Rapid prototyping of multi-scale biomedical microdevices by combining additive manufacturing technologies

The possibility of designing and manufacturing biomedical microdevices with multiple length-scale geometries can help to promote special interactions both with their environment and with surrounding biological systems. These interactions aim to enhance biocompatibility and overall performance by using biomimetic approaches. In this paper, we present a design and manufacturing procedure for obtaining multi-scale biomedical microsystems based on the combination of two additive manufacturing processes: a conventional laser writer to manufacture the overall device structure, and a direct-laser writer based on two-photon polymerization to yield finer details. The process excels for its versatility, accuracy and manufacturing speed and allows for the manufacture of microsystems and implants with overall sizes up to several millimeters and with details down to sub-micrometric structures. As an application example we have focused on manufacturing a biomedical microsystem to analyze the impact of microtextured surfaces on cell motility. This process yielded a relevant increase in precision and manufacturing speed when compared with more conventional rapid prototyping procedures.

Technologische Reife von generativen Herstellungsverfahren für Endanwendungen im Automobilbau

Technische Produktionssysteme und Prozesse - welcher Technologie auch immer - müssen den Bedürfnissen der industriellen Bauteilherstellung für Endanwendungen im Automobilbau entsprechen. Es stellt sich zunächst die Frage, auf welchem technologischen Reifegrad sich die generativen Technologien für den Automobilbau derzeit befinden? Welche außerordentlichen Vorteile können generative Prozessketten gegenüber konventionellen Herstellungsverfahren bieten und welche Hürden müssen genommen werden? Im Vordergrund der Untersuchung steht die Betrachtung von Pre-, In- und Post-Prozessen generativer wie auch konventioneller Produktionsverfahren. Bei der Gegenüberstellung der Prozessketten werden Maßstäbe angesetzt, die derzeit bei der Bauteilherstellung im Automobilbau Gültigkeit haben und auf Kriterien wie Effizienz, Reproduzierbarkeit und Kontrollierbarkeit aufbauen. Schließlich findet eine Einschätzung aus der Perspektive der Technologieintegration in derzeitige Produktionssysteme und Lieferketten statt. Es werden Restriktionen und Handlungsfelder von generativen Prozessen deutlich, die für den Einsatz für Endkunden-Bauteile im Fahrzeugbau behandelt werden müssen.

Technologische Reife von generativen Herstellungsverfahren für Endanwendungen im Automobilbau

Technische Produktionssysteme und Prozesse - welcher Technologie auch immer - müssen den Bedürfnissen der industriellen Bauteilherstellung für Endanwendungen im Automobilbau entsprechen. Es stellt sich zunächst die Frage, auf welchem technologischen Reifegrad sich die generativen Technologien für den Automobilbau derzeit befinden? Welche außerordentlichen Vorteile können generative Prozessketten gegenüber konventionellen Herstellungsverfahren bieten und welche Hürden müssen genommen werden? Im Vordergrund der Untersuchung steht die Betrachtung von Pre-, In- und Post-Prozessen generativer wie auch konventioneller Produktionsverfahren. Bei der Gegenüberstellung der Prozessketten werden Maßstäbe angesetzt, die derzeit bei der Bauteilherstellung im Automobilbau Gültigkeit haben und auf Kriterien wie Effizienz, Reproduzierbarkeit und Kontrollierbarkeit aufbauen. Schließlich findet eine Einschätzung aus der Perspektive der Technologieintegration in derzeitige Produktionssysteme und Lieferketten statt. Es werden Restriktionen und Handlungsfelder von generativen Prozessen deutlich, die für den Einsatz für Endkunden-Bauteile im Fahrzeugbau behandelt werden müssen.

Additive manufacturing of tissues and organs

Additive manufacturing techniques offer the potential to fabricate organized tissue constructs to repair or replace damaged or diseased human tissues and organs. Using these techniques, spatial variations of cells along multiple axes with high geometric complexity in combination with different biomaterials can be generated. The level of control offered by these computer-controlled technologies to design and fabricate tissues will accelerate our understanding of the governing factors of tissue formation and function. Moreover, it will provide a valuable tool to study the effect of anatomy on graft performance. In this review, we discuss the rationale for engineering tissues and organs by combining computer-aided design with additive manufacturing technologies that encompass the simultaneous deposition of cells and materials. Current strategies are presented, particularly with respect to limitations due to the lack of suitable polymers, and requirements to move the current concepts to practical application.

Electrospinning and additive manufacturing : converging technologies

A well-engineered scaffold for regenerative medicine, which is suitable to be translated from the bench to the bedside, combines inspired design, technical innovation and precise craftsmanship. Electrospinning and additive manufacturing are separate approaches to manufacturing scaffolds for a variety of tissue engineering applications. A need to accurately control the spatial distribution of pores within scaffolds has recently resulted in combining the two processing methods, to overcome shortfalls in each technology. This review describes where electrospinning and additive manufacturing are used together to generate new porous structures for biological applications.

Comparative analysis between a CAD model design and physical models obtained by manufacturing additive technologies using optical scan

This article presents a detailed study of the application of different additive manufacturing technologies (sintering process, three-dimensional printing, extrusion and stereolithographic process), in the design process of a complex geometry model and its moving parts. The fabrication sequence was evaluated in terms of pre-processing conditions (model generation and model STL SLI), generation strategy and physical model post-processing operations. Dimensional verification of the obtained models was undertook by projecting structured light (optical scan), a relatively new technology of main importance for metrology and reverse engineering. Studies were done in certain manufacturing time and production costs, which allowed the definition of an more comprehensive evaluation matrix of additive technologies.

Ansätze zum Management der Additive Manufacturing Supply Chain

Da sich Additive Manufacturing (AM) von traditionellen Produktionsverfahren unterscheidet, entstehen neue Möglichkeiten im Produktdesign und im Supply Chain Setup. Die Auswirkungen der Aufhebung traditionellen Restriktionen im Produktdesign werden unter dem Begriff „Design for Additive Manufacturing“ intensiv diskutiert. In gleicher Weise werden durch AM Restriktionen im traditionellen Supply Chain Setup aufgehoben. Insbesondere sind die folgenden Verbesserungen möglich: Reduktion von Losgrössen und Lieferzeiten, bedarfsgerechte Produktion auf Abruf, dezentrale Produktion, Customization auf Ebene Bauteil und kontinuierliche Weiterentwicklung von Bauteilen. Viele Firmen investieren nicht selbst in die AM Technologien, sondern kaufen Bauteile bei Lieferanten. Um das Potential der AM Supply Chain mit Lieferanten umzusetzen, entstehen die folgenden Anforderungen an AM Einkaufsprozesse. Erstens muss der Aufwand pro Bestellung reduziert werden. Zweitens brauchen AM Nutzer einen direkten Zugang zu den Lieferanten ohne Umweg über die Einkaufsabteilung. Drittens müssen geeignete AM Lieferanten einfach identifiziert werden können. Viertens muss der Wechsel von Lieferanten mit möglichst geringem Aufwand möglich sein. Ein mögliche Lösung sind AM spezifische E-Procurement System um diese Anforderungen zu erfüllen

Subtractive and additive manufacturing technology in moulding industry

This report is a review of additive and subtractive manufacturing techniques. This approach (additive manufacturing) has resided largely in the prototyping realm, where the methods of producing complex freeform solid objects directly from a computer model without part-specific tooling or knowledge. But these technologies are evolving steadily and are beginning to encompass related systems of material addition, subtraction, assembly, and insertion of components made by other processes. Furthermore, these various additive processes are starting to evolve into rapid manufacturing techniques for mass-customized products, away from narrowly defined rapid prototyping. Taking this idea far enough down the line, and several years hence, a radical restructuring of manufacturing could take place. Manufacturing itself would move from a resource base to a knowledge base and from mass production of single use products to mass customized, high value, life cycle products, majority of research and development was focused on advanced development of existing technologies by improving processing performance, materials, modelling and simulation tools, and design tools to enable the transition from prototyping to manufacturing of end use parts.

Expanding the Design Space: Forging the Transition from 3D Printing to Additive Manufacturing

Thesis (Master's)--University of Washington, 2016-08

A Study of the State of the Art of Process Planning for Additive Manufacturing

In the manufacturing industry the term Process Planning (PP) is concerned with determining the sequence of individual manufacturing operations needed to produce a given part or product with a certain machine. In this technical report we propose a preliminary analysis of scientific literature on the topic of process planning for Additive Manufacturing (AM) technologies (i.e. 3D printing). We observe that the process planning for additive manufacturing processes consists of a small set of standard operations (repairing, orientation, supports, slicing and toolpath generation). We analyze each of them in order to emphasize the most critical aspects of the current pipeline as well as highlight the future challenges for this emerging manufacturing technology.

AIR SIDE HEAT TRANSFER ENHANCEMENT IN HEAT EXCHANGERS UTILIZING INNOVATIVE DESIGNS AND THE ADDITIVE MANUFACTURING TECHNIQUE

Over the last decade, rapid development of additive manufacturing techniques has allowed the fabrication of innovative and complex designs. One field that can benefit from such technology is heat exchanger fabrication, as heat exchanger design has become more and more complex due to the demand for higher performance particularly on the air side of the heat exchanger. By employing the additive manufacturing, a heat exchanger design was successfully realized, which otherwise would have been very difficult to fabricate using conventional fabrication technologies. In this dissertation, additive manufacturing technique was implemented to fabricate an advanced design which focused on a combination of heat transfer surface and fluid distribution system. Although the application selected in this dissertation is focused on power plant dry cooling applications, the results of this study can directly and indirectly benefit other sectors as well, as the air-side is often the limiting side for in liquid or single phase cooling applications. Two heat exchanger designs were studied. One was an advanced metallic heat exchanger based on manifold-microchannel technology and the other was a polymer heat exchanger based on utilization of prime surface technology. Polymer heat exchangers offer several advantages over metals such as antifouling, anticorrosion, lightweight and often less expensive than comparable metallic heat exchangers. A numerical modeling and optimization were performed to calculate a design that yield an optimum performance. The optimization results show that significant performance enhancement is noted compared to the conventional heat exchangers like wavy fins and plain plate fins. Thereafter, both heat exchangers were scaled down and fabricated using additive manufacturing and experimentally tested. The manifold-micro channel design demonstrated that despite some fabrication inaccuracies, compared to a conventional wavy-fin surface, 15% - 50% increase in heat transfer coefficient was possible for the same pressure drop value. In addition, if the fabrication inaccuracy can be eliminated, an even larger performance enhancement is predicted. Since metal based additive manufacturing is still in the developmental stage, it is anticipated that with further refinement of the manufacturing process in future designs, the fabrication accuracy can be improved. For the polymer heat exchanger, by fabricating a very thin wall heat exchanger (150μm), the wall thermal resistance, which usually becomes the limiting side for polymer heat exchanger, was calculated to account for only up to 3% of the total thermal resistance. A comparison of air-side heat transfer coefficient of the polymer heat exchanger with some of the commercially available plain plate fin surface heat exchangers show that polymer heat exchanger performance is equal or superior to plain plate fin surfaces. This shows the promising potential for polymer heat exchangers to compete with conventional metallic heat exchangers when an additive manufacturing-enabled fabrication is utilized. Major contributions of this study are as follows: (1) For the first time demonstrated the potential of additive manufacturing in metal printing of heat exchangers that benefit from a sophisticated design to yield a performance substantially above the respective conventional systems. Such heat exchangers cannot be fabricated with the conventional fabrication techniques. (2) For the first time demonstrated the potential of additive manufacturing to produce polymer heat exchangers that by design minimize the role of thermal conductivity and deliver a thermal performance equal or better that their respective metallic heat exchangers. In addition of other advantages of polymer over metal like antifouling, anticorrosion, and lightweight. Details of the work are documented in respective chapters of this thesis.

Additive Manufacturing: Current Status and Future Prospects

Part 10: Sustainability and Trust

Processing and additive manufacturing of bones for the teaching of human anatomy

Traditionally, the teaching of human anatomy in health sciences has been based on the use of cadaveric material and bone parts for practical study. The bone materials get deteriorated and hardly mark the points of insertion of muscles. However, the advent of new technologies for 3D printing and creation of 3D anatomical models applied to teaching, has enabled to overcome these problems making teaching more dynamic, realistic and attractive. This paper presents some examples of the construction of three-dimensional models of bone samples, designed using 3D scanners for posterior printing with addition printers or polymer injection printers.

In vitro and in vivo assessment of bioactive composite scaffolds fabricated via additive manufacturing technology

Additive manufacturing (AM) technology was implemented together with new composite material comprising a synthetic materials, namely, polycaprolactone and bioactive glass with the ultimate aim of the production of an off-the-shelf composite bone scaffold product with superior bone regeneration capacity in a cost effective manner. Our studies indicated that the composite scaffolds have huge potential in promoting bone regeneration. It is our contention that owing to the fruits of such innovative efforts, the field of bone regeneration can metamorphose into a technology platform that allows clinicians worldwide to create tissue-engineered bone with economies of scale in the years to come.

Biofabrication of customized bone grafts by combination of additive manufacturing and bioreactor knowhow

This study reports on an original concept of additive manufacturing for the fabrication of tissue engineered constructs (TEC), offering the possibility of concomitantly manufacturing a customized scaffold and a bioreactor chamber to any size and shape. As a proof of concept towards the development of anatomically relevant TECs, this concept was utilized for the design and fabrication of a highly porous sheep tibia scaffold around which a bioreactor chamber of similar shape was simultaneously built. The morphology of the bioreactor/scaffold device was investigated by micro-computed tomography and scanning electron microscopy confirming the porous architecture of the sheep tibiae as opposed to the non-porous nature of the bioreactor chamber. Additionally, this study demonstrates that both the shape, as well as the inner architecture of the device can significantly impact the perfusion of fluid within the scaffold architecture. Indeed, fluid flow modelling revealed that this was of significant importance for controlling the nutrition flow pattern within the scaffold and the bioreactor chamber, avoiding the formation of stagnant flow regions detrimental for in vitro tissue development. The bioreactor/scaffold device was dynamically seeded with human primary osteoblasts and cultured under bi-directional perfusion for two and six weeks. Primary human osteoblasts were observed homogenously distributed throughout the scaffold, and were viable for the six week culture period. This work demonstrates a novel application for additive manufacturing in the development of scaffolds and bioreactors. Given the intrinsic flexibility of the additive manufacturing technology platform developed, more complex culture systems can be fabricated which would contribute to the advances in customized and patient-specific tissue engineering strategies for a wide range of applications.