The powder bed fusion (PBF) metal additive manufacturing (AM) method uses an energy source like a laser to melt the metal powders. The laser can locally melt the metal powders and creates a solid structure as it moves. The complexity of the heat distribution in laser PBF metal AM is one of the main features that need to be accurately addressed and understood to design and manage an optimized printing process. In this research, the dependency of local thermal rates and gradients on print after solidification (in the heat-affected zone) was numerically simulated and studied to provide information for designing the print process. The simulation results were validated by independent experimental results. The simulation shows that the local thermal rates are higher at higher laser power and scan speed. Also, the local thermal gradients increase if the laser power increases. The effect of scan speed on the thermal gradients is opposite during heating versus cooling times. Increasing the scan speed increases the local thermal gradients in the cooling times and decreases the local thermal gradients during the heating. In addition, these simulation results could be used in artificial intelligence (AI) and machine learning for developing digital additive manufacturing.

In recent years, Additive Manufacturing (AM), commonly referred to as 3D printing, has garnered the attention of the scientific community due to its capacity to transform ordinary and traditional items into customized materials at an affordable cost, through various AM processes. Antimicrobial/antibiofilm 3D printed materials are one of the most trending research topics, owing to the growing concerns over the emergence of complex microbial structures called "biofilms" on various surfaces. The review provides an overview of the evolution of additive manufacturing (AM) technologies and their various derivatives, along with a brief description of their materials and applications. It also introduces how biofilms can represent an advantageous lifestyle for microbial populations. The primary objective of this research was to conduct a systematic review on the development of planctonic or biofilm forms of microorganisms on 3D printed materials. The article summarizes commonly studied microorganisms on these materials and presents their 3D printing process, materials, as well as the fields covered by each of the analyzed papers. To the best of our knowledge, this is the first all-inclusive systematic review that amalgamated research conducted in diverse fields to assess the development of biofilms on surfaces produced through three-dimensional printing. Most notably, this review presents a comprehensive account of sustainable approaches for producing antimicrobial materials through 3D printing. Additionally, we assess their advancements in various fields such as medicine, environment, agri-food, and other relevant sectors. The findings of our literature review can be used to recommend appropriate microorganisms, 3D printing materials, and technologies for academic and industrial research purposes focusing on the development of microbial biofilms on 3D printed surfaces. Furthermore, it highlights the potential of environmentally-friendly modified AM technologies to combat biofilms in clinical and non-clinical areas. Our goal with this review is to help readers gain a better understanding of fundamental concepts, inspire new researchers, and provide valuable insights for future empirical studies focused on eradicating biofilms from 3D printed materials.

Design for Manufacture and Assembly (DfMA) in architectural, engineering, and construction (AEC) industry is attracting the attention of designers, practitioners, and construction project stakeholders. Digital fabrication (Dfab) and design for additive manufacturing (DfAM) practices are found in current needs for further research and development. The DfMA's conceptual function is to maximize the process efficiency of Dfab and AM building projects. This work reviewed 171 relevant research articles over the past few decades. The concept of DfMA and the fundamentals of DfMA in building and construction were explored. In addition, DfMA procedures associated with Dfab and DfAM, as well as its AM assembly process, were discussed. Lastly, the current machine learning research on DfMA in construction was also highlighted. Large research gaps in the DfMA for Dfab and DfAM can be filled to increase operational efficiency and sustainable practices.

Open-source 3-D printing has played a pivotal role in revolutionizing the additive manufacturing (AM) landscape, by making distributed manufacturing economic, democratizing access, and fostering far more rapid innovation than antiquated proprietary systems. Unfortunately, some 3-D printing manufacturing companies began deviating from open-source principles and violating licenses for the detriment of the community. To determine if a pattern has emerged of companies patenting clearly open-source innovations, this study presents three case studies from the three primary regions of open-source 3-D printing development (EU, U.S. and China) as well as three aspects of 3-D printing technology (AM materials, an open-source 3-D printer, and core open-source 3-D printing concepts used in most 3-D printers). The results of this review have shown that non-inventing entities called patent parasites are patenting open-source inventions already well-established in the open source community and in the most egregious cases commercialized by one (or several) firms at the time of the patent filing. Patent parasites are able to patent open-source innovations by using a different language, vague patent titles and broad claims that encompass enormous swaths of widely diffused open-source innovation space. This practice poses a severe threat to innovation and several approaches to irradicate the threat are discussed.

Additive manufacturing (AM) is an attractive technology for manufacturing industry due to flexibility in design and functionality, but inconsistency in quality is one of the major limitations that does not allow utilizing this technology for production of end-use parts. Prediction of mechanical properties can be one of the possible ways to improve the repeatability of the results. The part placement, part orientation, and STL model properties (number of mesh triangles, surface, and volume) are used to predict tensile modulus, nominal stress and elongation at break for polyamide 2200 (also known as PA12). EOS P395 polymer powder bed fusion system was used to fabricate 217 specimens in two identical builds (434 specimens in total). Prediction is performed for XYZ, XZY, ZYX, and Angle orientations separately, and all orientations together. The different non-linear models based on machine learning methods have higher prediction accuracy compared with linear regression models. Linear regression models have prediction accuracy higher than 80% only for Tensile Modulus and Elongation at break in Angle orientation. Since orientation-based modeling has low prediction accuracy due to a small number of data points and lack of information about material properties, these models need to be improved in the future based on additional experimental work.

Methacrylated silk (Sil-MA) is a chemically modified silk fibroin specifically designed to be crosslinkable under UV light. This allows the structuring of this material throught additive manufacturing techniques and then to easily prototype patient specific construct. In this study we used Sil-MA to produce single layer crosslinked structures that can be withdrawal and ejected recovering their shape after rehydration. A complete chemical and physical characterization of the material has been conducted. Additionally, we tested the material biocompatibility according to the International Standard Organization protocols (ISO 10993) ensuring the possibility to use it in future trials. The material was also tested to verify its ability to support the osteogenesis. Two different additive manufacturing techniques have been tested (a Digital Light Processing (DLP) UV projector and a pneumatic extrusion technique) to develop Sil-MA grid. Finally, we provide a proof-of-concept that the printed Sil-MA structures are injectable.

17-4PH steel is a widely used grade for precipitation hardening. The growing demand for modern materials with high corrosion and tribological resistance has led to its increased use for the production of medical devices. With additive manufacturing (AM), complex functional shapes can be achieved for medical applications. Direct laser metal sintering (DMLS) technology makes it possible to obtain products with complex architectures, but it also faces various challenges, including imperfections in the surface layer of products due to the use of 3D printing technology itself. This study analyzed the abrasive wear resistance in 0.9% NaCl solution of 17-4PH steel produced by DMLS technology. In order to improve the properties of the surface layer after 3D printing and to improve the tribological wear resistance of the steel, a shot peening (SP) process using CrNi shot and ceramic beads (based on ZrO2) was applied. The chemical and phase composition of the materials obtained, Vickers hardness, surface roughness, and microscopic and SEM imaging were investigated. Tribological tests were carried out using the ball-on-disc method, and the surfaces that showed traces of abrasion to identify wear mechanisms were subjected to SEM analysis. The chemical composition was in accordance with the EOS manufacturer's declarations, and the presence of austenite and martensite was found in the post-production state, while a higher content of martensitic phase was found in the case of peened samples due to phase transformations. The surface hardness of the peened samples increased more than twice, and the post-treatment roughness increased by 12.8% after peening CrNi steels and decreased by 7.8% after peening ZrO2 relative to reference surfaces. Roughness has an identifiable effect on sliding wear resistance. Higher roughness promotes material loss. After the SP process, the coefficient of friction increased by 15.5% and 20.7%, while the wear factor (K) decreased by 25.9% and 32.7% for the samples peened with CrNi steels and ZrO2, respectively. Abrasive and adhesive mechanism were dominant featured with slight fatigue. The investigation showed a positive effect of SP on the tribological properties of DMSL 17-4PH.

3D printing with cement-based materials is a promising manufacturing technique for civil engineering applications that already allows for the design and the construction of complex and highly customized structures using a layer-by-layer deposition approach. Usually, in this type of additive manufacturing, a mixture of cement, water, aggregate and additives is extruded through a specific print head and deposited in successive layers to form the desired shape. The extrusion mechanism is one of the most expensive parts of the 3D printer. Also, for low scale 3D printers, based on the shape of the extruder and the geometry limitation of the mixing blade, the 3D mixture is often limited to a narrow range of materials due to the risk of layer splitting or blockage. Therefore, there is a need to develop affordable and feasible alternatives to the current design-fabrication-application approach of 3D printers. In this paper, various new designed mixtures of fiber reinforced mortars that can be 3D printed using only a commercially available screw pump are analyzed based on their fresh properties and mechanical characteristics. The reduced facility requirements in this approach allow 3D-printing to be more available for civil engineering applications. With further innovation in the future, this method and mixtures can be extended for sustainable and economically feasible printing of single-family housing units.

Hybrid manufacturing processes that combine additive and machining operations are gaining relevance in modern industry thanks to the capability of building complex parts with minimum material and, many times, with process time reduction. Besides, as the additive and subtractive operations are carried out in the same machine, without moving the part, dead times are reduced and higher accuracies are achieved. However, it is not clear whether the direct material deposition after the machining operation is possible or intermediate cleaning stages are required because of the possible presence of residual cutting fluids. Therefore, different LMD tests are performed on a part impregnated with cutting fluid, both directly and after the removal of the coolant by techniques such as laser vaporizing and air blasting. The present work studies the influence of the cutting fluid in the LMD process and the quality of the resulting part. Resulting porosity is evaluated and it is concluded that if the part surface is not properly clean after the machining operation, deficient clad quality can be obtained in the subsequent laser additive operation.

To improve accessibility, this article describes a static, four-legged, walker that can be constructed from materials and fasteners commonly available from hardware stores coupled by open-source 3-D printed joints. The designs are described in detail, shared under an open-source license, and fabricated with a low-cost open-source desktop 3-D printer and hand tools. The resulting device is loaded to failure to determine the maximum load that the design can safely support in both vertical and horizontal failure modes. The experimental results showed the average vertical failure load capacity was 3680±694.3N, equivalent to 375.3±70.8kg of applied weight with the fractured location at the wood dowel handlebars. The average horizontal load capacity was 315.6±49.4N, equivalent to 32.2±5.1kg. The maximum weight capacity of a user of 187.1±29.3kg was obtained, which indicates the open-source walker design can withstand the weight requirements of all genders with a 95% confidence interval that includes a safety factor of 1.8 when considering the lowest deviation weight capacity. The design has a cost at the bottom of the range of commercial walkers and reduces the mass compared to a commercial walker by 0.5kg (19% reduction). It can be concluded that this open-source walker design can aid accessibility in low-resource settings.

Electronic devices are sensitive to electromagnetic (EM) emissions requiring electromagnetic shielding protection to assure good operation, preventing noise, malfunctioning, or even burning. To assure protection, it is important to develop suitable material and design solutions for electronic enclosures. Most common enclosures are made with metal alloys by traditional manufacturing methods. However, resourcing to thermoplastic composites combined with additive manufac-turing (AM) technologies emerges as an alternative that enables to fabricate complex parts that are lightweight, consolidated and oxidation and corrosion resistant. In this research, an AM technique based in material extrusion was used to print 2 mm thick specimens with a multi-material made of micro-carbon fiber (CF) filled polyamide, reinforced, at specific layers, by continuous carbon fibers stacked with a 90° rotation to each other. Specimens electromagnetic shielding effectiveness (EMSE) was evaluated in the frequency band of 0.03 – 3 GHz by coaxial transmission line method. De-pending on the number of CF layers, the EM shielding obtained can up to 70 dB, with a specific shielding up to 60 dB.cm3/g, predominantly by absorption mechanism, being 22 times higher that without the CF layers. These findings fundament this innovative approach for lightweight cus-tomizable solutions for EM shielding applications.

The use of commodity polymers such as polypropylene (PP) is key to open new market segments and applications for the additive manufacturing industry. Technologies such as powder-bed fusion (PBF) can process PP powder; however, much is still to learn concerning process parameters for reliable manufacturing. This study focusses in the process-property relationships of PP using laser-based PBF. The research presents an overview of the intrinsic and the extrinsic characteristic of a commercial PP powder as well as fabrication of tensile specimens with varying process parameters to characterize tensile, elongation at break, and porosity properties. The impact of key process parameters, such as power and scanning speed are systematically modified in a controlled design of experiment. The results were compared to the existing body of knowledge; the outcome is to present a process window and optimal process parameters for industrial use of PP. The computer tomography data revealed a highly porous structure inside specimens ranging between 8.46% and 10.08%, with porosity concentrated in the interlayer planes in the build direction. The results of the design of experiment for this commercial material show a narrow window of 0.122 ≥ Ev ≥ 0.138 J/mm³ led to increased mechanical properties while maintaining geometrical stability.

This research focused on the perception of visually impaired individuals regarding tactile image creation using 3D printing. We developed and applied an experiment with 28 participants with visual impairments. They performed tasks based on skills whose foundations are needed and used in their daily lives, such as scanning, tactile discrimination, picture and spatial comprehension. The tactile images used in this study were developed by additive manufacturing and printed over 180 g/m² sulphite paper. The best performances were obtained when (1) the tactile image contour line heights were between 0.2 mm and 0.4 mm; and (2) the texture presented densities between 10% and 50%, when alone, or between 10% and 90%, when combined with another texture. The tested line widths (0.8 mm and 1.2 mm) did not present statistically significant differences in the results. Vision status (low vision or blindness) and moment of vision loss (congenital or late blind) did not influence the results. Schooling affected the activities of identifying objects and locating their copies. In the Conclusion section, there is a detailed recommendation list for the production and application of tactile materials, which range from simplifying forms to encouraging the use of both hands during content assimilation.

A chairside polishing kit is an alternative to a laboratory polishing technique. This study aimed to evaluate the effects of different polishing techniques on the surface roughness of three-dimensional (3D)-printed acrylic denture bases (ADB). One hundred twenty disc-shaped specimens were fabricated from one conventional heat-polymerized (HP) ADB resin and two 3D-printed (Asiga (AS) and NextDent (ND)) ADB resins (n=40 per ADB resin). Each group was furtherly divided based on the polishing protocol (n=10) as follows: convectional polishing protocol (C), Microdont chairside polishing kit (M), Shofu chairside polishing kit (S), and unpolished group (U). The surface roughness (surface roughness average (Ra) and average maximum profile height (Rz)) of the printed specimens were measured using an optical profilometer, and the scanning electron microscope (SEM) was used to capture the surface at ×1000. Two-way ANOVA and post hoc tests were used for data analysis (α = 0.05) at significant levels. In unpolished groups, there was a statically significant difference between HP vs 3D-printed ADBs (p < 0.0001). For Ra values, the lowest values were presented in HP-C, AS-S, and ND-C. While the highest values were shown in all unpolished groups. Within the material, there were statistically significant differences between the three polishing protocols (C, M, and S) vs unpolished (p < 0.0001), while there was no significant between C, M, and S groups (p = 0.05). The Rz values had the same pattern as the Ra values. The two chairside polishing kits were comparable to conventional polishing technique, and it could be recommended for the clinical application.

In this research, a screw-barrel system was designed and implemented, coupled with material extrusion, to print high-melt-temperature thermoplastic materials. The aim was to integrate two methods: the direct extrusion of thermoplastic polymer pellets with material extrusion,utilize various polymers in the form of pellets, especially high melt temperature ones, instead of traditional filaments. This addresses one of the significant challenges in filament preparation for various materials that are not readily available in the market or nearly impossible to fabricate (such as highly filled plastics). First, the screw-barrel assembly performance and factors influencing feed rate were evaluated. Subsequently, specimens were printed with polyether ether ketone (PEEK), an advanced plastic material known for its outstanding mechanical properties, high-temperature tolerance, and broad applications in various sectors, such as medical. Additionally, the material was reinforced with 2.5% continuous glass fibers while printing, which presented a novel product. Upon comparing theoretical values with experimental data from the tensile testing, a notable observation emerged: the inclusion of 2.5% glass fibers led to an approximate 43% increase in the tensile strength of the material. Furthermore, SEM images provided visual evidence of satisfactory adhesion between layers and fibers.

The extrusion-based additive manufacturing is a popular fabrication method, which has attracted the attention of various industries due to its simplicity, cheapness, ability to produce complex geometric shapes, and high production speed. One of the effective parameters in this process is the feed of filament that is presented in the production G-code. The feed of filament is calculated according to the layer height, the extrusion width and the length of printing path. All the required motion paths and filling patterns created by commercial software are a set of straight lines or circular arcs that are placed next to each other at a fixed distance. In special curved paths, the distance of adjacent ones is not equal at different points, and due to the weakness of common commercial software, it is not possible to create curved paths for proper printing. Therefore, making a special computer code that can be used to create various functions of curved paths is investigated in this research, and also the feed of filament parameter is studied in detail. Next, by introducing a correction technique, the feed of filament is changed during the curved path to distribute the polymer material uniformly. Finally, composite samples (which have variable stiffness) consisting of curved fibers are produced with the proposed method, and the high quality of printed samples confirm the suggested code and technique.

Thermal sterilization is generally avoided for 3-D printed components because of the relatively low deformation temperatures for common thermoplastics used for material extrusion-based additive manufacturing. 3-D printing materials required for high-temperature heat sterilizable components for COVID-19 and other applications demands 3-D printers with heated beds, hot ends that can reach higher temperatures than polytetrafluoroethylene (PTFE) hot ends and heated chambers to avoid part warping and delamination. There are several high temperature printers on the market, but their high costs make them inaccessible for full home-based distributed manufacturing required during pandemic lockdowns. To allow for all these requirements to be met for under $1,000, the Cerberus – an open source three-headed self-replicating rapid prototyper (RepRap) was designed and tested with the following capabilities: i) 200^oC-capable heated bed, ii) 500^oC-capabel hot end, iii) isolated heated chamber with 1kW space heater core and iv) mains voltage chamber and bed heating for rapid start. The Cereberus successfully prints polyetherketoneketone (PEKK) and polyetherimide (PEI, ULTEM) with tensile strengths of 77.5 and 80.5 MPa, respectively. As a case study, open source face masks were 3-D printed in PEKK and shown not to warp upon widely home-accessible oven-based sterilization.

Additive Manufacturing (AM) has been proving suitable to support or even replace traditional manufacturing in several industries, offering many advantages such as delivery time and reduction in terms of material waste, energy consumption and greenhouse gas (GHG) emissions. This study aimed to carry out a comparative assessment of the life cycle, from gate to gate, in the production of a low alloy carbon steel flange part using ER-90 wire. The methods utilized were Wire and Arc Additive Manufacturing (WAAM) and conventional manufacturing (CM) by forging, and comparative factors were energy demands, GHG emissions and generated solid waste. The total energy consumption in WAAM was 10,239.40 MJ, total carbon footprint in CO2 equivalent (CO2e) was 714.1 kgCO2e kg-1, and generated solid waste was 68.6 kg, respectively, 90%, 95% and 76% lower than consumption calculated in conventional manufacturing.

Laser metal deposition with wire (LMD-w) is a developing additive manufacturing (AM) technology that has a high deposition material rate and efficiency, and is suitable for fabrication of large aerospace components. However, control of material properties, geometry, and residual stresses is needed before LMD-w technology can be widely adopted for the construction of critical structural components. In this study, we investigated the effect of interlayer cooling time, clamp constraints, and tool path strategy on part distortion and residual stresses in large-scale laser additive manufactured Ti-6Al-4V components using finite element method (FEM). The simulations were validated with the temperature and the distortion measurements obtained from a real LMD-w process. We found that a shorter interlayer cooling time, full clamping constraints on the build plates, and a bidirectional tool path with 180⁰ rotation minimized part distortion and residual stresses and resulted in symmetric stress distribution.

In the past few years, cloud-based additive manufacturing has shown its application and potential in industries. For this reason, when the demand for cloud-based additive products increases, efficient scheduling of related tasks becomes more important to achieve optimized duration. This research proposes a Heuristic Scheduling Algorithm (HSA) for use in Cloud-Based Additive Manufacturing (CBAM) with an approach to Critical Chain Buffer Management (CC/BM). This research aims to schedule and optimize the time in cloud-based additive manufacturing, in addition to the parts production process, it also includes the steps of receiving online orders and informing the manufacturing unit and sending them to the customer. The HSA proposed in this research consists of three phases 1- Buffer sizing, 2- Additive manufacturing and logistics scheduling, and 3- Buffer controlling. To evaluate, the performance of the algorithm is simulated. The finding shows that the proposed HAS can effectively solve the CBAM scheduling problem.

Ledge formation presents a significant challenge in endodontic treatment. Yet, there is still a lack of educational tooth models for hands-on practice. This study aimed to create and evaluate a tooth model for ledge management practice. A natural tooth with curved roots was collected for scientific use under ethics committee approval. Following initial root canal preparation, the tooth was scanned using micro-computed tomography (μCT) and 3D reconstructed. A K-file, created via computer-aided design (CAD), was partly inserted into the root canal wall of the 3D-reconstructed tooth. By subtracting the K-file from the tooth, a tooth model with a root canal ledge was produced. The models were then 3D printed for a hands-on workshop. A seven-item Likert scale questionnaire was administered to 20 postgraduate students and 10 endodontists to assess the model's quality and training effectiveness. The feedback from both students and experts was positive, with no statistically significant differences found between the two groups (p > 0.05). This novel tooth model is expected to address the existing gap in endodontic education and provide benefits for dental practitioners in future applications.

The parts obtained by FFF technology are anisotropic in any direction; while the whole part constitutes out of layers, each of the layers include one or more perimeters of shell and the infill with density from 0 to 100%. Mechanical performance of FFF parts depends on its shape, orientation, constitution and 3D printing parameters. A classification for shapes of parts obtained by FFF and stressed during its operation is provided. For the most questionable class (parts with interrupted shell critically stressed on interlayer boundaries) a representative sample and testing apparatus is developed. Different approaches to the sample shape modification were applied and tested. The part shape optimization resulted in increment of the force, required to fracture the part from 483 to 1096 N.

Three-dimensional (3D) printing technologies are transforming the design and manufacture of components and products across a variety of disciplines, however their application in the construction industry is still limited. Material deposition processes can achieve infinite geometries and have advanced from rapid prototyping and model-scale markets to their application in fabricating functional products, large objects and the construction of full-scale buildings. Many international projects have recently been realized and the construction industry is beginning to utilise these dynamic technologies. The potential advantages for integrating 3D printing into house construction are significant, these include the capacity for mass customization of designs and parameters for functional and aesthetic purposes, reduction in construction waste from highly precise material placement, and the use of recycled waste products in layer deposition materials. With the ultimate goal of improving construction efficiency and decreasing building costs, applying Strand7 Finite Element Analysis software, a numerical model was designed specifically for 3D printing in a cement mix incorporated with recycled waste product High Density Polyethylene (HDPE) and found that construction of an arched truss-like roof was structurally feasible without the need for steel reinforcements. The lab sizes prototypes were manufactured based on the destined numerical model by using a 3D printing technology. Currently available 3D printing technologies can be adopted for building construction and this paper discusses the applications, advantages, limitations and future directions of 3D printing as an innovative and viable solution for affordable house construction.

The radiation stability of polymer test objects fabricated by direct laser writing is studied. The two groups of 6 cubes (50×50×50 μm3) were printed on a common silicon substrate. 6 cubes were irradiated with X-rays in the synchrotron radiation beam (12 keV, 1010 photons/mm2/s), the other 6 kept non-irradiated for the reference. In each group, the fabrication parameters (laser power and slicing step) were uniformly varied from cube to cube. Each irradiated cube was exposed with the dose of 1013 X-ray photons. The calibration of this dose in the radiological units (Gy) was carried out using the tissue-equivalent thermoluminescent detectors (TLD-800). The corresponding exposition dose was estimated as 30 kGy for each cube. The radiation effects were evaluated by Raman spectroscopy and by morphological changes observed with the raster electron microscope. The primary radiation effect appears in the essential increase of the polymerization degree with consuming carbon-carbon double bonds in favor of the polymer cross-linking. Only one cube of 6 has changed the size and shape due to this effect, while the others retained the initial shape. Morphological changes are connected with the improper fabrication parameters (laser power and slicing step). Properly fabricated objects withstand the X-rays of the synchrotron radiation beam.

We overview recent findings achieved in the field of model-driven development of additively manufactured porous materials for development of a new generation of bioactive implants for orthopedic applications. Porous structures produced of biocompatible titanium alloys by selective laser melting can present a promising material to design scaffolds with regulated mechanical properties and with capacity to be loaded with pharmaceutical products. Adjusting pore geometry, one could control elastic modulus and strength/fatigue properties of the engineered structures to be compatible with bone tissues, thus preventing the stress shield effect when replacing a diseased bone fragment. Adsorption of medicals by internal spaces would make it possible to emit the antibiotic and anti-tumor agents into surrounding tissues. We critically analyze the recent advances in the field featuring model design approaches, virtual testing of the designed structures, capabilities of additive printing of porous structures, biomedical issues of the engineered scaffolds and so on. A special attention is paid to highlight the current troubles in the field and the ways of their solutions.

Natural rocks are highly heterogeneous due to various geological processes that constantly alter their properties. The accumulation, deposition, and cementation of mineral and organic particles continuously modify the spatial characteristics of rock properties. Property variability or anisotropy is commonly observed in most rock types and influences strength, transport, and thermal conductivity behavior. This unpredictability presents a significant challenge for laboratory testing. Binder-jet additive manufacturing (3D printing) has emerged as a valuable technology for characterizing rock properties in geoscience and engineering. This study proposes a methodology to evaluate the variability and repeatability of mechanical properties of 3D-printed sandstones during binder-jet additive manufacturing. The mechanical properties were analyzed statistically for samples located in various parts of the 3D printer build volume. The results showed that the 3D-printed sandstones exhibited significant variations in their strength and stiffness properties when measured from samples produced within the same build volume during binder-jet additive manufacturing. The Uniaxial Compressive Strength (UCS) varied from 23 to 38 MPa, with an average value of 29 MPa. The Young's modulus, on the other hand, ranged from 1.5 to 4.05 GPa, with an average value of 2.33 GPa. The variability of the mechanical properties, quantified by the standard deviation, decreased when the entire population of 3D-printed sandstones was divided into smaller samples situated at different elevations of the build platform.

Access to nasopharyngeal swabs for sampling remain a bottleneck in some regions for COVID-19 testing. This study develops a distributed manufacturing solution using only an open source manufacturing tool chain consisting of two types of open source 3-D printing and batch UV curing, and provides a parametric fully free design of a nasopharyngeal swab. The swab was designed using parametric OpenSCAD in two components (a head with engineered break point and various handles), which has several advantages: i) minimizing print time on relatively slow SLA printers, ii) enabling the use of smaller print volume open source SLA printers, iii) reducing the amount of relatively expensive UV resin, and iv) enabling production of handle on more accessible material extrusion 3-D printers. A modular open source UV LED box was designed, fabricated for $45 and tested for batch curing. Swabs can be fabricated for $0.06-$0.12/swab. The results of the mechanical validation tests showed that the swabs could withstand greater forces than would be expected in normal clinical use. The swabs were also able to absorb a significant amounts of synthetic mucus materials and passed abrasion and handling tests. The results show the open source swab are promising candidates for clinical trials.

Keywords: friction stir processing; additive manufacturing; wire; titanium alloy; material transfer; microstructure; microhardness

Sustainable manufacturing practices are becoming increasingly necessary due to the growing concerns regarding climate change and resource scarcity. Consequently, material recycling technologies have gradually become preferred over conventional processes. This study aimed to recycle waste polylactic acid (PLA) from household-disposed cups and lids to create 3D-printed parts and promote sustainable manufacturing practices. To achieve this, the current study utilised virgin and post-consumer PLA (sourced from household waste) blends. The PC-PLA wastes were shredded and sorted by size with the aid of a washing step, resulting in a filament with a 1.70 ± 0.5 mm diameter without fragmentation or dissolution. A 50:50 wt.% blend of virgin PLA (vPLA) and PC-PLA was selected as the standard recycling percentage based on previous research and resource conservation goals. The study investigated the impact of three 3D printing parameters (layer height (LH), infill density (I), and nozzle temperature (NT))on the quality of 3D-printed parts using a three-level L9 Taguchi orthogonal array. The findings revealed that blending PC-PLA with vPLA led to significant improvements in the tensile, flexural, and impact strengths by 18.40%, 8%, and 9.15%, respectively, compared to those of recycled PLA. This conclusion was supported by the investigation of the fracture surface area, which revealed fractographic features associated with printing parameters, such as plastic deformation and interfilament debonding. An ANOVA analysis revealed a positive influence of larger layer height and high nozzle temperature on the mechanical properties. Subsequently, the optimal printing parameters (LH: 0.3 mm, I: 100%, and NT: 215 °C) were determined using the S/N ratio, and a confirmation test using the optimum printing parameters exhibited a strong correlation with statistically predicted outcomes. Finally, the study used optimum printing parameters to fabricate 100% post-consumer recycled PLA 3D printed parts, demonstrating their potential for low-strength applications. Based on these findings, it can be concluded that virgin and post-consumer recycled PLA blended filament for fabricating 3D printed components is an effective way to support plastic recycling in the context of a circular economy.

Notwithstanding the advances achieved in the last decades in the field of synthetic bone substitutes, the development of biodegradable 3D scaffolds with ideal mechanical and biological properties remains an unattained challenge. In this work, a novel approach is explored to produce synthetic bone grafts mimicking the complex bone structure using additive manufacturing. For the first time, scaffolds were produced, using an extrusion technique, composed of a thermoplastic polymer, polycaprolactone (PCL), hydroxyapatite nanoparticles (HANp), and polyethylene glycol diacrylate (PEGDA). These scaffolds were further compared with two groups of scaffolds: one composed of PCL and another of PCL and HANp. After production, optimisation and characterisation of these scaffolds, an in vitro evaluation was performed using human dental pulp stem/stromal cells (hDPSCs). Through the findings it was possible to conclude that PEGDA scaffolds were successfully produced presenting networks of interconnected channels, presenting hydrophilic properties (15.15 4.06°), adequate mechanical performance (10.41MPa 0.934), and allowing a cell viability significantly superior to the other groups analysed. To conclude, findings in this study demonstrated that PCL, HANp and PEGDA scaffolds may have promising effects on bone regeneration and might open new insights for 3D tissue substitutes.

Selective laser melting (SLM) is one of the widely used techniques in metallic additive manufacturing, in which high-density laser powder is utilized to selectively melting layers of powders to create geometrically complex parts. Temperature distribution and molten pool geometry directly determine the balling effect, and concentrated balling phenomenon significantly deteriorates surface integrity and mechanical properties of the part. Finite element models have been developed to predict temperature distribution and molten pool geometry, but they were computationally expensive. In this paper, the three-dimensional temperature distributions are predicted by analytical models using point moving heat source and semi-ellipsoidal moving source respectively. The molten pool dimensions under various process conditions are obtained from the three-dimensional temperature predictions and experimentally validated. Ti-6Al-4V alloy is chosen for the investigation. Good agreements between the predictions and the measurements are observed. The presented models are also suitable for other metallic materials in the SLM process.

Currently, the number of approved veterinary medicines are limited, and human medications are used off-label. These approved human medications are of too high potencies for a cat or a small dog breed. Therefore, there is a dire demand for smaller doses of veterinary medicines. This study aims to investigate the use of three semi-solid extrusion 3D printers in a pharmacy or animal clinic setting for extemporaneous manufacturing of prednisolone containing orodispersible films for veterinary use. Orodispersible films with adequate content uniformity and acceptance values defined by the European Pharmacopoeia was produced with one of the studied printers, namely, the Allevi 2 bioprinter. Smooth and flexible films, with high mechanical strength, neutral pH, and low moisture content were produced with high correlation between prepared design and obtained drug amount, indicating that the Allevi 2 printer could successfully be used to extemporaneously manufacture personalized doses for animals at the point-of-care.

In this study, an optimized multi-material system was designed and developed to print samples in various applications, including biomedical fields (e.g., mandibular bone loss). To improve the mechanical and biological properties of scaffolds utilized for dental bone loss applications, a multi-material setup was devised, which employs digital light processing technology. This setup consists of a linear system comprising two resin vats and one ultrasonic cleaning tank, enabling the integration of diverse materials and structures to optimize the composition of the scaffold. This approach was used to print multi-material PLLA scaffolds containing 20 wt.%. HA on the interior side, and PLLA containing 1 wt.% GO on the exterior surface of the scaffold, which were evaluated mechanically and biologically after printing. The scaffold was designed using a triply periodic minimal surface (TPMS) lattice structure, which is known to possess favorable mechanical and biological properties. Various multi-material samples were successfully printed and evaluated to illustrate the multiple-material setup's potential for ensuring proper function, cleaning, and adequate interface bonding. By numerically evaluating several TMPS structures, a novel Gyroid TPMS scaffold with a nominal porosity of 50% was developed and validated experimentally. The biological properties of the scaffolds were also evaluated, including surface morphology, (3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazolium bromide) MTT assay, and cell adhesion. Based on the results, multi-material components with the least contaminations with suitable mechanical and biological properties were successfully printed. By combining PLLA-HA and PLLA-GO, this innovative technique holds tremendous potential for enhancing the effectiveness of regenerative procedures in the field of dentistry.

Life Cycle Assessment (LCA) is a technique developed to measure possible environmental impacts during the manufacture and use of a given product or service. Additive Manufacturing (AM) has proven to be suitable in several industries, especially wire and arc additive manufacturing (WAAM), offering many advantages such as delivery time and reduction in terms of material waste, energy consumption and equivalent CO₂ emissions (CO₂e). This study aimed to develop a methodology to evaluate environmental indicators during the life cycle assessment, from gate-to-gate, in the production of two low-alloy carbon steel metal parts (flanges) using ER-90 wire and allowed identifying the main stages that most influence environmental indicators. The total energy consumption in the production of flanges 1 and 2 were, respectively, 10,239.0 MJ, 12,754.0 MJ and the total carbon footprint, respectively, 714.1 kgCO₂e kg^-1 and 749.3 kgCO₂e kg^-1.

The Selective Paste Intrusion (SPI) method is a layer-by-layer additive manufacturing technique that allows for the production of complex geometries in concrete elements by selectively bonding aggregates with cement paste in a particle bed. To create reinforced concrete, the Wire and Arc Additive Manufacturing (WAAM) process shall be integrated into SPI. This technique allows the production of almost free-formed reinforcement and thus complements the advantage of SPI to produce free-formed structures of almost any geometry. However, integration of WAAM into SPI poses a considerable challenge, as high temperatures are generated during the welding process. These temperatures can negatively affect the rheological properties of the cement paste, in turn the penetration behavior of the paste in the particle bed and, subsequently, the mechanical properties of the hardened concrete. A possible passive cooling strategy is to increase the protruding length of the reinforcement bars out of the particle-bed. This requires that the distance of the print nozzle to the particle bed is as well increased, since it must be possible to move it across the reinforcement. The objective was thus to investigate the effect of that distance on print quality and to quantify a maximum allowable distance for an adequate print quality (for the printer setting used) in terms of shape accuracy and concrete strength. Compressive and flexural strength tests as well as geometrical measurements using a 3D scanning method were performed on specimen, printed with varying print nozzle to particle bed distances. It can be stated that for the used SPI print-heads, nozzle-types and parameter settings, the distance between the nozzle and the particle bed should not exceed 50 mm to ensure sufficient print quality in both shape accuracy and mechanical strength.

In this study composite with alternate layers of 5056 and 1580 alloys was manufactured by wire arc additive manufacturing technology. It is shown that increased strength characteristics of composite material can be obtained due to deformation treatment by high-pressure torsion (HPT) technique. The microstructure and mechanical properties of the HPT-processed material in different structural states were investigated. The HPT-processed material exhibits high value of ultimate tensile strength (~ 770 MPa) but low ductility. Short-term annealing at 250 oС and additional deformation by HPT to 0.25 of revolution at room temperature resulted in a slight decrease in material’s strength to ~ 700 MPa but provided ductility ∼ 9%. Physical mechanisms to improve plasticity in correlation with microstructure evolution is discussed.

Solidification microstructure is formed under high cooling rates and temperature gradients in powder-based additive manufacturing. In this study, a non-equilibrium multi-phase field method (MPFM), which was based on a finite interface dissipation model proposed by Steinbach et. al., coupled with a CALPHAD database was developed for a multicomponent Ni alloy. A qua-si-equilibrium MPFM was also developed for comparison. Two-dimensional equiaxed micro-structural evolution for the Ni (Bal.)–Al–Co–Cr–Mo–Ta–Ti–W–C alloy was performed at various cooling rates. The temperature–γ fraction profiles obtained under 10^5 K/s using non- and qua-si-equilibrium MPFMs were in good agreement with each other. Over 10^6 K/s, the differences between non- and quasi-equilibrium methods grew as the cooling rate increased. The non-equilibrium solidification was strengthened over a cooling rate of 10^6 K/s. Colum-nar-solidification microstructural evolution was performed under cooling rates from 5×10^5 K/s to 1×10^7 K/s at various temperature gradient values under the constant interface velocity (0.1 m/s). The results showed that as the cooling rate increased, the cell space decreased in both methods, and the non-equilibrium MPFM agreed well with experimental measurements. Our results show that the non-equilibrium MPFM can simulate solidification microstructure in powder bed fusion additive manufacturing.

Powder bed fusion (PBF) process is a metal additive manufacturing process which can build parts with any complexity from a wide range of metallic materials. PBF process research has predominantly focused on the impact of only a few parameters on product properties due to the lack of a systematic approach for optimizing a large set of process parameters simultaneously. The pivotal challenges regarding this process require a quantitative approach for mapping the material properties and process parameters onto the ultimate quality; this will then enable the optimization of those parameters. In this study, we propose a two-phase framework for optimizing the process parameters and developing a predictive model for 316L stainless steel material. We also discuss the correlation between process parameters -- i.e., laser specifications -- and mechanical properties and how to achieve parts with high density (> 98%) as well as better ultimate mechanical properties. In this paper, we introduce and test an innovative approach for developing AM predictive models, with a relatively low error percentage of 10.236% that are used to optimize process parameters in accordance with user or manufacturer requirements. These models use support vector regression, random forest regression, and neural network techniques. It is shown that the intelligent selection of process parameters using these models can achieve an optimized density of up to 99.31% with uniform microstructure, which improves hardness, impact strength, and other mechanical properties.

This work investigates how the user-controlled parameters of the 3D printing process define temperature conditions on the boundary between layers of the part being fabricated and how these conditions influence the structure and strength of the part. The process studied is fused filament fabrication with a desktop 3D printer and the material utilized is PLA (polylactic acid). As a characteristic of the part strength the fracture load in the case of a three-point bend and calculated related stress were used. During the printing process parts were oriented with the long side along the Z axis, thus, in the bend tests, the maximum stress occurred orthogonally to the layers. During the fabrication process, temperature distribution on the sample surface was monitored with thermal imager. Sample mesostructure was analyzed using SEM. The influence of the extrusion temperature, the intensity of part cooling, the printing speed and the time between printing individual layers were considered. The influence of all the parameters can be expressed through two generalizing factors: the temperature of the previous layer and the flow efficiency, determining the ratio of the amount of extruded plastic to the calculated. A regression model was proposed that describes the effect of the two factors on the printed part strength. Along with interlayer bonding strength, these two factors determine the formation of the part mesostructure (the geometry of the boundaries between individual threads). It is shown that the optimization of the process parameters responsible for temperature conditions makes it possible to approximate the strength of the interlayer cohesion to the bulk material strength.

Artificial intelligence (AI) and 3D printing (3DP) play critical roles in what is known as the 4th Industrial Revolution by developing data- and machine-intelligence-based integrated production technologies. This shift has led to increasingly complex design requirements and fabrication methods, posing several challenges for implementing design, fabrication process, and architectural quality standardization. This paper systematically reviews AI techniques applied in diverse stages of 3DP production in architecture. The research goals are to (1) offer a comprehensive critical analysis of the body of literature; (2) identify and categorize approaches to integrating AI in the production of 3D-printed structures; (3) identify and discuss challenges and opportunities of AI integration in architectural production of 3DP structures; and (4) identify gap and provide recommendations for future research. The findings indicate that topics related to AI applications are current and trending, receiving increasing attention from researchers in general and particularly those working in machine and deep learning, artificial neural networks, and pattern recognition. However, the potential of the application of AI in architectural production using additive manufacturing still needs to be explored. Considering this, the paper emphasizes the necessity of redefining traditional field boundaries and opening new opportunities in the sector.

In the previous work, the pure fatigue behavior of AM60 magnesium alloy (PF-AM60) was compared with the corrosion fatigue behavior of these specimens (CF-AM60). In this research, in continuation of the previous job, the pure fatigue behaviors of AM60 with polylactic acid (PLA) coating (PF-AM60-PLA) and also, corrosion fatigue behaviors of magnesium alloy with PLA coating (CF-AM60-PLA) were evaluated. Polymer coating was made by fused deposition modeling (FDM) with a 3D printer and attached to standard fatigue test specimens with a glue. Then, they were immersed in the simulated body fluid (SBF) for 27 days. In the end, a high-cycle bending fatigue test was performed on samples. The fracture surface of the samples was also observed using the field emission scanning electron microscopy (FESEM). Due to corrosion, the weight of the specimens redcued by an average of 35%. The corrosion rate decreased in the first 7 days and then increased. PF samples with coating had an average of 49% increase in fatigue lifetime. Regarding the CF samples, despite the use of a 10 times stronger solution, the fatigue lifetime of these samples decreased by only 35%. FESEM results also showed cleavage plates and striations. In addition, the separation of the glue from the coating and Mg was observed. Corrosion products including microcracks and holes were seen on the fracture surface of CF specimens, which caused stress concentration and crack growth. Holes caused by the release of gases were also observed in polymer coatings.

Traditional metals such as stainless steel, titanium and cobalt chrome are used in biomedical applications (implants, scaffolds etc.) but suffer from issues such as osseointegration and compatibility with existing bone. One way to improve traditional biomaterials is to incorporate ceramics with these metals so that their mechanical properties can be similar to cortical bones. Tricalcium phosphate is such a ceramic with properties so that it can be used in human body. This research explores the use of binder jetting based additive manufacturing process to create a novel biocomposite made of cobalt chrome and tricalcium phosphate. Experiments were conducted and processing parameters were varied to study their effect on the printing of this biocomposite. Layer thickness, binder saturation and drying time affected the dimensional tolerance and the density of the green samples. This effect is important to understand so that the material can be optimized for use in specific applications.

We present progress in fast, high-resolution imaging, material classification, and fault detection using hyperspectral X-ray measurements. Classical X-ray CT approaches rely on data from many projection angles, resulting in long acquisition and reconstruction times. Additionally, conventional CT cannot distinguish between materials with similar densities. However, in additive manufacturing, the majority of materials used are known a priori. This knowledge allows to vastly reduce the data collected and increase the accuracy of fault detection. In this context, we propose an imaging method for non-destructive testing of materials based on the combination of spectral X-ray CT and discrete tomography. We explore the use of spectral X-ray attenuation models and measurements to recover the characteristic functions of materials in heterogeneous media with piece-wise uniform composition. We show by means of numerical simulation that using spectral measurements from a small number of angles, our approach can alleviate the typical deterioration of spatial resolution and the appearance of streaking artifacts.

Producing complex shaped tungsten carbide cobalt (WC-Co) tools by classical technologies is difficult and often impossible due to their high hardness and brittle fracture behavior. Additive Manufacturing (AM) is a suitable technology for creating complex structures and simultaneously shortening expensive machining processes. Binder Jetting (BJ) is an innovative AM technology that offers several advantages over laser-based processes, for example low manufacturing costs and high build-up rates. Binders with nanoparticle additives have already proven to be effective in in- creasing the packing density of the powder bed and improving the sintering properties. Addition- ally, they offer the possibility of selectively changing the material composition in the part. This paper presents a concept for the use of nanoparticles to generate gradients in the green compact, which leads to a cobalt gradient in the part after sintering. The possibility of introducing particles locally into complex structures allows local modification of the material properties.

Understanding the equilibrium saturation level is crucial to Binder Jetting (BJ). Saturation level influences dimensional accuracy, print time, green strength, and final material properties. Improved understanding of the saturation level can reduce development time for new materials and improve existing processes in BJ. Attempts have been made to predict saturation levels of parts with simple calculations from droplet primitives and capillary pressure. There is, however, limited experimental validation for these methods and they do not include the impact of drop velocity and droplet spacing. This study incorporates the influences of drop velocity and droplet spacing on the saturation level of the part. Drop primitives of varying droplet velocity and droplet spacing were compared. Results show that velocity impacts the feasible parameter space.

Powder Bed Fusion (PBF) is a type of Additive Manufacturing (AM) technology that builds parts in a layer-by-layer fashion out of a bed of metal powder via the selective melting action of a laser or electron beam heat source. The technology has become widespread, however the demand is growing for closed loop process monitoring and control in PBF systems to replace the open loop architectures that exist today. This paper demonstrates the simulated efficacy of applying closed-loop state estimation to the problem of monitoring temperature fields within parts during the PBF build process. A simplified LTI model of PBF thermal physics with the properties of stability, controllability and observability is presented. An Ensemble Kalman Filter is applied to the model. The accuracy of this filters’ predictions are assessed in simulation studies of the temperature evolution of various test parts when subjected to simulated laser heat input. The significant result of this study is that the filter supplied predictions that were about 2.5x more accurate than the open loop model in these simulation studies.

Additive manufactured interlocking structures often face challenges in achieving suitable joinability due to thermal deformation. This issue becomes particularly interesting when fabricating structures that require high density but not fully connected layers, such as soft-magnetic materials. This study focuses on systematical investigation of the deformation as a function of finger thickness and building direction in model interlocking structure. In the perpendicular direction to the build plate, the distortions of joint part were significantly reduced due to lower thermal stress. In addition, the effect of laser power and scan speed on interlocking structure are systematically discussed. Additionally, through stress and thermal simulations of additive manufacturing process, it was confirmed that the compensated model can enhance the joinability of interlocking structures. These findings contribute to the development of optimal design for additive manufactured parts of soft magnetic materials such as stators in electric motor components, which needs insulations and density.

Nitrate and nitrite are the most extensively used food additives in the food industry for their multifunctional properties, and they have been in the spotlight for decades for its controversial back effects. The conversion of nitrate and nitrite to various nitroso compounds, specifically N-nitrosamine raises the question of the integrity of these additives. Nitrosamine is a well-known carcinogen and mutagen. A large number of studies demonstrate the carcinogenic effects of these salts. Are these findings credible? Nonetheless, the regulatory agencies approve its usage; is it biased? Are we feeding on the carcinogens in processed foods? The current work provides an insight into the basic and toxicological findings of the food additives -nitrate and nitrite.

Sulphites are the most widely used food additives for their versatile applications in processing; perhaps we are negligence of its shortcomings. On account of various research studies, sulphites induce serious allergic reactions and other health alignments, but still regulatory agents permit its usage. Is it a wiser choice? The purpose of this paper is to clear up ambiguity and provide a clear view on why sulphites are employed in the food industry, why its usage is restricted, and why sulphite is a toxicant

Engine oil degradation and tribological properties are strongly interrelated. Hence, understanding the chemical processes resulting in additive depletion and degradation products is necessary. In this study, in-service engine oils from petrol and diesel vehicles were analyzed with conventional and advanced methods (mass spectrometry). Additionally, the effect of the utilization profile (short- vs. long-range) was studied. Petrol engine oils generally showed accelerated antioxidant and antiwear degradation and higher oxidation, especially in case of a short-range utilization profile, which can be attributed to the higher air-to-fuel ratio (more rich combustion) compared to diesel engines. A detailed overview of oxidation and nitration products, as well as degradation products resulting from zinc dialkyl dithiophosphate and boron ester antiwear additives, diphenylamine antioxidants and salicylate detergents is given. A side-reaction between oxidation products (aromatic carboxylic acids) and the boron ester antiwear is highlighted. This reaction was only detected in the petrol engine oils, where the oxidation products were measured in a high abundance. However, no side reaction was found in the samples from the diesel vehicle, since there the aromatic carboxylic acids were largely absent due to lower oxidation.

Aseptic implant loosening after total joint replacement is partially influenced by material-specific factors when cobalt-chromium alloys are used, including osteolysis induced by wear- and corrosion products, and stress shielding. Here, we aim to characterize a hybrid material consisting of alumina-toughened zirconia ceramics (ATZ) and additively manufactured Ti-35Nb-6Ta (TiNbTa), joined by a glass solder. The structure of the joint, static and fatigue shear strength, the influence of accelerated aging, and the cytotoxicity using an elution assay with human osteoblasts is characterized. Furthermore, the biomechanical properties of functional demonstrators of a femoral component for total knee replacements are evaluated. TiNbTa-ATZ specimens showed a homogenous joint with statistical distributed micro-pores and a slight accumulation of Al-rich compounds at the glass solder-TiNbTa interface. The static shear strength was 26.4 ± 4.2 MPa (Ti-ATZ reference: 38.2 ± 14.4 MPa, p = 0.117), all specimens survived 107 cycles of shear loading to 10 MPa, and aging did not reduce the strength. TiNbTa-ATZ did not impair the proliferation and metabolic activity of human osteoblasts. Functional demonstrators of TiNbTa-ATZ provided a maximum bearable extension-flexion moment of 40.7 ± 2.2 Nm. Biomechanical and biological properties of TiNbTa-ATZ demonstrate potential application for endoprosthetic implants.

Biocomposite membranes based on polylactic acid (PLA) and cellulose nanocrystals (CNCs) were developed using a scientific approach. Dicumyl peroxide (DCP) was used as a polymerization ini-tiator, while tin octoate (Sn(Oct)2) and triphenylphosphane (P(C6H5)3) were used as catalysts. A torque rheometer was used to mix the components of the biocomposite, and thin films was prepared by solvent casting. Fourier transform infrared (FTIR) spectroscopy confirmed the coupling between the PLA and CNCs. Field emission scanning electron microscopy (FESEM) showed that the CNCs were well-dispersed in the PLA matrix with an unimodal particle size distribution and a maximum particle size of around 200 nm. Thermogravimetric analysis (TGA) and differential scanning calo-rimetry (DSC) analysis demonstrated good thermal stability and improved biodegradability of the biocomposite membrane compared to pure PLA. Mechanical characterization showed a Young's modulus of 1.65 GPa, which is comparable to that of other composite materials, and a maximum tensile strength of 20.31 MPa, which is higher than that of pure PLA. These results suggest that the developed biocomposite membrane has potential applications in water filtration, food packaging, and biomedical devices.

The study conducts a comparative life cycle assessment (LCA) analysis to assess the environmental impact of two different manufacturing processes used to produce transparent dental aligners. The former method consists of thermoforming a polymeric disc over 3D printed, customized models, while the second, more innovative approach involves the direct printing of aligners using additive manufacturing (AM), specifically applying digital light processing (DLP) technology. The analysis results highlight how adopting direct printing through AM brings significant advantages in terms of environmental sustainability, thanks to the substantial reduction in raw materials and electricity consumption. These drops translate into decreased potential environmental impacts across all impact categories considered within the EF 3.1 method. Furthermore, lowering the amount of raw materials needed in the direct printing process contributes to a notable decrease in the overall volume of waste generated, emphasising the environmental benefits of this innovative technique.

Metal fabrications experience complex physical metallurgical processes during additive manufacturing, leading to residual stress and coarse microstructure with directional growth. It significantly affects the comprehensive performance of the fabrications, which limits the application of additive manufacturing. Ultrasonic impact treatment (UIT), as a strengthening means to assist additive manufacturing, can effectively improve the stress state and refine the microstructure and the comprehensive performance. This paper introduces the effect of UIT on AM metal fabrications on microstructure morphology, stress distribution, surface roughness, internal defects, and comprehensive performance to gain a deeper understanding of the role of UIT on additively manufactured metal fabrications, which is based on the working principle and effect of process parameters. In addition, the strengthening mechanism of UIT in additive manufacturing is described from the perspective of surface plastic deformation and substructure formation, providing support for the shape and property control of metal fabrications in the process of additive manufacturing assisted by UIT. Finally, the issues that need to be studied in depth on UIT in additive manufacturing are summarized, and an outlook on future research directions is taken.

The power conversion efficiency (PCE) of polymer solar cells (PSCs) are strongly depended on the bulk-heterojunction active layer. Here, the 1,8-diiodooctane (DIO) additives have been added into the PCDTBT: PC70BM blend PSCs. Based on the higher boiling point than host solvent ODB and better solubility of PC71BM, the device photovoltaic properties with DIO additive were changed obviously. The investigations of EQE indicate that the DIO can influence the charge recombination and transportation process, and absorption studies demonstrate that the charge carriers generation process can also be affected by DIO. The overall impact reflected on the decreased equivalent resistant. With 3% v/v DIO, the Jsc, Voc and FF are both increased. Correspondingly, a highest PCE is achieved of 6.15%, while the reference device without DIO only has a PCE of 5.23%. Hence, adding DIO solvent additive is a effective method for the photovoltaic properties improving of PCDTBT: PC70BM blend PSCs.

This work opens a new pathway to fabricate high dimensional stability Invar36 aerospace devices with Binder Jetting technology, for applications where temperature fluctuations directly interfere in the correct performance of high sensibility systems. Since full density part fabrication is one of the main ongoing challenges for Binder Jetting, the leading objective of this work is to study and optimise the main process parameters to increase the final density of Invar36 printed parts. Microstructural analysis and obtained density and CTE values, confirmed the feasibility to fabricate Invar36 parts.

Additive manufacturing (AM) is today’s buzzword—and not only in commercial production. One of the AM techniques produces 3D objects with complex geometry using a laser beam. The relationship between the morphology of individual powder particles and the printing process has not been adequately documented yet. This article presents a detailed microscopic analysis of virgin and reused powder particles of maraging steel. Metallographic observation was performed using a scanning electron microscope (SEM). Detailed analyses of individual particles were carried out using SEM with a focused ion beam (FIB) milling capability. Analyses of elemental distribution and phase distribution were performed using EDS and EBSD, respectively. The findings have led to a better understanding and prediction of defects in additive-manufactured products.

As the additive manufacturing industry grows, it is compounding the global plastic waste problem. Distributed recycling and additive manufacturing (DRAM) offers an economic solution to this challenge, but it has been relegated to either small-volume 3D printers (limiting waste recycling throughput) or expensive industrial machines (limiting accessibility and lateral scaling). To overcome these challenges, this paper provides proof-of-concept for a novel open-source hybrid 3D printer that combines a low-cost hanging printer design with a compression screw-based end-effector that allows direct extrusion of recycled plastic waste in large expandable printing volumes. Mechanical testing of the resultant prints from 100% waste plastic, however, showed that combining challenges of non-uniform feedstocks and a heavy printhead for a hangprinter reduced the strength of the parts compared to fused filament fabrication. The preliminary results are technologically promising, however, and provide opportunities to improve on the open source design to help process the volumes of waste plastic needed for DRAM to address the negative environmental impacts of global plastic use.

Skeletal muscle is a specialized tissue consisting of nondividing and multinucleated muscle fibers. Skeletal muscle-specific myostatin (MSTN) is a secreted protein that acts as a negative regulator of muscle mass by inhibiting proliferation and differentiation of myoblasts. In this study, we established a screening platform to monitor myostatin promoter activity in rat L8 myoblasts. Extract of Glycyrrhiza uralensis (GUE), an oriental herbal medicine, was identified through this screening platform and, the active fractions of GUE were identified by process-scale liquid column chromatography system. For in vivo study, the GUE as a feed additive was investigated in growth-finishing pigs. The results showed that GUE significantly increased body weight, carcass weight and lean content in pigs. Microbiota analysis indicated that GUE did not affect the composition of gut microbiota in pigs. In summary, this established rodent myoblast screening platform was used to identify a myogenesis-related phytogenic, GUE, and further demonstrated that the active fractions inhibited MSTN expression. These finding suggest a novel application for GUE in growth performance enhancement through modulation of MSTN expression. Furthermore, this established screening platform has great potential for identification and evaluation of a wide variety of phytogenics involving in myogenesis.

In this study, 3D printing of poly-l-lactic acid (PLLA) scaffolds reinforced with graphene oxide (GO) nanoparticles via Digital Light Processing (DLP) was investigated to mimic bone tissue. Stereolithography is one of the most accurate additive manufacturing method, but the dominant available materials used in this method are toxic. In this research, a biocompatible resin (PLLA) was synthetized and functionalized to serve the purpose. Due to the low mechanical properties of the printed product with the neat resin, graphene oxide nanoparticles in three levels (0.5, 1, and 1.5 Wt.%) were added with the aim of enhancing the mechanical properties. At first, the optimum post cure time of the neat resin was investigated. Consequently, all the parts were post-cured for three hours after printing. Due to the temperature-dependent structure of GO, all samples were placed in an oven at 85 ° C for different time periods of 0, 6, 12, and 18 hours to increase mechanical properties. The compression test of heat treated samples reveals that the compressive strength of the printed parts containing 0.5,1, and 1.5 % of GO increased by 151,162 ad 235%, respectively. Scaffolds with the designed pore sizes of 750 microns and a porosity of 40% were printed. Surface hydrophilicity test was performed for all samples showing that the hydrophilicity of the samples increased with increasing GO percentage. The degradation behavior of the samples was evaluated in a PBS environment, and it revealed that by increasing GO, the rate of component degradation increased, but the heat treatment had the opposite effect and decreased the degradation rate. Finally, besides improving biological properties, a significant increase in mechanical properties under compression can introduce the printed scaffolds as a suitable option for bone implants.

The popularity and growth of additive manufacturing(AM) in recent years are due to its ability to provide innovative solutions to complex manufacturing challenges and its potential to transform the way products are designed, developed, and produced. In this work, the numerical simulation geometry of the model extruder from nozzle is established along with the material extrusion process. The high gravity material extrusion system (HG-MEX) properties and characteristics during filament fabrication are evaluated. This work investigates the effects of gravity on the material extrusion process from nozzle extrusion. This work is unique in the incorporation of fluid surface characteristics to represent the performance and contact with the material extrusion in additive manufacturing. The use of simulation in high gravity material extrusion in additive manufacturing is a meaningful and valuable approach to improving the quality and efficiency of the process.

Powder and SLM additively manufactured parts of X5CrNiCuNb17-4 maraging steel were systematically investigated by electron microscopy to understand the relationship between the properties of the powder grains and the microstructure of the printed parts. We prove that satellites, irregularities and superficial oxidation of powder particles can be transformed into an advantage through the formation of nanoscale (AlMnSiTiCr)-oxides in the matrix during the printing process. The nano-oxides showed extensive stability in terms of size, spherical morphology, chemical composition and crystallographic disorder upon in situ heating up to 950°C in the scanning transmission electron microscope. Their presence thus indicates a potential for oxide-dispersive strengthening of this steel, which may be beneficial for creep resistance at elevated temperatures. The nucleation of copper clusters and their evolution into nanoparticles as well as the precipitation of Ni and Cr particles upon in situ heating have as well been systematically documented.

The paper describes problems with the current additive manufacturing chain before considering additive manufacturing as part of a modern manufacturing chain. Additive manufacturing can be used for near net-shape for finishing, for repair or for adding special features which cannot be made with traditional manufacturing. This paper describes how STEP-NC deals with these different scenarios in terms of accuracy, multi-material and variation of slice direction. The possibilities of multi-material objects also raises questions about the design of such objects and how these need to be handled by an advanced controller. The paper also describes non-planar slicing. Curved direction and cylindrical direction are shown to improve the accuracy of curved structure additive manufacturing. STEP-NC using boundary representation has better capability of depicting complex internal structures for additive processes. By using exact model of the final product represented by STEP-NC, the paper demonstrates improvements in data size reduction, slicing accuracy, and precise manipulation of internal structure.

Metal powder bed fusion (PBF) additive manufacturing (AM) builds metal parts layer by layer upon a substrate material. The strength of this interface between substrate and printed material is important to characterize, especially in applications where the substrate is retained and included in the finished part. This paper studied the tensile and torsional strengths of wrought and additively manufactured (through PBF) SS316L and compared them to specimens composed of half wrought material and half PBF material. The PBF specimens consistently exhibited higher strength and lower ductility than the wrought specimens. The hybrid PBF/wrought specimens performed similarly to the wrought material. In no specimens did any failure appear to occur at or near the interface between wrought substrate and PBF material. In addition, most of the deformation in the PBF/wrought specimens appeared to be limited to the wrought portion of the specimens. These results are consistent with microscopy showing smaller grain size in the PBF material, which often leads to increased strength in SS316L due to the Hall-Petch relationship.

One of the challenges facing the industrial adoption of additively manufactured parts is the surface roughness on the as-built part. The surface roughness of parts is frequently characterized by metrics specified by international standards organizations. However, these standards list many surface metrics that can make it unclear which to use to best describe the surface. In this work, the ability of the various surface metrics to successfully classify the as-built and post-processed surfaces is studied using linear classification models. Laser polishing via remelting and manual grinding are the post-processing techniques used to smooth the as-built surface. The ability of the linear classifier to successfully categorize the various surfaces is demonstrated, and the various surface metrics are ranked according to the strength of their individual ability to classify the surfaces. This work promotes the method as a potential way to autonomously classify as-built and laser polished surfaces.

Selective Laser Melting (SLM) is an additive manufacturing technique. It allows to produce elements with very complex geometry using metallic powders. A geometry of manufacturing elements bases only on 3D CAD data. The metal powder is melt selectively layer by layer using ytterbium laser. The paper contains results of porosity and microhardness analysis made on specimens which were manufactured during specially prepared process. Final analysis helped to discover connections between changing hatching distance, exposure speed and porosity. There was no significant differences in microhardness and porosity measurement results in the planes: perpendicular and parallel to the machine building platform surface.

The heat values of waste mineral oils are equal to the heat value of the fuel oil. However, heat value alone is not sufficient for the use of waste mineral oils. as fuel. However, the critical physical properties of fuels such as density and viscosity need to be adapted to the system in order to be used. In this study, the engine oils used in the first 10,000 km of the vehicles were used as waste mineral oil. An organic-based Mn additive was synthesized to improve the properties of the waste mineral oil. It was observed that mixing the Mn additive with the waste mineral oil at different doses (4, 8, 12 and 16 ppm) improves the viscosity of the waste oil and the flash point. The resulting fuel was evaluated for emission using different loads in a 5 kW capacity generator to compare the fuel with standard diesel fuel and to determine the effect of Mn addition. In the experimental study, it was observed that the emission characteristics of the fuel obtained from waste mineral oil were worse than diesel fuel, but some improvement with Mn addition. As a result, we found that the use of waste mineral oils in engines in fuel standards was not appropriate, but may be improved with additives.

Cladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these residual stresses could be effectively utilized by modifying processes and geometrical parameters. This paper introduces a novel methodology for using the weld-cladding process as a cost-effective alternative to various existing reinforcement techniques. The numerical analyses are performed to maximize the reinforcement of a cylindrical tool. The investigation of how the weld cladding develops compressive stresses on the specimen in response to a change in the weld beads and the welding sequence is presented. For the benchmark shape, experimental verification of the numerical model is performed. The impact of the distance between the weld beads and the effect of the tool diameter is numerically investigated. Furthermore, the variation in compressive stresses due to temperature fluctuations during the extrusion process has been evaluated. The results showed that adequate compressive stresses are generated on the welded parts through the cladding process after cooling. Hence, the targeted reinforcement of the substrate can be achieved by optimizing the welding sequence and process parameters.

A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.

As a crucial part of head protection equipment, research on the material and structural application of helmet liners has always been a hot topic in the field of helmet manufacturing. This paper aims to introduce the most common helmet liner materials, including traditional polystyrene, polyethylene, polypropylene, and others, as well as emerging materials such as anisotropic materials, and polymer nanocomposites. In addition, the design principles of helmet liner structure are discussed, including the evolution of multi-layer structure, integration of geometric irregular bubbles, etc., to enhance energy absorption capacity. Advanced manufacturing processes such as additive manufacturing technology are introduced to fabricate complex structures. Finally, the application of biomimetic structures in helmet liner design is explored. For example, the structure of biological tissue can be used to design a helmet liner structure with superior energy absorption performance. On this basis, the idea of bionic structures is extended to the combination of plant stalks and animal skeletal structures, and additive manufacturing technology is used to significantly reduce energy loss during elastic yield energy absorption, thus designing a reusable helmet. This provides a promising research direction for future helmet liner materials and structural applications.

In the article, the results of research on a NiTi alloy with a high nickel content (51.7 at.%), produced using the additive technology SLM method and subjected to isothermal aging after so-lution annealing, are presented. The study involved the determination of the sequence of phase transformations occurring using differential scanning calorimetry (DSC), and the determination of the temperature range of these transformations. In parallel, the phase composition was determined using the XRD method; hardness and the Young’s modulus were also determined. The analysis of the DSC results obtained indicates the following characteristic features of the NiTi alloy, which change with ageing time: (1) during cooling (from +1500C to -500C), the type of transformation changes from a one-step transformation after solution annealing to a two-step transformation after the ageing process over 1, 20 and 100 hours at 500°C; (2) during heating (from -500C to +1500C) for all the samples, regardless of the ageing time, only a one-step transformation from martensite M(B19’) to austenite A(B2) is observed; (3) the temperature at which the transformation starts increases with the ageing time, (4) the width of the total temperature range of the transformation M(B19’)  A(B2) during heating changes from large (∆T=49,7°C), after solution annealing, to narrow (∆T=19.3°C and ∆T=17.9°C after 20 h and 100 h of ageing) and, most importantly, (5) a comparison with literature data shows that, irrespective of the composition of the NiTi alloy and the manufacturing technology of the alloy samples (regardless of the fact whether this was traditional or additive technology), a sufficiently long ageing process period leads to the occurrence of the martensite  austenite transformation in the same temperature range.

Once on Mars, maintenance and repair will be crucial for humans as supply chains including Earth andMars will be very complex. Consequently, the raw material available on mars must be processed and used. Factors such as the energy available for material production play just as important a role as the quality of the material that can be produced and the quality of its surface. With the aim of developing and technically implementing a process chain that meets the challenge of producing spare parts from oxygen-reduced Mars regolith, this paper addresses the issue of low-energy handling. Expected statistically distributed high roughnesses of sintered regolith analogs are approximated in this work by parameter variation in the PBF-LB/M process. For low-energy handling, a dry-adhesive microstructure is used. Investigations are carried out to determine the extent to which the rough surface resulting from the manufacturing process can be smoothed by deep rolling in such a way that the microstructure adheres and enables samples to be transported. For the investigated AlSi10Mg samples (12 mm x 12 mm x 10 mm), the surface roughness varies in a wide range from Sa 7.7 µm to Sa 64 µm after the additive manufacturing process, pull-off stresses of up to 6.99 N/cm² could be realized after deep rolling. This represents an increase in pull-off stresses by a factor of 392.94 compared to the pull-off stresses before deep rolling, enabling handling of even larger specimens. It is noteworthy that specimens with roughness values that were previously difficult to handle can be treated post-deep rolling, indicating a potential influence of additional variables that describe roughness or ripples and are associated with the adhesion effect of the microstructure of the dry adhesive.

There is evidence that Additive Manufacturing plays a crucial role in the fourth industrial revolution. The design freedom provided by this technology is disrupting limits and rules from the past enabling engineers to have new products otherwise unfeasible. Recent developments in the field of SLM have led to a renewed interest in lattice structures that can be produced non-stochastically in previously unfeasible dimensional scales. One of the primary applications is aerospace engineering where the need of lightweight and performance is urgent to reduce the carbon footprint of civil transport around the globe. Of particular concern is fatigue strength. Being able to predict fatigue life in both LCF (Low Cycle Fatigue) and HCF (High Cycle Fatigue) is crucial for a safe and reliable design in aerospace systems and structures. In the present work, an experimental evaluation of compressive-compressive fatigue behavior has been performed to evaluate the fatigue curves of different cells, varying sizes and relative density. A Design of Experiment approach has been adopted in order to maximize the information extractable in a reliable form.

The paper contains the results of the 100-hour test campaign of the Additive Manufactured (AM) spare part (retainer – slipper) dedicated for an exact axial piston pump. The material of the retainer-slipper has been identified by using energy dispersive spectroscopy and replaced by other – with similar material properties as the original one. The obtained spare part had been subjected to only one postprocessing type (sandblasting) to analyze the influence of the rough part after the AM process. The whole test campaign has been divided into stages, where after each stage microscopic measurements have been made. During microscopical investigation roughness and geometrical measurements were conducted. The results revealed that it is possible to replace parts in hydraulic pumps with the use of AM. 100-hour test campaign caused about 500% increase in the surface roughness of the pump’s original part which was cooperated with the AM spare retainer-slipper, without any damages to the test system.

The effects of build orientation and heat treatment on the crack growth behavior of 316L stainless steel (SS) fabricated via a selective laser melting (SLM) additive manufacturing process were investigated. Significant growth of available research results of additively manufactured metallic parts still needs to be improved. The most important issue connected with properties after additive manufacturing is properties high anisotropy, especially from the fatigue point of view. The research included crack growth behavior of additively manufactured 316L in comparison to conventionally made reference material. Both groups of samples were obtained using precipitation heat treatment. Different build orientation in additively manufactured samples and rolling direction in reference samples were taken into account as well. Precipitation heat treatment of additively manufactured parts allowed to reach similar microstructure and tensile properties to elements conventionally made. The heat treatment positively affected fatigue properties. Additionally, precipitation heat treatment of additively manufactured elements significantly affected the reduction of fatigue cracking velocity and changed the fatigue cracking mechanism.

Binder jet printed components typically have low overall density in the green state and high shrinkage and deformation after heat treatment. It has previously been demonstrated that, by including nanoparticles of the same material in the binder, these properties can be improved as the nanoparticles can fill the interstices and pore throats between the bed particles. The beneficial effects from using these additive binder particles can be improved by maximising the binder particle size, enabling the space within the powder bed to be filled with a higher packing efficiency. The selection of maximum particle size for a binder requires detailed knowledge of the pores and pore throats between the powder bed particles. In this paper, a raindrop model is developed to determine the critical radius at which binder particles can pass between pores and penetrate the bed. The model is validated against helium pycnometry measurements and binder particle drop tests. It is found that the critical radius can be predicted, with acceptable accuracy, using a linear function of the mean and standard deviation of the particle radii. Percolation theory concepts have been employed in order to generalise the results for powder beds that have different mean particle sizes and size distributions. The results of this work can be employed to inform the selection of particle sizes required for binder formulations, to optimise density and reduce shrinkage in printed binder jet components.

It is a common practice to detect outliers in a financial time series in order to avoid the adverse effect of additive outliers. This paper investigated the performance of GARCH family models (sGARCH; gjrGARCH; iGARCH; TGARCH and NGARCH) in the presence of different sizes of outliers (small, medium and large) for different time series lengths (250, 500, 750, 1000, 1250 and 1500) using root mean square error (RMSE) and mean absolute error (MAE) to adjudge the models. In a simulation iteration of 1000 times in R environment using rugarch package, results revealed that for small size of outliers, irrespective of the length of time series, iGARCH dominated, for medium size of outliers, it was sGARCH and gjrGARCH that dominated irrespective of time series length, while for large size of outliers, irrespective of time series length, gjrGARCH dominated. The study further leveled that in the presence of additive outliers on time series analysis, both RMSE and MAE increased as the time series length increased.

The main development direction of energy efficiency technologies in construction is the creation of various materials with a complex structure and unique strength, thermal and other properties. The aerogel is a material with high porosity and excellent thermal insulation properties. This paper provides the state-of-the-art of aerogel applications for the additive manufacturing of energy efficient buildings. This work provides the experimental and numerical assessment results of thermal conductivity of aerogel-enhanced blanket, the experimental assessment results of thermal performance of aerogel-enhanced building structure, the experimental assessment results of the aerogel application as mixture powder component of the concrete mixture to printing building and the experimental assessment results of the aerogel application as parget powder component. Experimental results show the effect of aerogel powder component application: thermal conductivity decreased by 25%.

Ceramic composites have good strength, fracture toughness and hardness characteristics and are widely used in industry, medicine. The properties of ceramic composites can be controlled at the production stage by setting the internal structure. This is made possible by the development of additive manufacturing. However, not all properties are well understood, especially dynamic fracture resistance and fracture toughness. In order to predict the mechanical behavior of ceramic composites in the manufacturing phase with a controlled structure under dynamic loads, it is convenient to use methods of numerical analysis. The aim of this work was to investigate the influence of loading speed and internal structure on dynamic resistance and fracture toughness of ATZ nanocomposites. Within the framework of the study physical and mathematical model that is used in computational mechanics of materials is developed. In the paper is shown the influence of the loading rate on the strain rate in the region of the shock transition for materials based on ZrO2 - Al2O3 system. The research shows nonlinear effects under intense dynamic loads in the shown composite materials are bound up with either the processes of self-organisation of deformation modes at the mesoscopic level or the occurrence of martensitic phase transformations in matrix volumes adjacent to the strengthening particles.

Material Extrusion is a popular additive manufacturing technology due to its low cost, wide market availability, ability to construct complex parts, safety, and cleanliness. However, optimizing the process parameters to obtain the best possible mechanical properties has not been extensively studied. This paper aims to develop ensemble learning-based models to predict the ultimate tensile strength, Young's modulus, and strain at break of PLA and PLA-CF 3D-printed parts, using printing temperature, printing speed, and layer thickness as process parameters. Additionally, the study investigates the impact of process parameters and material selection on the mechanical properties of the printed parts and uses Genetic Algorithms for multi-objective optimization according to user specifications. The results indicate that process parameters and material selection significantly influence the mechanical properties of the printed parts. The Genetic Algorithm successfully identifies optimal parameter values for the desired mechanical properties. Moreover, this work is the first to model Process-Structure-Properties relationships for an additive manufacturing process and to use a multi-objective optimization approach for multiple mechanical properties, utilizing ensemble learning-based algorithms and Genetic Algorithms.

Biogas production from organic waste is a promising renewable energy source, but achieving optimal production and digester stability can be challenging. This study investigated the impact of the Evogen microbial additive on biogas production and digester quality through microbial abundance and physicochemical parameter analysis. Two biogas plants, BG01 and BG02, were examined using 16S rRNA profiling to assess microbial abundance. Simultaneously, physicochemical parameters, including FOS/TAC ratio, total solids, volatile solids, biogas production, and VFA profile, were measured to evaluate digester performance. Results revealed distinct microbial community shifts in Evogen-treated digesters. Increased abundance of methanogenic archaea and hydrolytic bacteria indicated improved anaerobic digestion. Evogen supplementation also positively affected digester performance, with higher FOS/TAC ratios indicating enhanced acidification and methanogenesis. Reductions in total solids and volatile solids demonstrated improved organic matter degradation. Significantly higher biogas production was observed in Evogen-treated digesters, highlighting its potential as a microbial additive. Furthermore, VFA profiling demonstrated improved process stability and reduced substrate inhibition in Evogen-treated digesters. In summary, Evogen microbial additive positively influenced microbial dynamics, improving biogas production and digester quality. These findings contribute to optimizing biogas production systems and understanding the complex microbial interactions within anaerobic digesters.

Nature provides plenty of good examples for simple and very efficient joint assemblies. One example is the enormously flexible cervical spine of American barn owls, which consists of 14 cervical vertebrae. Each pair of vertebrae produces a comparatively small individual movement in order to provide a large overall movement of the entire cervical spine. The biomimetic replication of such joints is difficult due to the delicate and geometric unrestricted joint shapes as well as the muscles that have to be mimicked. Using X-ray as well as micro computed tomography images and with the utilisation of additive manufacturing, it is possible to produce the owl neck vertebrae in scaled-up form, to analyse them and then to transfer them into technically usable joint assemblies. The muscle substitution of these joints is realised by smart materials actuators in the form of shape memory alloy wire actuators. This actuator technology is outstanding for its muscle-like movement and for its enormous energy density [1,2]. The disadvantage of this wire actuator technology is the low rate of contraction, which means that a large length of wire has to be installed to generate adequate movement. For this reason, the actuator wires are integrated into additively manufactured carrier components to mimic the biological joints. This results in joint designs that compensate for the disadvantages of the small contraction of the actuators by intelligently installing large wire lengths on comparatively small installation spaces, while also providing a sufficient force output. With the help of a test rig, the developed technical joint variants are examined and evaluated. This demonstrates the technical applicability of this bionic joints.

With increasing constraints on energy and resource markets and the non-decreasing trend in energy demand, the need for relevant clean energy generation and storage solutions is growing and is gradually reaching the individual home. But small-scale energy storage is still an expensive investment in 2022 and the risk/reward ratio is not yet attractive enough for individual homeowners. One solution is for homeowners not to store excess clean energy individually but to produce hydrogen for mutual use. In this paper a collective production of hydrogen for a daily filling of a bus is considered. Following our previous work on the subject, the investigation consists of finding an optimal buy/sell rule to the grid, and the use of the energy with an additional objective: mobility. The dominant technique in the energy community is reinforcement learning, which is however difficult to use when the learning data is limited as in our study. We chose a less data-intensive and yet technically well-documented approach. Our results show that rulebooks, different but more interesting than the usual robust rule, exist and can be cost-effective. But they require fine-tuning as to not deteriorate system performance. In some cases, it is worth missing the H2 production requirement in exchange for higher economic performance.

For orthopaedic applications, additive manufactured (AM) porous scaffolds made of absorbable metals like magnesium, zinc or iron are of particular interest. They do not only offer the potential to design and fabricate bio-mimetic or rather bone equivalent mechanical properties, they also do not need to be removed in further surgery. Located in a physiological environment, scaffolds made of absorbable metals show a decreasing Young’s modulus over time, due to product dissolution. For WE43 scaffolds, during the first days an increase of the smeared Young's modulus can be observed, which is mainly attributed to a forming substrate layer of degradation products on the struts surfaces. In this study the influence of degradation products on the stiffness properties of metallic scaffolds is investigated. For this, analytical calculations and finite element simulations are performed to study the influence of the substrate layer thickness and Young's modulus for single struts and for a new scaffold geometry with adapted polar f2cc,z unit cells. The finite element model is further validated by compression tests on AM scaffolds made from Zn1Mg. The results show, that even low thicknesses and Young's moduli of the substrate layer increases significantly the smeared Young's modulus under axial compression.

This study aims to identify an optimal heat-treatment parameter set for an additively manufactured AlSi10Mg alloy in terms of increasing the hardness and eliminating the anisotropic microstructural characteristics of the alloy in as-built condition. Furthermore, the influence of these optimized parameters on the fatigue properties of the alloy investigated. In this respect, microstructural characteristics of an AlSi10Mg alloy manufactured by Laser-Based Powder Bed Fusion in non-heat-treated and heat-treated conditions were investigated. Their static and dynamic mechanical properties were evaluated, and fatigue behavior was explained by a detailed examination of fracture surfaces. Much of the microstructure in the non-heat-treated condition was composed of columnar grains oriented parallel to the build direction. Further analysis revealed a high fraction of pro-eutectic α-Al. Through heat-treatment, the alloy was successfully brought to its peak-hardened condition, while eliminating the anisotropic microstructural features. Yield strength and ductility increased simultaneously after heat-treatment, which is due to the relief of residual stresses, preservation of refined grains, and introduction of precipitation strengthening. The fatigue strength, calculated at 10^7 cycles, improved as well after heat-treatment and finally detailed fractography reviled that a more ductile fracture mechanism has happened in the heat-treated condition compared to the non-heat-treated condition.

Metal additive manufacturing (AM) has gained much attentions in recent years due to its advantages including geometric freedom and design complexity, appropriate to a wide range of potential industrial applications. However, conventional metal AM methods have high-cost barriers due to the initial cost of the capital equipment, support and maintenance, etc. This study presents a unique low-cost metal material extrusion (MME) technology. The filaments used have polylactic acid (PLA) as the matrix and metal powders (copper, bronze, stainless steel, high carbon iron, and aluminum) as reinforcements. Using the proposed fabrication technology, test specimens were built by extruding polymer/metal composite filaments, which were then sintered in an open-air furnace to produce solid metallic parts. In this research, the mechanical and thermal properties of the built parts are examined using tensile tests, thermogravimetric-, thermomechanical- and microstructural analysis.

The sudden pervasive of severe acute respiratory syndrome Covid-19 has been leading the universe into a prominent crisis. It has influenced each zone, for example, industrial area, horticultural zone, Public transportation, economic zone, and so on. So as to see how Covid-19 affected the globe, we conducted an investigation characterizing the effects of the pandemic over the world using Machine Learning (ML) method. Prediction is a typical data science exercise that helps the administration with function planning, objective setting, and anomaly detection. We propose an additive regression model with interpretable parameters that can be naturally balanced by experts with domain intuition about the time series. We focus on global data beginning from 22^nd January 2020, till 26^th April 2020 and performed dynamic map visualization of Covid-19 expansion globally by date wise and predicting the spread of virus on all countries and continents. The major advantages of this work include accurate analysis of country-wise as well as province/state-wise confirmed cases, recovered cases, deaths, prediction of pandemic viral attack and how far it is expanding globally.

This paper presents a physical and mathematical model that has been developed in the framework of the approach used in the computational mechanics of materials. The model is designed to enable the study of the patterns of deformation and fracture of ceramic composites with a transformation-hardened matrix that are obtained by additive technologies at the mesoscopic and macroscopic levels under intense dynamic loading. The influence of the loading rate on the formation of the fracture and energy dissipation fronts for composite materials, based on the Al2O3 20%ZrO2 system, is shown. Nonlinear effects under intense dynamic loading in the considered composites are associated with the processes of self-organization of structural fragments at the mesoscopic level, as well as the occurrence of martensitic phase transformations in matrix volumes adjacent to the strengthening particles.

Live fuel moisture content (LFMC) influences fire activity at landscape scale and fire behavior in laboratory experiments. However, field evidences linking LFMC to fire behavior are very limited despite numerous field experiments. In the present study, we reanalyze a shrubland fire dataset with a special focus on LFMC to explain this counterintuitive outcome. We found that this controversy might result from three reasons. First, the range of experimental LFMC data was too moist to reveal significant effect with the widespread exponential or power functions. Indeed, LFMC exhibited a strong effect below 100%, but marginal above this threshold, contrary to these functions. Second, we found that the LFMC significance was unlikely when the size of the dataset was smaller than 40. Finally, a complementary analysis suggested that 10 to 15% of random measurement error in variables could lead to an underestimation by 30 % of the LFMC effect. The effect of LFMC in field experiments is thus stronger than previously reported in the range prevailing during the actual French fire season and in accordance with observations at different scales. This highlights the need to improve our understanding of the relationship between LFMC and fire behavior to refine fire danger predictions.

The aim of this study was to investigate the possibility of a freeform fabrication of porous ceramic parts through selective laser sintering (SLS). SLS was proposed to manufacture ceramic green parts because this additive manufacturing technique can be used to fabricate three-dimensional objects directly without a mold, and the technique has the capability of generating porous ceramics with controlled porosity. However, ceramic printing has yet fully achieved its 3D fabrication capabilities without using polymer binder. Except for the limitation of high melting point, brittleness and low thermal shock resistance from instinct ceramic material properties, the key hurdle lies on very poor absorptivity of oxide ceramics to fiber laser which is widely installed in the commercial SLS equipment. An alternative solution to overcome the poor laser absorptivity via improving material compositions was presented in this study. The positive effect of carbon additive on the absorptivity of silica powder to fiber laser will be discussed. To investigate the capabilities of the SLS process, 3D porous silica structures were successfully prepared and characterized.

In this study, a new structure is proposed based on the body-centered cubic (BCC) lattice structure: adding a cubic truss in the center of the BCC structure, which is denoted by TLC (Truss-lattice-cube). The different dimensions of the central cube can affect the mechanical properties of the lattice structure notably. With a fixed length (15mm) of a unit cell, the optimal size for the central cube is determined to be 5 mm. Quasi-static compressive tests are performed on specimens made of Polylactic Acid (PLA) using additive manufacturing technology. The deformation characteristics of the new structure is analyzed in detail by experiments and numerical simulations. Compared to the BCC structure, the mechanical properties of the TLC structure are significantly improved. The initial flow stress of the TLC has been increased by 122% at a strain of 0.1; the specific strength has been enhanced by 293% at a strain of 0.5; and the specific energy absorption has been improved by 312% at the strain of 0.6. Printing defects in the lattice structure could deteriorate the mechanical property remarkably. In this work, incorporation of microcracks into the finite element model makes the simulation capture the influence of printing defects and improve the predictive accuracy of simulation significantly.

In this study, additive manufacturing of reinforced parts using metallic wire as both a reinforcement component and a shape memory stimulus through Fused Deposition Modeling (FDM) was investigated. A Shape Memory Polymer (SMP) restores its original shape and recovers it upon specific stimuli. This research employed chromium-nickel metal wire as a reinforcing component to enhance mechanical properties and introduce the capability for thermal stimulation of polylactic acid (PLA) via electrical current using the "in-situ impregnation" method within FDM process. Reinforced specimens were fabricated with wire with two diameters of 0.1 and 0.15 mm, along with two volume percentages of 5 and 10. Comprehensive evaluations encompassing mechanical (tensile and flexural) and thermal properties of the printed specimens were conducted. The outcomes revealed a significant enhancement in both tensile and flexural properties of the polymer matrix due to the embedding metallic wire, even under elevated temperatures during bending test. Furthermore, the thermal properties of the reinforced specimens were examined by subjecting them to various voltages, resulting in temperature ranging from 36.4 to 150.1°C. These findings highlight the ability to tailor a wide range of mechanical properties and shape recovery in the reinforced specimens by carefully selecting the wire volume fraction, voltage, and wire diameter, thus regulating the materials properties with specific application requirements.

(1) The study using the quails of the Manchurian golden breed was aimed at the efficacy of the food supplement based on micro-incapsulated phytase of Obessumbacterium proteus in the recombinant yeast producer Yarrowia lipolytica at a dose of 500 FYT/kg of the feed. (2) The effect of the supplement in the poultry diets on the productivity of young and adult quails was assayed; (3) It was found that the keeping the quails on the diets using the microencapsulated phytase O. proteus provided the highest live weight, the highest intensity of egg production, and the slaughter yield of animals, the lowest feed conversion compared to those in control groups and the groups getting a commercial phytase supplement based on Aspergillus ficuum. Taken together the data obtained in our experiments indicate a high degree of assimilation of phytate-containing products by the quails when using the encapsulated phytase compared to both the control and commercial preparation of phytase of the PhyA class. It can be concluded that it is a highly expedient and promising supplement based on the microencapsulated phytase of class D for feeding, which shows the best kinetic features compared to the phytases of PhyA and PhyC classes when working in the chyme of the poultry.

In this paper, the characterization of 3D printed materials that are considered in the design of multirotor unmanned aerial vehicles (UAVs) for specialised purposes was carried out. The multirotor UAV system is briefly described, primarily from the aspect of system dynamics, considering that the airframe parts connect the UAV components, including the propulsion configuration, into a functional assembly. Three additive manufacturing (AM) technologies were discussed, and a brief overview was given of selective laser sintering (SLS), fused deposition modeling (FDM), and continuous fiber fabrication (CFF). Using hardware and related software, 12 series of specimens were produced which were experimentally tested utilizing a quasi-static uniaxial tensile test. The results of the experimental tests are given graphically with displacement-force characteristics. In this work, the focus is on CFF technology and the testing of materials that will be used in the production of mechanically loaded airframe parts of multirotor UAVs. Furthermore, an overview was given in such a way that the specimens were grouped, and the mean values of the maximum stress were presented, so that the tested materials could be more easily compared with conventional materials, such as aluminum alloys.

The Laser Thermal-Joule Heating Composite Process was studied by orthogonal tests based on an analysis of fabrication parameters such as the laser power, wire feeding speed, and electric current. Temperature profiles and the geometric morphology of deposited layers under different process parameters were analyzed, and the overlaps between the layers and the substrate were observed. Results show that when the temperature at the bottom layer of the additive manufacturing is higher than the melting point of the substrate, and the highest temperature at the top layer does not exceed the over-firing temperature, good morphology and close bonding with the substrate can be obtained. Finally, appropriate process parameters were identified and verified to print multiple layers continuously.

Classification predictive modeling involves the accurate assignment of observations in a dataset to target classes or categories. There is an increasing growth of real-world classification problems with severely imbalanced class distributions. In this case, minority classes have much fewer observations to learn from than those from majority classes. Despite this sparsity, a minority class is often considered the more interesting class yet developing a scientific learning algorithm suitable for the observations presents countless challenges. In this article, we suggest a novel multi-class classification algorithm specialized to handle severely imbalanced classes based on the method we refer to as SAMME.C2. It blends the flexible mechanics of the boosting techniques from SAMME algorithm, a multi-class classifier, and Ada.C2 algorithm, a cost-sensitive binary classifier designed to address highly class imbalances. Not only do we provide the resulting algorithm but we also establish scientific and statistical formulation of our proposed SAMME.C2 algorithm. Through numerical experiments examining various degrees of classifier difficulty, we demonstrate consistent superior performance of our proposed model.

Background: Residents of a large area of North-Eastern Italy were exposed for decades to high concentrations of perfluoroalkyl and polyfluoroalkyl substances (PFAS) via drinking water. Despite the large amount of evidence in adults of a positive association between serum PFAS and metabolic outcomes, studies focusing on children and adolescents are limited. We evaluated the associations between serum PFAS concentrations and lipid profile, blood pressure and body mass index (BMI) in highly exposed adolescents and children. Methods: A cross-sectional analysis was conducted in 6669 adolescents (14-19 years) and 2693 children (8-11 years) enrolled in the health surveillance program of the Veneto Region. Non-fasting blood samples were obtained and analyzed for perfluorooctanoic acid (PFOA) perfluorooctane sulfonate (PFOS), perfluorohexanesulfonic acid (PFHxS), perfluorononanoic acid (PFNA), total cholesterol (TC) high-density lipoprotein cholesterol (HDL-C) and triglycerides. Low-density lipoprotein cholesterol (LDL-C) was calculated. Systolic and diastolic blood pressure (BP) were measured and BMI z-score accounting for age and sex was estimated. The associations between ln-transformed PFAS (and categorized into quartiles) and continuous outcomes were assessed using generalized additive models. Analyses were stratified by gender and adjusted for potential confounders. Results: Among adolescents, significant associations were detected between all investigated PFAS and TC, LDL-C, and to a fewer extent HDL-C. Among children, PFOS and PFNA had significant associations with TC, LDL-C and HDL-C, while PFOA and PFHxS had significant associations with HDL-C only. Increased serum concentrations of PFAS, particularly PFOS, were associated with decreased BMI z-score. No statistically significant associations were observed between PFAS concentrations and BP. Conclusions: Our study supports a consistent association between PFAS concentration and serum lipids, stronger for PFOS and PFNA and with a greater magnitude among children compared to adolescents, and a negative association of PFAS with BMI.

Welding processes offer a unique capability with a wide range of applications in industries. In recent times, welding has established itself as a tool for large scale additive manufacturing. In general, the quality and repeatability assurance for welding and specifically for additive manufacturing necessitates integrating process monitoring techniques with existing welding and additive manufacturing processes. The process-specific signals such as welding current fluctuations, temperature, and acoustic, generated during the welding operations, make them a suitable candidate for digitization. This chapter comprehensively describes the process monitoring techniques relevant to welding and additive manufacturing. Firstly, various sensors used during welding are described for their construction and working. Subsequently, specific applications of the sensors in digitizing the welding processes are presented.

The use of flexible sensors has tripled over the last decade due to the increased demand in various fields including health monitoring, food packaging, electronic skins and soft robotics. Flexible sensors have the ability to be bent and stretched during use and can still maintain their electrical and mechanical properties. This gives them an advantage over rigid sensors that lose their sensitivity when subject to bending. Advancements in 3D printing have enabled the development of tailored flexible sensors. Various additive manufacturing methods are being used to develop these sensors including inkjet printing, aerosol jet printing, fused deposition modelling, direct ink writing, selective laser melting and others. Hydrogels have gained much attention in the literature due to their self-healing and shape transforming. Self-healing enables the sensor to recover from damages such as cracks and cuts incurred during use and this enables the sensor to have a longer operating life and stability. Various polymers are used as substrates on which the sensing conductive material is placed. Polymers including polydimethylsiloxane (PDMS), polyvinyl acetate (PVA), and Kapton are extensively used in flexible sensors. The most widely used nanomaterials in flexible sensors are carbon and silver, however, other nanomaterials such as iron, copper, manganese dioxide and gold are also used to provide controlled levels of conductivity or other functional properties.

Porous tantalum (Ta) is a promising biomaterial and has been applied in orthopedics and dentistry for nearly two decades. The high porosity and interconnected pore structure of porous Ta promise fine bone ingrowth and new bone formation within the inner space, which further guarantee rapid osteointegration and bone-implant stability in long term. Porous Ta has high wettability and surface energy that can facilitate adherence, proliferation and mineralization of osteoblasts. Meanwhile, low elastic modulus and high friction coefficient of porous Ta can effectively avoid stress shield effect, minimize marginal bone loss and ensure primary stability. Accordingly, the satisfactory clinical application of porous Ta based implants or prostheses are mainly derived from its excellent biological and mechanical properties. With the advent of additive manufacturing, personalized porous Ta based implants or prostheses have shown their clinical value in the treatment of individual patient who need specially designed implant or prosthesis. In addition, many modification methods have been introduced to enhance the bioactivity and antibacterial property of porous Ta with promising in vitro and in vivo research results. In any case, choosing suitable patients is of great importance to guarantee surgical success after porous Ta insertion.