvent to help load the resin with agomelatine for the potential of obtaining microneedle transdermal systems. It was shown that in terms of stability of properties, the most favorable system was resin with the addition of alcohol at a concentration of 15%. The greatest changes induced by the presence of the solvent in the resin were observed in the case of tensile properties, where the alcohol caused a decrease in the plasticity of the material, reducing the relative elongation at break from 14% for the pure resin to 4% when the alcohol concentration was 35%. Young’s modulus and tensile strength also decreased with the addition of alcohol by 18% and 31%, respectively, for testable samples with the maximum amount of alcohol in the resin. The deterioration in properties is most likely related to the effect of the solvent on the radical polymerization process of the resin, particularly the phenomenon of chain transfer to the solvent, which is important in view of the intended application of the developed material. Full article

Growth in the advancement of 3D printing technology has made it easy to fabricate complicated bio-inspired structures (BISs). In this paper, the sandwich structure of the beetle elytron structure (BES) hollow cylinder, influencing every corner of the honeycomb structure, is designed by considering parameters like the thickness, length, and diameter of the hollow cylinder, with the different ranges taken giving minimum and maximum values in the response surface methodology (RSM). Sandwich structures are fabricated using VAT polymerization technology. A Universal Testing Machine (UTM) tests the fabricated structures for compression, and results are recorded from the tests of each specimen. All specimens’ compressive strength (CS) and energy absorptions (EA) values are calculated. Design parameters at which the energy absorbed and the compression strength are high are evaluated and considered optimal parameters for a specific range of values. Full article

Vat photopolymerization (VP), as an additive manufacturing process, has experienced significant growth due to its high manufacturing precision and excellent surface quality. This method enables the fabrication of intricate shapes and structures while mitigating the machining challenges associated with non-oxide ceramics, which are known for their high hardness and brittleness. Consequently, the VP process of non-oxide ceramics has emerged as a focal point in additive manufacturing research areas. However, the absorption, refraction, and reflection of ultraviolet light by non-oxide ceramic particles can impede light penetration, leading to reduced curing thickness and posing challenges to the VP process. To enhance the efficiency and success rate of this process, researchers have explored various aspects, including the parameters of VP equipment, the composition of non-oxide VP slurries, and the surface modification of non-oxide particles. Silicon carbide and silicon nitride are examples of non-oxide ceramic particles that have been successfully employed in VP process. Nonetheless, there remains a lack of systematic induction regarding the curing mechanisms and key influencing factors of the VP process in non-oxide ceramics. This review firstly describes the curing mechanism of the non-oxide ceramic VP process, which contains the chain initiation, chain polymerization, and chain termination processes of the photosensitive resin. After that, the impact of key factors on the curing process, such as the wavelength and power of incident light, particle size, volume fraction of ceramic particles, refractive indices of photosensitive resin and ceramic particles, incident light intensity, critical light intensity, and the reactivity of photosensitive resins, are systematically discussed. Finally, this review discusses future prospects and challenges in the non-oxide ceramic VP process. Its objective is to offer valuable insights and references for further research into non-oxide ceramic VP processes. Full article

Additive manufacturing has revolutionized manufacturing across a spectrum of industries by enabling the production of complex geometries with unparalleled customization and reduced waste. Beginning as a rapid prototyping tool, additive manufacturing has matured into a comprehensive manufacturing solution, embracing a wide range of materials, such as polymers, metals, ceramics, and composites. This paper delves into the workflow of additive manufacturing, encompassing design, modeling, slicing, printing, and post-processing. Various additive manufacturing technologies are explored, including material extrusion, VAT polymerization, material jetting, binder jetting, selective laser sintering, selective laser melting, direct metal laser sintering, electron beam melting, multi-jet fusion, direct energy deposition, carbon fiber reinforced, laminated object manufacturing, and more, discussing their principles, advantages, disadvantages, material compatibilities, applications, and developing trends. Additionally, the future of additive manufacturing is projected, highlighting potential advancements in 3D bioprinting, 3D food printing, large-scale 3D printing, 4D printing, and AI-based additive manufacturing. This comprehensive survey aims to underscore the transformative impact of additive manufacturing on global manufacturing, emphasizing ongoing challenges and the promising horizon of innovations that could further elevate its role in the manufacturing revolution. Full article

Vat photopolymerization is an additive manufacturing technique that utilizes photosensitive resins to fabricate 3D polymeric objects with high precision. However, these objects often lack mechanical strength. This study investigated the strengthening of a resin based on epoxidized soybean oil acrylate, specifically designed for vat photopolymerization, by the in situ formation of hydroxyapatite nanocrystals. First, a stable alpha tricalcium phosphate (α-TCP)-resin feedstock mixture was developed (~30 vol.% α-TCP), which proved suitable for fabricating monoliths as well as complex triply periodic minimal surface (gyroid, diamond, and Schwarz) porous structures through vat photopolymerization. The results demonstrated that the incorporation of α-TCP particles led to a significant mechanical improvement of the resin. Second, post-printing hydrothermal treatments were utilized to transform the α-TCP particles into hydroxyapatite crystals within the resin. It was observed that the space between hydroxyapatite crystals within the composites was occupied by the cured resin, resulting in a more compact, stronger, and mechanically more reliable material than the porous hydroxyapatite produced by the hydrolysis of α-TCP mixed with water. Moreover, water absorption during the hydrothermal treatments caused the plasticization of the cured resin. As a consequence, the hydroxyapatite-resin composites displayed slightly lower mechanical properties compared to the as-printed α-TCP-resin composite. Full article

The mechanical behaviors of three distinct lattice structures—Diamond, Gyroid, and Schwarz—synthesized through vat polymerization, were meticulously analyzed. This study aimed to elucidate the intricacies of these structures in terms of their stress–strain responses, energy absorption, and recovery characteristics. Utilizing the described experiments and analytical approaches, it was discerned, via the described experimental and analytical procedure, that the AM lattices showcased mechanical properties and stress–strain behaviors that notably surpassed theoretical predictions, pointing to substantial disparities between conventional models and experimental outcomes. The Diamond lattice displayed superior stiffness with higher average loading and unloading moduli and heightened energy absorption and dissipation rates, followed by the Gyroid and Schwarz lattices. The Schwarz lattice showed the most consistent mechanical response, while the Diamond and Gyroid showed capabilities of reaching larger strains and stresses. All uniaxial cyclic compressive tests were performed at room temperature with no dwell times. The efficacy of hyper-elastic-graded models significantly outperformed projections offered by traditional Ashby–Gibson models, emphasizing the need for more refined models to accurately delineate the behaviors of additively manufactured lattices in advanced engineering applications. Full article

Additive manufacturing technologies have developed rapidly in recent decades, pushing the limits of known manufacturing processes. The need to study the properties of the different materials used for these processes comprehensively and in detail has become a primary goal in order to get the best out of the manufacturing itself. The widely used thermoplastic polymer material acrylonitrile butadiene styrene (ABS) was selected in the form of both filaments and ABS-like resins to investigate and compare the mechanical properties through a series of different tests. ABS-like resin material is commercially available, but it is not a sufficiently mechanically studied form of the material, which leads to the rather limited literature. Considering that ABS resin is a declared material that behaves like the ABS filament but in a different form, the objective of this study was to compare these two commercially available materials printed with three different 3D printers, namely Fused Deposition Modelling (FDM), Stereolithography (SLA) and Digital Light Processing (DLP). A total of 45 test specimens with geometries and test protocols conforming to the relevant standards were subjected to a series of tensile, three-point bending and compression tests to determine their mechanical properties. Characterization also included evaluation of morphology with 2D and 3D microscopy, dimensional accuracy of 3D scans, and Shore A hardness of each material and 3D printing process. Tensile testing results have shown that FDM toughness is 40% of the value for DLP. FDM elongation at break is 37% of DLP, while ultimate tensile stress for SLA is 27% higher than FDM value. Elastic modulus for FDM and SLA coincide. Flexure testing results indicate that value of DLP flexural modulus is 54% of the FDM value. SLA strain value is 59% of FDM, and DLP ultimate flexure stress is 77% of the value for FDM. Compression test results imply that FDM specimens absorb at least twice as much energy as vat polymerized specimens. Strain at break for SLA is 72% and strain at ultimate stress is 60% of FDM values. FDM yield stress is 32% higher than DLP value. SLA ultimate compressive stress is half of FDM, while value for DLP compressive modulus is 69% of the FDM value. The results obtained are beneficial and give a more comprehensive picture of the behavior of the ABS polymers used in different forms and different AM processes. Full article

In the present work, the recent advancements in additive manufacturing (AM) techniques for fabricating nanocomposite parts with complex shaped structures are explained, along with defect non-destructive testing (NDT) methods. A brief overview of the AM processes for nanocomposites is presented, grouped by the type of feedstock used in each technology. This work also reviews the defects in nanocomposites that can affect the quality of the final product. Additionally, a detailed description of X-CT, ultrasonic phased array technology, and infrared thermography is provided, highlighting their potential application in non-destructive inspection of nanocomposites in the future. Lastly, it concludes by offering recommendations for the development of NDT methods specifically tailored for nanocomposites, emphasizing the need to utilize NDT methods for optimizing nano-additive manufacturing process parameters, developing new NDT techniques, and enhancing the resolution of existing NDT methods. Full article

Stereolithography additive manufacturing (SLA-AM) can be used to produce ceramic structures by selectively curing a photosensitive resin that has ceramic powder in it. The photosensitive resin acts as a ceramic powder binder, which is burned, and the remaining ceramic part is sintered during post-processing using a temperature–time-controlled furnace. Due to this process, the ceramic part shrinks and becomes porous. Moreover, additive manufacturing leads to the orthotropic behavior of the manufactured parts. This article studies the effect of the manufacturing orientation of ceramic parts produced via SLA-AM on dimensional accuracy. Scaled CAD models were created by including the calculated shrinkage factor. The dimensions of the final sintered specimens were very close to the desired dimensions. As sintering induces porosity and reduces the mechanical strength, in this study, the effect of orientation on strength was investigated, and it was concluded that the on-edge specimen possessed by far the highest strength in terms of both compression and tension. Full article

Digital light processing (DLP) is a vat photopolymerization 3D printing technique with increasingly broad application prospects, particularly in personalized medicine, such as the creation of medical devices. Different resins and printing parameters affect the functionality of these devices. One of the many problems that biomedical implants encounter is inflammation and bacteria growth. For this reason, many studies turn to the addition of antibacterial agents to either the bulk material or as a coating. Zinc oxide nanoparticles (ZnO NPs) have shown desirable properties, including antibacterial activity with negligible toxicity to the human body, allowing their use in a wide range of applications. In this project, we developed a resin of poly(ethylene glycol) diacrylate (PEGDA), a cross-linker known for its excellent mechanical properties and high biocompatibility in a 4:1 weight ratio of monomers to water. The material’s mechanical properties (Young’s modulus, maximum elongation, and ultimate tensile strength) were found similar to those of human cartilage. Furthermore, the ZnO NPs embedding matrix showed strong antibacterial activity against Escherichia coli (E. coli) and Staphylococcus aureus (S.A.). As the ZnO NPs ratio was changed, only a minor effect on the mechanical properties of the material was observed, whereas strong antibacterial properties against both bacteria were achieved in the case of 1.5 wt.% NPs. Full article