Casting materials and their application in research and teaching

From a biological point of view, casting refers to filling of anatomical and/or pathological spaces with extraneous material that reproduces a three-dimensional replica of the space. Casting may be accompanied by additional procedures such as corrosion, in which the soft tissue is digested out, leaving a clean cast, or the material may be mixed with radiopaque substances to allow x-ray photography or micro computed topography (µCT) scanning. Alternatively, clearing of the surrounding soft tissue increases transparency and allows visualization of the casted cavities. Combination of casting with tissue fixation allows anatomical dissection and didactic surgical procedures on the tissue. Casting materials fall into three categories namely, aqueous substances (India ink, Prussian blue ink), pliable materials (gelatins, latex, and silicone rubber), or hard materials (methyl methacrylates, polyurethanes, polyesters, and epoxy resins). Casting has proved invaluable in both teaching and research and many phenomenal biological processes have been discovered through casting. The choice of a particular material depends inter alia on the targeted use and the intended subsequent investigative procedures, such as dissection, microscopy, or µCT. The casting material needs to be pliable where anatomical and surgical manipulations are intended, and capillary-passable for ultrastructural investigations.

Experimental studies on the accuracy of wax patterns used in investment casting

Investment casting is often used to produce fully functional prototype components from sacrificial patterns. These patterns (prototypes) may be made using specialized rapid prototyping techniques such as stereolithography or three-dimensional printing. When multiple functional prototypes are required, interim tools for making wax patterns are employed. The objective of this research work was to determine the precision and accuracy of wax patterns produced using several prototype tools. Linear contraction was used to determine the accuracy as a function of the wax injection parameters used in low-pressure injection moulding. Wax patterns were produced using polyurethane and silicone rubber tools. It has been shown that the accuracy of patterns from both tools is similar. However, silicone tools produce patterns with much higher contraction than those produced by polyurethane tools. Unconstrained patterns dimensions contracted as much as 3.44 +/- 0.40 per cent and 1.70 +/- 0.60 per cent for silicone and polyurethane tools respectively. The constrained dimensions contracted by 2.20 +/- 0.20 per cent in the case of silicone tools and 1.40 +/- 0.20 per cent in the case of polyurethane tools.

Inter- and intralaboratory variation of in vitro diffusion cell measurements: An international multicenter study using quasi-standardized methods and materials

In vitro measurements of skin absorption are an increasingly important aspect of regulatory studies, product support claims, and formulation screening. However, such measurements are significantly affected by skin variability. The purpose of this study was to determine inter- and intralaboratory variation in diffusion cell measurements caused by factors other than skin. This was attained through the use of an artificial (silicone rubber) rate-limiting membrane and the provision of materials including a standard penetrant, methyl paraben (MP), and a minimally prescriptive protocol to each of the 18 participating laboratories. Standardized calculations of MP flux were determined from the data submitted by each laboratory by applying a predefined mathematical model. This was deemed necessary to eliminate any interlaboratory variation caused by different methods of flux calculations. Average fluxes of MP calculated and reported by each laboratory (60 +/- 27 mug cm(-2) h(-1), n = 25, range 27-101) were in agreement with the standardized calculations of MP flux (60 +/- 21 mug cm(-2) h(-1), range 19-120). The coefficient of variation between laboratories was approximately 35% and was manifest as a fourfold difference between the lowest and highest average flux values and a sixfold difference between the lowest and highest individual flux values. Intra-laboratory variation was lower, averaging 10% for five individuals using the same equipment within a single laboratory. Further studies should be performed to clarify the exact components responsible for nonskin-related variability in diffusion cell measurements. It is clear that further developments of in vitro methodologies for measuring skin absorption are required. (C) 2005 Wiley-Liss, Inc.

An investigation into the network structures of eThylene propylene terpolymer elastomers

A series of ethylene propylene terpolymer vulcanizates, prepared by varying termonomer type, cure system, cure time and cure temperature, are characterized by determining the number and type of cross-links present. The termonomers used represent the types currently available in commercial quantities. Characterization is carried out by measuring the C1 constant of the Mooney Rivlin Saunders equation before and after treatment with the chemical probes propane-2-thiol/piperidine and n-hexane thiol/piperidine, thus making it possible to calculate the relative proportions of mono-sulphidic, di-sulphidic and poly- sulphidic cross-links. The cure systems used included both sulphur and peroxide formulations. Specific physical properties are determined for each network and an attempt is made to correlate observed changes in these with variations in network structure. A survey of the economics of each formulation based on a calculated efficiency parameter for each cure system is included. Values of C1 are calculated from compression modulus data after the reliability of the technique when used with ethylene propylene terpolymers had been established. This is carried out by comparing values from both compression and extension stress strain measurements for natural rubber vulcanizates and by assessing the effects of sample dimensions and the degree of swelling. The technique of compression modulus is much more widely applicable than previously thought. The basic structure of an ethylene propylene terpolymer network appears to be independent of the type of cure system used ( sulphur based systems only), the proportions of constituent cross-links being nearly constant.

Application of long-period-grating sensors to respiratory plethysmography

A series of in-line curvature sensors on a garment are used to monitor the thoracic and abdominal movements of a human during respiration. These results are used to obtain volumetric tidal changes of the human torso in agreement with a spirometer used simultaneously at the mouth. The curvature sensors are based on long-period gratings (LPGs) written in a progressive three-layered fiber to render the LPGs insensitive to the refractive index external to the fiber. A curvature sensor consists of the fiber long-period grating laid on a carbon fiber ribbon, which is then encapsulated in a low-temperature curing silicone rubber. The sensors have a spectral sensitivity to curvature, d lambda/dR from similar to 7-nm m to similar to 9-nm m. The interrogation technique is borrowed from derivative spectroscopy and monitors the changes in the transmission spectral profile of the LPG's attenuation band due to curvature. The multiplexing of the sensors is achieved by spectrally matching a series of distributed feedback (DFB) lasers to the LPGs. The versatility of this sensing garment is confirmed by it being used on six other human subjects covering a wide range of body mass indices. Just six fully functional sensors are required to obtain a volumetric error of around 6%. (C) 2007 Society of Photo-Optical Instrumentation Engineers.

An optical fiber Bragg grating tactile sensor

Tactile sensors are needed for many emerging robotic and telepresence applications such as keyhole surgery and robot operation in unstructured environments. We have proposed and demonstrated a tactile sensor consisting of a fibre Bragg grating embedded in a polymer "finger". When the sensor is placed in contact with a surface and translated tangentially across it measurements on the changes in the reflectivity spectrum of the grating provide a measurement of the spatial distribution of forces perpendicular to the surface and thus, through the elasticity of the polymer material, to the surface roughness. Using a sensor fabricated from a Poly Siloxane polymer (Methyl Vinyl Silicone rubber) spherical cap 50 mm in diameter, 6 mm deep with an embedded 10 mm long Bragg grating we have characterised the first and second moment of the grating spectral response when scanned across triangular and semicircular periodic structures both with a modulation depth of 1 mm and a period of 2 mm. The results clearly distinguish the periodicity of the surface structure and the differences between the two different surface profiles. For the triangular structure a central wavelength modulation of 4 pm is observed and includes a fourth harmonic component, the spectral width is modulated by 25 pm. Although crude in comparison to human senses these results clearly shown the potential of such a sensor for tactile imaging and we expect that with further development in optimising both the grating and polymer "finger" properties a much increased sensitivity and spatial resolution is achievable.

Respiratory monitoring using fibre long period grating sensors

We demonstrate the use of a series of in-line fibre long period grating curvature sensors on a garment, used to monitor the thoracic and abdominal volumetric tidal movements of a human subject. These results are used to obtain volumetric tidal changes of the human torso showing reasonable agreement with a spirometer used simultaneously to record the volume at the mouth during breathing. The curvature sensors are based upon long period gratings written in a progressive three layered fibre that are insensitive to refractive index changes. The sensor platform consists of the long period grating laid upon a carbon fibre ribbon, which is encapsulated in a low temperature curing silicone rubber.

Application of long period gratings sensors to respiratory function monitoring

A series of in-line curvature sensors on a garment are used to monitor the thoracic and abdominal movements of a human during respiration. These results are used to obtain volumetric tidal changes of the human torso showing reasonable agreement with a spirometer used simultaneously to record the volume at the mouth during breathing. The curvature sensors are based upon long period gratings written in a progressive three layered fibre that are insensitive to refractive index changes. The sensor platform consists of the long period grating laid upon a carbon fibre ribbon, which is encapsulated in a low temperature curing silicone rubber. An array of sensors is also used to reconstruct the shape changes of a resuscitation manikin during simulated respiration. The data for reconstruction is obtained by two methods of multiplexing and interrogation: firstly using the transmission spectral profile of the LPG's attenuation bands measured using an optical spectrum analyser; secondly using a derivative spectroscopy technique.

Highly sensitive liquid level monitoring system utilizing polymer fiber Bragg gratings

A novel and highly sensitive liquid level sensor based on a polymer optical fiber Bragg grating (POFBG) is experimentally demonstrated. Two different configurations are studied and both configurations show the potential to interrogate liquid level by measuring the strain induced in a POFBG embedded in a silicone rubber diaphragm, which deforms due to hydrostatic pressure variations. The sensor exhibits a highly linear response over the sensing range and a good repeatability. For comparison, a similar sensor using a FBG inscribed in silica fiber is fabricated, which displays a sensitivity that is a factor of 5 smaller than the POFBG. The temperature sensitivity is studied and a novel multi-sensor arrangement proposed which has the potential to provide level readings independent of temperature and the liquid density.

Application of long-period-grating sensors to respiratory plethysmography

A series of in-line curvature sensors on a garment are used to monitor the thoracic and abdominal movements of a human during respiration. These results are used to obtain volumetric tidal changes of the human torso in agreement with a spirometer used simultaneously at the mouth. The curvature sensors are based on long-period gratings (LPGs) written in a progressive three-layered fiber to render the LPGs insensitive to the refractive index external to the fiber. A curvature sensor consists of the fiber long-period grating laid on a carbon fiber ribbon, which is then encapsulated in a low-temperature curing silicone rubber. The sensors have a spectral sensitivity to curvature, dλ/dR from ∼7-nm m to ∼9-nm m. The interrogation technique is borrowed from derivative spectroscopy and monitors the changes in the transmission spectral profile of the LPG's attenuation band due to curvature. The multiplexing of the sensors is achieved by spectrally matching a series of distributed feedback (DFB) lasers to the LPGs. The versatility of this sensing garment is confirmed by it being used on six other human subjects covering a wide range of body mass indices. Just six fully functional sensors are required to obtain a volumetric error of around 6%. © 2007 Society of Photo-Optical Instrumentation Engineers.

Fiber-optic liquid level monitoring system using microstructured polymer fiber Bragg grating array sensors:performance analysis

A highly sensitive liquid level monitoring system based on microstructured polymer optical fiber Bragg grating (mPOFBG) array sensors is reported for the first time. The configuration is based on five mPOFBGs inscribed in the same fiber in the 850 nm spectral region, showing the potential to interrogate liquid level by measuring the strain induced in each mPOFBG embedded in a silicone rubber (SR) diaphragm, which deforms due to hydrostatic pressure variations. The sensor exhibits a highly linear response over the sensing range, a good repeatability, and a high resolution. The sensitivity of the sensor is found to be 98 pm/cm of water, enhanced by more than a factor of 9 when compared to an equivalent sensor based on a silica fiber around 1550 nm. The temperature sensitivity is studied and a multi-sensor arrangement proposed, which has the potential to provide level readings independent of temperature and the liquid density.

Aviation fuel gauging sensor utilizing multiple diaphragm sensors incorporating polymer optical fiber Bragg gratings

A high-performance fuel gauging sensor is described that uses five diaphragm-based pressure sensors, which are monitored using a linear array of polymer optical fiber Bragg gratings. The sensors were initially characterized using water, revealing a sensitivity of 98 pm/cm for four of the sensors and 86 pm/cm for the fifth. The discrepancy in the sensitivity of the fifth sensor has been explained as being a result of the annealing of the other four sensors. Initial testing in JET A-1 aviation fuel revealed the unsuitability of silicone rubber diaphragms for prolonged usage in fuel. A second set of sensors manufactured with a polyurethane-based diaphragm showed no measurable deterioration over a three month period immersed in fuel. These sensors exhibited a sensitivity of 39 pm/cm, which is less than the silicone rubber devices due to the stiffer nature of the polyurethane material used.

Molecular breakdown of different forms of natural rubber and its influence on properties of their mixes and vulcanizates

The forms of natural rubber studied were sheet [RSS 4 and RSS 5], ISNR 20 and EBC. In the case of the latter two forms samples from estate and nonestate sectors were included. The samples were collected from different locations at specified intervals, for a particular period. The effect of the extent of mastication on raw rubber properties as well as the properties of the compounds and vulcanizates also studied. The consistency in raw rubber properties and breakdown behavior of skim rubber were studied by collecting samples periodically from selected processing units. The effect of incorporation of skim with ISNR 20 has also been investigated

Conductive composites of natural rubber and carbon black for pressure sensors

Composites of natural rubber and carbon black have attracted great interest due to their technological applications. In this work natural rubber (NR) and carbon black (CB) were compounded, aiming the development of composites with good mechanical properties, processability and electrical conductivity for use as pressure sensors. The electrical conductivity changes from 10(-11) to 10(-2) S.cm(-1) depending on the percentage of CB in the composite. It was also observed that the conductivity varies reversibly and linearly with the applied pressure. The latter demonstrates that this material can be used as pressure sensors.

Radiopaque materials from natural polymers: Special emphasis on chitosan and natural rubber

The present work is to impart radiopacity in various natural polymers like chitosan, natural rubber and derivatives of chitosan and to characterize it. This thesis collated the radiopaque properties of these radiopaque polymers and various technological applications in the medical field. The applications of radiopaque polymers leads to an exploitation of radiopaque properties like X-ray visibility, optical density, effective atomic number, attenuation coefficient of biopolymers like chitosan, chitosan formate, chitosan acetate, carboxy methyl chitosan and natural rubber. The radiopaqe properties of these materials highly depend upon the size, shape, amount of radiopacifier and crystallinity of the radiopaque material. Radiopaque chitosan microspheres were prepared by cross linking with glutaraldehyde followed by the encapsulation of barium sulpahte. The effect of different emulsion systems on the morphology of chitosan microspheres were studied. The study concentrates radiopaque natural rubber for shielding applications. It reveals that to improve the particle size, morphology and crystalline phase of the zinc oxide particles, a novel method for the preparation of zinc oxide is adopted. A detailed radiopacity study was done in natural rubber containing 100phr precipitated zinc oxide prepared from different zinc salts. One of the significant findings of this investigation is that NR vulcanizates containing precipitated zinc oxide (from zinc acetate) shows higher attenuation coefficient. These interesting findings reveal the applications of these natural radiopaque systems in various fields like surgical tools, medical tubings, catheters, radiation shielding,etc.